As Builts and IOMs Booster Pump 2 Bldg 30.pdf

As Built Drawing & IOM’s for Kaena Booster Pump No. 2 (Bldg 30)

Startup/Commission: Aug 3, 2017

Submitted By:

BEYLIK DRILLING & PUMP SERVICE, INC.

91-259A Olai Street Kapolei, HI 96707

Ph: 808-682-5554 ● 808-682-5866 ● email: gonsalves@beylik.com

Job No.: 2065T Project Manager: Toni Gonsalves

TABLE OF CONTENTS

Section 1 .................. As Built Drawings

Section 2 .................. Performance Curve

Section 3 .................. Installation, Operation Manuals

Section 4 .................. Warranty Letter

Section 1

As Built Drawing

Cheryl Beylik Drilling & Pump Svc, Inc

Beylik Job No.: Well Name:

Project Manager: Start-up Date:

Witnessed By:

Prior to Startup

SWL: ft Vab V Freq Hz

Flowrate: gpm Vbc V

Pressure: psig Vac V

Startup (immediate)

Time: am pm

Water To Surface Time:

Dump Valve Open Time:

Drawdown: ft

Vab V Ia amps Power Factor

Flowrate: gpm Vbc V Ib amps Freq Hz

Pressure: psig Vac V Ic amps

Startup (after 30 minutes)

Time: am pm

Drawdown: ft

Vab V Ia amps Power Factor

Flowrate: gpm Vbc V Ib amps Freq Hz

Pressure: psig Vac V Ic amps

Shutdown

Time: am pm

Backspin Time:

Installer's Pump Startup Readings

Cheryl Typewritten Text 2065T Booster 2

Cheryl Typewritten Text

Cheryl Typewritten Text Toni Gonsalves 07/13/17

Cheryl Typewritten Text J.Mole

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BDI

Cheryl Typewritten Text 51 51

Cheryl Typewritten Text 45 45 N/A

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Cheryl Typewritten Text N/A 235 60

Cheryl Cross-Out

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98.9 238

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SWL

Cheryl Typewritten Text Notes: Pit S.W.L - 8' Start, 4' Stop. Motor Run - Min 10:13 Off, 10: 26 Start, 10:43 Off

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Section 2

Performance Curve

Project : Kaena Booster Pump No. 2 (Bldg 30) Quote No. :

Fax :Phone :

Date : January 9, 2013

Contact :

Page No : 1

Flow - US gpm 20015010050

P ow er hp 2520

H ea d

- f t

200 E ffi ci en cy

10D5

D1

D1-4.47 x 4.47, D2-4.32 x 4.47, D3-4.17 x 4.47, D4-4.03 x 4.47, D5-3.88 x 4.47

N P

S H ft 20

Comments Refer to factory for all single point bowl performance guarantees. Pumps must be selected with Hydraulic Institute-Peerless Std. See Std Hydraulic Performance document in RAPID for testing tolerances & contractual guarantees.

Pump Model: Peerless Vertical - 6LB 12 Stages Nom. Speed: 3500 RPM, 60 Hz Electric

Impeller No.: 2616324 / LC Material Spec. Group: A - B: CIE; I: Brz = Standard Item : 1

Viscosity: 1.007 cSt

Fluid: Water

Sp. Gravity: 1.000

Flow rate Q:

Bowl Total Head:

Bowl Power Required:

NPSH Required

Bowl Efficiency:

17.1

52.4

US gpm ft hp ft

Stage No. Trim Status Imp. Dia. (inch)

----- Full ----- D2-in x D2-out

----- Full 4.47 x 4.47 1 - 12 Trimmed 4.04 x 4.47

Performance curve according to Hyd Inst-Base Line Data

Your Ref. :

Market : Vertical Turbine Pump

(base temp. 68 °F)

Temperature: 68 °F

Flow (US gpm)

Head (ft)

Efficiency

Power Required (hp)

NPSH Required (ft)

Thrust (lb)

0.0 816.8 0.0 11.8 1945

20.6 766.1 28.3 14.1 1765

41.3 725.1 46.4 16.3 1631

61.9 689.0 59.2 18.2 7.9 1504

82.5 641.0 67.5 19.8 7.7 1345

103.1 565.4 71.2 20.7 8.3 1130

123.8 458.7 70.0 20.5 10.1 868

144.4 329.3 63.1 19.0 13.6 584

165.0 175.7 50.6 14.5 19.9 292

Grundfos - RAPID v8.25.9.1 (Windows 7) - 06th 970.1005.

Toni Beylik Logo Medium tgonsalves Typewritten Text

Section 3

Installation, Operation Manuals

Peerless Pump Company

Vertical Turbine Industrial Pumps Open Line Shaft (OLS)

Installation, Operation and Maintenance Manual

Pump No.:

Serial Number:

Invoice No.:

Item No.:

PO. No.:

Bulletin 97891917

OLS Vertical Turbine Installation, Operation and Maintenance Manual

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without prior notice.

