19BY7024Q0023_Attachment A SOW.pdf

1. PROJECT STATEMENT

1.1. The goal is to supply and replace faulty booster Triplex pumps plant (DWTP) booster pumps in Utility building located at 50, Av. Des Etats Unis at New Embassy compound.

The middle pump is in bad state and produces abnormal sound during operation, the plan is to replace all three (3) pumps and bring the plant back to its original operation efficiency as per manufacturers recommendations.

2. TERMS

2.1. The project will be performed by qualified and licensed water system contractors.

2.2. The contractor will be responsible for supplying the pumps, install and commissioning of the three (3) pumps according to manufacturer’s recommendations that will be highlighted in this SOW.

2.3. The contractor will be responsible for renting a crane to aid in replacement process due to height of the pump.

2.4. Contractor shall make arrangements for one full time project manager/supervisor/engineer at the site who will inspect the quality of work and the conduct of its workers.

3. SAFETY

3.1. Contractor workers will be required to adhere to the safety standards found in the Safety and Health Requirements Manual, EM 385-1-1, dated 30 November 2014.

3.2. The Contractor responsible is required to submit a Project Safety Plan as part of their proposal. The safety plan should list all significant safety risks associated with the project and how the contractor plans to minimize each. A sample safety plan for this project is included in Appendix A.

3.3. The project may not start until the Contracting Officer Representative (COR) has reviewed the safety plan and has inspected the safety equipment that will be used on the project.

3.4. The Contractor must have adequate Personal Protective Equipment (PPE) for each task that is performed. Adequate PPE in this case indicates that there is enough for every employee and that it is in good condition. PPE must be worn at all times while on the job site.

3.5. The Embassy POSHO reserves the right to issue a “Stop Work” order at any point if there are safety violations or unsafe work practices.

4. SCHEDULE

4.1. The completion of this project must be 3 calendar days from the project start date.

4.2. Contractor will be responsible for providing all materials, labor, and equipment necessary to meet the requirements of this project.

5. MATERIALS

5.1. All material and equipment necessary to complete the project in accordance with this SOW are the responsibility of the Contractor.

5.2. All material and equipment must be approved in writing by the COR prior to being used on the project.

5.3. List of materials:

Hydroflo VTP: Three (3) each

ITE TAG # QT DESCRIPTION MANUFACT MODEL

M # Y URER #

A1

90 gpm @ 188 tdh (5.68 lps @ 5.61 bar) 1500 rpm; 7LH9 WL bowl assembly; std wall column assy. (SS shaft), 4” ductile iron discharge head with NSF coating, SS basket strainer, 7 ½ hp US VHS premium efficient TEFC motor, assembled and std. crating, NSF

6010 Approved Coatings.

EnviroSep

7LH9 WL

6. PROJECT EXECUTION

6.1 INSTALLATION:

6.1.1. RECEIVING, UNCRATING, AND INSPECTING

A. Using the packing list as a guide, make certain that all equipment arrived in the shipment and inspect for obvious damage incurred during shipment.

B. Immediately report any damage to carrier.

C. Uncrate and lay out all the equipment in the order of installation on clean boards or floor.

6.1.2. INSTALLATION EQUIPMENT AND TOOLS

The following is a checklist of tools and equipment needed for the installation. Assemble prior to starting the installation.

1. A portable or permanent derrick of sufficient strength to safely lift the total weight of the pump. A conservative weight for the pump will be listed on the freight bill. The minimum travel of the derrick should be at least 6’ greater than the longest piece of pump equipment. Hoist must have swivel hook.

2. One or two cable slings of sufficient strength to lift the entire pump and long enough to clear greatest shaft projection.

3. One erector sling for lifting the driver.

4. Dial indicator calibrated in .001” divisions with a stand.

5. SAE 10 viscosity, low cold pour point mineral oil if pump is to be oil lubricated.

6. Wire brush, paint brush, three-cornered file, flat file, and emery cloth.

7. Set of mechanic’s tools including an assortment of socket wrenches.

8. Bucket of solvent, coal oil or naphtha, etc.

9. Machinist’s level

10. Steel tape measure.

11. Two pipe wrenches of sufficient size to handle shaft and couplings. (Always required for hollow shaft drive).

12. One set of steel clamps to fit the pump bowl.

13. Two sets of steel clamps to fit the column pipe. NOTE: One set is required if only one section of column is furnished with the pump assembly.

14. Two 4 x 4 timbers or “H” beams (if the unit is extra-large and heavy). Long enough to span the installation opening.

15. Two “V” blocks for checking shaft straightness.

16. Two chain tongs of sufficient size to handle column pipe.

17. 17. 15’ of ¾” rope.

18. Thread compound and gasket compound with thinner.

19. Two pipe wrenches of sufficient size to handle oil tube if pump is to be oil lubricated.

20. Enough wedges to level discharge head or foundation plate (if applicable).

21. Enough top-quality non-shrink grout.

22. Teflon Paste compound for stainless threads, anti-seize compound for the other threads.

23. Bundle of cleaning rags.

24. Putty knife.

6.1.3. SPECIAL PRECAUTIONS

A. Make certain that no rags, wood scraps, etc., are lodged in any exposed openings. Check pit depth and anchor bolt Spacing with pump dimensions. Lift and handle unit carefully to prevent bending strain damage caused by the hanging weight of the unit. Do not lift any item by the shaft.

