Item 0501_T6225-JP-MMC-010_0_0 Ballast Pump.pdf

7-6225-JP- M C - 0 1 0

RldARD BALLAST PUN

TYPE 1%- TBM-14H

T A O - 1 8 7 CLASS - SERIES T A O - 1 9 8

N00024-88-C-2050

WRRREN PUMPS INC.

WFIRREN, MASSACHUSETTS 0108J

” D I STR I BUT O N AUTHOR 3N STATEMENT ‘ C ’ D I S T R I B U T ZED

TO U.S. GOVERNMENT A G E N C I E S AND T H E I R CONTRACTORS;

ADMINISTRATIVE/OPERATIONAL USE: ( D A T E O F P U B L I C A T I O N ) .

OTHER REQUESTS FOR T H I S DOCUMENT SHALL B E REFERRED TO

THE COMMANDER, M I L I T f i R Y S E A L I F T COMMAND, CODE N-7 , WASHINGTON, DC 20390-5100.”

”WARNING: T H I S DOCUMENT C O N T A I N S T E C H N I C A L DATA

WHOSE EXPORT I S R E S T R I C T E D BY THE ARMS EXPORT CONTROL

ACT ( T I T L E 22, 0.3.0 SEC 2751 E T . SEQ. OR E X E C U T I V E ORDER

12470. V I O L A T I O N S O F THESE EXPORT LAWS ARE SUBJECT TO

SEVERE C R I M I N A L P E N A L T I E S ” .

“ D E S T R U C T I O N N O T I C E : DESTROY BY ANY METHOD THAT WILL

PREVENT D I S C L O S U R E O F CONTENTS OR RECONSTRUCTION OF

THE DOCUMENT. ”

I

2 ~1 0918LP5371300

I ! llllRllllll1111111111 lllllllllllllllllill1111111111 II I

T6225-JP-MMC-818

1 1 I

L I S T O F E F F E C T I V E PAGES

t

I n s e r t l a t e s t c h a n g e d p a g e s a n d d e s t r o y s u p e r s e d e d p a g e s .

I NOTE: T h e p o r t i o n of t h e t e x t a f f e c t e d by t h e c h a n g e s i s i n d i c a t e d , by a v e r t i c a l l i n e i n t h e o u t e r m a r g i n s o f t h e p a g e . C h a n g e s t o t o w i r i n g d i a g r a m s a r e i n d i c a t e d by s h a d e d a r e a s .

I i l l u s t r a t i o n s a r e i n d i c a t e d by m i n i a t u r e p o i n t i n g h a n d s . C h a n g e s

I Dates of i s s u e f o r o r i g i n a i a n d c h a n g e d p a g e s a r e

O r i g i n a l . . O . . 15 MARCH 1992

I T o t a l n u m b e r o f p a g e s i n t h i s p u b l i c a t i o n is 71 c o n s i s t i n g of t h e

I f o l l o w i n g :

P a g e No .

I C h a n g e No.

T i t l e A R e c o r d of C h a n g e s

V a l i d a t i o n C e r t i f i c a t e . 0 i t h r u v i 1-1 t h r u 1-6 2-1 t h r u 2-2 3-1 t h r u 3-2 4-1 t h r u 4-5 4-6 b l a n k 5-1 t h r u 5-6 6-1 t h r u 6-19 6-20 b l a n k 7-1 t h r u 7-11 7-12 b l a n k 8-1 t h r u 8-5 8-6 b l a n k

A&PR Page

Y Zero i n t h i s co lumn i n d i c a t e s a n o r i g i n a l p a g e .

A

CHANGE

NUMBER

DGTE

Z N T E R E D

RECORD O F CHANGES

T I T L E OR B R I E F

D E S C R I P T I O N ENTERED BY

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: T 6 2 2 5 - J P - M M C - 0 1 0

T I T L E O F MANUAL: FORWARD B A L L A S T PUMP - T Y P E 12-DTBM-14H

APPROVAL AUTHORITY: Superv i so r o f S h i p b u i l d i n g , C o n v e r s i o n & R e p a i r , USN, N e w O r l e a n s , T - A 0 198 S e r i e s , L e t t e r S e r i a l No. 500-14293 d a t e d 02 D e c 1991

W A N T I T Y

CONTRACT SHIP O F

NUMBER A P P L I C A B L I L I T Y MANUALS

B U I L D I N G

YARD

N 0 0 0 2 4 - 8 8 - C - T - A 0 198-204 2 per sh ip A v o n d a l e I n d u s t r i e s I n c .

2050 A v o n d a l e S h i p y a r d s D i v

New O r l e a n s , L o u i s i a n a

REMARKS:

DATE: 15 M a r c h 1992

C E R T I F I C A T I O N : I t i s hereby c e r t i f i e d t h a t T6225-JP-MMC-010 t o be .

p rov ided under c o n t r a c t n u m b e r N 0 0 0 2 4 - 8 8 - C - 2 0 5 0 has been approved b y the a p p r o v a l d a t a s h o w n above.

WARREN, f lASSAdH6SETTS

FSCM 63857

T E C H N I C A L M A N U A L V A L I D A T I O N C E R T I F I C A T E

T E C H N I C A L MANUAL T I T L E

F o r w a r d B a l l a s t P u m p - T y p e 1 2 - D T B M - 1 4 H

NAVSEA T E C H N I C A L MANUAL NUMBER

T 6 2 2 5 - J P - M M C - 0 1 0

D A T E 9/1/70

CONTRACT/TMCR NO.

N 0 0 0 2 4 - 8 8 - C - 2 0 5 0

I - V A L I D A T I O N

E x c e p t as s t a t e d i n 11, the t e c h n i c a l m a n u a l i d e n t i f i e d above has been s a t i s f a c t o r i l y v a l i d a t e d i n accordance w i t h a l l r e q u i r e -m e n t s o f the a p p l i c a b l e TMCR and the approved V a l i d a t i o n P l a n .

T h e t e c h n i c a l m a n u a l i s hereby c e r t i f i e d t o be a c c u r a t e and c o m p l e t e , and the i n f o r m a t i o n , i n s t r u c t i o n s , t e x t , and i l l u s t r a -t i ons c o n f o r m i n a l l r e s p e c t s t o the a p p l i c a b l e genera l and d e t a i l e d s p e c i f i c a t i o n s .

1 1 - E X C E P T I O N S

E X C E P T I O N S A U T H O R I Z E D B Y

S I G N A T U R E O F P U B L I C A T I O N S Q U A L I T Y ASSURANCE O F F I C E R I D A T E

T A B L E OF CONTENTS

C h a p t e r Page

L I S T OF I L L U S T R A T I O N S ...................................... i i i L I S T OF T A B L E S ............................................. i i i SAFETY SUMMARY ............................................. iv

1 . GENERAL I N F O R M A T I O N

1-1 . SAFETY PRECAUTIONS ............................... 1-1

1-2 . I N T R O D U C T I O N ..................................... 1-1

1-3 . EQUIPMENT D E S C R I P T I O N ............................ 1-1

1-4 . REFERENCE DATA ................................... 1-3

1-5 . L I S T OF MAJOR COMPONENTS ......................... 1-4

1-6 . STORAGE .......................................... 1-4

1-7 . TOOLS AND TEST E W I P M E N T ......................... 1-4

2 . O P E R A T I O N

2.1 . I N T R O D U C T I O N ..................................... 2-1

2-2 . CONTROLS AND I N D I C A T O R S .......................... 2-1

2-3 . S T A R T I N G ......................................... 2-1

2-4 . NORMAL OPERATION...............................^. 2-1

2-5 . SHUTDOWN ......................................... 2-2

3 . F U N C T I O N A L D E S C R I P T I O N

3.1 . E Q U I P M E N T D E S C R I P T I O N ............................ 3-1 3-2 . O P E R A T I N G P R I N C I P L E .............................. 3-2

