Attach 2_TECH_MANUAL_S6226-RT-MMC-010.pdf

TECHNICAL MANUAL

FOR

PUMP, POTABLE WATER RECIRCULATION

2 X 1-1/2 X 10H, PART NO. 999-1110-B-01

INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR

INSTRUCTIONS

SUPERSEDURE NOTICE: THIS MANUAL SUPERSEDES S6226-RT-MMC-010

DATED 01 JUNE 2001, AND ALL CHANGES THERETO.

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE OR OPERATIONAL USE; 01 JUNE 2001. OTHER REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NSWC, PHILADELPHIA CODE 944.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE

ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2751, ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979 (TITLE 50, U.S.C., APP 2401 ET SEQ.), AS AMENDED. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVI-

SIONS OF DOD DIRECTIVE 5230.25.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS

OR RECONSTRUCTION OF THIS DOCUMENT.

S6226-RT-MMC-010

REVISION 1

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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

*0910LP1129387* 30 OCT 2013

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RECORD OF REVISIONS

REV NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY

0 01 JUN 2001 ORIGINAL PUBLICATION

1 30 OCT 2013 TECHNICAL MANUAL WAS DIGITIZED; NO TECHNICAL

CHANGES WERE MADE.

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READER SHOULD BE SINGLE PAGE. CONTINUOUS PAGE DISPLAY CAN CAUSE PROBLEMS WITH

LINK REFERENCES AND THE BOOKMARKS.

S6226-RT-MMC-010

RECORD OF REVISIONS-1 / (RECORD OF REVISIONS-2 Blank)

RECORD OF REVISIONS-2

FOREWORD

This technical manual describes the installation, operation, maintenance, repair, and parts list information for the Potable Water Recirculation Pump, 2 X 1-1/2 X 10H, Part No. 999-1110-B-01. This manual is intended for guidance of and use by personnel operating and maintaining the equipment described herein.

This manual consists of eight chapters arranged as follows:

Chapter 1 - Introduction and Preparation for Use and Installation

Chapter 2 - Operation

Chapter 3 - Preventative Maintenance

Chapter 4 - Troubleshooting

Chapter 5 - Corrective Maintenance

Chapter 6 - Repair

Chapter 7 - Parts List

Chapter 8 - Factory Service

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER

CODE 310 TMDERs

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY BLDG 1389

PORT HUENEME, CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting there-from. One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency submittals via the Naval Systems Data Support Activity Web site located at:

https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm

FOREWORD-1 / (FOREWORD-2 Blank)

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

1 INTRODUCTION AND PREPARATION FOR USE AND INSTALLATION . . 1-1

1-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 CAPABILITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3 PERFORMANCE CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4 EQUIPMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-4.1 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-4.2 Casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-4.3 Impeller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-4.4 Suction Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-4.5 Shaft Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-4.6 Motor Adaptor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-4.7 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-5 POWER AND UTILITY DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-6 ENVIRONMENTAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-7 EQUIPMENT, ACCESSORIES, AND DOCUMENTS SUPPLIED. . . . . . . . . . . 1-4

1-8 ADDITIONAL EQUIPMENT, ACCESSORIES, AND DOCUMENTS NOT

SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-9 TOOLS, MATERIALS, AND TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . 1-5 1-9.1 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-10 STORAGE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-11 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-12 PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1-12.1 Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1-12.2 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-13 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1-13.1 Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1-13.2 Site Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1-13.3 Piping Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1-13.4 Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 1-13.5 Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-14 INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-14.1 Phase 1 - Installation, Inspection, and Pre-Energizing Procedures. . . . . . . 1-10 i

TABLE OF CONTENTS - Continued

1-14.2 Phase 2 - Initial Turn-On and Preliminary Test. . . . . . . . . . . . . . . . . 1-10 1-14.3 Phase 3 - Installation Verification Test. . . . . . . . . . . . . . . . . . . . . . 1-10 1-14.4 Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 THEORY OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.1 Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.2 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2.3 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-3 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-4 OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-5 OPERATOR’S MAINTENANCE INSTRUCTIONS AND SCHEDULES. . . . . . . 2-1

3 PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 GENERAL OPERATING CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1.1 Daily Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1.2 Weekly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1.3 Monthly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1.4 Quarterly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1.5 Semiannual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 TROUBLE ISOLATION AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-2.1 Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-2.2 Electrical Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-2.3 Motor Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-3 TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 ADJUSTMENTS AND ALIGNMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1.1 Performance Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1.2 Hydrostatic Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ii

TABLE OF CONTENTS - Continued

6-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 PUMP REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2.1 Pump Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2.2 Parts Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-2.3 Pump Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6-2.4 Suction Cover Wear Wing Replacement. . . . . . . . . . . . . . . . . . . . . 6-4