Take extra precautions when handling a mechanical seal or packing gland assembly since this is a delicate and precision component.

B. ALWAYS USE THREAD COMPOUND ON

SHAFT AND COLUMN JOINTS. Do not allow pipe compound, Solvent, or any petroleum products to get on the rubber bearings.

C. Shaft threads are usually left hand; column threads are right hand. If unit is shipped assembled and has threaded Column pipe; pipe joints may have loosened during shipment. Before installation check threaded connections for tightness. A chain tong pipe wrench should be used to verify tightness of pipe connections.

6.1.4. PREPARATION AND CLEANING

A. Clean all threads and flange faces with a wire brush or paint brush and solvent. If required, clean threads with a three-cornered file. The protective coating on the threads and flanges is a rust preventive and not a thread compound or gasket material.

B. Clean all shafts and couplings with a rag soaked in solvent.

Make certain that all bearings are clean.

C. If applicable, remove protective caps from ends of oil tubing and clean all tubing threads and shaft bearings thoroughly with solvent. Make certain tubing faces are free of nicks, dents, and burrs.

D. Remove gland assembly from discharge head. Remember to be very careful with this item.

E. Make a physical check of the discharge head or foundation plate for proper fit to foundation.

F. Check pipe and oil tube ends and couplings to be sure there are no dents, nicks, or burrs.

G. Check shaft end for nicks, burrs, etc. The shaft alignment is dependent on the point of the shaft ends.

H. Check all boxed shafting for straightness using “V” blocks and dial indicator as follows:

1. Start with “V” blocks as close to the threads as possible. Check two or more places between “V” blocks and straighten shaft to within .003” to .005” of the Total Indicated Run-Out. Straightening may be performed by mechanical or high pressure on the high point.

2. Move one “V” block about 20% of shaft length inward from the end. Check between the “V” blocks and the overhanging ends; straighten as in step 1 above.

3. If straightening was required in Step 2 repeat Step 1.

Repeat the above steps until shaft checks within tolerance in both positions. Wipe the shaft clean after checking.

I. Check run-out on bowl shaft extensions by placing dial indicator toward the end of the shaft and turning slowly making certain the shaft stays to one side of the upper most bowl bearing. Total Indicating Run-Out should not exceed .005”.

J. Check and record the total bowl lateral or end play. If prime mover is solid shaft, this information will be required for Flanged coupling assembly.

6.1.5. INSTALLATION INSTRUCTIONS

A. FOUNDATION PLATE (IF SUPPLIED)

1. Place foundation plate over anchor bolts and allow to rest on foundation.

Full contact with foundation is important for vibration free operation.

2. If the final elevation of the plate is critical, this should be checked at this time.

3. Attach hex nuts to anchor bolts and turn until snug against foundation plate to protect the anchor bolt threads.

4. The foundation plate serves as a good surface for

ILLUSTRATION 1.1

ILLUSTRATION 1 2

the foundation.

See Illustration 1.1

B. PUMP BOWL

1. Place the two beams on the foundation plate or foundation opening.

2. Secure the proper clamp to the upper end of the bowl beneath a convenient shoulder. If only one sling is used, Attach the sling to the clamps far enough out on the ears to allow for easy removal after setting the unit down on the beams.

3. Hoist the bowl to a vertical position using the derrick.

If the bowl is equipped with a strainer, do not drag the strainer across the floor.

4. If there is any auxiliary piping to the bowl bearing or the thermo-wells, make certain the bowl portion of the piping is attached to the bowl at this time.

5. Center the bowl over installation opening then carefully lower until the clamp ears are resting squarely on the beams. Remove the sling.

6. Clean the following items: shaft threads, discharge threads, flange face (if applicable), threads and face of oil tubing (if applicable). Lightly oil the shaft threads and screw the coupling on halfway. Place a rag over the coupling to prevent entrance of foreign matter during the next step in assembly.

C. COLUMN OPEN LINESHAFT

Refer to the installation plan or the overall dimension sheet of the submittal to determine correct sequence for installation of column lengths.

1. Secure pipe clamp immediately beneath column coupling. If column is flanged, insert bolts and secure clamp below bottom of flange.

Clamp should keep bolts in position. See Illustration 1.2.

2. Slide the line shaft into bottom of column pipe and allow it to extend approximately 15” below the bottom end of the pipe. Make certain the sleeve area of the line shaft (if applicable) is toward the top of the pipe. Tie a series of half hitches to the column pipe and line shaft with ¾” rope. (Tie the rope to a chain pipe vise on the line shaft, if needed.) Attach the sling to the clamp ears as described under Section B, Step3.

3. Hoist column and line shaft to a vertical position with the derrick. Do not drag shaft across the floor. Before centering column over bowl, tap the side of column to remove any loose matter.

4. Position the column and line shaft over the bowl. Align the line shaft and remove the rag from the bowl shaft coupling. Lightly oil the threads. Lower until the line shaft contacts coupling. Remove the rope. Hold coupling and turn the line shaft (left hand threads) until the shaft ends butt up. Place one pipe wrench on the coupling and one on the line shaft. Tighten securely.

ILLUSTRATION 1.3

Remove the wrench marks form the shaft and coupling with a flat file and emery cloth.

