T6225-MS-MMC-010_0_0_(Tech_Manual).pdf

T6225-MS-MMC-010

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

0910-LP-103-0619

TECHNICAL MANUAL

PUMPS, CENTRIFUGAL,

0510 VORTEX

Gray Water Transfer Pump

FOR

USNS LEWIS AND CLARK (T-AKE 1) CLASS

OPERATION, MAINTENANCE, & REPAIR

( BUFFALO PUMPS, INC. )

NORTH TONAWANDA, NY 14120

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

T6225-MS-MMC-010

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

DATE: 12 MAY 2005

0910-LP-103-0619

TECHNICAL MANUAL

PUMPS, CENTRIFUGAL,

0510 VORTEX

Gray Water Transfer Pump

FOR

USNS LEWIS AND CLARK (T-AKE 1) CLASS

OPERATION, MAINTENANCE, & REPAIR

( BUFFALO PUMPS, INC. )

NORTH TONAWANDA, NY 14120

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

[FOR REPRODUCTION PURPOSES ONLY 3 ]

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TABLE OF CONTENTS

TITLE

CHAPTER PAGE

LIST OF ILLUSTRATIONS ........................................................................................... iii

CHAPTER 1 GENERAL INFORMATION AND SAFETY PRECAUTIONS…………. 1-1

1-1 Safety Precautions .......................................................................................… 1-1

1-2 Introduction ................................................................................................….. 1-1

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

1-4 Motor..........................................................................................................….. 1-2

1-5 Weights.......................................................................................................…. 1-3

1-6 Overall Dimensions of Assembled Unit........................................................... 1-3

1-7 Reference Drawings.....................................................................................… 1-3

1-8 Pump Clearances.........................................................................................… 1-3

1-9 Procedure for Preservation, Packing, and Long Term Storage......................................................................................…. 1-4

1-10 Special Tools and Test Equipment..............................................................… 1-4

CHAPTER 2 OPERATION.......................................................................………….. 2-1

2-1 Introduction..................................................................................................…. 2-1

2-2 General.........................................................................................................… 2-1

2-3 Safety Precautions......................................................................................… 2-1

2-4 Initial Start-Up Instructions..........................................................................… 2-2

2-5 Normal Starting................................................................................................ 2-2

2-6 Running........................................................................................................…. 2-3

2-7 Securing.......................................................................................................…. 2-3

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ii

TABLE OF CONTENTS (Continued)

CHAPTER 3 SCHEDULED MAINTENANCE..........................................…………. 3-1

3-1 Introduction................................................................................................…. 3-1

3-2 Safety Precautions.....................................................................................…. 3-1

3-3 General and Daily Operational Checks........................................................… 3-1

3-4 Tests and Inspections..................................................................................… 3-1

3-5 Preventative Maintenance............................................................................. 3-2

3-6 Lubrication..................................................................................................… 3-2

CHAPTER 4 PARTS LIST.......................................................................…………. 4-1

4-1 Introduction………………………………………………………………………… 4-1

4-2 Special Tools………………………………………………………………………. 4-1

APPENDICES

APPENDIX TITLE PAGE

A-1 Buffalo Pumps, Inc. Service A-1-0 Manual #3362B For CR-FV & CR-AV Vortex Pumps

A-2 Buffalo Pumps, Inc. Centrifugal A-2-0 Pumps General Information Service Manual Bulletin #3321-I

A-3 Marathon Electric Motor Information A-3-0

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iii

TABLE OF CONTENTS (Continued)

LIST OF ILLUSTRATIONS

FIGURE NUMBER TITLE PAGE

1-1 Gray Water Transfer Pump 1-5 Outline Drawing No. CA16788

1-2 Gray Water Transfer Pump 1-6 Performance Curve

4-1 Gray Water Transfer Pump 4-2 Parts List

4-2 Gray Water Transfer Pump 4-7 Sectional Drawing No. CA16787

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iv

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following are general safety precautions that are not related to specific procedures and, therefore, do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance.