Page 2 of 30 Bulletin No.: 97891918 Rev 12-2011

Original installation and operating instructions

Table of Contents

1. Symbols used in this document 2

2. General information 3

2.1 Warranty 3

2.2 Personnel qualification 3

2.3 Warnings 3

2.4 Material safety data sheet 3

2.4.1 Noise level 3

3. Transport and storage 3

3.1 Transport and handling requirements 3

3.2 Receipt and inspection 3

3.3 Rigging and lifting 4

3.4 Storage 4

3.4.1 Controlled storage 4

3.4.2 Uncontrolled storage 4

3.4.3 Standard short-term storage 5

3.4.4 Long-term storage 5

3.4.5 Accessories storage 6

3.5 Disposal of packaging materials 6

4. Identification 6

4.1 Nameplate 6

4.1.1 Certifications 6

4.1.2 Pump 6

4.2 Type key for vertical turbine pump 7

4.3 Type key for vertical turbine fire pump 8

5. Installation 9

5.1 Factory support 9

5.2 Location 9

5.2.1 Checking wells 9

5.2.2 Checking wet pits 9

5.3 Foundation 9

5.3.1 Seismic analysis 10

5.4 Rigging and lifting 10

5.4.1 Leveling 10

5.4.2 Grouting 11

5.5 Installation preparations 11

5.5.1 Inspection 11

5.5.2 Assembling the pump 12

5.5.3 Installing the bowl assembly 12

5.5.4 Installing the column and shaft 13

5.5.5 Installing the bearing retainer 13

5.5.6 Installing the discharge head 14

5.6 Base plate or pump 15

5.6.1 Leveling 15

5.6.2 Grouting 15

5.7 Piping and connections 15

5.7.1 Pipe supports, anchors or joints 15

5.7.2 Vibration dampers 15

5.7.3 Suction piping 15

5.7.4 Suction valves and manifolds 15

5.7.5 Discharge valves 15

5.7.6 Air and vacuum release valves for wet pit and well

pumps 16

5.7.7 Siphons 16

5.7.8 Nozzle loads 16

5.7.9 Non-return valves 16

5.7.10 Strainer 16

5.8 Setting the impeller clearance 17

5.9 Alignment 20

5.9.1 Auxiliary (driver, coupling, etc) 20

5.10 Lubrication, priming and cooling systems 20

5.11 Electrical installation 20

5.12 Control, monitoring and alarm equipment 20

5.12.1 Stopping the unit/reverse runaway speed 20

6. Startup, operation and shutdown 21

6.1 Frost protection 21

6.2 Lubrication 21

6.2.1 Recommended products 21

6.3 Rotation 21

6.4 Guards 22

6.5 Check list 22

6.5.1 System flushing 22

6.5.2 System decontamination 22

6.5.3 Priming 22

6.5.4 Shaft sealing 22

6.6 Startup, operation Sand shutdown 23

6.6.1 Air in system 23

6.6.2 Minimum continuous flow 23

6.6.3 Minimum thermal flow 23

6.6.4 Lubrication system 23

6.6.5 Driver settings 23

6.6.6 Valve settings and operation 23

6.6.7 Parallel and series operation 24

6.6.8 Condition monitoring 24

6.6.9 Vibration 24

6.6.10 Performance testing 24

7. Maintenance 24

7.1 Schedule 24

7.2 Wear rings 24

7.3 Recommended spare parts 25

7.4 Consumables 25

7.5 Required tools and fixtures 25

7.6 Tightening torques 25

7.7 Pump decontamination 25

7.8 Dismantling 25

7.8.1 Wear ring 26

7.9 Assembly 26

7.10 Accessories 27

8. Fault finding (Trouble Shooting) 28

9. Parts list and sectional drawing 29

10. Disposal 29

Warning Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.

1. Symbols used in this document

Warning If these safety instructions are not observed, it may result in personal injury.

Warning If these instructions are not observed, it may lead to electric shock with consequent risk of serious personal injury or death.

Warning When pumping hazardous liquids, special attention must be paid to the risk of personal injury.

Warning The surface of the product may be so hot that it may cause burns or personal injury.

Warning The sound pressure level is so high that hearing protection must be used.

Warning These instructions must be observed for explosion-proof pumps. It is advisable also to

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 3 of 30 Bulletin No.: 97891918 Rev 12-2011 follow these instructions for standard pumps.

If these safety instructions are not observed, i may result in malfunction or damage to the equipment.

t

Notes or instructions that make the job easier and ensure safe operation.

2. General information These instructions should be retained for reference regarding maintenance and operation near the pump. Additional copies can be found at www.peerlesspump.com.

These are general instructions and may not take into account local regulations. The user should ensure such regulations are observed by all parties.

Information in this manual is believed to be reliable. In spite of all the efforts to provide sound and all necessary information, the content of this manual may appear insufficient and is not guaranteed to be compete or accurate in all instances.

2.1 Warranty

This unit is manufactured under a quality management system standard as certified and audited by external quality assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use.

Damage or failure caused by misuse, abuse or failure to follow these instructions are not covered by our warranty.

Any modification of our products or removal of original components may impair the safety of these products in their use.

Standard warranty conditions can be found at www.PeerlessPump.com.

2.2 Personnel qualification

All operations must be carried out by qualified personnel.

2.3 Warnings

Warning If the site is left unattended before the installation is complete, all openings must be covered to prevent entry of children, animals, stones or any other foreign objects.

Use unbreakable covers that cannot be removed without tools.

Warning When a pump has experienced temperatures over 400 °F (205 °C), skin contact must be avoided with components. Additionally, partial decomposition of fluoro-elastomers (when fitted) will occur.

Warning Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components.

Warning Hot or freezing components or auxiliary heating supplies can present a danger to operators and persons entering the immediate area.

Action must be taken to avoid accidental contact. If complete protection is not possible, the machine access must be limited to maintenance staff only, with clear visual warnings and indicators to those entering the immediate area.

Warning Rapid changes in the liquid temperature can cause thermal shock that can result in damage of pump components and should be avoided.