5. a. If bowl to column connection is threaded, apply thread compound to the pipe threads. Attach chain tongs to bowl and to column for support. Lower the column pipe, and at the same time, turn the pipe until it seats against the mating shoulder on the bowl. Tighten pipe into bowl securely.

b. If bowl to column connection is flanged, spread a thin, even film of gasket compound on the bowl discharge flange. Lower pipe and align studs in the bowl with the holes in the flange. Seat the column flange against bowl flange. Install and tighten hex nuts evenly.

6. Hoist assembly enough to remove the clamp on the bowl assembly.

7. If there is any auxiliary piping to bowl bearing or thermo-well being used, that portion that attaches to the column section should now be installed. Also, if the bowl and column are coated with any special coating, any required patch work should be done before lowering unit.

8. Slide beams in close to column. Lower the assembly and rest the clamp ears on the beams. Remove the sling.

9. a. If there is more than one section of threaded column, a centering spider may be used. Slip the spider over the line shaft with lock ring on top (if rubber bearings are used). Screw the centering spider into the column coupling until it butts against the column pipe. See Illustration 1.3, figure 1.

b. If column is flanged, clean flange and the O.D. of the spider. Slip the spider over the line shaft with lock ring on top (if rubber bearings are used) and seat into spider recess. See Illustration 1.3, figure 2.

10. Clean all line shaft threads and faces thoroughly. Screw the coupling on half of its length. Cover the coupling with a rag to prevent foreign matter from dropping into the entrance.

11. If there is more than one section of column, repeat

Section C, steps 1 through 10, for each additional section until all of the column is assembled. Clean the thread/flange face of the column pipe and the line shaft projection thoroughly. Do not attach the shaft coupling to the top piece of shaft.

D. COLUMN ENCLOSED LINESHAFT

1. Secure pipe clamp immediately beneath column coupling. If column is flanged, insert bolts and secure clamp below bottom of flange. Clamp should keep bolts in position.

2. Slide the correct tubing section with shaft into the column pipe. Allow the tubing to extend six inches below the bottom end of the pipe. Allow the shafting to extend about six inches beyond the bottom end of the oil tube assembly. With the ¾ inch rope, tie a series of half hitches to the pipe, to the tubing and then to the shaft. A chain pipe vise may be used on the shaft, if needed.

Attach the sling to the clamp. Leave room for removal of the sling while the clamps are resting on the beams in the following steps.

3. Hoist column to the vertical position with the rope and derrick. Do not drag the shaft across the floor.

Before Centering column over bowl, tap side of column to remove any loose matter.

4. Position the column and line shaft over the bowl. Align the line shaft and remove the rag from the bowl shaft coupling. Lightly oil the threads. Lower until the line shaft contacts coupling, then remove the rope. Hold coupling and turn the line shaft (left hand threads) until the shaft ends butt up. Place one pipe wrench on the coupling and one on the line shaft. Tighten securely.

Remove the wrench marks from the shaft and coupling with a flat file and emery cloth.

5. Lower assembly until tubing contacts the line shaft bearing, then remove the rope. Apply a small amount of thread Compound to the upper bearing threads. Make certain not to get any thread compound on the faces of the oil tubes. Place one pipe wrench on the stick-up tube of the bowl assembly and one wrench on the oil tube assembly in the column pipe. Align vertically and tighten.

If the oil tubing is coated with any special application, any touch- up required resulting from using the pipe wrench should be done now.

6. a. If the bowl to column connection is threaded, apply thread compound to the pipe threads. Attach chain tongs to bowl and to column for support. Lower the column pipe, and at the same time, turn the pipe until it seats against the mating shoulder on the bowl. Tighten pipe into bowl securely.

b. If bowl to column connection is flanged, spread a thin, even film of gasket compound on the bowl discharge flange. Lower pipe and align studs in the bowl with the holes in the flange. Seat the column flange against bowl flange. Install and tighten hex nuts evenly.

7. Hoist assembly enough to remove the clamp on the bowl assembly.

8. If there is any auxiliary piping to bowl bearing or thermo-well being used, that portion that attaches to the column section should now be installed. Also, if the bowl and column are coated with any special coating, any required patch work should be done before lowering unit.

9. Slide beams in close to the column. Lower the assembly and rest the clamp ears on the beams. Remove the sling.

10. After the column has been lowered and is resting on the setting beams, pour about half a cup of SAE 10 oil into the oil tubing. Apply joint compound to the leading threads of the line shaft bearing. Oil bore lightly, slide over the shaft and thread into the oil tubing for half of its length. It should not be necessary to exert any side pressure on the shaft to start the bearing. The need for such pressure indicates misalignment, a bent shaft, or a bent oil tube in this or the preceding sections and must be corrected before proceeding.

11. a. If the column is threaded and the setting is deep enough to require a rubber centering spider, slip the spider over the oil tubing and force into the column pipe about an inch or two below the top end. Spacing of the spiders is generally 20 feet from the bowl and from the head with 40 feet between each spider.

b. If the column is flanged, clean the registers in the flanges and insert the aligning ring. Slide the rubber centering spider over the oil tubing and into the column.

12. Clean all line shaft threads and faces thoroughly. Screw the coupling on half of its length. Cover the coupling with a rag to prevent foreign matter from entering.