Personnel responsible for the equipment should become thoroughly familiar with and frequently review the following information. Should situations arise that are not covered in the general safety precautions, a necessary order will be issued by the commanding officer or other authority.

DO NOT SERVICE OR ADJUST ALONE

Under no circumstances should any person reach into or enter the enclosure for the purpose of servicing or adjusting the equipment, except in the presence of someone who is capable of rendering aid.

RESUSCITATION

Personnel working with or near high voltages should be familiar with modern methods of resuscitation. If someone is injured and stops breathing, initiate resuscitation immediately. A delay could cost the victim’s life.

TAGGING OPEN SWITCHES

De-energize, disconnect and tag OUT OF SERVICE all sources of power before working on equipment. High Voltage, High Capacitance components shall be discharged to ground to prevent personnel injury or death. All tag out procedures shall be performed in accordance with current switchboard instructions to prevent personnel injury or death. Before working on electrical equipment, use a voltmeter to ensure that system is not energized.

TEST EQUIPMENT

Make certain that test equipment is in good working condition. If a test meter must be held, ground the case of the meter before starting measurement. Do not touch equipment or personnel working on live equipment while holding a test meter. Some types of measuring devices should not be grounded; these devices should not be held when taking measurements. When connecting a meter to terminals for measurements, use a range higher than expected.

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1-1

CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1 SAFETY PRECAUTIONS

WARNING

The pump covered in this chapter of the manual is driven by an electric motor using 460 volts AC. All safety precautions required when using electric motor driven equipment must be strictly adhered to. Do not use water on an electrical fire, use carbon dioxide. When working on a pump, disconnect from power source and tag out of service.

a. Specific safety precautions required for this equipment are listed immediately prior to the instructions to which the precaution applies. For example, safety precautions to be followed prior to staring the equipment for the first time are listed in Chapter 2, Operation. Safety precautions to be followed prior to maintenance are listed in Chapter 3.

1-2 INTRODUCTION

a. List of Items Furnished

One (1) Buffalo Pumps 0510 VORTEX Pump close coupled to a Marathon 900104 motor (Fig. 1-1).

b. This chapter of the technical manual covers the description, operation, and maintenance of a Buffalo Pumps Type 0510 vortex Pump used as a Gray Water Transfer Pump. The pump is manufactured by Buffalo Pumps, Incorporated, North Tonawanda, New York 14120.

c. The 0510 vortex Pump is a horizontal, single end suction, single stage, volute type centrifugal pump. The pump adapter bracket (60) to which the casing is attached, is mounted directly to the end bell of the driving motor. The pump rotating element is mounted directly on the motor shaft extension.

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1-2

1-3 PUMP

Application............................................................................................. Gray Water Pump

Buffalo Pumps Type............................................................................… 0510 Vortex Buffalo Shop Order Location of Discharge……………………………………………………… Vertical Up Rotation................................................................................................. CW Capacity................................................................................................ 51 GPM Total Head............................................................................................. 115 Feet Liquid Handled....................................................................................... Gray Water Specific Gravity of Liquid Pumped...........................................................................………… 1.0 Suction Pressure.................................................................................… 13 Feet Suction Temperature............................................................................. 35 o C

RPM

Efficiency.............................................................................................. 22%

Brake Horsepower At Rating................................................................. 7.0 Brake Horsepower At Any Condition..................................................…… 9.98 Actual Shut-Off Head..........................................................................…. 115 Hydrostatic Test Pressure...................................................................... 100 psi Final Impeller Diameter.......................................................................... 10"

1-4 MOTOR

Frame.................................................................................................... 215 JP