6-3 MOTOR REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-3.1 Motor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-3.2 Motor Parts Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-3.3 Motor Ball Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6-3.4 Motor Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 PUMP PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3 MOTOR PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-4 LIST OF MANUFACTURERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

8 FACTORY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2 PARTS ORDERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 iii

LIST OF TABLES

Table Title Page

1-1 Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-2 Equipment Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3 Tools, Materials, and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-4 Installation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

2-1 Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 Normal Operation Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-3 Normal Operation Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-4 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-5 Differential Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-6 Surface Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-7 Leakage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-8 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-9 Motor and Bearing Temperature Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-5

4-1 Pumping Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5-1 Pumping Unit Maintenance and Repair Standards . . . . . . . . . . . . . . . . . . . . 5-2

6-1 Pump Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-2 Pump Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-3 Motor Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-4 Motor Clearances and Assembly Information . . . . . . . . . . . . . . . . . . . . . . 6-11

6-5 Motor Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

7-1 Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3 List of Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 iv

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Pumping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-4 Dimensional Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

2-1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

5-1 Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6-1 Proper Pinning of Pressed-In Composite Casing Ring . . . . . . . . . . . . . . . . . 6-6

8-1 Sectional Assembly and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8-2 Motor, Alternating Current (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-3 Pot Water Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 v

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the general or spe-cific safety precautions, the commanding officer or other authority will issue orders as deemed necessary to cover the situation. No work shall be undertaken on energized equipment or circuits until approval of the commanding officer is obtained, and then only in accordance with Naval Ships’ Technical Manual (NSTM) S9086-KC-STM- 010/Chapter 300.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances shall repair or adjustment of energized equipment be attempted alone. The imme-diate presence of someone capable of rendering first aid is required. Before making adjustments, be sure to pro-tect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to attempting repairs. Equipment should be deenergized and properly tagged out according to the ship’s Standard Operating Procedures.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a metal-cased test meter must be held, ground the case of the meter before starting measurement. Do not touch live equipment or personnel working on live equipment while holding a test meter. Do not ground any measuring devices; these devices should not be held when taking measurements.

INTERLOCKS

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended. They should not be battle shorted or otherwise modified except by authorized maintenance personnel.

Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at the power distri-bution source.

MOVING EQUIPMENT

Personnel shall remain clear of moving equipment. If equipment requires adjustment while in motion, a safety watch shall be posted. The safety watch shall be qualified to administer CPR, have a full view of the operations being performed, and have immediate access to controls capable of stopping equipment motion.

FIRST AID

An injury, no matter how slight, shall never go unattended. Always obtain first aid or medical attention immediately, and file an injury report in accordance with OPNAVINST 5102.1 series, subj: Mishap Investigation and Reporting.

vi

SAFETY SUMMARY - Continued

RESUSCITATION

Personnel working with or near high voltage shall be familiar with approved methods of resuscitation.

Should someone be injured and stop breathing, begin resuscitation immediately. A delay could cost the victim’s life. Resuscitation procedures shall be posted in all electrically hazardous areas.

GENERAL PRECAUTIONS

The following general precautions are to be observed at all times:

a. Install and ground all electrical components associated with this system/equipment in accordance with applicable Navy regulations and approved shipboard practices.

b. Ensure that all maintenance operations comply with Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 series.

c. Observe precautions set forth in NSTM S9086-KC-STM-010/Chapter 300 with respect to electrical equipment and circuits.

d. Ensure that protective guards and shutdown devices are properly installed and maintained around rotating parts of machinery and high voltage sources.

e. Do not wear loose clothing while working around rotating parts of machinery.

f. Ensure that special precautionary measures are employed to prevent applying power to the system/ equipment any time maintenance work is in progress.

g. Do not make any unauthorized alterations to equipment or components.

h. Before working on electrical system/equipment, use the correct tag-out procedure and check with voltmeter to ensure that system is not energized.

i. Consider all circuits not known to be ″dead,″ ″live″ and dangerous at all times.

j. When working near electricity, do not use metal rules, flashlights, metallic pencils, or any other objects having exposed conducting material.

k. Deenergize all equipment before connecting or disconnecting meters or test leads.

l. When connecting a meter to terminals for measurement, use range higher than expected voltage.

m. Before operating equipment or performing any tests or measurements, ensure area is dry of water or other liquid conductive material and that frames of all motors and starter panels are securely grounded.

n. Ensure that area is well-ventilated when using cleaning compound or solvent. Avoid prolonged breathing of fumes and compound or solvent contact with skin or eyes.

vii

SAFETY SUMMARY - Continued

WARNINGS AND CAUTIONS

Specific warnings and cautions applying to the system/equipment covered by this manual are summarized below. These warnings and cautions appear elsewhere in the manual following paragraph headings and immedi-ately preceding the text to which they apply. They are repeated here for emphasis.