13. If there is more than one section of column, repeat Section D, steps 1 through 12, for each additional section until all of the column is assembled. Note that the top end of the top piece of oil tubing, the stretch tube, is chamfered and filed smooth on the O.D. and has extra-long threads for the tension assembly.

E. PUMP HEAD

1. Wipe a thin layer of joint compound on the top column threads, or, if connection is flanged, on the top flange face. Remove the packing gland assembly from the discharge head or motor stand. Clean all machined faces of the discharge head/motor stand thoroughly. Attach a sling to the discharge head/motor stand, hoist and center over the column. Lower the discharge head/motor stand being careful not to damage the top section of shafting known as the head shaft, or, the stretch tube (if applicable).

2. a. Align the holes of the discharge head/motor stand with the holes of the column pipe flange, then lower until head is resting squarely on flange. Install bolts and tighten.

b. Set the discharge head on the top section of threaded column pipe. Screw the discharge head onto the column Pipe.

3. If there is an underground outlet, place the head as close as possible to the final position in relation to the outlet.

4. a. If an adjustable top flange or threaded head is used, the head can be readily turned to place it in alignment to the underground outlet. In addition, the head should be turned as needed to attain the proper shaft projection and the correct distance from the outlet center line to the bottom of the head. Back the packing ring off to allow ample working room, fill the chamfer on the lower end of the flange with lamp wick packing that has been precoated with joint compound. Use a generous amount of the packing and wind the packing around in such a manner that it is screwed into place. Screw the packing ring against the flange or bottom of the head and tighten.

b. If the adjustable flange is being used in conjunction with oil tubing, the top of the tubing should be approximately 1-1/4 inches below the tension box mounting face of the head after the flange is adjusted.

5. Hoist head slightly. Remove the clamp from the top piece of column. Remove setting beams and clean surface of the foundation itself. If there is an auxiliary line to the bowl bearing or thermo-well, that portion immediately below and attaching to the head should now be installed.

Properly place discharge outlet and align mounting holes with anchor bolts and lower until head is resting squarely on the foundation.

6. a. If head is resting on foundation plate, align mounting holes of the head with tapped holes in the foundation plate. Install and tighten cap screws.

b. Mix a sufficient quantity of rather dry non-shrink grout. Force as much grout under the foundation plate as possible. If grout holes are provided, grout can be pressure-fed through the grout holes until all cavities are filled.

c. As the head is resting on the foundation, drive wedges under head until proper elevation is achieved and continue working with wedges until head is within .005 inches of the Total Indicated Run-out with respect to top or head shaft. Install and tighten hex nuts to anchor bolts. Grout under the outer perimeter of the head and cover the wedges with the grout.

d. If a motor stand is used, as in an underground discharge application, it should first be determined that the outlet in the column aligns with the discharge piping so that no strain will be placed on the pump.

Do not make this correction at this time, however.

After checking the pipe alignment follow Step 4a for leveling and grouting.

e. Step 6d should be followed if there is a suction connection to the header. It is recommended that a flexible joint of some description be used between the suction flange and header to compensate for any slight misalignment. If no flexible joint is used, the header flange must be perfectly aligned so that no misalignment is transferred to the pump.

F. PACKING GLAND OR MECHANICAL SEAL

1. Packing Gland Open Line Shaft

a. Remove the packing gland, packing rings and lantern ring from the gland assembly. Clean the packing box thoroughly and apply a neoprene O-ring to the receiving hole in the discharge head.

b. Slide the packing box over the head shaft. Properly adjust mounting holes so that the grease ports of the Packing gland are directed toward the access windows of the discharge head or motor stand. Seat the packing gland against the discharge head/motor stand then install and tighten cap screws. It should not be necessary to exert any side pressure on the shaft in order to seat the packing box properly.

c. Reseat packing. See Section 7.4 for details.

d. Slip rubber slinger over shaft and position just above the packing gland.

2. Mechanical Seal Open Line Shaft

a. Inspect the seal assembly to be sure O-rings are included on the seal housing cover and the shaft sleeve. On the lock ring, be sure the lower set screws are tight and upper set screws are loose. See Illustration 1.4.

b. Prior to installing the shaft sleeve O-ring

ILLUSTRATION 1.4

lubricate with light grease, then slide complete assembly overhead shaft. Seat and bolt down the assembly against the seal housing, taking care to be sure that the O-ring of the seal housing cover is in its groove.

c. To set seal, first set impeller lateral, then tighten top set of set screws of the lock ring.

Remove paper spacers and keep for future use.

3. Oil Lube Enclosed Line Shaft

a. If a motor stand is employed, go to Section F, step 3b. Screw the oil tube lock nut onto the extension tube.

b. Place the gasket around the tube tension nut seat of the discharge head/motor stand. Screw the tube tension nut onto the extension tube until it seats against the gasket.

Tighten the tube tension nut one-quarter turn for close coupled applications. Tighten the tube tension nut enough to take up 3/16” per every hundred feet in deep well application.

c. If a motor stand is employed, go to Section F, step3d.

Insert a short piece of shafting or a board through the discharge opening of the discharge head. Place it against the tube lock nut and tighten the lock nut against the tube tension nut.

d. Seat two rings of packing into the tube tension nut and around the extension tube. Screw on the packing follower and tighten securely against the packing rings. Position the dust cover on the tube tension nut and align the holes of the dust cover with the tapped holes in the discharge head/motor stand. Install and tighten cap screws.

