S6226-C9-MMA-010 AIR CONDITIONING CHILLED WATER PUMP.pdf

TECHNICAL MANUAL

FOR

AIR CONDITIONING

CHILLED WATER PUMP

TYPE DH5060M

SUPERSEDURE NOTICE: THIS PUBLICATION SUPERSEDES S6226-C9-MMA-010,

REVISION 2, DATED 31 MARCH 2014, AND ALL CHANGES THERETO.

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE/OPERATIONAL USE; 31 MARCH 2014. OTHER U.S. REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NSWC PHILADELPHIA, CODE 314.

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

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

PROVISIONS OF DOD DIRECTIVE 5230.25.

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

OR RECONSTRUCTION OF THE DOCUMENT.

S6226-C9-MMA-010

REVISION 3

TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

*0910LP1152564* 1 OCT 2016

TITLE-2

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RECORD OF REVISIONS

REVISION

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

A 15 AUGUST 1997 INCORPORATED CHANGES FOR REVISION TO FLEXIBLE COU-

PLING ALIGNMENT PROCEDURES, EXPANDS COVERAGE TO

INCLUDE 60 HP DRIVE MOTOR MANUFACTURED BY RELIANCE

ELECTRIC THAT REPLACES THE WELCO DRIVE MOTOR AND COV-

ERAGE FOR THE ADDITIONAL DDG HULLS THAT UTILIZE PUMP

DH5060M.

B 5 MAY 2000 INCORPORATED CHANGES TO REFLECT THE INSTALLATION OF

ECP 503-06A-C003.

C 15 JULY 2003 MACHALT 514-78001 (ECP-547) REMOVES EXISTING COUPLING ON

AIR CONDITIONING CHILL WATER PUMP AND INSTALLS A MAG-

NETIC COUPLING.

1 1 JUNE 2009 INCORPORATED MATERIAL CHANGE, ADDED A ONE-HALF KEY,

TO MACHALT 514-78001 (ECP-547).

2 31 MARCH 2014 REVISION 2 DOCUMENTS IMPACT OF ECP 503-06D-C001 IN THE

TECHNICAL MANUAL. POC: SOS BATH MAINE, N62786, CODE 240.

3 1 OCTOBER 2016 REVISION 3 DOCUMENTS THE INCORPORATION OF THE WARD

LEONARD A/365TN/58 REPLACEMENT MOTOR INTO THE TECHNI-

CAL MANUAL.

FOR OPTIMAL VIEWING OF THIS TECHNICAL MANUAL THE PAGE LAYOUT IN ADOBE ACROBAT

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

LINK REFERENCES AND THE BOOKMARKS.

S6226-C9-MMA-010

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

RECORD OF REVISIONS-2

FOREWORD

This technical manual provides maintenance instructions with a parts list for the Air Conditioning Chilled Water Pump, Type DH5060M. The pump is manufactured by Buffalo Pumps, Inc., North Tonawanda, New York 14120. The technical manual covers the following chapters:

CHAPTER 1 General Information and Safety Precautions

CHAPTER 2 Operation

CHAPTER 3 Functional Description

CHAPTER 4 Scheduled Maintenance

CHAPTER 5 Troubleshooting

CHAPTER 6 Corrective Maintenance

CHAPTER 7 Parts List

CHAPTER 8 Installation .

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

COMMANDER

CODE 310 TMDERs

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY BLDG 1389

PORT HUENEME, CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting there-from. One copy of NAVSEA form 4160/1 is at the end of this technical manual. Users are encouraged to trans-mit deficiency submittals via the website located at:

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

FOREWORD-1 / (FOREWORD-2 Blank)

FOREWORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

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

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

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

1-3. FUNCTION OF EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4. REFERENCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-5. EQUIPMENT, ACCESSORIES, AND DOCUMENTS. . . . . . . . . . . . . . . . . . 1-5

1-6. EQUIPMENT REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . 1-5

1-7. WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

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

2-2. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-3. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

2-5. OPERATOR’S MAINTENANCE INSTRUCTIONS AND SCHEDULES. . . . . . . 2-3

2-6. EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1. EQUIPMENT DESCRIPTION (refer to Figure 3-1). . . . . . . . . . . . . . . . . . . 3-1

3-2. MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1. INTRODUCTION (refer to Figure 7-2). . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 i

TABLE OF CONTENTS - Continued

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

SECTION I ADJUSTMENTS & ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-2. ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-2A REPLACEMENT OF MAGNETIC COUPLING. . . . . . . . . . . . . . . . . . . . . 6-11

SECTION II REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-3. PUMP DISASSEMBLY. (Figures 6-16, 6-17). . . . . . . . . . . . . . . . . . . . . . . 6-16

6-4. PUMP MAINTENANCE AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-5. PUMP REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-6. MOTOR REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-7. MOTOR DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-7.1 BEARING REPLACEMENT FOR WARD LEONARD MOTOR. . . . . . . 6-35

6-7.1.1 Front End (Non-Drive End) Bearing Access. . . . . . . . . . . . 6-36 6-7.1.2 Back End (Drive End) Bearing Access. . . . . . . . . . . . . . . 6-36 6-7.1.3 Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 6-7.1.4 Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 6-7.1.5 Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 6-7.1.6 Back End Bearing Bracket Installation. . . . . . . . . . . . . . . 6-37 6-7.1.7 Front End Bearing Bracket Installation. . . . . . . . . . . . . . . 6-37

6-7.2 MOTOR REWIND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 6-7.2.1 Motor Rewind Information. . . . . . . . . . . . . . . . . . . . . . 6-38 6-7.2.2 Stator Rewind. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