Warning When the pump is handling hazardous liquids, care must be taken to avoid exposure to the liquid by appropriate setting of the pump, limiting personnel access and by operator training. If the liquid is flammable and/or explosive, strict safety procedures must be applied.

Gland packing must not be used when pumping hazardous liquids.

Caution Do not use pump as a support for piping.

Do not mount expansion joints, unless allowed by Peerless in writing, so that their force, due to internal pressure, acts on the pump flange.

Caution

Products used in potentially explosive atmospheres. Special consideration must be taken when pumps are installed in these applications. Contact Peerless for more information.

2.4 Material safety data sheet

As a general practice, material safety data sheets (MSDS) are not supplied with pumps unless required. They may be requested from Peerless.

2.4.1 Noise level

Caution

Whenever pump noise level exceeds 85 dBA, attention must be given to the prevailing health and safety legislation to limit the exposure of plant operating personnel to the noise. The usual approach is to control exposure time to the noise or to enclose the machine to reduce emitted sound.

3. Transport and storage

3.1 Transport and handling requirements

The pump has been prepared for shipment at the factory in such a way as to minimize potential damage due to handling and transport.

Caution The equipment should not be subjected to excessive g-forces during the handling or transport.

3.2 Receipt and inspection

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 4 of 30 Bulletin No.: 97891918 Rev 12-2011

Receiver should report any shortage or damage to the transport company handling the shipment and to Peerless Pump.

Prior to installation, take inventory of the shipment to ensure that the parts received match the list of parts on your order.

Note the extent of damage or shortage on the freight bill and bill of lading. Failure to note damage or missing parts may result in declined warranty or replacement of parts.

Note If the shaft sections were shipped crated, one end or the top of the crate may be opened for a count. Leave the rest of the crate intact to protect the shaft sections during unloading.

It is important that all the components for a pump unit be identified and properly stored until installation is to be done.

There may be many small parts (such as line shaft couplings or hardware) that are best left in their shipping container until installation.

Do not unpack any more than required to verify that the equipment is complete and undamaged unless installation is to be done immediately. Check all packaging material that is to be discarded to verify that no parts or instructions are being accidentally discarded. In some shipments, small boxes containing additional parts are bound to pump skids. Leave small parts in their shipping container until installation so they don’t get lost. Upon unpacking make certain that accessories with a pump unit are clearly marked showing which pump unit they are to be used with.

3.3 Rigging and lifting

For a pump with an overall length up to 30 feet (9 m) it may be convenient to install the column and shaft sections directly from the transporting vehicle (block and brace).

When pumps are received unassembled, all the parts should be located close to the location where the pump will be installed.

Arrange timbers parallel on the ground to support the pump column and shafts.

Caution

Pump parts that are too heavy to be lifted by hand must be lifted from the transporting vehicle with a suitable hoist. Lifting chains or cables must not contact machined surfaces.

Crated shaft sections should be unloaded from the vehicle in the crate and not be uncrated until ready for installation.

Caution

Parts which are provided with lifting lugs, lifting ears or eyebolts should be lifted by these points only. They may not be used for lifting the entire pump.

When lifting the entire pump, use the lifting lugs on the discharge head.

Caution

Column, tube and shaft sections should be handled with extreme care to prevent misalignment and pump malfunction. Shafts are especially sensitive. Bent or dropped shafts should not be used as they are certain to cause pump failure.

Certain extra-long, relatively small-diameter bowl assemblies may be shipped attached to skids bearing a special notation such as:

CAUTION - DO NOT REMOVE THIS PROTECTIVE SKID

UNTIL THE BOWL ASSEMBLY IS IN A VERTICAL

POSITION, READY TO BE INSTALLED IN THE WELL OR

SUMP. RETAIN THIS SKID FOR USE WHEN REMOVING

THE BOWL ASSEMBLY FROM THE WELL OR SUMP.

Caution

Remove suction accessory (such as strainer or vortex plate), if installed, from the suction manifold or case prior to lifting the pump assembly. This action will prevent damage to the suction accessory, ensuring the device is not used as a pivot point during lifting. It is very important to observe this precaution when handling these units.

Warning Do not work under a suspended object unless you have taken precautions to stop its fall in event of sling or hoist failure.

3.4 Storage

Standard factory packaging is suitable for protection during shipment and during covered storage at jobsite for a short period between installation and startup. The preservatives applied at the factory have an effective life of two to three months from date of shipment from factory, depending on the severity of the environment in which the equipment is exposed. For international destination this will vary depending on the sea worthiness of export boxing.

3.4.1 Controlled storage

Storage facilities should be maintained at an even temperature of at least 10 °F (5.5 °C) above the dew point with relative humidity lower than 50 % and little or no dust. The equipment is to be inspected weekly to ensure that all preservatives are intact and internals are protected.

Inspect and recoat periodically the equipment with water displacement rust inhibitors (VPCI-368-021, Rust-Ban 392 or equal), crusting grease (Rust-Ban 326 or equal), vapor phase inhibitor (Shell VPI-260 or equal) or rust preventative coating (Rust-Ban 373 or equal).

Caution

Protect the equipment from flooding or from harmful chemical vapors.

Storage should be free from ambient vibration.

Excessive vibration can cause bearing damage.

Precautions should be taken to prevent rodents, snakes, birds or insect from nesting inside the equipment.

3.4.2 Uncontrolled storage

For uncontrolled storage periods of three months or less, the equipment is to be inspected weekly to ensure that all preservatives are intact and internals are protected.