4. Water Flushed Enclosed Line Shaft

a. If a motor stand is employed, go to Section F, Step 3b. Screw the oil tube lock nut onto the extension tube.

b. Place the gasket around the tube tension nut seat of the discharge head/motor stand. Screw the tube tension nut onto the extension tube until it seats against the gasket. Tighten the tube tension nut one-quarter turn for close coupled applications. Tighten the tube tension nut enough to take up 3/16” per every hundred feet in a deep well application.

c. If a motor stand is employed, go to Section F, step 3d. Insert a short piece of shafting or a board through the discharge opening of the discharge head. Place it against the tube lock nut and tighten the lock nut against the tube tension nut.

d. Seat two rings of packing into the tube tension nut and around the extension tube. Screw on the packing follower and tighten securely against the packing rings.

e. Position the water flushed packing box on the tube tension nut and align the holes with the tapped holes on the discharge head/motor stand. Install and tighten cap screws.

f. Reseat packing. See Section 7.4 for details. There will be three rings of packing and no lantern ring.

g. Slip rubber slinger over shaft and position just above the packing gland.

G. VERTICAL MOTORS

1. Hollow Shaft Motor

a. Clean threads and face of head shaft projecting above packing gland thoroughly, then oil threads lightly. Thread coupling on shaft for half of its length. Stuff a rag into open end of the shaft coupling.

b. Remove the top cover from the motor. Unbolt the coupling (clutch or drive block) from the motor and remove the coupling.

c. Run a fine flat file over the motor mounting surface of the head to remove any nicks or burrs.

Thoroughly clean face and register with solvent.

Wipe a thin layer of light oil over the surface. This will help prevent rust and will also facilitate slight driver shifting during coupling alignment.

d. Attach the erector sling to the motor lifting lugs.

Hoist motor sufficiently to allow easy access to mounting Flange. Remove nicks and burrs on the mounting flange with a fine flat file and thoroughly clean with solvent.

e. If there is sufficient head room to install the motor shaft after placing the motor on the head, prepare the shaft as described in Step g below, then lower the motor shaft through the motor with the keyway end up. Install the head nut and thread it on 4 or 5 threads, then allow the shaft to suspend inside the motor.

f. Hoist motor sufficiently to clear the stand and swing it over until motor is resting on mounting ring. Properly place conduit box, align mounting holes and install, but do not tighten cap screws.

g. Clean the head shaft thoroughly and dress the threads and keyway with a 3-cornered file, if necessary. Lift the motor shaft and carefully lower it through the quill or hollow shaft (end with keyway goes toward the top) and allow shaft to contact head coupling. Remove the rag in the coupling. Screw the motor shaft into the motor coupling on the head shaft and tighten.

h. Make temporary electrical connection to motor, bump starter to determine correct rotation (counterclockwise as viewed from above). Install and tighten cap screws to the motor and discharge head/motor stand. If power is not available, DO NOT make final drive shaft connections (Steps I, j, & k) until power is available and correct rotation is determined.

i. Place the gib key on the drive plate over the hollow shaft against the drive shaft. Turn the rotor observing the clearance between key and shaft, shift driver until the key touches all around.

Tighten the cap screws.

j. Slide clutch over drive shaft, seat against drive plate, install and tighten bolts.

k. IMPELLER ADJUSTMENTS: Turn clutch until keyways in shaft and clutch align; install and seat gib key. Thread head nut onto shaft until it seats against top of the clutch. Hold to keep the clutch from turning and turn head nut until impellers clear the bottom by the amount shown in chart on page 16 for the bowl being used, allowing the rotor to turn freely. Continue to tighten head nut until impellers are elevated a sufficient distance to accommodate pump hydraulic thrust and associated shaft stretch (see 6. ENGINEERING section of this manual for details). Align holes in head nut with taps in clutch, install and tighten machine screws.

Place top cover on driver and secure.

2. Solid Shaft Motor

a. Clean the threads and face of head shaft, then oil threads lightly. Thread coupling on the shaft for half of its length. Stuff a rag into open end of the shaft coupling.

b. Slide the pump hub of the adjustable motor coupling onto the head shaft and insert the key.

Screw the adjuster nut onto the head shaft.

c. Attach the erector sling to the motor lifting lugs.

Hoist motor sufficiently to allow easy access to mounting Flange. Remove nicks and burrs on the mounting flange with a fine flat file and thoroughly clean with solvent.

d. While the motor is suspended from the erector sling, slide the motor hub of the adjustable motor coupling onto the motor shaft. Insert the key into the keyway of the motor hub far enough up the motor shaft to expose the keeper key seat on the motor shaft. Seat the keeper key onto the motor shaft. Pull the motor hub down over the keeper key.

e. Bolt the spacer to the motor hub, if applicable.

f. Hoist motor sufficiently to clear the stand and lower it until the motor is resting on the discharge head. Properly place the conduit box, align mounting holes and install cap screws.

g. IMPELLER ADJUSTMENT: Adjust the adjuster nut until the clearance between the spacer/adjuster nut and the motor hub is equal to the impeller adjustment as stated in the Hydraulic Thrust Technical Data Chart in Section 6.