4 . SCHEDULED MAINTENANCE

4.1 . P R E V E N T I V E MAINTENANCE ........................... 4-1

4-2 . O P E R A T I N G STANDARDS .............................. 4-1

4-3 . CHECK FOR LEAKAGE FROM M E C H A N I C A L S E A L GLANDS . ... 4-2

4-4 . CHECK B E A R I N G TEMPERATURES ....................... 4-2

4-5 . ROTATE SHAFT OF I D L E U N I T S ....................... 4-3

4-6 . L U B R I C A T E PUMP B A L L B E A R I N G S ..................... 4-3

4-7 . L U B R I C A T E JACKSHAFT P A C K I N G ...................... 4-4

4-8 . CHECK PUMP PERFORMANCE ........................... 4-4

5 . TROUBLESHOOTING

5-1 . TROUBLESHOOTING G U I D E ............................ 5-1

6 . C O R R E C T I V E MAINTENANCE

6.1 . F L O A T I N G SHAFT C O U P L I N G A L I G N M E N T ................ 6-1

6-2 . PUMP D I S A S S E M B L Y ................................. 6-4

6-3 . OVERHAUL, MAINTENANCE AND R E P A I R STANDARDS ....... 6-6

i

T A B L E O F CONTENTS ( C o n t ' d )

Chap te r Page

6.4 . I N S P E C T I O N O F PUMP P A R T S ......................... 6-7

6-5 . I N S T A L L A T I O N O F CASE R I N G S ....................... 6-12

6-6 . PUMP REASSEMBLY .................................. 6-12

6-7 . R O T A T I N G ASSEMBLY CHECKOUT ....................... 6-17

6-8 . ASSEMBLY O F BULKHEAD S T U F F I N G BOX ................ 6-17

7 . P A R T S L I S T 7 -1 . I N T R O D U C T I O N ..................................... 7-1

7-2 . L I S T O F MAJOR COMPONENTS ......................... 7-2

7-3 . PUMP P A R T S L I S T . , ................................ 7-2

7-4 . L I S T O F MANUFACTURERS ............................ 7-9

8 . I N S T A L L A T I O N

8-1 . GENERAL .......................................... 8-1

8-2 . L O C A T I O N ......................................... 8-1 8-3 . I N S T A L L A T I O N ..................................... 8-2 8-4 . P I P I N G ........................................... 8-3

8-5 . P R E P A R A T I O N FOR O P E R A T I O N ........................ 8-4

ii

LIST O F ILLUSTRATIONS

Fig. Nom Title

I I I I I

Page

1-1 Forward Ballast Pump 1-2 1-2 . . . . . . . . m D O . Performance Curve . . . D ~ . D ~ . . . . . . . . . . . . . 1-6 6-1 ..I....am... Mechanical Seal Assembly . . . . . . . . . . . . . . O 6-10 6-2 Coupling . . . . . . . . . . . . . . . . . O . . . . . . . . . . . . . ~ . ~ 6-16 7-1 D . O . . . . D D D . o Sectional Assembly . D . O . . . . . . . . . O D . . . D . . 7-11 8-1 . . m . . . . . . O . . Outline Drawing . D . . D D D D . . D . . D . O . D . . ~ * ~ ~ 8-5

Fig. No.

1-1 e.... m .

1-2 1-3 . . . . a m .

1-4 1-5 4-1 4-2 m m I . a . .

5-1 ....(..- 6-1 7-1 7-2 . . O . D . .

8-1

LIST O F TABLES

Title Page

Pump Operating Characteristics .............. 1-3 Motor Operating Characteristics . . . . . O . . . . I . . 1-3 Weights, Approximate . . . . l l . . . O O . . . . . . O . . . . . . 1-3 List of Major Components . D . . . . . . . . . . . . . . . . . . 1-4 Tools and Test Equipment List ............-.. 1-5 Maintenance Plan . . . . . . . . D . . . . . . . . . . .. ........ 4-1 Operating Standards . . . . . . D . . . . O . . . . ~ . . . . . . . . 4-2 Troubleshooting Guide ....................... 5-1 Overhaul, Maintenance and Repair

Standards . . .- D . . . . . . . . O . . . . m . . . . . . . 6-7 Pump Parts List ...D......I..................... 7-2 List of Manufacturers 7-9 Installation Requirement5 . D . . . . . . D . . . D . . . . . . 8-1 iii

SAFETY S UMM FbRY

GENERAL SAFETY NOTICES

The f o l l o w i n g genera l s a f e t y p r e c a u t i o n s a r e n o t r e l a t e d t o any s p e c i f i c procedures and, t h e r e f o r e , do n o t appear e lsewhere i n t h i s p u b l i c a t i o n . These a r e recommended p r e c a u t i o n s t h a t personnel m u s t unders tand and app ly d u r i n g many phases o f o p e r a t i o n and mainte-nance. Should s i t u a t i o n s a r i s e t h a t a r e n o t covered i n t h e g e n e r a l o r s p e c i f i c s a f e t y p r e c a u t i o n s , t h e commanding o f f i c e r o r o t h e r a u t h o r i t y w i l l i s s u e o r d e r s as deemed necessary t o cover t h e s i t u a -t i o n .

1. NEVER work on t h e pump u n l e s s i t has been i s o l a t e d b o t h e l e c -t r i c a l l y and h y d r a u l i c a l l y f rom t h e system. T h i s shou ld be done w i t h an a p p r o p r i a t e tag-out system on e l e c t r i c a l c o n t r o l l e r s and on any v a l v e s i n v o l v e d .

2. D o n o t wipe down i n t h e v i c i n i t y uf moving p a r t s .

3. Avo id g e t t i n g o i l o r o t h e r combus t ib les on h o t s u r f a c e s .

4. I f t h e pump r o t o r b i n d s and does n o t turn when s t a r t e d , secu re t h e d r i v e r and a t t a c h warn ing t a g s t o e l e c t r i c c i r c u i t s b e f o r e a t t e m p t i n g t o t u r n r o t o r by hand o r j a c k i n g bar .

5. I n case o f severe v i b r a t i o n o r unusual no i se , s h u t down t h e u n i t .

6. Do n o t t a k e up on any j o i n t . u n d e r p ressu re .

7. Be s u r e proper h o i s t o r c rane i s used when r i g g i n g heavy assem-b l i e s f o r removal , i n s t a l l a t i o n , e t c .

8. Be s u r e a l l f i t t i n g s a r e p r o p e r l y t i g h t e n e d t o p r e v e n t leak hazards t o personne l .

DO NOT SERVICE OR ADJUST ALONE.

Under no c i rcumstances shou ld any persun reach i n t o t h e e n c l o s u r e f o r t h e purpose o f s e r v i c i n g o r a d j u s t i n g t h e equipment except i n t h e presence o f someone w h o i s capable o f r e n d e r i n g a i d .

RESUSCITATION.

Personne l work ing w i t h o r near t h e equipment shou ld be f a m i l i a r w i t h modern methods o f r e s u s c i t a t i o n .

SAFETY SUMMARY ( c o n t d . )

TEST EQUIPMENT

Make c e r t a i n t e s - equipment i s i n good c o n d i t i o n . If t e s t meter must be he ld , ground the case o f t he meter be fo re s t a r t i n g measure-ment; do n o t t ouch l i v e equipment o r personnel work ing on l i v e equipment w h i l e h o l d i n g a t e s t meter . Some types o f measuring d e v i c e s should n o t be grounded; these dev i ces should n o t be h e l d when t a k i n g measurements.