HP

RPM (Synchronous).............................................................................…. 1800 RPM (Full Load)...................................................................................…. 1765 Phase/Cycles/Volts.............................................................................…… 3/60/460 Speed Class.........................................................................................… Constant Duty....................................................................................................... Continuous Calculated FL Amps...........................................................................…… 12.5 Ambient Temperature.........................................................................… 50oC Enclosure............................................................................................... TEFC Rotor Type............................................................................................. Squirrel

Cage Bearing.................................................................................................. Ball Mounting................................................................................................ Horizontal Winding.................................................................................................. Single Insulation Class...................................................................................... F

NOTE

Refer To Appendix A-3 For Additional Motor Data

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1-3

1-5 WEIGHTS (Calculated)

Pump (Dry)............................................................................................. 265 Lbs.

Pump (Operating)................................................................................... 270 Lbs.

Motor...................................................................................................... 475 Lbs.

Total One Unit (Dry)............................................................................... 740 Lbs.

Total One Unit (Operating)..................................................................... 745 Lbs.

1-6 OVERALL DIMENSIONS OF ASSEMBLED UNIT

Height.................................................................................................... 17-3/4” Length................................................................................................... 32”

Width (Approximate)............................................................................. 18-1/4”

1-7 REFERENCE DRAWINGS

Buffalo Pumps Dwg. No. CA16788 Outline Elevation

Buffalo Pumps Dwg. No. CA16787 Sectional Assembly

List of Materials 0510 Vortex-1

1-8 PUMP CLEARANCES (See Figure 4-2)

Part CLEARANCE INCHES

RADIAL AXIAL

A- Impeller (3) and Casing ----- 3/16 Nom.

Cover (6)

B- Impeller (3) and Casing (2) 5/32 Nom.

* C- Impeller (3) and Casing .006 ------ Cover Wearing Ring (10) .008

* D- Impeller (3) and Casing .006 ------ Wearing Ring (9) .008

* Renew clearance between impeller (3) and casing and casing wearing rings (9) and (10) when radial clearance is double the initial value and/or when pump performance is reduced (refer to Figure 1-2).

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1-4

1-9 PROCEDURE FOR PRESERVATION, PACKING AND LONG TERM STORAGE

The following procedures are applicable to all pumps covered in this manual to provide adequate protection for the pumps during shipment and storage for a period of up to one year.

Pumps may be stored indoors or out as long as the temperature and weather conditions are moderate.

a. Preservation. All unpainted metal surfaces subject to corrosion shall be treated with Rust-Ban #394 or equivalent. The Rust-Ban may be applied by dipping, flow coating, slushing, brushing, filling or flushing, fogging or spraying.

b. Packaging. All open flanges shall be covered with barrier material and a blank flange or wood, plywood, or metal shall be bolted over the barrier. The use of tape on openings and internal surfaces is prohibited. On smaller openings, a plastic plug may be used. The size of the opening and the component for which the seal is intended shall be marked on the plug or cap.

c. All surfaces preserved with Rust-Ban #394, including couplings, shall be wrapped with a greaseproof barrier material and secured in place with pressure sensitive tape.

d. Packing. The pump unit and base shall be resiliently mounted in a nailed wood box with a skid type base or in a sheathed crate. Each container shall be fully enclosed.

The inside of the wood box shall be lined with waterproof paper. For those pumps intended for long term storage, Desiccant shall be placed inside the box. Desiccant should be used at the rate of one package per cubic foot of enclosed air. Each container shall be closed and strapped with flat steel strapping.

e. Motors. Refer to applicable instructions in Appendix -3.

f. Marking. For those units intended for long term storage, each container shall be marked “For Long Term Storage”, with the date the unit was packed clearly visible on the outside of the container. Each container shall further be marked on the outside with the pump serial number, customer’s name, purchase order, job number, and item number.

Letters shall be a minimum 1-1/2” high.

1-10 SPECIAL TOOLS AND TEST EQUIPMENT

a. No special tools or test equipment is required to maintain or disassemble the pump

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Page 1-5 Figure 1-1

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1-6 Figure 1-2

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2-1

CHAPTER 2

OPERATION

2-1 INTRODUCTION

a. This section lists all of the information required for operation of the pump unit.