ENGINEERING. Add additional clearance to the above adjustments to accommodate pump hydraulic thrust and the associated shaft stretch (see the Shaft Elongation Chart in Section 6. ENGINEERING of this manual for details).

h. Make temporary electrical connections to motor, bump starter to determine correct rotation (counterclockwise when viewed from above). If power is not available, DO NOT make final drive shaft connections (Step i) until power is available and correct rotation is determined.

i. Align holes and taps of the motor hub, pump hub, adjuster nut, and spacer (if applicable). Install and tighten cap screws.

H. MISCELLANEOUS ASSEMBLIES

1. LUBRICATOR

Install the oil pot on the discharge head. Install the necessary pipe fittings from the oil pot to the oil dripper (sight glass down) to the inlet on the tube tension nut. If there is a solenoid oiler, install it between oil pot and oil dripper.

2. DISCHARGE PIPING

a. Above and below floor piping should be installed in such a manner as to eliminate the possibility of the discharge head being strained. Gate valves, check valves, and other piping items must not depend upon the pump head for support.

b. If a flexible joint, such as a dresser coupling, is to be used, the tie bolts and lugs used to span the flexible joint should be of sufficient strength to resist the force created by the discharge pressure at the pump head. None of this force should be imposed on the head or the foundation bolts. The tension should be taken carefully on these tie bolts so that any amount of forward movement induced to the head will be counteracted during operation so that alignment is maintained throughout the operation.

3. AIR RELEASE VALVE

Install the air release valve on the pump head or just beyond on the discharge piping. It is suggested that if a throttling valve is not furnished, a throttling device be used to restrict the discharge of air to ensure that a cushion of air is available in the discharge head. Placement of the throttling device should be such that the air release valve is between the discharge head and throttling valve. Note: Exhausting the air from a head too quickly often causes breakage.

4. GAUGES AND MISCELLANEOUS PIPE CONNECTIONS

a. Connect the pressure gauge to the tap in the discharge and, if required, in the suction flange. Position dial face to facilitate reading.

b. Make drainpipe connections. Route piping so that it will not interfere with normal maintenance procedures.

c. If packing gland bypass line is to be installed use the following chart to determine correct port for connection. The ports on the housing are marked “U” and “L” as referred to in chart.

Pressure “L”

Port “U” Port

0-

100PSI

Grease Grease

100-

300PSI

Grease Bypass

300-

450PSI

Bypass Grease

5. ELECTRICAL CONNECTIONS

a. All connections to the motor such as main leads, space heater leads, winding protection leads, etc., should be made in accordance with prevailing specifications.

b. Motor wiring can be identified by the following designations: H – Space Heaters

P – Thermostats T – main leads (Connect per nameplate and voltage required) on motor.

6.2 STORAGE

6.2.1. CONSIDERATIONS

When a pump is made for use in a sump or a can, it is usually a short coupled or close coupled pump assembly. A short or close coupled pump is simply a short pump assembly. Short coupled pump assemblies are usually shipped assembled but with the driver separate. Storage for such a pump is an easy matter with little common sense. See Section 2-3 below.

Pumps used for well applications on the other hand, tend to be deep setting pumps. These are shipped unassembled. The unassembled pieces are generally the driver, the discharge or motor stand, column pipe, tube and shaft assemblies, and the bowl assembly. Again, common sense is the best tool for determining storage techniques. The following is a general listing.

6.2.2. SHORT COUPLED PUMPS

A. Cover suction and discharge ports to prevent entrance of any foreign materials.

B. Cover all other miscellaneous holes, i.e. pressure relief, prelube and pressure gauge holes, etc.

C. Avoid exposure to weather and elements: either store indoors or cover with a tarp.

D. Use a support framework so that no side pressure is exerted on the pump when placed in storage.

6.2.3. MISCELLANEOUS ITEMS

The best storage for most parts will cover any openings and keep items from exposure to adverse conditions. Provide level support for all tubes and shafts so the parts will not fall or be knocked over. Protect any threads from damage.

6.3 BOWL DIASSEMBLY & ASSEMBLY

6.3.1 BOWL DISASSEMBLY

1. Remove the bowl assembly from the column assembly.

2. Remove the bell suction from the bowl assembly.

3. Remove the grease plug from the suction bowl.

4. Remove the cap screws connecting the discharge bowl to the top bowl and slide the discharge bowl off of the pump shaft. DO NOT let the weight of the bowls rest on the bowl shaft while removing.

5. Remove the cap screws connecting the top bowl to the suction bowl if single staged or the intermediate bowl if multiple staged. Slide the top bowl from the bowl shaft.

ILLUSTRATION 3.1

6. Slide the female end of a collet knocker (see illustration 3.2) toward the impeller collet. Slide the collet back and forth on the bowl shaft, knocking the impeller with enough force to jar the impeller loose from the collet.

Remove the collet knocker.

7. Use a screwdriv er to spread the collet.

Remove the collet and the impeller from the bowl shaft.

ILLUSTRATION 3.2

8. Rep eat Step s 6 thro ugh until all imp eller s are rem ove d.

9. Pull the bowl shaft from the suction bowl.

10. L o o s e n t h e s et s c r e w o n t h e s a n d c o ll a r a n d sl i d e o ff o f t h e b o w l s h a ft

6.3.2. BOWL ASSEMBLY

Before assembly, check the clearances of the bowl bearings and the impeller skirts. Check the bowl shaft for excessive wear.