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 5 of 30 Bulletin No.: 97891918 Rev 12-2011

Inspect and recoat periodically the equipment with water displacement rust inhibitors (Rust-Ban 392 or equal), crusting grease (Rust-Ban 326 or equal), vapour phase inhibitor (Shell VPI-260 or equal) and/or rust preventative coating (Rust-Ban 343 or equal).

All pipe threads and flanged pipe covers are to be sealed with tape. Furthermore you should place 10 pounds (4.5 kg) of moisture-absorbing desiccant or 5 pounds (2.3 kg) of vapor phase inhibitor crystals near the centre of pump.

If the pump is assembled, place an additional one pound in the discharge of the pump securely fastened.

Install a moisture indicator near the perimeter of the pump.

Cover the equipment with black polyethylene or equal with a minimum thickness of 0.006 (0.15 mm). Provide a small ventilation hole approximately the size of a small coin.

Provide a roof or shed shelter to protect from direct exposure to the elements.

If equipped, connect space heaters on equipment such as motors, engines or controls.

3.4.3 Standard short-term storage

The pump and equipment, as shipped, have adequate protection for short-term (two to three months) storage in a covered, dry and ventilated location at the job site prior to installation.

For packed-type pumps, remove stuffing box packing and place it in a sealed plastic bag. Apply a film of compatible lube oil over the water displacement rust preventative (Rust-Ban 632 or equal). Seal the end of the stuffing box with rolled vapor phase inhibitor paper and seal with weatherproof tape.

For packed-type pumps the packing gland may be left on the pump shaft, but should be securely fastened in position.

If mechanical seals are to be used, the annular opening between gland plate and shaft should be closed to exclude airborne dust.

Additionally, all connections in the seal cartridge must be plugged or sealed.

All exposed machined surfaces should be thoroughly coated with a firm film rust preventative material (Rust-Ban 373 or equal) that is readily removable with a petroleum distillate product.

All exposed painted surfaces should be dry, clean and free of grease and other contaminates.

After pump has been thoroughly drained, cover the pump suction and discharge flanges with a cover (typically cardboard or wood) to blank off these openings.

Rotate pump shaft per the rotation arrow on pump several revolutions at least once per week to coat the bearing with lubricant and to retard oxidation and corrosion, flat spots and staining. Shaft should end up 90 ° from starting point.

To place the pump in operation, all protective coverings and coatings should be properly removed. For packed-type pumps, repack the stuffing box with the proper number of packing rings from bag. If the packing appears to be damaged or otherwise unfit, it should be replaced.

See section 3.4.4 Long-term storage when the startup of equipment is made over three months from the date of shipment from the factory.

3.4.4 Long-term storage

Long-term storage protection from the factory does not extend the warranty in any manner. Warranty policy is twelve months from startup or eighteen months from time of shipment, whichever occurs first. This warranty is valid only if equipment has been properly handled and stored as per the stated requirements.

Should the equipment be stored or handled improperly, then the warranty is invalid and may be reinstated only after a factory representative is allowed to inspect the equipment prior to startup. Expenses for the representative will be billed in accordance with the latest schedule for field service engineer.

Any repairs or repair parts needed will be billed to the customer at prices in effect at time of shipment of these repairs/parts.

At the time of pump specification and/or order placement Peerless Pump should be advised about the extended storage duration so that special long-term storage protection can be provided for the equipment prior to shipping to the job site.

Inspection of the equipment by a factory representative prior to startup is normally required to ensure equipment integrity and compliance with warranty requirements.

In addition to complying with the standard short-term and storage atmosphere conditions, the following considerations are required:

Dry pump internals and spray the liquid end with a water displacement rust inhibitor (Rust-Ban 392 or equal).

Enclose vapor inhibitor in pump internals (Shell VPI 260 or equal).

Apply a film of compatible lube oil over the water displacement rust preventative (Rust-Ban 632 or equal).

After pump has been thoroughly drained, cover the pump suction and discharge flanges with full natural rubber gasket material and blank off these openings with metal blank flanges and a minimum of four full sized bolts. Cover the pump stuffing box opening with a non-hygroscopic tape.

Cover the equipment with black polyethylene or equal with a minimum thickness of 0.006 (0.15 mm) and seal it with tape.

Provide a small ventilation hole approximately the size of a small coin.

The pump should be inspected at regular periods.

Rotate the pump shaft per the rotation arrow on the pump several revolutions at least once per week to coat the bearing with lubricant and to retard oxidation and corrosion, flat spots and staining. The shaft should end up 90 ° from starting point.

To place the pump in operation, all protective coverings and coatings should be properly removed. For packed-type pumps, repack the stuffing box with the proper number of packing rings from bag. If the packing appears to be damaged or otherwise unfit, it should be replaced.

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 6 of 30 Bulletin No.: 97891918 Rev 12-2011

3.4.5 Accessories storage 4.1.1 Certifications

Store accessories according to the manufacturer’s instructions.

If the product carries an industry certification (UL fire or other), it will be noted on the pump nameplate. Contact Peerless Pump for additional information.

Long-term storage should not be undertaken without written understanding from manufacturer. 4.1.2 Pump

The pump size/model is given with a number, letter(s) followed by a number such as 12MB-4. These would represent the nominal bowl diameter or well size the bowl assembly would go into, the pump model and the number of stages.

3.5 Disposal of packaging materials

See section 10. Disposal

4. Identification

4.1 Nameplate

Each pump has a nameplate which list serial number. See fig.