The f o l l o w i n g warn ings and c a u t i o n s appear i n t h e t e x t and a r e repeated here f o r emphasis:

P o s s i b l e h o t su r faces . Touch b e a r i n g housing s u r f a c e CAREFULLY.

(Pages 2-2, 4-2)

P r i o r -0 work ing on equipment, p -ace a l l sw i t ches and c i r c u i t b reakers i n t h e open ( o f f ) p o s i t i o n and tag : "DANGER SHOCK HAZARD. Do n o t change p o s i t i o n o f s w i t c h except by d i r e c t i o n o f NAME.. .RATE/RANK."

(Pages 4-3,6-2,6-4)

Wire s h u t system i n l e t and o u t l e t v a l v e s and tag :

"DO NOT OPEN."

(Page 6-41

The two case cover e y e b o l t s a r e f o r l i f t i n g t h e case cover o n l y . The e n t i r e pump shou ld be l i f t e d by wrapping cha in around o p p o s i t e ends o f t h e case.

Be su re t o use l i f t i n g equipment capable o f sup-p o r t i n g t h e e n t i r e w e i g h t o f t h e pump (1800 pounds).

(Page 8-21

V

SAFETY SUMMfiRY ( c o n t d . 1

CAUT I ON

T h i s pumping u n i t has been des igned and manufac-t u r e d t o min imize mechanica l and e l e c t r i c a l v i b r a -t i o n s and n o i s e t o t h e e x t e n t t h a t t h e u n i t i s cons idered t o be a p r e c i s i o n i n s t r u m e n t . I t shou ld be handled as such. Rough h a n d l i n g cou ld upse t t h e balance.

(Page 2-1)

CAUT I ON

Overgreas ing o r t h e use o f i n c o r r e c t grease w i l l cause t o t a l and r a p i d f a i l u r e o f t h e bear ings . Use D O D - G - 2 4 5 0 8 grease o n l y and do n o t r e i n s t a l l v e n t p l u g s p r i o r t o warm-up o f pump.

(Page 4-3)

CAUT I ON

When machin ing case r i n g i n s i d e d iameters , t a k e ca re t o make c o n c e n t r i c c u t s . I t must b e remem-bered t h a t t h e above r e s u l t s a r e d i a m e t r a l dimen-s i o n s . The depth of any c u t taken i s equal t o h a l f o f t h e t o t a l amount o f meta l t ( 3 be removed by t h e c u t . F i n i s h d iamete rs shou ld be h e l d w i t h i n 2 . 002" .

(Page 6-12)

CAUT I ON

Use ca re when h a n d l i n g and i n s t a l l i n g t h e mechani-c a l s e a l . Refer t o F i g u r e 6-1. The pr imary r i n g and b e l l o w s must be k e p t c lean and f r e e o f n i c k s and s c r a t c h e s . D o n o t handle t h e s e p a r t s as even a f i n g e r p r i n t m a y cause a s e a l t o l e a k .

(Page 6-13)

CAUT I ON

When h a n d l i n g , t a k e c a r e n o t tc:, j o l t o r j a r t h e u n i t as t h i s may cause an i n c r e a s e i n t h e opera-t i o n a l n o i s e l e v e l .

(Page 8-2) v i

1-1. s

CHAPTER 1

GENERAL I NFORMAT I O N

FETY PRECAUTIONS.

The f r o n t m a t t e r of t h i s manual c o n t a i n s a s a f e t y summary. The u s e r must r e f e r t o and be f a m i l i a r w i t h t h e s a f e t y p recau t ions con ta ined i n t h e s a f e t y summary p r i o r t o p e r f o r m i n g any maintenance, r e p a i r o r o p e r a t i o n a l task

T h i s pump i s n o t t o be opera ted a t speeds, work ing ( d i s c h a r g e ) p ressu res o r temperatures h i g h e r than those s t a t e d i n t h i s manual, n o r used w i t h l i q u i d s o t h e r than s t a t e d i n t h i s manual w i t h o u t w r i t t e n pe rm iss ion o f Warren Pumps I n c .

1-2. INTRODUCTION.

T h i s manual p r o v i d e s the necessary i n f o r m a t i o n f o r i n s t a l l a t i o n , o p e r a t i o n , maintenance, r e p a i r and p a r t s suppor t f o r t h e Forward B a l l a s t Pump, t y p e 12-DTBM-14H9 h e r e i n a f t e r r e f e r r e d t o as t h e pumping u n i t

1-3. EQUIPMENT DESCRIPTION.

The Forward B a l l a s t pump i s a s i n g l e s tage, doub le s u c t i o n , h o r i z o n -t a l l y mounted c e n t r i f u g a l pump. The pump c o n t a i n s grease l u b r i c a t e d b a l l b e a r i n g s f o r r a d i a l and thrust loads. The pump i s connected to an e l e c t r i c motor by use o f two f l o a t i n g s h a f t coup l i ngs and a j a c k s h a f t t h rough a bulkhead s t u f f i n g box.

The pump enc losu re i s composed o f two p a r t s - t h e case and cover .

The e n c l o s u r e i s s p l i t a long t h e h o r i z o n t a l c e n t e r l i n e f o r removal o f t h e cover . The case i s des igned so t h a t t h e s u c t i o n and d i s -charge f l a n g e s a r e c a s t w i t h t h e case and, because o f t h i s a r range-ment, t h e cover may be removed w i t h o u t t h e n e c e s s i t y o f d i sconnec t -i n g p i p i n g a t t h e s u c t i o n o r d i s c h a r g e f l a n g e s o r d i s t u r b i n g t h e d r i v e r and pump mounting. The c a s i n g i s cons t ruc ted o f aluminum bronze p e r ASTM B148 A l l o y C95500.

For a p i c t o r i a l i l l u s t r a t i o n o f t h e pumping u n i t showing t h e compo-n e n t s wh ich make up t h e u n i t , r e f e r t o F i g u r e 1-1.

For complete c a p a b i l i t i e s and l i m i t a t i o n s o f t h e pumping un i t , r e f e r t o t h e g raph o f t h e performance curve, F i g u r e 1-2.

1-1

1-2

1-4. REFERENCE DATA.

w e i g h t s o f t h e ma jo r components which make up t h e pumping u n i t , r e f e r to Tab le 1-3. For pump d imensions and c e n t e r o f g r a v i t y , r e f e r t o t h e o u t l i n e drawing, F i g u r e 8-1.

Tab le 1-1. P u m p Opera t i nq C h a r a c t e r i s t i c s i l

I

I

Manufac turer .................................. ..Warren Pumps I n c .

Type .................................................. 12-DTBM-14H Capac i t y ~ 3 0 0 0 GPM T o t a l Head.. ............................................. ~ ~ 5 4 FT.

Speed .................................................... 1175 RPM S u c t i o n Pressure. . . . . ................................ ~~~~~~~9 FT.

L i q u i d .................................................. Sea Water S p e c i f i c G r a v i t y .......................................... ~ ~ ~ 1 ~ 0 ~ E f f i c i e n c y .................................................. 7 6 . 5 ~ B.H.P... ~ 5 5 ~ 1 Max. Working P ressu re ................................... ~ ~ ~ 6 0 PSI Hydro. Tes t Pressure................................ ~ ~ - ~ ~ ~ . 9 0 PSI

NPSHR. ................................................... ~~~? FT.

NPSHA ................................................. ~ ~ ~ 1 0 . 8 FT.