When handling the pumping unit, do not exceed the rated capacity of the hoist-ing equipment. Hoisting equipment should be capable of lifting 2375 pounds.

Use of inadequate hoisting equipment may result in serious injury or death to personnel and/or damage to the pumping unit. (Page 1-7)

Be sure to adequately support suction and discharge piping prior to disconnect-ing the pump assemblies. Failure to adequately support piping could result in serious injury or death to personnel and/or damage to equipment or parts. (Page 1-9, page 6-1)

Before activating the pumping unit, make sure no one is working on the unit.

Serious injury or death to personnel could result if power is turned on while unit is being worked on. (Page 2-3)

In case of fire, turn off motor immediately. A carbon dioxide extinguisher should be used. If it is possible to approach motor, it should be covered with canvas.

Smothering steam should be turned on if available. Inadequate fire control could result in serious injury to personnel or damage to equipment. (Page 2-4)

To prevent injury or death to personnel, do not wear loose clothing when work-ing with rotating equipment. (Page 2-4, page 2-5) viii

To prevent injury or death to personnel, do not service electrical equipment alone. The immediate presence of someone capable of rendering aid is required.

All circuits not known to be dead must be considered live at all times. (Page 4-1)

Do not use test equipment known to be in poor condition. Serious injury or death to personnel could result if testing equipment is operated while in poor condition.

(Page 4-1)

Precautions set forth in NSTM S9086-KC-STM-000/Chapter 300, NSTM S9086- KN-STM-010/Chapter 310, and NSTM S9086-KY-STM-000/Chapter 320 shall be observed with respect to electrical equipment and circuits. Serious injury or death to personnel could result if proper cautions are not followed when work-ing with electrical equipment and circuits. (Page 4-2)

To prevent injury or death to personnel during hydrostatic testing, vent all air from casing to eliminate risk of explosion. (Page 5-1)

Before attempting to disassemble the pump, the motor electrical power supply must be locked and tagged in the OFF position to prevent injury to personnel servicing the pump. (Page 6-1, page 6-4)

Due to the weight (540 pounds) of the motor, hoisting equipment is required.

Fatal injury or damage to the motor could result if the weight of the motor is not properly controlled. (Page 6-7) ix

Due to the weight (over 50 pounds) of bracket, a two-man lift or hoisting equip-ment is required. Failure to comply with this requirement may result in serious injury to personnel and/or damage to bracket if dropped. (Page 6-7, page 6-11)

Due to the weight (110 pounds) of the rotor, a two-man lift or hoisting equip-ment is required. Failure to comply with this requirement may result in serious injury to personnel and/or damage to the rotor if dropped. (Page 6-8, page 6-10)

Do not allow heated bearings to come in contact with skin. Serious burns could result if bearings that are heated 80-90 °C (176-194 °F) come into contact with the skin. (Page 6-10)

A hoist or suitable lifting device should be used to lift pumping unit. Do not pick up the complete unit by the motor or lifting eyes. (Page 1-6)

Extreme care should be taken when connecting new piping lines to be sure that no foreign matter such as dirt, chips, tools, etc., is in the piping, tank, or return piping as this debris will be drawn into the pump and cause excessive damage.

(Page 1-9)

Do not operate pumping unit without liquid in the pump casing because the impeller, wear rings, and/or mechanical seal will be damaged. (Page 2-3) x

To prevent equipment damage, keep the interior and exterior of the equipment clean. Dust and dirt tend to soak up oil or grease, forming a gum. Do not allow dirt and oil to accumulate, either inside or outside of the equipment. Dust may prevent heat dissipation and restrict ventilating passages, thereby causing over-heating and insulation breakdown in the motor. (Page 2-4)

Composite parts should never be struck with a hard tool or other object during installation. Excessive force should never be used during the installation of com-posite parts. The use of pullers or similar extraction devices is prohibited for parts that are to be reinstalled. Although CPC composite components are dimen-sionally stable to elevated temperatures, a direct flame should never be applied to these parts. (Page 6-1)

Use of a hoist with adequate capacity is recommended when handling unit. (Page 6-2, page 6-4, page 6-5, page 6-6)

Dynamic balancing of composite products by weight adjustment (i.e., grinding off material or adding balancing weights such as setscrews) should not be done.