1 and 2. The serial number is needed when contacting Peerless Pump with questions or service request.

When a driver is supplied, there will also be a nameplate on the driver. When requesting information about the driver, both the driver serial number and the pump serial number will be required.

Information on the discharge head nameplate includes the following:

• serial number

• rated flow rate

• rated speed

• rated head

• pump size/model

• pump manufacturer and location.

• certification mark (UL fire or other), if any.

Information of the bowl assembly nameplate includes the following:

• pump size/model

• serial number

• pump manufacturer and location.

Fig. 1 Nameplate of discharge head

Fig. 2 Nameplate of bowl assembly

Model

Serial

TM

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 7 of 30 Bulletin No.: 97891918 Rev 12-2011

4.2 Type key for vertical turbine pump

Code Example 10HH 12MB-5 L4-O -1/8 -F-8-1.50 -G -P -H

10HH 12MB -5 -L4 -O -1 /8 -

F

-8 -1.5 -G -P -H

Special First Stage Bowl (if supplied):

Bowl Size and Hydraulic Design Bowl Size and Hydraulic Design Total # of Stages Configuration Code L1 – Suction Case / Threaded Discharge Bowl L2 – Suction Case / Threaded Discharge Case L3 – Suction Case / Flanged Column L4 – Suction Bell / Threaded Bowl L5 – Suction Bell / Threaded Case L6 – Suction Bell / Flanged Column Shaft Enclosure Type

O- OLS

E - ELS

Bowl/Casing Material 1 – Cast Iron 2 – Ductile Iron

4 – 316LSS

5 – CD4MCu 9 – Nickel-Aluminium Bronze Z – Special Impeller Material 1 – Cast Iron

4 – 316LSS

5 – CD4MCu 8 – Aluminium Bronze 9 – Nickel-Aluminium Bronze Z – Special Column Connection T – Threaded F – Flanged Column Diameter (inches) Line Shaft Diameter (inches) Head Type B – Bowl Only S – “S” Type C – “C” Type G – “G” Type U – “UG” Type R – ”FRA” Type A – ”FA” Type Z – Special Type of Sealing P – Packing S- Seal Motor Type

H – VHS

S – VSS

T – Thrust Pod & VSS Z – Special

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 8 of 30 Bulletin No.: 97891918 Rev 12-2011

4.3 Type key for vertical turbine fire pump

Code Example 12MBF-9-L4-UF-1/8-8-O-G-US-F-N

12MB

F

-9 -L4 -UF -1 /8 -8 -O -G -US -F -N

Bowl Size and Hydraulic Design Total # of Stages Configuration Code L1 – Suction Case / Threaded Discharge Bowl L2 – Suction Case / Threaded Discharge Case L3 – Suction Case / Flanged Column L4 – Suction Bell / Threaded Bowl L5 – Suction Bell / Threaded Case L6 – Suction Bell / Flanged Column Fire Listing

UF – UL/FM

UL – UL Only FM – FM Only NF – NFPA Compliant ZZ - Special Bowl/Casing Material 1 – Cast Iron 2 – Ductile Iron

4 – 316LSS

5 – CD4MCu 9 – Nickel-Aluminium Bronze Z – Special Impeller Material 1 – Cast Iron

4 – 316LSS

5 – CD4MCu 8 – Aluminium Bronze 9 – Nickel-Aluminium Bronze Z – Special Column Diameter (inches) Shaft Enclosure Type

O- OLS

E - ELS

Head Type B – Bowl Only S – “S” Type C – “C” Type G – “G” Type U – “UG” Type R – ”FRA” Type A – ”FA” Type Z – Special Driver Type:

BO - By Other

US - USEM

GR - Grundfos GE - General Electric MA - Marathon

WE - WEG

ZZ - Special CL - Clarke CU - Cummins Controller Type:

N - None By other G - Grundfos F - Firetrol T - Tornatech M - Master Gear Type:

N - None By other D- DeRan A- Amarillo R- Randolph

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 9 of 30 Bulletin No.: 97891918 Rev 12-2011

5. Installation

5.1 Factory support

For customized products, we recommend that you have a Peerless Pump service engineer supervise installation and startup.

This is to ensure that the machinery is properly installed. You will then also have the opportunity to review, and see implemented, factory-recommended instructions.

5.2 Location

Note

Locate pump discharge piping (and suction piping when applicable) as well as auxiliary equipment, control and starting panels so that adequate access is provided for maintenance.

Adequate floor space and working room should also be provided for maintenance

Note

To minimize frictional head loss, locate the pump so that it can be installed with a short and direct discharge pipe and with the least number of elbows and fittings. If practical, it should be placed so that it will be accessible for inspection during operation. Pumps, drivers and controls should be protected against flooding.

5.2.1 Checking wells

Inspect the well before beginning installations. See fig. 3.

Caution

A crooked well may bind and distort the pump column or pump-motor assembly resulting in potential malfunction.

Well straightness should be in accordance with local standards such as AWWA-A100. If straightness is in doubt, the well should be checked prior to installation by lowering a dummy assembly, slightly longer and larger on the diameter than the actual pump or pump-motor assembly, on a cable. This is also important when a stepped well casing is used, with the lower part of the well casing having a smaller inside diameter.

Wells that have not been properly constructed or developed, or which produce sand, can be detrimental to a pump. If a well is suspected of producing an excessive amount of sand, a unit other than the production pump should be used to clear the well.