I

Tab le 1-2. Motor Opera t i nq C h a r a c t e r i s t i c s Manufacturer.,...... reliance Drawing No .................................... ~ ~ ~ 7 0 6 5 3 7 - 2 1 3 / 2 6 MA frame.................^^*.^. ~ ~ ~ ~ . ~ ~ ~ ~ ~ ~ . - ~ ~ ~ ~ ~ ~ * ~ - ~ * ~ ~ ~ ~ . ~ ~ . ~ 4 0 5 T Type .................................................. horizontal Horsepower ..................................................... 6~ Speed .................................................... 1175 RPM V o l t s ........................................................ ~ 4 4 ~ Frequency .............................................. ~ ~ 6 0 H e r t z Phase Enc losu re . ............................................ . .D r ipp roo f F u r n i s h e d by ............................................. Sh ipya rd Mounted by ............................................... Sh ipya rd

Tab le 1-3. Weiqhts. Approx imate

R o t o r Assembly ............................. 280 l b s .

Case.....................................~llZO l b s .

Cover.. . ............................ ~ ~ ~ ~ ~ ~ ~ 4 0 0 l b s .

Pump Complete ............................. 1800 lbs .

J a c k s h a f t ................................. ..44 l b s .

Coup l i ngs ................................... 35 l b s .

T o t a l . . ................................ ~ ~ ~ 1 8 7 9 l b s .

1-3

1-5. L I S T O F MAJOR COMPONENTS.

The ma jo r components a re l i s t e d i n Table 1-4 .

Table 1-4 . L i s t o f Ma jor Components

C I D , R I C o r U n i t Number Q u a n t i t y

Name o r Nomenclature

Name o f U n i t

Pump

Coup 1 i n g (Pump 1

Coup l i ng (P lo to r )

Jackshaf t

Guard (Pump End)

Guard (Motor End)

B u 1 k head S t.u f f i n g Box Housing

Design a t i on

12-DTBM-14H

SN 200

SN 262

079C0083

687A0975

687A0976

776D0064

1-6. STORAGE.

If t h e u n i t i s n o t scheduled f o r i n s t a l l a t i o n w i t h i n a s h o r t p e r i o d , p l a c e i t as r e c e i v e d i n a s t o r a g e area wh ich is c lean, d r y , and n o t s u b j e c t t o f r e e z i n g temperatures. Whi le i n s to rage , i n s p e c t t h e pump month ly t o de termine t h a t i t i s n o t be ing a f f e c t e d by d i r t o r dampness. A t each i n s p e c t i o n , turn t h e r o t o r by hand th rough seve r -a l r e v o l u t i o n s t o p revent p o s s i b l e s e i z u r e .

1-7. TOOLS AND TEST EQUIPMENT.

The r e q u i r e d t o o l s and t e s t equipment a r e l i s t e d i n Table 1-5.

1-4 i

' i

Tab le 1-5. T o o l s and Test Equipment L i s t

1. Tag, Sa fe ty , WARNING " O u t of S e r v i c e "

2. Rags, Wiping

3. Wire, N o n - E l e c t r i c a l

4. Scraper

5. M a l l e t , Rawhide 6.

7 .

8.

9 .

10 m 11 a 12.

13.

15.

16.

17.

18.

19 .

20 * 21 .

22.

24.

2 5 .

26 .

27 .

Brush, Wire L i g h t , Ex tens ion , P o r t a b l e C l e a n i n g S o l v e n t (MIL-C-81302) P u l l e r , Mechanica l , Bear ing Gage Set , Th ickness D i a l I n d i c a t o r w/Attachment Device C a l i p e r , M ic rometer , I n s i d e and Ou ts ide A 1 l e n Wrench S e t Sc rewdr i ve r , F l a t T i p , Normal D u t y , 6 " and 10" Wrench Set , Combinat ion Box and Open End Wrench Set , Socket , 1/22 Square D r i v e Wrench, Spanner, No. 461 P l i e r s , S l i p J o i n t , 6 " Watch Thermometer, Con tac t Grease G u n Grease, Bear ing (DOD-G-24508A) Grease Pack ing (John Crane L u b r i c a n t No. 1;

C h e s t e r t o n S t y l e 3600; o r e q u i v a l e n t ) Tamping S t i c k S i l i c o n e Compound (Dow Corn ing 7 Compound, NSN 6850-00-975-0712, o r e q u i v a l e n t ) P i n , Hardened S t e e l Tachometer, Hand-Held

1-5 i > L 3 U aJ U C a E

L

Y L aJ a

N

CHAPTER 2

OPERAT I O N

2-1. INTRODUCTION.

T h i s chap te r d e s c r i b e s t h e procedures and p r e c a u t i o n s which shou ld be f o l l o w e d t o s t a r t and s h u t down t h e pumping u n i t . The pumping u n i t w i l l ope ra te w i t h o u t o p e r a t o r i n t e r v e n t i o n once system v a l v e s have been opened f u l l y and t h e motor has been s t a r t e d . S t a r t t h e pump momentar i ly t o check d i r e c t i o n o f r o t a t i o n . The r o t a t i o n i s c l o c k w i s e when viewed from t h e d r i v e r end.

CfiUT I ON

T h i s pumping u n i t has been des igned and manufac-t u r e d t o min imize.mechanica1 and e l e c t r i c a l v i b r a -t i o n s and n o i s e t o t h e e x t e n t t h a t t h e u n i t is cons idered t o be a p r e c i s i o n i n s t r u m e n t . I t should be handled as such. Rough h a n d l i n g cou ld upset the ba 1 ance

2-2. CONTROLS AND INDICATORS.

There a r e no c o n t r o l s o r i n d i c a t o r s s u p p l i e d w i t h the pump.

2 - 3 . STARTING.

1. Open pump s u c t i o n and d i scha rge v a l v e s . L i q u i d must be p resen t i n t h e pump cas ing and s u c t i o n p i p i n g p r i o r t o s t a r t -i n g .

2. Open cas ing vent v a l v e . Keep t h e v a l v e open d u r i n g i n i t i a l r u n n i n g u n t i l a l l a i r i s e x p e l l e d , then close t h e vent v a l v e .

3. Check t h a t t h e system v a l v e s a r e s e t i n t h e c o r r e c t p o s i t i o n t o i n s u r e f l o w o f l i q u i d t o the pump.

4. S t a r t t h e motor by depress ing t h e START b u t t o n on the c o n t r o l pane l .

NOTE

Do n o t r e s t r i c t pump f l o w w i t h t h e s u c t i o n o r d i scha rge va l ves .

2-4. NORMAL OPERATION.

1. Check p ressu re gauges f r e q u e n t l y t o be s u r e t h e pump is o p e r a t i n g a t c o r r e c t p ressures .

2-1 i i I

I WARNING 1

P o s s i b l e h o t su r faces . Touch b e a r i n g housing s u r f a c e ChREFULLY.

2. Check bear ing housing tempera ture by touch. I f a b e a r i n g hous ing f e e l s ho t , de te rm ine temperature w i t h a thermometer.

B e a r i n g temperatures u p to 180 deg. F. a r e normal. Wi th in l i m i t s , t h e s t a b i l i t y o f t he temperature, r a t h e r than t h e number o f degrees, i s the bes t i n d i c a t i o n o f normal opera-t i o n . A sudden i n c r e a s e i n tempera ture i n d i c a t e s t h a t a b e a r i n g problem is deve lop ing . S top t h e pump and check t h e b e a r i n g .

3 . Check f o r leakage f rom t h e mechanical sea l g l a n d areas.

Leakage from a p r o p e r l y o p e r a t i n g mechanical s e a l shou ld n o t exceed 5 drops per m inu te .