1. Slide the bowl shaft into the suction bowl. Align the end of the shaft with the bottom of the bowl bearing.

2. Slide the sand collar on the bowl shaft and seat it over the bowl bearing.

Temporarily tighten the setscrew.

3. The shaft stick-up must be set at this time. Slide the discharge bowl over the bowl shaft leaving enough space for the top bowl and the intermediate bowl(s) where applicable. Slide the bowl shaft in or out to allow for the proper stick-up. See Illustration 3.3. The stick-up is the distance from the top end of the bowl shaft to where the column pipe butts up to the bowl assembly. Attach a retainer plate as shown in Illustration 3.1. Tighten the sand collar setscrew.

4. Insert the retaining bolt through the suction bowl and tighten the locknut (finger tight).

5. Slide the discharge bowl off of the bowl shaft. Be careful not to damage the bowl shaft threads.

6. Slide the impeller and the collet on the pump shaft and follow with the collet knocker (male side toward the impeller). Hold the impeller all the way to the bottom of the bowl with one hand and slide the collet into the impeller with the collet knocker. Drive the collet with the knocker until collet adequately holds impeller on shaft. Remove the collet knocker. See illustration 3.4.

7. Slide the intermediate bowl housing onto the pump shaft. Use caution to avoid putting the bowl weight on the bowl shaft. Bolt the intermediate bowl to the suction bowl with caps crews.

8. Continue Steps 6 to 7 until the assembly is complete.

9. Remove retainer bolt from the bowl shaft. Check the bowl shaft for rotation and lateral movement. Lateral should be as stated on page 16.

10. Fill the bearing cavity in the suction bowl with a non-soluble grease and insert the pipe plug in the bottom of the suction bowl.

BOWL BEARING

DIAMETER

CLEARANCE

Shaft Diameter

Clearanc e

1.000 .007- .010

1.187 .0075- .0105

1.500 .009- .012

1.687 .0095- .013

1.937 .0105- .014

2.187 .0115- .015

2.687 .0125- .0165

ILLUSTRATION 3.3

6.4 OPERATION

6.4.1. PRIOR TO START-UP

1. WARNING: If unit is equipped with VFD (variable frequency drive) consult the factory for minimum and Critical pump speeds before start-up.

2. Perform initial servicing on the driver as recommended by the driver manufacturer. Also perform initial servicing on all auxiliary assemblies if required.

3. Recheck all fasteners and fittings for tightness.

4. If the air release is manual or if air vent is automatic but equipped with a valve, make certain the valve is opened partially but not all of the way.

5. If there is a control valve on the discharge side of the pump, make certain it is partially open so that the pump will not be damaged if normal back pressure is not available until the long line, etc. is filled.

6. If unit is oil lubricated, fill lubricator with a good grade SAE 10 viscosity rating, low cold pour point mineral oil.

Manually open needle valve and allow about a cup of oil to drain into tubing. Refill lubricator.

7. If pump is equipped with grease line to suction bowl bearing DO NOT add grease on initial start-up.

See preventative chart on page 20 for schedule.

8. If unit is open lineshaft and equipped with pre-lubrication, turn on the pre-lubrication system and allow it to flow for 2 to 3 minutes.

9. If unit is force water lubricated, turn on and regulate flow from 10 to 15 PSI above normal discharge pressure. Lubrication should continue during entire pump operation time. If the tail bearing is also lubricated by outside water, pressure need only be 5 to

10 PSI.

10. Bump starter to ensure that the unit has correct rotation.

6.4.2. INITIAL START-UP

1. Energize starter. After pump has come up to the rated

ILLUSTRATION 3.4

speed and all air has been exhausted, regulate control valve to achieve desired pressure.

2. If the air release is manual, close it off after air is exhausted. If air release is automatic, determine if the air was Exhausted too quickly (which causes the pump to jerk violently when the valve is closed) or too slowly and regulate manual valve or throttling device to correct this.

3. If oil lubricated, regulate lubricator as shown in the following table.

SHAFT

SIZE

PER 100 FEET OF COLUMN TOTAL

COLUMN

LENGTH

FIRST 2

WEEKS

AFTER 2

WEEKS

¾ TO 2-3/16 5 TO 6

DROPS

3 DROPS ALL

ABOVE 2-

3/16

10 TO 12

DROPS

6 DROPS 20 FEET

4. Check all joints for leakage and correct if evident.

5. Make certain the driver is operating satisfactorily as to temperature, bearing temperature, etc., as prescribed by the driver manufacturer.

6. Check for excessive vibration. If this is evident, shut down unit immediately and begin checking for the cause.

7. Adjust the packing gland (see Section 7-4.8 and 7-4.9) to allow some leakage past the packing.

Booster Pump Sequence of Operation

1. The lead pump is controlled by the HAND-OFF-AUTO switch on the panel.

2. In HAND position the pump will run at full speed until it is switched to OFF or AUTO position.

3. In OFF position the pump will be disabled.

4. In the AUTO position the pump will start automatically as system pressure drops below the lead setpoint and cutoff when system flow drops below the low flow alarm point.