Air Vent Air Line

Starting Water Level

Drawdown

Working Water Level

TM

Fig. 3 Typical deep well installation

5.2.2 Checking wet pits

The configuration of the intake structure should be in accordance with industrial standards, such as HI 9.8, Pump Intake Design.

Dimensional checks should be made as follows to prevent installation and servicing problems.

1. Length of pump versus depth of sump.

2. Correct fit of anchor bolts sole plate (if supplied) or discharge head. If sole plate is supplied, check fit of holes from sole plate to discharge head.

3. Satisfactory angular location of anchor bolts or correct alignment of discharge head to discharge piping.

4. Proper conduit location provided for driver.

5. Sufficient head room for handling.

5.3 Foundation

The pump must be installed on a foundation rigid enough to support the entire weight of the pump plus the weight of the fluid contained in it. Weak foundations or foundations on unstable ground can cause misalignment, vibration, and even total foundation failure.

The mass of the foundation should be sufficient, preferably five times that of the rotating element of the pumping equipment, to form a permanent and rigid support for the base plate or discharge head. This is equally important whether the pump is installed over a pit, over a well or into a suction barrel.

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 10 of 30 Bulletin No.: 97891918 Rev 12-2011

Foundation and base plate bolt sizing is critical, particularly on high-pressure pumps, to adequately restrain reaction forces such as from directional flow change, system transients and sudden valve closure. Concrete foundations may have anchor bolts installed in sleeves that are two times the diameter of the bolt to allow alignment and should be located by a drawing or template.

Caution

Steel support structures may not be stiff enough even if their mass exceeds five times that of the rotating element. A civil engineer should review and approve a steel support structure before pump installation.

A barrier or frame (dam) to retain the grout between the pump base and the foundation must be provided around the hole for the pump column.

Some pumps are provided with a base plate or suction barrel that fits between the discharge head and the foundation. In this case, the foundation bolts must align with the holes in the base plate or suction barrel rather than those in the discharge head. The base plate is normally installed with the pump, but can be installed before the pump.

Whether the base plate is installed prior to the pump installation or at the same time, the discharge head must be attached to the base plate. Check that the bottom of the discharge head has been machined over its entire surface and is clean and free of burrs and nicks. The machined surface of the base plate is installed against the machined surface of the discharge head.

Failure to have each component's surface machined will result in excessive vibration.

Follow the instructions in sections 5.4.1 Leveling and 5.4.2 Grouting. After the grout is cured (a minimum of 48 hours), the discharge head may be removed to start the pump installation.

Peerless Pump does not recommend installation of the base plate without the discharge head. If, however, there is no choice except to install the base plate alone, use the machined surface at the top of the base plate (the discharge mounting surface) for leveling.

Caution Position the foundation and the foundation bolts so that the discharge head will be in accurate alignment with the discharge piping.

5.3.1 Seismic analysis

When pumps are located in seismically active areas and for certain critical installations the pumps, supports and accessories should be earthquake-resistant. The design specifications to achieve earthquake resistance vary, depending upon geographical area, class of the equipment (defining how critical the survival of the equipment is) and the characteristics (acceleration response) of the structure or foundation supporting the pump.

Complete specifications for earthquake-resistance requirements should be supplied by the customer. This includes the following:

• the seismic criteria, such as acceleration, magnitudes, frequency spectrum, location and direction relative to pump

• the qualification procedure required, i.e., analysis, testing or a combination of these, and requirements for operability during and/or after test.

5.4 Rigging and lifting

For typical installations, suitable overhead lifting equipment of adequate capacity to lift the driver, the entire pump (without driver) or the heaviest subassembly of the pump should be available at the job site when installing or removing the pump.

Adequate headroom should be provided to accommodate the longest section of the pump to be handled, including rigging.

Caution

Properly sized slings, chains and shackles should be available for attaching to the lifting lugs (eyes). Eyebolts are required for handling pump sections when lifting lugs are not provided.

I-beams or column clamps for supporting pump subassemblies at the foundation should be available when it is necessary to install the pump in sections. Common tools are used for this type of work, including a machinist level to ensure proper leveling of the foundation plate.

5.4.1 Leveling

1. Remove the supporting timbers, rope and any other equipment from the top of the foundation.

2. Cover the discharge head to protect it from dust, and sweep the foundation clean.

Note

If the base plate is not already grouted in place, be certain that the grouting dam around the foundation opening is in place before lowering the pump assembly onto the foundation.

3. Lower the pump until the base of the discharge head or base plate is just above the foundation bolts.

4. Orient the pump so that the discharge outlet is in the desired direction and the holes in the base align with the foundation bolts.

5. Continue to lower the pump until the bolts just enter the holes in the base.

6. If the foundation is concrete, place the wedges (furnished with the pump) under the discharge head or base plate, adjacent to the bolt holes, one under each of the four sides.

For structural foundations (made up of I-beams or H-beams), use shims under the corners.

7. Continue to slowly lower the pump until the base of the discharge head or base plate rests on the shims or anchor bolts with washers and nuts.

Caution Accurate alignment of the discharge head in relation to the pump shaft is absolutely essential for smooth and trouble-free operation.

8. By using the wedges or washers and nuts on the anchor bolts, adjust the discharge head flange centre line to the correct elevation.

9. While maintaining the correct elevation, adjust the nuts and washers or shims to achieve the specified levelness of 0.005" per foot (0.4 mm per meter) in both directions as shown in fig.

4. The levelness should be measured by placing a precision level on the machined face of the discharge head motor register.