4. Check u n i t f o r unusual n o i s e o r v i b r a t i o n . A n y change i n sound shou ld be c a r e f u l l y checked as i t may be t h e f i r s t s i g n o f impending t r o u b l e . Inc reased v i b r a t i o n and sudden change o f b e a r i n g temperature a r e i n d i c a t i o n s o f p o s s i b l e pump t roub 1 es

5. I f u n i t v i b r a t e s e x c e s s i v e l y o r becomes n o i s y , secure immedi-a t e l y I

6. Check f o r l e a k s a t c a s i n g j o i n t s and p i p i n g f l a n g e s .

2 - 5 . SHUTDOWN

1. Close pump d i scha rge v a l v e .

2. S top t h e motor by momentar i l y p r e s s i n g t h e STOP b u t t o n on t h e c o n t r o l l e r panel . Check t o i n s u r e t h a t t h e pump s t o p s r o t a t -i n g and does n o t go t o r e v e r s e r o t a t i o n .

3. Close pump s u c t i o n v a l v e .

2-2

CHAPTER 3

FUNCTIONAL DESCRIPTION

3-1. EQUIPMENT DESCRIPTION.

The p r i n c i p a l f e a t u r e s o f t h e Forward B a l l a s t pump a r e i l l u s t r a t e d and i d e n t i f i e d by t h e p i e c e numbers i n F i g u r e 7-1 and c o n s i s t o f t h e f o l l o w i n g :

C A S I N G . The pump enc losu re i s composed o f two h a l v e s - t h e case ( 1 ) and t h e cover ( 2 ) . The e n c l o s u r e i s s p l i t a long t h e h o r i z o n t a l c e n t e r l i n e f o r removal o f t h e cover . The case i s designed so t h a t t h e s u c t i o n and d i scha rge f l a n g e s a r e c a s t w i t h t h e case and, be-cause o f t h i s arrangement, t h e cover may be removed f o r i n s p e c t i o n , r e p a i r s , o r removal o f t h e e n t i r e r o t a t i n g element w i t h o u t t h e n e c e s s i t y o f d i s c o n n e c t i n g p i p i n g a t t h e s u c t i o n o r d i scha rge f l a n g e s o r d i s t u r b i n g the pump o r d r i v e r mount ings. A lso i n c l u d e d as p a r t o f t h e case a r e t h e mount ing f e e t and rabbeted pedes ta l s t o r e c e i v e and suppor t t h e b e a r i n g housings.

ROTATING ELEMENT. The i m p e l l e r (38) i s keyed t o t h e s h a f t ( 3 5 ) by t h e i m p e l l e r key ( 3 6 ) . The i m p e l l e r i s p o s i t i o n e d and secured on t h e s h a f t by use o f s h a f t s l e e v e s (42,431. The s l e e v e s a r e screwed o n t o t h e s h a f t and f u r t h e r secured by use o f se tscrews ( 4 4 ) . T h e s h a f t s l e e v e s a l s o se rve t o p r o t e c t t h e s h a f t f rom wear a t t h e p o i n t where i t passes th rough t h e s t u f f i n g boxes. The s h a f t i s suppor ted r a d i a l l y by a b a l l bea r ing ( 4 8 ) . A x i a l t h rus t i s absorbed by angu-l a r c o n t a c t b a l l bea r ings ( 4 9 ) i n duplex mount ing, back t o back.

The b e a r i n g s a r e grease l u b r i c a t e d (DOD-G-24508).

S l i n g e r s ( 4 7 ) a r e mounted on t h e s h a f t t o p r o t e c t t h e bear ings a g a i n s t t h e en t rance o f l i q u i d t h a t may l e a k f rom t h e s t u f f i n g boxes.

I n t e r n a l leakage and p ressu re loss i s min imized by t h e c lose r u n n i n g c l e a r a n c e s between t h e i m p e l l e r hub wear ing s u r f a c e s and t h e case r i n g s ( 3 3 ) . These r i n g s a r e r e p l a c e a b l e when worn i n o rde r t h a t p roper c lea rances may be ma in ta ined . The i m p e l l e r hub wearing s u r f a c e s t h i c k n e s s i s s u i t a b l e f o r r e d u c i n g d iameter o f t he hubs as much as 0.050 i n c h t o accomodate u n d e r s i z e case r i n g s (34) t o r e -s t o r e d e s i g n r u n n i n g c learance.

Leakage a l o n g t h e s h a f t t o t h e atmosphere i s p revented by mechanica l s e a l s ( 4 5 ) . Each s e a l c o n s i s t s o f a r o t a t i n g p o r t i o n mounted on t h e s h a f t s l e e v e and a s t a t i o n a r y p o r t i o n mounted i n t h e f lush g l a n d p l a t e . A n a b r a s i v e s s e p a r a t o r ( 5 8 ) i s i n s t a l l e d i n t h e mechanica l s e a l f l ush p i p i n g ( 5 6 ) l i n e t o remove any p a r t i c l e s o f g r e a t e r d e n s i t y than t h e sea water . The sea water p iped f rom t h e pump d i s c h a r g e i s r o t a t e d a t a v e l o c i t y dependent on t h e pressure d i f f e r -e n t i a l . The p a r t i c l e s course downward t o t h e d i s c h a r g e o u t l e t a t t h e b o t t o m o f t h e separa to r . From t h e r e they a r e p iped w i t h a s m a l l amount o f l i q u i d back t o t h e s u c t i o n s i d e o f t h e pump. The c l e a n l i q u i d e x i t s t h rough t h e o u t l e t a t t h e t o p o f t h e separa to r and i s

' I I I

! I

3-1 t h e n p i p e d t o t h e m e c h a n i c a l s e a l f l u s h g l a n d p l a t e .

3-2. OPERATING PRINCIPLE.

The o p e r a t i n g p r i n c i p l e o f t h e pump is t h e e n t r y o f l i q u i d t h r o u g h t h e s u c t i o n f l a n g e o p e n i n g w h e r e i t is d i r e c t e d i n t o t h e e y e s o f t h e d o u b l e s u c t i o n i m p e l l e r . D u r i n g f l o w t h r o u g h t h e r o t a t i n g i m p e l l e r , t h e l i q u i d r e c e i v e s e n e r g y f r o m t h e v a n e s , r e s u l t i n g i n a n i n c r e a s e i n b o t h p r e s s u r e a n d a b s o l u t e v e l o c i t y . T h e l i q u i d is e x p e l l e d f r o m t h e v a n e e x i t s a n d o u t t h r o u g h t h e pump d i s c h a r g e b y c e n t r i f u g a l f o r c e . T h e moving l i q u i d is f o r c e d t o f o l l o w t h e d e s i g n e d c h a n n e l s o f t h e v o l u t e a s i t is e x p e l l e d o u t w a r d , r e s u l t i n g i n a p r e d e t e r -m i n e d , c o n t r o l l e d d i s c h a r g e of l i q u i d a t t h e v o l u t e d i s c h a r g e .

3-2

CHAPTER 4

SCHEDULED MAINTENANCE

4-1. PREVENTIVE MAINTENANCE.

Shipboard maintenance s h a l l be performed as d e t a i l e d i n t h i s chapter u s i n g t h e Maintenance Plan, Tab le 4-1, as a bas is . The f o l l o w i n g paragraphs c o n t a i n i n s p e c t i o n and check ing procedures t o be f o l l o w e d i n p e r f o r m i n g sh ipboard maintanence d u t i e s . A l l p i e c e numbers r e f e r e n c e d i n t h i s chapter r e f e r t o F i g u r e 7-1 u n l e s s o the rw ise i n d i c a t e d . Before a t t e m p t i n g any maintenance work o f any k i n d on t h e pumping u n i t , r e f e r t o t h e Sa fe ty Summary, page i v .

Table 4-1. Maintenance P lan

P e r i o d i c i t v

D a i l y

D a i l y

Weekly

Q u a r t e r l y

Q u a r t e r l y

Annua l l y

Annual l y

Annua l l y

Maintenance A c t i o n

Check f o r leakage from mechanical sea l g lands .