5. The lag pump is controlled by the HAND-OFF-AUTO switch on the panel.

6. In HAND position the pump will run at full speed until it is switched to OFF or AUTO position.

7. In OFF position the pump will be disabled.

8. In the AUTO position the pump will start up automatically as the load increases on the lead pump past the current setpoint.

9. The lag lag pump is controlled by the HAND-OFF-AUTO switch on the panel.

10. In HAND position the pump will run at full speed until it is switched to

OFF or AUTO position.

11. In OFF position the pump will be disabled.

12. In the AUTO position the pump will start up automatically as the load increases on the lag pump past the current setpoint.

13. Designation of lag pump and lag lag pump is determined by the selector switch on front of the panel. If pump 2 is selected as lag pump, then pump 3 will be lag lag. If pump 3 is selected as lag pump the pump 2 will be lag lag.

14. An external low-level switch will disable all pumps.

15. Outputs to the BAS is to include Pump Status and Pump Fault

6.4.3. ROUTINE/NORMAL

1. Start the pump in accordance with the starting equipment used.

2. Driver lubricants should be checked following the instructions in the

Motor O & M manual attached.

3. The packing gland should be checked for proper leakage.

6.4.4. SHUTDOWN/EMERGENCY

1. Shutdown in accordance with the starting equipment used. Refer to Section 8 Trouble Shooting for further instructions.

6.5 FIELD TEST

When a field test of the pump’s performance is required, make the following readings: Volume, Total Head and Horsepower Measurements, Rotating Speed, and liquid Temperature. Compare the results of the field test with performance curve for your pump.

All volume, total head and efficiency guarantees are based on a shop test when handling clear, cold, fresh water at a temperature not exceeding 85 Degrees F. and under certain specified suction conditions.

(1) Volume (Capacity) Measurement- Measure the rate of flow from the pump discharge in gallons per minute.

The volume measurement may be made using any one of the following pieces of equipment: A calibrated Venturi meter, a thin-plate calibrated orifice, a calibrated pilot tube, or an accurately measured reservoir.

(2) Total Head Measurement- The total pumping head consists of: distance from the water level in the sump (when pumping) to the center of the discharge pressure gauge, plus the discharge gauge reading, the friction loss through the column and head, and the velocity head at the discharge.

NOTE: Convert pressure gauge reading to feet of liquid by multiplying the reading times 2.31 times the Specific Gravity of Liquid.

(3) Horsepower Measurement- Measure horsepower consumption of the pump by a direct reading of a wattmeter and applying the reading to the following formula.

Horsepower Formula:

Bhp = (KW Input x Eff) * 0.746 Where:

B h p = brake h or se p o w er de li ve re d K W In p ut re al in p ut p o w er

K W

Eff = motor efficiency

Eff = pump efficiency

Sg = specific gravity of liquid

The motor efficiency can be determined from dynamometer tests.

Pump Efficiency Formula:

Pump Eff.

= (TDH x GPM x Sg)/(3960 x

BHP)

Where: TDH = total dynamic head

GPM = gallons per minute

6.5.1. DOWNTHRUST

Downthrust is the total thrust load expressed in pounds carried by the thrust bearings in the motor, gear drive or pump head. It is the sum of the weight of the rotating elements and the hydraulic downthrust of the bowl unit.

The shaft length is the sum of the setting (column length), the length of the discharge head and the driver (from dimension sheet) and the length of the bowl assembly (from the pump curve).

Example:

Given a 6 stage 10RC bowl assembly, 75 HP. 1770 RPM motor, HF6 discharge head, 200’ setting, 1-1/2” shaft, 6” column, and 312’ total dynamic head.

For K factors, lateral, and shaft weights, see page 16.

For impeller weight, see performance curve for the unit.

(1) 200’ (setting) + 6.5’ (bowl shaft) + 5’ (head shaft) = 211.5’ feet of shafting

(2) 211.5 x 6.01 lbs. (shaft weight per foot) = 1271 lbs. of shaft

(3) 312’ TDH x 4.7 (K factor) = 1466 lbs. hydraulic thrust

(4) 6 (number of impellers) x 11 lbs.

(weight of one impeller) = 66 lbs. Add (2), (3), and

(4) and get 2803 lbs. of total thrust load

The motor data sheet shows a 75 HP motor at 1800 RPM to have a normal thrust capability of 4800 lbs., so no additional thrust load capacity is required. Note: Coupling weight may be added for deep setting pumps.

6.5.2. SHAFT STRETCH

The hydraulic thrust when the pump is operating imposes an axial tensile load on the shaft, which causes the shaft and column pipe to stretch. It is necessary, therefore, to determine the magnitude of the net elongation and whether or not the elongation exceeds the clearance provided in the pump bowls. If there is insufficient clearance, the impeller skirts will rub on the bowl seal rings, resulting in excessive wear and power consumption.

From the example above, we have 1466 lbs. of hydraulic thrust.

From the shaft elongation chart (page 17), it is found by interpolation that the elongation for 1-1/2” shaft at 1466 lbs.

hydraulic thrust is .034” per 100’ of shaft-

Elongation for 200’ of shaft = (200/100) x .034” = .068” Column elongation is found by the same method using the column elongation chart (page 17) – Elongation for 200’ of column = (200/100) x .006” = .012”

Shaft elongation minus column elongation equals net elongation – .068” - .012” = .056”

END OF STATEMENT OF WORK