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 11 of 30 Bulletin No.: 97891918 Rev 12-2011

Fig. 4 Check for levelness in two directions

10. For other applications, place a machinist's level on the driver mounting surface of the discharge head, orienting it parallel with one of the edges of the base.

11. Move the wedges or add more shims until the level reading reaches 0.005" per foot (0.4 mm per meter).

12. Reorient the level on the same surface, 90 ° from the original position.

13. Again adjust the wedges or shims until a 0.005" (0.12 mm) level reading is reached, taking care not to upset the levelness is the first direction.

14. After each adjustment, check for levelness in both directions.

15. Push in or add to any loose shims to distribute the weight evenly.

16. Fit nuts on the foundation bolts and tighten them gradually and uniformly.

17. Check the level readings in both directions.

18. If necessary, loosen the foundation bolts and readjust the wedges or shims, tighten the bolts again and check the level readings.

5.4.2 Grouting

After the discharge head is at the correct location and leveled with a precision level, the discharge head and/or base plate need to be grouted to the foundation.

Discharge Head

Nut

Anchor Bolt

Washer

Dam for Grout

Wedge

TM

15Grout

TM

Foundation

Fig. 5 Typical foundation without base plate

Fig. 6 Typical foundation with base plate

Use only non-shrinking grouting material for grouting the discharge head, base plate or suction barrel to the foundation

1. Build a dam on the foundation, enclosing an area around the discharge head that includes all alignment wedges. The top of the dam should be approximately 1/2 inch (12 mm) above the bottom of the discharge head base. See fig. 5 and

2. Pour the grouting material into the dammed-in area and force it between the discharge head and the foundation all around.

3. Level off the grout flush with the top of the dam.

4. Allow the grout to cure at least 48 hours before tightening the foundation bolts or starting the pump.

5.5 Installation preparations

5.5.1 Inspection

All pump parts were carefully inspected before leaving the factory, but may have become soiled or damaged in shipping and handling or storage at site. The installer must therefore check that all parts are clean and undamaged before installing them.

Caution Do not step or walk on the shafts. Do not place other parts or equipment on the shafts.

Caution

Never attempt to align the discharge head of a well pump using a spirit (carpenter’s) level. If the pump column does not hang freely in the well, as might be the case when the well is drilled at a slight slant, leveling the discharge head will not ensure the necessary shaft alignment and clearance in the driver spindle.

The discharge head base must be square with the pump shaft regardless of the result indicated by a spirit level. A bent shaft could occur, causing early pump failure and expensive repair.

Discharge Head

Nut Anchor Bolt

Washer Dam for Grout

TM

Wedge Sole Plate

Grout

Foundation

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 12 of 30 Bulletin No.: 97891918 Rev 12-2011

Use appropriate solvent to wash off any protective coating from the shaft sections and wipe thoroughly clean and dry.

Clean the shaft coupling threads using a wire brush and solvent, cover both ends, and store couplings in a clean place until ready for use.

Unless the pump is less than 30 feet (9 m) and was shipped from the factory pre-assembled, all installation and assembly must be done vertically. If the unit was shipped assembled from the factory, check all pump, tube (if applicable) and column joints for tightness with the pump in the vertical position and with its weight borne by support clamps around the well or sump opening.

Caution

Do not attempt to assemble the bowl, column, shaft and discharge head horizontally on the ground. This could cause bending and damage the shaft sections, tubing (if applicable) and possibly the column pipe and lead to malfunction of the pump

The well or sump must be thoroughly cleaned of dirt, debris and contaminants before installing the pump. After the installation, the well or sump should again be inspected for foreign matter and cleaned, if necessary. If it is suspected that the fluid will contain sizable solid particles or that foreign objects may enter the sump or well, a suction strainer should be installed with the pump and cleaned periodically. Your Peerless Pump dealer will be glad to advise you on the need for a suction strainer. Dirt, sand, etc. in the sump or well will cause premature wear on the critical pump internal surfaces, resulting in reduced pump performance.

Check that shaft sections are straight and have not been bent in shipping or handling.

1. Set a pair of rollers or V-blocks on a firm base next to the pump site to support one shaft section. See fig. 7.

2. Provide a solid mounting for a dial indicator at points 1, 2 and 3.

3. Place a shaft on the rollers or V-blocks and rotate it slowly by hand while checking the eccentricity (runout) at points 1, 2 and 3. It should not exceed 0.005 inches (0.12 mm).

4. Check all shaft sections in this manner. Do not use any shaft section that exceeds the limits given. Shafts that do not meet the runout may be straightened.

A B C

Fig. 7 Checking the shaft straightness

The shaft may be re-straightened by either the heating and cooling technique or bending it back to straight by use of a press. All re-straightened shaft sections must have a cleanup cut machined on both ends and must be checked for eccentricity.

Larger shafts and shafts for non-threaded (split-ring) couplings may have an internal threaded hole on one end; this end goes up.

In a flanged column pump, the intermediate column sections have identical ends; either end may be upward. However, the top and bottom sections may not have identical ends. See the assembly drawing for the proper orientation. If the flanged column has an integral bearing retainer, that end faces upward.

5.5.2 Assembling the pump

The preferred method is to install the shaft and couple it, then install the column over the shaft, provided that head room permits.

Caution When inserting the shaft sections into the column section, take care not to bend the shaft or damage the threads.