Check b e a r i n g temperatures.

Ro ta te s h a f t o f i d l e un i t s .

L u b r i c a t e pump b a l l bear ings .

L u b r i c a t e j a c k s h a f t pack ing .

Check pump performance.

Check mount ing bo1 t s f o r t i g h t n e s s .

Check a l i g n m e n t o f pump and d r i v e r s h a f t s

Reference

4-3

4-4

4-5

4-6

4-7

4-8

8-3

6-1

4-2. OPERATING STANDARDS.

Tab le 4-2 s p e c i f i e s t h e o p e r a t i n g s tandards f o r t h e p a r t s o f t h e pumping u n i t which should be checked d a i l y and main ta ined i n o r d e r t o p r e v e n t unscheduled maintenance and r e p a i r s .

4-1

Table 4-2. Clperat inq Standards

I

S tandard P a r t C r i t e r i a

Leakage Mechanical S e a l s (45) Leakage shou ld n o t I exceed 5 d rops pe r m inu te p e r s t u f f i n g box.

Temperature Bear ings (48,491 180°F maximum

4-3. CHECK FOR LEAKAGE FROM MECHANICAL SEAL GLANDS.

1. The pump s h a l l be i n o p e r a t i o n bJhen mehcanical s e a l ( 4 5 ) leakage checks a r e b e i n g made. I f t h e pump i s n o t i n opera-t i o n , s t a r t t h e u n i t i n accordance w i t h i n s t r u c t i o n s i n Chapter 2.

NOTE

A new mechanica l s e a l may a l l o w some i n i t i a l l e a k -age. T h i s leakage w i l l d i sappear a f t e r a s h o r t p e r i o d . I f leakage i s no ted on i n i t i a l s t a r t - u p a f t e r i n s t a l l a t i o n o r ove rhau l , a l l o w a few hours o f o p e r a t i o n t o p e r m i t s e a l fac:es t o seat . If leakage con t inues , i t w i l l be necessary t o i n s p e c t t h e s e a l .

2. V i s u a l l y i n s p e c t f o r leakage f rom each s t u f f i n g box.

3. I f e x c e s s i v e leakage f rom a s e a l i s i n d i c a t e d , i n s t a l l a new s e a l .

4. To r e p l a c e mechanical s e a l , r e f e r t o Chapter 6, C o r r e c t i v e Maintenance.

4-4. CHECK BEARING TEMPERATURES.

T o o l s Requ i red : Con tac t Thermometor o r Pyrometer.

1. Operate t h e u n i t f o r a t l e a s t 30 minu tes b e f o r e check ing b e a r i n q (48,491 tempera tures .

P o s s i b l e h o t su r faces . Touch b e a r i n g housing s u r f a c e CAREFULLY.

2 . Check b e a r i n g housing ( 2 4 ) tempera ture by hand.

4-2

3. I f bea r ing housings a r e t o o h o t t o touch, check temperature u s i n g a c o n t a c t thermometer o r pyrometer . Bear ing tempera-t u r e s up t o 180 deg. F. a r e normal .

4. Pay p a r t i c u l a r a t t e n t i o n t o an i n c r e a s e i n temperature o f any bear ing . W i t h i n l i m i t s , t h e s t a b i l i t y o f t h e temperature r a t h e r than t h e number o f degrees i s t h e b e s t i n d i c a t i o n o f normal o p e r a t i o n . A sudden i n c r e a s e i n temperature i n d i c a t e s t h a t a b e a r i n g problem i s deve lop ing . S top t h e pump and check t h e bear ing .

4-5. ROTATE SHAFT O F IDLE UNITS.

P r i o r t o work ing on equipment, p l a c e a l l sw i t ches and c i r c u i t b reake rs i n t h e open ( o f f ) p o s i t i o n and tag : ”DANGER SHOCK HAZARD. Do n o t change p o s i t i o n o f s w i t c h except by d i r e c t i o n o f NAME...RATE/RANK.”

1. Remove t h e pump end c o u p l i n g guard (84, F i g u r e 8-1).

2 . T u r n t h e s h a f t t h rough s e v e r a l r e v o l u t i o n s by hand. I f t h e r e is any r u b b i n g o r b i n d i n g , do n o t s t a r t t h e u n i t u n t i l t h e cause o f t h e rubb ing o r b i n d i n g has been l o c a t e d and c o r r e c t -ed a

3. Remove t h e s a f e t y t a g and e n e r g i z e t h e c i r c u i t .

4. R u n t h e pump f o r s e v e r a l m inu tes by power. T h i s w i l l a l s o make i t necessary t o o p e r a t e v a l v e s a s s o c i a t e d w i t h t h e u n i t , thus keep ing them f rom s t i c k i n g .

5. Shutdown t h e pump.

4-6. LUBRICATE PUMP BALL BEARINGS.

T o o l s Requi red: Clean Rags, A d j u s t a b l e Wrench, Grease G u n , Bear ing Grease (DOD-G-24508).

1. Remove d i r t f rom b e a r i n g grease f i t t i n g (30 ) and r e l i e f f i t t i n g ( 4 0 ) areas u s i n g c l e a n rags .

2 . Remove v e n t p l u g s ( 3 1 ) f rom b e a r i n g heads (25,291 and probe v e n t p l u g opengings t o ensure open ings a r e c l e a r .

CAUTION

Overgreas ing o r t h e use o f i n c o r r e c t grease w i l l cause t o t a l and r a p i d f a i l u r e o f t h e bear ings . Use DOD-G-24508 grease o n l y and do n o t r e i n s t a l l v e n t p l u g s p r i o r t o warm-up o f pump.

4-3

3. U s i n g a g rease gun,v i n j e c t grease (DOD-G-24508) t h rough g rease f i t t i n g s ( 3 0 ) u n t i l grease appears a t t h e ven t p l u g open ings e

4. Opera te t h e pump f o r 1 5 minu tes o r u n t i l excess grease i s e x p e l l e d f rom vent p l u g opening.;.

5. R e i n s t a l l v e n t p lugs ( 3 1 ) ; wipe away any excess grease.

4-7. LUBRICATE JACKSHAFT PACKING.

T o o l s Requi red: Clean Rags, Grease G u n , Pack ing

L u b r i c a n t (John Crane L u b r i c a n t No. 1;

Ches te r ton S t y l e 3600; o r e q u i v a l e n t ) .

1. Remove d i r t f rom grease f i t t i n g ( 7 7 ) a rea u s i n g c lean r a g s .

2. U s i n g a g rease gun, a p p l y a commercial g rade pack ing l u b r i -c a n t (John Crane L u b r i c a n t No.1, C h e s t e r t o n S t y l e 3600, or e q u i v a l e n t ) a t grease f i t t i n g ( 7 7 ) u n t i l a s l i g h t back p res -s u r e b u i l d s up.

4-8. CHECK PUMP PERFORMANCE

T o o l s Requ i red : Contac t Thermomet:er o r Pyrometer, Hand-Held

Tachometer

1. S t a r t t h e u n i t i n accordance w i t . h i n s t r u c t i o n s i n pa rag raph 2-3.

2 . R u n t h e pump f o r 1 5 m inu tes , then p e r f o r m t h e checks o u t l i n e d i n paragraph 2-4.

3. Determine t h e s h a f t speed u s i n g a hand-held tachometer o r s i m i l a r speed measur ing dev i ce . S h a f t speed shou ld be w i t h i n t h e range o f 1150-1200 RPM. I f the s h a f t i s n o t r o t a t i n g w i t h i n t h i s speed range, check t h e f requency o f the o p e r a t i n g c u r r e n t . M a i n t a i n t h e f requency a t 60 H e r t z + 3 . The c o r r e c t speed m u s t be ma in ta ined i n o r d e r t o d e l i v e r t h e d e s i r e d p r e s s u r e and c a p a c i t y .