If necessary, contact a representative at Carver for assistance. (Page 6-4)

Protect motor internals from coming in contact with contaminants. Contaminants will reduce ball bearing life. (Page 6-7)

To avoid damage to motor windings and shaft bearings, brace rotor when bracket is removed. (Page 6-8) xi

Adequately support rotor and shaft assembly during disassembly to prevent dam-age to windings. (Page 6-8)

To remove ball bearings, use government standard bearing puller, specification GGG-P-781, type 1, size 1 and puller attachment type XII, size 3. Failure to use proper tools in removing ball bearings may cause damage to motor shaft. (Page 6-9)

Be sure to adequately support rotor assembly when it is reinstalled in stator frame. Failure to support ends of motor shaft may result in damage to windings.

(Page 6-10) xii

CHAPTER 1

INTRODUCTION AND PREPARATION FOR USE AND INSTALLATION

1-1. SCOPE.

This manual is designed to provide adequate instructions for the safe and efficient installation, operation, and maintenance of the pump. Failure or neglect to properly install, operate, or maintain the pump may result in per-sonal injury, property damage, or unnecessary damage to the pump. The information as presented should improve the user’s knowledge and understanding of this pump, thus upgrading the quality of pump maintenance and care.

The pumping unit contains parts made of composite materials approved to NAVSEA Drawing 7226047.

When used with a basic knowledge of pump assembly and sound maintenance practices, these instructions will ensure optimum life of the composite part and improved mean time between failures (MTBF) of the pump.

Carver Pump Company products are carefully engineered and manufactured and, if properly installed, main-tained, and operated, will provide maintenance-free operation and long service life.

1-2. CAPABILITIES.

The pump’s rated capacity is 230 gallons per minute (GPM) at 198 feet. The 25 horsepower (HP), 3600 revolutions per minute (RPM), L286TNCZ frame motor is used to convert electrical energy into mechanical energy. For complete capabilities and limitations of the unit, refer to Table 1-1 and the performance curve, Figure 5-1.

1-3. PERFORMANCE CHARACTERISTICS.

Refer to Table 1-1 for performance characteristics of the pump and motor.

1-4. EQUIPMENT DESCRIPTION.

The pumping unit consists of a Carver centrifugal pump and Reliance electric motor. The horizontal pump-ing unit (Figure 1-1) is designed as a back pullout unit. Normally, the casing and suction cover should be left in place and remain connected to the suction and discharge piping.

1-1

1-4.1 Pump. Refer to Figure 1-2 for the location of pump parts. The principal features of the pump end por-tion of the pumping unit consists of the following.

1-4.2 Casing. The casing houses the impeller and consists of the discharge flange.

1-4.3 Impeller. The pump is equipped with an enclosed composite impeller. The impeller is keyed to the shaft by the impeller key and locked in place by impeller capscrew. The impeller washer fits between the impeller cap-screw and the impeller.

1-4.4 Suction Cover. The suction cover consists of the suction flange. The suction cover is held in place between the casing and suction piping. A composite wear ring is secured to the suction cover with two setscrews.

1-4.5 Shaft Sleeve. The composite shaft sleeve protects the shaft and is positioned up against the impeller. The shaft sleeve O-ring prevents leakage from around the motor shaft. The rotating elements of the mechanical seal sits on the shaft sleeve.

1-4.6 Motor Adaptor. The motor adaptor has two parallel-machined faces. It provides a rigid connection between the motor and the casing. The machined rabbet connects, aligns, and positions the casing. The station-ary element of the mechanical seal sits in the motor adaptor.

1-4.7 Motor. The motor consists of a rotor enclosed in a frame. The frame contains and supports the stator and end brackets. The end brackets hold the bearings that support the rotating element. Refer to Figure 1-3 for loca-tion of motor parts.

Figure 1-1 Pumping Unit

1-2

Figure 1-2 Pump

1-3

1-5. POWER AND UTILITY DATA.

The electrical system power is supplied from the ship supply load center through a motor controller. The cir-cuit for the pump motor is controlled by a motor controller.

1-6. ENVIRONMENTAL DATA.

To allow the pumping unit to operate properly, the following requirements are necessary:

a. Maximum ambient temperature of 122 °F (50 °C) for motor.

b. Normal room ventilation for motor cooling.

c. Power supply of 440 volts, 3 phase, and 60 hertz.

1-7. EQUIPMENT, ACCESSORIES, AND DOCUMENTS SUPPLIED.

Refer to Table 1-2 for a list of equipment supplied. There are no other equipment, accessories, or documents supplied with this pumping unit other than this manual.

Table 1-1 Performance Characteristics

CHARACTERISTIC DESCRIPTION

Pump Manufacturer Carver Pump Company

Muscatine, IA 52761

Figure 1-3 Motor

1-4

Table 1-1 Performance Characteristics - Continued

CHARACTERISTIC DESCRIPTION

Pump Size 2 x 1-1/2 x 10H Suction Size 2 inches

Discharge Size 1-1/2 inches Capacity 230 GPM

Total Head 198 Feet Fluid Potable Water

Motor Manufacturer Reliance Electric

Cleveland, OH 44117 Frame Size L286TNCZ

Horsepower (HP) 25 Volts 440 Speed 3600 RPM

Phase/Hertz 3/60 Enclosure Total Enclosed Fan Cooled (TEFC)

Table 1-2 Equipment Supplied

Item Name Drawing No.