2-2 GENERAL

a. The operating instructions do not include procedures for positioning accessories which are not furnished by the pump manufacturer, but which are installed as features of the system in which the pump is installed and hence, may affect the operation of the pump.

b. The operator should line up the system in accordance with applicable instructions before actually starting the pump.

2-3 SAFETY PRECAUTIONS

WARNING

This pump is driven by an electric motor using 460 volts AC. All safety precautions required when operating electric motor driven equipment must be strictly adhered to. Do not use water on an electrical fire, use carbon dioxide. When working on this pump, disconnect from power source and tag “Out Of Service”.

a. The following safety precautions and operating checks shall be made before staring the unit after initial installation, after an overhaul, or after a long period of idleness (i.e. three (3) months or more). Refer to Appendix A-1, for overhaul instructions.

b. Make sure the pump casing is filled with liquid. The mechanical seal may fail if the pump is run dry.

c. Prior to remaking the ship system piping, check to ensure that exposed pump internals and attached piping are free of foreign material. Ensure that all discs used to blank off piping are removed.

d. Ensure that exposed parts of the rotating element are free of all foreign material and the unit is free to rotate. Rotate the pump shaft manually to ensure that it will rotate easily without binding, noise, or grinding.

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2-2

e. Ensure correct motor direction of rotation. The correct direction of rotation is indicated by an arrow on the pump casing. When rotation is reversed, refer to the motor electrical connection instructions provided.

f. Ensure that the ship system arrangement and valve line up provides a flow path for this pump.

g. Check all piping for leaks.

2-4 INITIAL START-UP INSTRUCTIONS

CAUTION

Do not run this pump dry. Even momentary operation without an adequate supply of cooling water in the stuffing box could cause the mechanical seal to fail.

a. Prime the pump using system instructions (Refer to Appendix A-2, Page A-2-16).

Check if the pump is completely filled with liquid by loosening the vent plug or seal lubrication line fitting and observing for liquid flow. Re-tighten loosened plug or fitting.

b. Check that the motor shaft is free to rotate.

c. Check that the pump suction valve is open and the discharge valve is shut.

d. Start the motor.

e. Open the discharge valve in the system slowly when discharge pressure is reached.

2-5 NORMAL STARTING

a. Prime the pump using system instructions (Refer to Appendix A-2, Page A-2-16).

Check if the pump is completely filled with liquid by loosening the vent plug or seal lubrication fitting and observing for liquid flow. Re-tighten loosened plug or fitting.

b. Check that the pump suction valve is open and discharge valve is shut.

c. Start the motor.

d. Open the discharge valve when the pressure in the discharge line shows design discharge pressure.

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2-3

2-6 RUNNING

a. The stuffing box is lubricated with liquid from the discharge volute. If the stuffing box runs hot, check for liquid flow through the seal water piping.

b. Inspect the motor and pump temperatures and pressures as required. If the values vary from normal or change suddenly, investigate and correct the trouble immediately.

c. Watch for oil, grease, or liquid spillage and correct causes if found.

d. Check for any unusual noise or vibration and correct any trouble found.

e. The mechanical seal should reduce leakage from the stuffing box to almost nil. If leakage occurs and increases, the stuffing box mechanical seal should be replaced.

2-7 SECURING

a. Close the pump discharge valve.

b. Stop the pump motor.

c. Close the pump suction valve if required by the system instructions. If possible, leave this valve open at all times.

d. Refer to the system instructions and position all valves as directed.

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3-1

CHAPTER 3

SCHEDULED MAINTENANCE

3-1 INTRODUCTION

a. This section contains preventative maintenance procedures to be used at the intervals specified in the instructions.

b. Refer to Appendix A-3 for the motor maintenance data.