4-4

4. Check pump c a p a c i t y , p ressure , and power requ i rements a g a i n s t t h e performance curve, F i g u r e 1-2. I f p ressu re and c a p a c i t y have dropped o f f 10% o r more, o r i f t h e pump i s drawing ove r maximum horsepower, t h e pump shou ld be removed f r u m s e r v i c e and i n s p e c t e d as o u t l i n e d i n paragraph 6-4. I f performance i s s a t i s f a c t o r y , t h e r e is no need t o d isassemble t h e pump.

5. S a t i s f a c t o r y performance can o n l y be determined by a c t u a l l y o p e r a t i n g t h e u n i t i n accordance w i t h procedures i n Chapter 2.

4-5(4-6 b l a n k )

CHAPTER 5

TROUBLESHOOTING

5-1. TROUBLESHOOTING GUIDE.

The pumping u n i t f u n c t i o n s w i t h o u t o p e r a t o r i n t e r v e n t i o n . T roub le -s h o o t i n g is r e q u i r e d o n l y when m a l f u n c t i o n s are d e t e c t e d d u r i n g p e r i o d i c checks and i n s p e c t i o n s o f t h e pumping u n i t , and then, o n l y i f t h e cause is n o t obv ious . T h i s chap te r p rov ides a gu ide f o r pumping u n i t t r o u b l e s .

Table 5-1. T r o u b l e s h o o t i n q Guide

SYMPTOM PROBABLE CAUSE REMEDY

Pump does 1. Pump o r s u c t i o n 1. Check t h a t a l l v a l v e s n o t d e l i v e r p i p e n o t comp le te l y i n t h e s u c t i o n system l i q u i d o r f i l l e d w i t h l i q u i d . a r e wide open; v e n t deve lops low cas ing c a p a c i t y .

2. Discharge v a l v e n o t 2. Open d i scha rge v a l v e .

f u l l y opened

3. Excess ive amount o f 3. Check i n t e g r i t y o f a i r o r gas i n l i q u i d , s u c t i o n p i p i n g .

a i r pocket i n s u c t i o n l i n e , a i r l e a k s i n t o s u c t i o n l i n e .

4. Check frequency o f o p e r a t i n g c u r r e n t .

M a i n t a i n f requency a t 60 h e r t z 2 3 .

5. In te rchange o n l y two leads i n motor c o n d u i t box -

6. Remove case cover and c lean i m p e l l e r . See para. 6-4.

4. Speed t o o low.

5. Wrong d i r e c t i o n o f r o t a t i o n .

6. Fo re ign m a t t e r i n i m p e l l e r .

7. A i r l eaks i n t o pump th rough s t u f f i n g boxes

8. Case r i n g s worn.

7. Check t h a t mechan-i c a l s e a l and g l a n d a re p r o p e r l y i n s t a l l e d

8. Replace case r i n g s .

See para. 6-5.

Tab le 5-1. Troub leshoot i r iq Guide ( con td . 1

SYMPTOM PROBABLE CAUSE REMEDY

Pump does 9. I m p e l l e r damaged. 9 . Repa i r o r r e p l a c e n o t d e l i v e r i m p e l l e r .

l i q u i d o r deve lops low 10. Casing gaske t defec- 10. Remove case cover c a p a c i t y t i v e p e r m i t t i n g in- - and i n s t a l l new gas- ( c o n t d . ) t e r n a l leakage. k e t .

Loss o f 1. Pump o r s u c t i o n 1. Check t h a t a l l v a l v e s pr ime a f t e r p i p e n o t complete 1y i n t h e s u c t i o n system s t a r t i n g . f i l l e d w i t h l i q u i d . a r e wide open; v e n t cas ing

2. Excess ive amount o f 2. Check i n t e g r i t y o f a i r o r gas i n l i q u i d ; s u c t i o n p i p i n g .

a i r pocket i n s u c t i o n l i n e ; a i r l e a k s i n t o s u c t i o n 1 i n e .

3. A i r l e a k s i n t o pump 3. Check t h a t mechan-through s t u f f i n g i c a l s e a l and g l a n d boxes a r e p r o p e r l y i n s t a l l -ed

I Excess i ve 1. Speed t o o h i g h .

power r e -q u i r e d i

5-2

2. Wrong d i r e c t i o n o f r o t a t i o n .

3. S p e c i f i c g r a v i t y o f l i q u i d d i f f e r e n t from des ign .

4 . Fo re ign m a t t e r i n impel l e r

5. B ind ing (caused by misa l ignment , bent s h a f t , o r r o t a t i n g p a r t r u b b i n g on s t a t i o n a r y p a r t )

1. Check frequency o f c u r r e n t . M a i n t a i n f requency 60 h e r t z ?se

2. In te rchange any two leads i n motor c o n d u i t b o x

3. L i q u i d pumped m u s t be t h e same a5 s t a t e d i n t a b l e 1-1.

4. Remove case cover and c lean i m p e l l e r .

See para. 6-4.

5 . Check a l ignment . See para. 6-1. I f a l i g n -ment i s s a t i s f a c t o r y , d isassemble pump and r e p a i r o r r e p l a c e de-f e c t i v e p a r t s .

I Table 5-1. Troubleshootinq Guide (contd.) I

SYMPTOM PROBABLE CAUSE REMEDY

Excessive 6. Bearings worn or 6. Disassemble pump and power re- improperly lubri- inspect bearing. See quired. ca ted. para. 6-4.

(contzd. 1

7. Mechanical seal 7. Correct mechanical improperly seal installation.

instal led. See para. 6-6.

I Short life 1. Mechanical seal 1. Remove and clean of mechanical flush water tubing tubing seal a plugged.

I

2. Bent shaft. 2. Straighten or re-place shaft. See para. 6-4.

3 . Mechanical seal 3. Check that gland gland plate im- plate is not cocked properly installed. on shaft; gland nuts must exert even pres-sure at all points.

See para. 6-6 for installation instruc-t i o n s .

4. Shaft running off 4. Inspect bearing (see center because para. 5-4) and/or of worn bearings check alignment (see o r misalignment. para. 6-1).

5. Rotor out of bal- 5. Remove rotor assem-ance, causing vibra- bly and check balance.

tion

Vi bration 1. Pump or suction 1. Check that all valves or noise. pipe not completely in the suction system filled with liquid are wide open.

(cavitation).

2. Foundation bolts 2. Tighten or replace not secure. foundation bolts.

3 . Bent shaft. 3 . Straighten or re-place shaft. See para. 6-4.

5-3

Tab le 5-1. Troub leshoo t ins Guide ( con td . 1

I

SYMPTOM PROBABLE CAUSE REMEDY

4. Disassemble pump, V i b r a t i o n 4. R o t a t i n g p a r t rub-o r n o i s e . b ing on s t a t i o n a r y ( c o n t d . 1 p a r t .

5. I m p e l l e r damaged.

6. S h a f t r u n n i n g o f f cen te r because o f worn b e a r i n g s o r misa l ignment .

7. Rotor o u t o f ba lance.

8. I n s u f f i c i e n t o r excess i ve b e a r i n g l u b r i c a t i o n a

9. Improper f i t t i n g o f bea r ings ( t o o t i g h t i n housing; t o o loose on s h a f t )

10. Use o f unmatched bear ings as a p a i r .

11. D i r t i n bea r ings .

12. Bear ings r u s t e d from water e n t e r -i n g housing.

r e p a i r o r r e p l a c e d e f e c t i v e p a r t s .