2 x 1-1/2 x 10H Carver Pump 998-1110-B-02 25 HP, AC Reliance Motor 801631-573

1-8. ADDITIONAL EQUIPMENT, ACCESSORIES, AND DOCUMENTS NOT SUPPLIED.

Equipment not furnished with the basic equipment covered by this manual, but which attach or relate impor-tantly to basic equipment are as follows: motor controller for starting and stopping the electric motor; foundation and foundation bolts for mounting the pumping unit; suction, discharge, vent, and drain valves to control flow of fluid; and, pressure gauges. Refer to applicable manual for motor electric power supply and Ship Information Book.

1-9. TOOLS, MATERIALS, AND TEST EQUIPMENT.

Recommended on-board tools, materials, and test equipment for the pumping unit are listed in Table 1-3.

Table 1-3 Tools, Materials, and Test Equipment

TOOLS MATERIALS TESTING EQUIPMENT

Wrench set Brush Flowmeter Flashlight Towel Pressure gauges Impact wrench Grease (DOD-G-24508) Dial indicator Centigrade thermometer Parker Super O-Lube Micrometer Bearing puller Megger Grease gun

1-9.1 Handling.

1-5

A hoist or suitable lifting device should be used to lift pumping unit. Do not pick up the complete unit by the motor or lifting eyes.

Complete pumping unit must be handled with care. Attach slings so as to distribute the load and not allow a shift or slip. Install and locate pump unit in accordance with Figure 1-4.

1-10. STORAGE REQUIREMENTS.

If the equipment is not immediately installed and operated, store the equipment in a clean, dry, well-ventilated place, free from vibrations, moisture, and rapid or wide variations in temperature. Rotate the motor shaft at least 12 turns every month so that bearings are fully protected by periodic distribution of fresh lubricant during the inoperative period.

Composite parts should be kept in their protective shipping containers or packaging until the time of instal-lation. Bubble wrap, poly-foam, or equivalent packaging is recommended to prevent damage to parts.

Consider a unit to be in storage when:

a. It has been delivered to the job site and is waiting to be installed.

b. It has been installed but operation is delayed pending completion of construction.

c. There are long (30 days or more) periods between operation cycles.

d. The plant (or department) is shut down for periods of longer than 30 days.

Storage requirements vary depending on the length of storage, the climatic envi-ronment, and the equipment. For storage periods of three months or longer, con-tact a representative from Carver Pump Company for specific instructions.

Improper storage could damage the equipment and would result in non-warranty covered restoration or non-warranty covered product failures.

1-11. SAFETY PRECAUTIONS.

Installation, use, and operation of pumping equipment are affected by various federal, state, and local laws.

Compliance with such laws relating to the proper installation and safe operation of pumping equipment is the responsibility of the equipment owner.

CPC composite parts are safe to work with, and, when conventional environmental safety practices are fol-lowed, will not adversely affect the health of personnel during servicing and repair operations. CPC composite parts are non-toxic and pass the requirements for contaminant levels established under the Environmental Protec-tion Agency’s National Primary Drinking Water Regulations (NPDWR). The toxicological requirements are in accordance with NAVSEA Drawing 803-7226047.

1-6

1-12. PREPARATION.

1-12.1 Foundation. The foundation should be ready to accept the pumping unit with no further preparation of the foundation necessary. The foundation must be capable of accommodating the pumping unit dimensions given in Figure 1-4.

When handling the pumping unit, do not exceed the rated capacity of the hoist-ing equipment. Hoisting equipment should be capable of lifting 2375 pounds.

Use of inadequate hoisting equipment may result in serious injury or death to personnel and/or damage to the pumping unit.

1-12.2 Unpacking. Remove pumping unit from wooden crate by disassembling crate with a claw hammer and/or crowbar. Unbolt pumping unit from floor of crate. Remove covering from flanges.

1-13. INSTALLATION.

Skilled personnel in accordance with engineering standards should install the pump. Faulty installation will result in operating troubles and premature wear of parts.

1-13.1 Tools Required. Refer to Figure 1-4 to install the pumping unit. Tools normally found in shipboard maintenance should be sufficient for installing the pumping unit. Refer to Table 1-4 for special materials for installation.