3-2 SAFETY PRECAUTIONS

a. Before performing any maintenance on a pump, isolate the pump from the system by closing and tagging or locking all valves closed. Tag or lock all switches to motor or controller in the open position. All safety precautions required when using electric motor driven equipment must be strictly adhered to.

3-3 GENERAL AND DAILY OPERATIONAL CHECKS

a. Personnel should frequently check the operating pump and familiarize themselves with normal pressures, temperatures, and operating noises. Any deviation from normal should be reported and investigated.

b. Listen carefully for any unusual noises. A peculiar sound could be a sign of potential pump failure and, therefore, should be checked out.

3-4 TESTS AND INSPECTIONS (See Figure 4-2)

3-4-1 Weekly.

a. Turn the idle pump shaft by hand.

b. Check pump and piping for leaks during operation. Leakage at the pump stuffing box should be almost nil. If leakage appears at the stuffing box, it indicates a defective or improperly installed mechanical seal, which should be replaced.

c. Check operation of all valves in the system.

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3-2

3-5 PREVENTATIVE MAINTENANCE (See Figure 4-2)

a. When pump performance degrades or discharge pressure decreases, inspect pump for worn running clearances.

b. Open the pump casing in accordance with the disassembly instructions listed in Appendix A-1. Inspect, check clearances, and clean or replace parts as necessary.

Clearances should not exceed twice the initial radial clearance between the impeller ring turns and the casing or casing cover wearing rings (9) and (10). When this clearance becomes twice the initial value, (refer to Chapter 1, Paragraph 1-8), the wearing ring clearance should be renewed by replacing parts.

c. Check impeller (3), shaft sleeve (8), and shaft (7) for wear, damage, or deterioration.

NOTE

These inspections and checks are the minimum necessary to give an adequate assurance of safe, reliable operation of the equipment. Indications of low discharge pressure, or other manifestations of improper operation, indicates the need for more frequent or extensive inspections and checks.

3-6 LUBRICATION

a. The pump does not require any lubrication.

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4-1

CHAPTER 4

PARTS LIST

4-1 INTRODUCTION

a. When ordering parts for pumps, refer to Figure 4-1 for the list of materials. Item numbers referenced on the list of materials refer to item numbers shown on the pump sectional drawing, Figure 4-2. Include the nameplate data, piece number, etc.

(as much information as is available) in each order to the manufacturer.

4-2 SPECIAL TOOLS

a. No special tools are required to install or maintain the pump.

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4-2 Figure 4-1

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4-3 Figure 4-1

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4-4 Figure 4-1

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4-5 Figure 4-1

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4-6 Figure 4-1

Please note that additional parts breakdowns appear in Appendices.

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Page 4-7 Figure 4-2

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A-1-0

APPENDIX A-1

Buffalo Pumps, Inc.

Service Manual #3362B

For

CR-FV & CR-AV Vortex Pumps

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A-1-1

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A-2-0

APPENDIX A-2

Buffalo Pumps, Inc.

Centrifugal Pumps General

Information Service Manual

Bulletin #3321-I

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A-3-0

APPENDIX A-3

Marathon Electric Motor Information

1-1 CONTENTS

A) Marathon Electric Instruction Manual

B) Marathon Electric Dimension Sheet # 900104

C) Marathon Electric Parts List

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N60827

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MARINE PLAN # 900104/900105

ITEM ID # 215TTFS29032AN

BASIC DESCRIPTION

DE BEARING MARATHON PART # A-90009R-45 1.00 pcs

EQUIVALENT AFBMA # 45BC03JPPX30X

ODE BEARING MARATHON PART # A-90008R-30 1.00 pcs

EQUIVALENT AFBMA # 30BC02JPPX30X

EXTERNAL FAN C-67991 1.00 pcs

SPACE HEATER NOT APPLICABLE

MOTOR BILL OF MATERIAL

10/7.5,1800/1500,TEFC,215TCZ,3/60/50/460/380

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