5. Repa i r o r r e p l a c e i m p e l l e r .

6. I n s p e c t bea r ings ( s e e para. 6 - 4 ) and/or check a l ignment ( s e e para. 6-11.

7. Remove r o t o r assemb-l y and check ba lance.

8. Disassemble pump and c l e a n bear ings . S e e para. 6-4. R e i n s t a l l bea r ings and l u b r i c a t e as o u t l i n e d i n pa ra .

4-6 *

9. Disassemble pump and check bear ing f i t .

See para. 6-4.

10. Bear ings m u s t be t h e t ype l i s t e d i n Tab le 7-1. I n s t a l l a t i o n m u s t be pet- para.

6-6; l u b r i c a t i o n p e r para. 4-6.

11. See 8 above.

12. Replace bear ings .

Determine cause o f water e n t e r i n g hous-i n g and c o r r e c t .

S h o r t l i f e 1. Misa l ignment .

o f pump b e a r i n g s .

2. Bent s h a f t .

1. Check a l ignment .

See para. 6-1.

2. S t r a i g h t e n o r r e -p l a c e s h a f t . See para. 6-4.

5-4

Tab le 5-1. Troub leshoo t inq Guide ( con td . 1

Pump o v e r - 1. Pump n o t comple te ly 1. Check t h a t a l l hea ts and f i l l e d w i t h l i q u i d v a l v e s i n the suc-se i zes . ( r u n n i n g d r y ) . t i o n system a r e w ide open. I

SYMPTOM PROBABLE CAUSE REMEDY

Shor t l i f e 3. R o t a t i n g p a r t 3. Disassemble pump, o f pump rubb ing on s t a t i o n - r e p a i r o r r e p l a c e bear ings . a ry p a r t . d e f e c t i v e p a r t .

( c o n t d . )

4. Improper b e a r i n g 4. Check end f l o a t .

I end f l o a t . See para. 6-7.

5. Rotor o u t o f ba lance, 5. Remove r o t o r assern-caus ing v i b r a t i o n . b l y and check b a l -ance.

6 . Improper bea r ing 6. Disassemble pump l u b r i c a t i o n . and c lean bear ings .

See para. 6-4.

R e i n s t a l 1 bear ings and l u b r i c a t e as o u t l i n e d i n para.

4-6

I a

7. Improper f i t t i n g o f 7. Disassemble pump bear ings ( t o o t i g h t and check bear ing i n housing; t oo f i t . See para. 6-4.

l oose on s h a f t ) -

8. Use o f unmatched 8. Bear ings must be bear ings as a p a i r . t h e t y p e l i s t e d i n t a b l e 7-1.

9. D i r t i n bea r ings . 9. See 6 above.

10. Bear ings r u s t e d 10. Replace bear ings .

from water e n t e r - Determine cause o f i n g housings. water e n t e r i n g hous ing and c o r r e c t .

2. Speed t o o h i g h . 2. Check frequency o f o p e r a t i n g c u r r e n t .

M a i n t a i n f requency a t 60 h e r t i 53.

3. R o t a t i n g p a r t rub- 3. Disassemble pump, b i n g on s t a t i o n a r y r e p a i r o r r e p l a c e p a r t . d e f e c t i v e p a r t .

5- 5

' I

Tab le 5-1. T r o u b l e s h o o t i n s Guide ( c o n t d . )

SYMPTOM PROBABLE CAUSE REMEDY

Pump o v e r - 4. S h a f t r u n n i n g o f f 4 . I n s p e c t b e a r i n g s h e a t s and c e n t e r because o f (see para . 6-41 s e i z e s a worn b e a r i n g s o r and/or check a l i g n - ( c o n t d . 1 m isa l i gnmen t . ment. (See para. 6-11.

5. Ro to r o u t of 5. Remove r o t o r assem-balance, caus ing b l y and check b a l -v i b r a t i o n . ance.

6. Case r i n g c lea rance 6. Disassemble pump and too t i g h t . check r i n g c l e a r a n c e

See para . 6-4.

5-6

CHAPTER 6

CORRECTIVE MAINTENANCE

6-1. FLOATING SHAFT COUPLING ALIGNMENT.

The coupling alignment should be checked after performing any repair or part replacement on the pumping unit. As with any low vibration equipment, alignment is very important. Align the unit cold as outlined below. After the initial operation of the unit after installation or overhaul, the alignment should be given a final check for misalignment caused by piping strain or temerature strain.

This check should be made immediately after the unit is shutdown, while it is still at operating temperature. When final alignment is correct, dowel the pump to its foundation on diagonally opposite feet.

A floating shaft coupling is not designed to compensate for exces-sive misalignment. Its purpose is to permit slight movement of pump and driver shafts while transmitting power. Excessive misalignment is one cause for rapid wear of bearings and vibration during opera-tion. The maximum acceptable angular misalignment is .011" total indicator reading (TIR) on the pump end coupling and =014" TIR on the motor end cocrpling. The couplings cannot accommodate parallel misalignment.

NOTE

Every effort should be made to reduce misalignment to .OOO" TIR even though .011" on pump end and *014" on motor end are acceptable.

Due to the difference between operating temperatures of pump and driver, it is necessary to set the driver coupling hub above or below the pump coupling hub to compensate for unequal vertical expansion. This procedure is used for aligning cold only, and can be estimated from the formula:

coefficient of expansion x temperature rise x centerline height

The coefficient of expansion is a specific figure for each material expressed in millionths of an inch per inch per degree Fahrenheit temperature rise. The following coefficient of expansion should be used for the pump casing material when making calculations:

Nickel Aluminum Bronze. o m ..- e e - . 9 ~ 1 0 - ~ in/in/deg.F.

The second piece of the formula deals with temperature rise and is fairly straight forward. The temperature rise is the difference between the ambient temperature and operating temperature in degrees Fahrenheit.

The third piece of the formula, centerline height, is the distance

6-1

( i n i n c h e s ) f rom t h e bottom o f t he pump o r d r i v e r f e e t t o t h e c e n t e r o f t h e s h a f t . Re fe r t o t h e o u t l i n e drawing , F i g u r e €3-1, f o r pump c e n t e r 1 i n e h e i g h t .

By p e r f o r m i n g t h i s c a l c u l a t i o n f o r b o t h t h e pump and d r i v e r and comparing the r e s u l t s , the approx imate d i s t a n c e the d r i v e r hub i s s e t above o r below the pump hub w i l l be ob ta ined . The thermal g rowth fo rmu la i s t h e bes t method o f d e t e r m i n i n g c e n t e r l i n e r i s e w i t h o u t a c t u a l l y checking a h o t u n i t . However, t h e method i s j u s t an approx ima t ion and does n o t account f o r t h e i n f l u e n c e s o f p i p i n g p c a s i n g geometry, and ho t and c o l d s p o t s c r e a t e d by c i r c u l a t i n g a i r .

A f t e r i n i t i a l o p e r a t i o n , w h i l e b o t h pump and d r i v e r a r e a t o p e r a t i n g tempera ture , recheck a l ignment t o i n s u r e i t i s c o r r e c t f o r t h e o p e r a t i n g c o n d i t i o n s .

Method o f check ing a l ignment i s as f o l l o w s :

P r i o r t o work ing on equipment, p l a c e a l l sw i t ches and c i r c u i t b reakers to t h e open ( o f f ) p o s i t i o n and tag:

"DANGER SHOCK HAZARD. Do n o t change p o s i t i o n o f s w i t c h except by d i r e c t i o n o f NAME..RATE/RANK".

1. Check t h e d i s t a n c e between t h e end o f t he pump s h a f t and t h e end o f t h e d r i v e r s h a f t .