Table 1-4 Installation Materials

MATERIAL QUANTITY PURPOSE

Gasket 1 Suction flange Gasket 1 Discharge flange Foundation bolts 4 Grade 5 Lead wire 3 Electrical connection

1-7

Figure 1-4 Dimensional Illustration

1-8

1-13.2 Site Information. Install and locate the pumping unit in accordance with Figure 1-4. The shipboard compartment containing each pumping unit shall accommodate the pumping dimensions given in Figure 1-4. In addition, the overhead shall be capable of accommodating attached hoisting equipment for maintenance purposes.

1-13.3 Piping Information. The pump is shipped with flange covers to protect flange faces and to prevent for-eign matter from entering pump. Flange covers should remain intact until discharge and suction piping is con-nected to pump flanges. The pump should be installed as close as possible to the fluid to be pumped. A short direct suction pipe should be used to keep suction losses at a minimum. If possible, locate the pump so fluid will flow by gravity to the suction opening. The discharge piping should be direct with as few elbows and fittings as possible.

Be sure to adequately support suction and discharge piping prior to disconnect-ing the pump assemblies. Failure to adequately support piping could result in serious injury or death to personnel and/or damage to equipment or parts.

1-13.4 Installation Procedures. Install the pumping unit as follows:

a. Remove any rust preventative that may have been applied to the pumping unit prior to shipment.

b. Make sure the foundation is level. Bolt pump unit to foundation. Check that pump rotates freely.

Extreme care should be taken when connecting new piping lines to be sure that no foreign matter such as dirt, chips, tools, etc., is in the piping, tank, or return piping as this debris will be drawn into the pump and cause excessive damage.

c. Connect system suction and discharge piping to respective pump flanges.

d. Connect any necessary auxiliary piping and gauge lines.

e. Turn motor shaft by hand to be sure it rotates freely. If necessary, recheck pipe connection for pipe strain.

f. Compare the motor nameplate data to system (ship) wiring plan to ensure that the power supply is the correct voltage, frequency, and phase for the motor. Connect wiring to motor. Due to high voltage required to oper-ate the pumping unit, personnel working with the equipment should be familiar with electrical safety practices and modern methods of resuscitation.

g. Add wire terminals to wire and connection box.

h. Connect electrical power supply to motor.

i. Open system valves.

1-13.5 Alignment. To keep the pump and motor properly aligned, shims are added to the foundation. Specific procedures for disassembly/reassembly of the pump and motor are addressed in the appropriate procedure in Chapter 6.

1-9

1-14. INSTALLATION CHECKOUT.

1-14.1 Phase 1 - Installation, Inspection, and Pre-Energizing Procedures. Refer to Table 1-3 for a list of required test equipment before starting the pumping unit for the first time. Use the following checklist for veri-fication:

a. The pumping unit has been installed in the proper location and orientation. Piping has been installed accord-ing to plans and specifications and continuity exists in all interconnections.

b. Test equipment listed in Table 1-3 is on board, and operating satisfactorily.

c. Allowance Parts List (APL) is on board and the Coordinated Shipboard Allowance List (COSAL) includes the equipment data.

d. All field changes, SHIPALTS, and mandatory retrofits have been accomplished.

e. All installation and reference standards have been completed.

f. All rotating devices are free from obstacles.

g. There is access to the pumping unit for maintenance (refer to Figure 1-4).

h. All pre-energizing procedures have been accomplished.

i. It is safe to turn on the pumping unit.

1-14.2 Phase 2 - Initial Turn-On and Preliminary Test. Before starting the pumping unit for the first time, make the following checks:

a. Check the nameplate of the controller to see that it agrees with the power supply and the motor rating.

b. Check the controller enclosure to be sure it is mounted rigidly to a firm foundation or mounting support. If possible, the mounting should be free from vibration.

c. Visually inspect unit with regard to appearance, material, and workmanship.

d. Visually check for mismatch at flange joints.

e. Check all fasteners to determine that they are tightly seated. All fasteners must have full-thread engagement.

f. ″Jog″ start the motor briefly to check direction of motor shaft rotation. Correct shaft rotation is clockwise when viewed from the motor end. If rotation is incorrect, turn off, lock off, tag out electrical power supply, and switch two of three leads at motor terminal box.

g. Further installation checkout can only be accomplished by starting the pumping unit as outlined in Table 2-1.

During initial starting, check all gauges and meters to be sure pump is operating at design-point conditions (refer to Table 1-1).

1-14.3 Phase 3 - Installation Verification Test. Record actual test results. Test results should conform to the graph of the actual pump test (refer to Figure 5-1) and the design-point conditions listed in Table 1-1.

1-14.4 Test Procedure.

a. Start the pumping unit.

1-10

b. Check and record operating conditions. If the pump is not operating within the reference standards specified, refer to Table 4-1 for troubleshooting procedures.

c. Record actual test values and certify proper installation.