1. Check the total length of the bowl assembly, suction pipe and strainer (if any) to see whether the hoist clearance is sufficient to handle these parts as a unit. If the clearance is sufficient, fit the strainer to the suction pipe and the suction pipe to the bowl assembly. Lay this assembly across the timbers, close to the sump, ready for installation.

If head room is limited, pre-assemble all the standard shaft and column sections. Alternatively the unit may be assembled over the well. Do not insert the top shaft section into the top column section at this time.

2. Before proceeding with the actual installation, check to see that all the pump parts and equipment have been prepared according to the directions given in this section.

5.5.3 Installing the bowl assembly

1. Place two eyebolts diametrically opposite in the upper flange of the bowl assembly.

2. Attach a sling to the eyebolts using suitable shackles and pass the looped end of the sling over the hoist hook.

3. Lift the bowl assembly in such a way so that it is not dragged or bumped in order to prevent damage to any part of the pump.

4. While the bowl is in the vertical position, install the strainer, if provided.

5. Fasten a box-type clamp or elevator clamp to the bowl assembly, just below the upper flange. See fig. 8.

Caution Never attempt to handle or lift the bowl assembly by the shaft protruding from the upper end. This could result in bending of the shaft.

6. Lower the bowl assembly until it rests securely on the support beams. See fig. 8.

TM

TM

Fig. 8 Bowl assembly supported by a box-type clamp

7. Place over the top of the bowl assembly a specially made wood or metal apron that covers the opening and fits closely around the impeller shaft. Wrap a clean rag tightly around the

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 13 of 30 Bulletin No.: 97891918 Rev 12-2011 shaft, over the apron. This will prevent entry of foreign matter into the bowl assembly.

Caution

Take care not to drop tools, screws, nuts or any other foreign objects into the bowl assembly or sump. Such an object could impair pump performance or ruin the impellers. If passed by the pump into the discharge piping, a solid object could cause serious damage to downstream components.

Any foreign object dropped into the pump column must be retrieved before proceeding with the pump installation. If any foreign object is dropped into the sump, it must be retrieved prior to starting the pump.

5.5.4 Installing the column and shaft

1. Head room permitting, lift the appropriate-length shaft into a vertical and plumb position. Check shaft threads for any foreign materials or damage, and clean threads with a wire brush and solvent as required.

Caution Shaft threads are left-hand and must be clean and deburred.

2. Coat the shaft face and threads with anti-seize compound.

3. Check the shaft coupling for any damage or foreign material and clean, if necessary.

4. Screw the coupling onto shaft for half its distance.

Approximately 1 1/2 shaft threads will be visible when coupling is in half-way position. Another check for correct positioning of the coupling on the shaft is to insert a fine wire into the drilled hole in the centre of the coupling.

5. Visually inspect the shaft threads and face of the mating shaft. Coat them with antiseize compound.

6. Lower the shaft and coupling onto the lower (bowl assembly) shaft.

7. Manually screw coupling until tight. If resistance is encountered, remove the coupling and shaft, and inspect the threads at both the coupling and shaft to determine the problem. Because the threads of the shaft and coupling are straight (not tapered), one should be able to tighten them by hand until the two faces mate.

8. Check the tightness of the mating by using two pipe wrenches as shown in fig. 9. No noticeable movement should occur when the pipe wrenches are used to check the tightness of the hand-mating. If movement is noticed, it would be an indication that foreign material has gotten between the faces of the two shafts and, by using the wrenches, you are causing movement by compressing the foreign material. Separate the shafts, remove the foreign material and correct any scoring on the shaft faces.

Fig. 9 Making a shaft joint

9. Connect a dragline to the lower end of the column flange, to be used in guiding and aligning the column over the shaft.

See fig. 10. The use of the dragline will prevent accidental bumping of the shaft by the column that could bend the shaft.

10. If gaskets or O-rings are used between the flange joint, fit the appropriate gasket/O-ring on the bowl flange.

11. If the column pipe is threaded and coupled, the threads should be thoroughly cleaned and lubricated. With column supported, start the threads by hand to be sure the no cross-threading occurs. Then completely tighten the pipe against the discharge bowl using a chain wrench.

12. With the column aligned over the shaft-bowl assembly, lower it onto the bowl flange.

13. Check that the two flanges are properly registered, and fit and cross-tighten fasteners.

TM

Fig. 10 Column section with dragline attached

5.5.5 Installing the bearing retainer

Note Keep rubber bearings free of any lubricant or sealing compound.

1. If using a flanged column, nest the rim of the bearing retainer into the counter bore in the column flange. See fig. 11.

2. Fit a column flange O-ring or gasket.

3. Slide the bearing retainer assembly over the protruding shaft section.

4. If the pump has only one column section, continue the installation procedure as described in section 5.5.6 installing the discharge head.

If the pump has additional column sections, proceed with the following instructions.

5. Fit a removable shaft sleeve, if supplied, over the shaft and into the bearing bore. The sleeve should be centered axially in the bearing.

6. Tighten the sleeve set screw. Apply a seizing compound, such as Loctite, on the set screw threads to prevent loosening of screw.

TM

Additional column sections

1. Fit the bearing retainer with bearing over the extending shaft and onto the female register of the column flange.

It is the policy of Peerless Pump to continually seek ways to improve its products and reserves the right to alter documentation without

Page 14 of 30 Bulletin No.: 97891918 Rev 12-2011

2. Fit the O-ring over the bearing retainer resting in the chamfered part of the lower column flange.

3. Install the remaining shaft and column sections, including the top sections, bearing retainers and removable sleeves, if applicable.

4. For pumps having a…