1-11 / (1-12 Blank)

1-12

CHAPTER 2

OPERATION

2-1. INTRODUCTION.

The pumping unit will operate without operator intervention once pump has been energized and system valves have been adjusted to the specified pumping conditions (refer to Table 1-1).

2-2. THEORY OF OPERATION.

Refer to Figure 2-1.

2-2.1 Starting. When the start button on the motor controller is pressed, the line contactor connects the motor directly to the line.

2-2.2 Motor. The available 440-volt, three-phase, 60-hertz electrical power is brought into the motor via cables through the terminal box. When electric power is supplied to the motor, the voltage impressed stator winding produces a rotating magnetomotive force (MMF) that, by transformer action, is transformed across the air gap and induces voltage into the rotor. This induced voltage in the rotor produces currents that circulate through the squirrel cage winding that produces a counter MMF. The interaction of the current in the rotor and the rotating field of the stator causes the shaft to turn. The mechanical work produced is transmitted as torque to the pump impeller by the motor shaft.

2-2.3 Pump. The motor shaft rotates the impeller. Fluid flows into the impeller eye where, by means of cen-trifugal effect, the fluid is directed to the outside diameter of the impeller. As the fluid moves from the impeller eye to the outside diameter, it is greatly accelerated by means of the impeller vanes. This resulting higher veloc-ity fluid at the vane tips is then converted into head pressure by the design of the volute. The collector portion of the pump casing then directs the fluid flow to the casing discharge.

2-3. CONTROLS AND INDICATORS.

There are no controls or indicators on the pump and motor assemblies. Refer to applicable manual for the motor electric power supply and the Ship Information Book.

2-4. OPERATING PROCEDURES.

Operating procedures are presented in Table 2-1, Table 2-2, Table 2-3, and Table 2-4.

2-5. OPERATOR’S MAINTENANCE INSTRUCTIONS AND SCHEDULES.

Operator’s maintenance tasks for the pumping unit includes pressure monitoring, surface inspection, leakage inspection, and lubrication. Operator maintenance instructions and schedules for the motor controller are provided in the controller technical manual. Operator’s maintenance tasks are presented in Table 2-5, Table 2-6, Table 2-7, Table 2-8, and Table 2-9.

2-1

Figure 2-1 Theory of Operation

2-2

Table 2-1 Initial Startup

STEP PROCEDURE

a. If the pumping unit has been idle for a period of time, make sure that the unit is firmly anchored to its foundation.

b. Check motor shaft for freedom of rotation. Rotate motor shaft at least one revolution manually. If rub-bing occurs, refer to troubleshooting in Table 4-1.

c. If pump was filled with mineral oil or other non-corrosive fluid while it was shut down for extended period of time, drain pump and flush with water.

d. Prime pump by opening the vent valve on the pump casing and filling chamber completely full with water. Replace vent valve before starting pump.

Table 2-2 Normal Operation Startup

STEP PROCEDURE

a. Open system valve in suction line to pump.

b. Close system valve in discharge line to pump.

c. Open valves to pressure gauges in system.

Before activating the pumping unit, make sure no one is working on the unit. Serious injury or death to personnel could result if power is turned on while unit is being worked on.

Do not operate pumping unit without liquid in the pump casing because the impeller, wear rings, and/or mechanical seal will be damaged.

d. Check the motor shaft rotation. Rotation should be clockwise when viewed from motor end. If neces-sary to correct rotation, turn off, lock off, tag out electrical power supply, and switch any two motor leads.

e. Start the pumping unit in accordance with the directions on the motor electric power supply.

f. Slowly open system valves in discharge line until pumping unit reaches specified pumping conditions

(refer to Table 1-1).

g. Pumping unit is now in full operation.

Table 2-3 Normal Operation Shutdown

STEP PROCEDURE

a. Stop the pumping unit in accordance with the directions on the motor electric power supply.

b. Close system valve in discharge line to pump.

c. Close system valve to suction line to pump.

d. Close valves to pressure gauges in system.

e. The pumping unit is now off.

2-3

Table 2-4 Emergency Operation

In case of fire, turn off motor immediately. A carbon dioxide extinguisher should be used. If it is possible to approach motor, it should be covered with canvas. Smothering steam should be turned on if available. Inadequate fire control could result in serious injury to personnel or damage to equipment.

a. If fire is detected in the motor electric power supply, turn off the power supply. In case of fire in the motor, the motor electric power supply will automatically shut down the motor.

b. If there is a loss of fluid to the pump, shut down the pump according to Table 2-3.

c. Isolate the problem according to the troubleshooting in Table 4-1. Correct the problem according to applicable correct maintenance procedures in Chapter 6, motor electric power supply manual, and Ship Information Book.

Table 2-5 Differential Pressure Monitoring

STEP PROCEDURE

a. Record the suction pressure gauge reading on the pump.

b. Record the discharge pressure gauge reading of the pump.

c. Record the difference between the suction and discharge pressures as the differential pressure.

Table 2-6 Surface Inspection

STEP PROCEDURE

To prevent injury or death to personnel, do not wear loose clothing when working with rotating equipment.

To prevent equipment damage, keep the interior and exterior of the equipment clean. Dust and dirt tend to soak up oil or grease, forming a gum. Do not allow dirt and oil to accumulate, either inside or outside of the equipment. Dust may prevent heat dissipation and restrict ventilating passages, thereby causing overheating and insulation breakdown in the motor.

a. Clean equipment by removing accumulated gum, dust, and dirt from equipment with dry cloth.

b. Clean all electrical connections and cables. Check tightness of electrical connections. Cables should be unstressed.

c. Remove hard-to-reach deposits with a non-metallic vacuum cleaner.

2-4

Table 2-7 Leakage Inspection

To prevent injury or death to personnel, do not wear loose clothing when working with rotating equipment.

a. Immediately after starting the pumping unit, check leakage around seal housing. Leakage should not exceed five drops per minute.

b. If leakage exceeds limitations, refer to Chapter 6 for repairs.

Table 2-8 Lubrication

STEP PROCEDURE

The pump is a sealed unit and is lubricated by the fluid being pumped. Motor bearings require lubrication if the motor has been in storage for six months or more, or when it has been operating under standard conditions for six months or more, and once a year thereafter. When lubricating motor bearings, the instructions for bearing lubrica-tion and maintenance in NSTM S9086-HN-STM-000/Chapter 244, paragraph 1.7.7 should be followed to ensure maximum bearing life. Lubricant capacity is identified on lubricant plate. Use lubricants in accordance with NSN S9150-00-149-1593 for recommended lubricants.

Table 2-9 Motor and Bearing Temperature Inspection

STEP PROCEDURE

Note temperature of motor and bearings during a three-hour trial run. Observe temperature of various parts of motor.

Temperature should not exceed 82 °C (180 °F). Where excessive temperature exists, determine actual temperature with a centigrade thermometer where bulb is protected from surrounding atmosphere by putty. Place thermometer directly on the part to be checked. At conclusion of three-hour trial run, while motor is still at operating temperature, test insulation resistance of windings to ground.

2-5 / (2-6 Blank)

2-6

CHAPTER 3

PREVENTATIVE MAINTENANCE

3-1. GENERAL OPERATING CHECKS.

The pump should always run quietly and smoothly, without vibration. To ensure such operation, the follow-ing maintenance inspections should be carried out at regular intervals during operation of the pump. A pump ser-vice record and inspection and repair record are provided for this purpose in the front of this manual.

3-1.1 Daily Inspection.

a. Visually inspect unit according to Table 2-6.

b. Check motor bearing temperatures according to Table 2-9.

3-1.2 Weekly Inspection.

a. Check power (amps) readings.

b. Check pump discharge pressure. Prescribed discharge pressure should never drop below 90 percent of design point pressure at design rated flow.

c. Check vibration on motor bearings. Vibration should not be excessive.

3-1.3 Monthly Inspection.

a. Check foundation bolts on pumping unit.

3-1.4 Quarterly Inspection.

a. Check motor insulation resistance to ground with an approved megger to determine whether the equipment is in satisfactory operating condition. When insulation resistance drops to 25 megohms, a complete check of the motor is recommended.

3-1.5 Semiannual Inspection.

a. Lubricate motor bearings according to Table 2-8. Do not over-grease.

b. If standby pumps are installed, it is advisable to operate pumps on a rotation system to give each pump a cer-tain amount of operational duty. This ensures that standby pumps will always be in condition for instant star-tup.

c. Check all motor electrical connections to be sure they are clean and tight. Cables should be clean and unstressed.

3-1 / (3-2 Blank)

3-2

CHAPTER 4

TROUBLESHOOTING

4-1. INTRODUCTION.

To prevent injury or death to personnel, do not service electrical equipment alone. The immediate presence of someone capable of rendering aid is required.

All circuits not known to be dead must be considered live at all times.

This chapter contains instructions and information necessary to locate trouble and conduct tests on the pump-ing unit. The troubleshooting in Table 4-1 provides step-by-step procedures for logical isolation of faults and possible situations wherein malfunction, fault, or failure of the equipment could render it inoperative or unable to perform its intended function. At the first opportunity, shut down the pumping unit and use the troubleshoot-ing procedures in paragraph 4-2 and the troubleshooting guide in Table 4-1 to identify the cause and corrective action. The following steps shall be performed to determine the nature of the malfunction:

a. Determine that…