6-7.2.2.1 Sealed Insulation System. . . . . . . . . . . . . 6-38 6-7.2.2.2 Stator Stripping. . . . . . . . . . . . . . . . . . 6-38

6-8. MOTOR REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

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

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

7-2. MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

8-2. SITE PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 ii

TABLE OF CONTENTS - Continued

8-4. INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8-5. INITIAL STARTUP (Figure 8-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 iii

LIST OF TABLES

Table Title Page

1-1. Pump Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2. Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3. Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-4. Weights (Actual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-5. Dimensions of Assembled Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-6. Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-7. Equipment and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-8. Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

5-1. Pump Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. Electrical Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

6-1. Flexible Coupling Alignment Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-2. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-3. End Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-4. Driving Hub Runout Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-5. Angular Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-6. Offset Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-7. Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-8. Motor (Welco) Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6-9. Motor (Reliance) Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

7-1. List of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. List of Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3. Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-4. WelcoMotor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-4.1 Reliance Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-4.2 Ward Leonard Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-5. Flexible Coupling Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 iv

LIST OF TABLES - Continued

Table Title Page

8-1. Site Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 v

LIST OF ILLUSTRATIONS

Figure Title Page

1-1. Air Conditioning Chilled Water Pump, Type DH5060M. . . . . . . . . . . . . . . . . 1-1

2-1. Pump Type DH5060M, Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

3-1. DH5060M Pump Partial Disassembled to show Components. . . . . . . . . . . . . . 3-2

3-2. Mechanical Seal Cutaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. Flexible Coupling Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3A. Magnetic Coupling Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Volute-Type Centrifugal Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

6-1. Flexible Coupling Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-2. End Gap Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-3. Driving Hub Runout Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4. Driven Hub Runout Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-5. Angular Alignment Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-6. Offset Alignment Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-6A. Magnetic Coupling Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-7. Mechanical Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-8. Packing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-9. Rotor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-10. Rotor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-11. Bearing Expansion Allowance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-12. Mechanical Seal Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-13. Back-to-Back Arrangement of Ball Bearings. . . . . . . . . . . . . . . . . . . . . . . 6-26

6-14. Pump Performance Curve. (For Ships Without ECP 503-06D-C001 Installed). . . . . 6-29

6-14.1 Pump Performance Curves. (For Ships With ECP 503-06D-C001 Installed). . . . . . 6-30

6-15. Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-16. Chilled Water Pump, Type DH5060M Exploded View Diagram. . . . . . . . . . . . 6-39

6-17. Chilled Water Pump, Type DH5060M Sectional Assembly Diagram. . . . . . . . . . 6-41 vi

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

6-18. Welco Motor Cross-Sectional and Parts Identification Drawing (Sheet 1 of 3). . . . . 6-43

6-18. Welco Motor Cross-Sectional and Parts Identification Drawing (Sheet 2 of 3). . . . . 6-45

6-18. Welco Motor Cross-Sectional and Parts Identification Drawing (Sheet 3 of 3). . . . . 6-47

6-19. Reliance Motor Cross-Sectional and Parts Identification Drawing (Sheet 1 of 3). . . 6-49

6-19. Reliance Motor Cross-Sectional and Parts Identification Drawing (Sheet 2 of 3). . . 6-51

6-19. Reliance Motor Cross-Sectional and Parts Identification Drawing (Sheet 3 of 3). . . 6-53

6-20. Ward Leonard Motor Cross-Sectional and Parts Identification Drawing (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6-20. Ward Leonard Motor Cross-Sectional and Parts Identification Drawing (Sheet 2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

6-20. Ward Leonard Motor Cross-Sectional and Parts Identification Drawing (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

7-1. Flexible Coupling Parts Identification Drawing. . . . . . . . . . . . . . . . . . . . . . 8-1

7-2. Chilled Water Pump, Type DH5060M Exploded View Diagram. . . . . . . . . . . . 8-3

7-3. Welco Motor Cross-Sectional and Parts Identification. . . . . . . . . . . . . . . . . . 8-5

7-4. Reliance Motor Cross-Sectional and Parts Identification. . . . . . . . . . . . . . . . . 8-7

8-1. Installation Footprint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-2. Removing Pump from Pallet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-3. Moving Pump with Sling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-4. Resilient Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-5. Chilled Water Pump, Type DH5060M Outline Elevation Diagram.(Welco or Reliance Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 vii

SAFETY SUMMARY

The following general safety precautions are not related to any 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.

Keep Away From Live Circuits Operating personnel must at all times observe safety regulations. Do not replace components or make adjustments inside the equipment with the high voltage supply turned on. To avoid casualties, always remove power from the unit and tag-out a circuit before touching it.

Interlocks - Safety Devices Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended.

Never tamper with or render ineffective any safety device, interlock, ground strap or similar device intended to protect operators or the equipment without specific approval of the Commanding Officer. Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at the distribution source.

Do Not Service Or Adjust Alone Never reach into the equipment for the purpose of servicing or adjusting it 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. Such information may be obtained from the Bureau of Medicine and Surgery.

Cleaning Materials Materials used for cleaning components require special handling.

Dry cleaning solvent is toxic and flammable. Do not breathe vapors. Use in a well ventilated area away from sparks, flame, or hot surfaces. Wear splash goggles, solvent resistant gloves, and other protective gear. In case of eye contact, flush with water and seek medical attention. In case of skin contact, wash with soap and water.

Perchloroethylene used in many degreasers is toxic. Do not breathe vapors. Use in a well ventilated area free from sparks, flame, or hot surfaces. Wear splash goggles, solvent resistant gloves or other protective gear. In case of eye contact, flush with water and seek medical attention. In case of skin contact, wash with soap and water.

When using compressed air for cleaning or drying, regulate pressure to 29 pounds per square inch or less.

Wear goggles or a face shield to protect eyes.

The following Cautions and Warnings appear in the text and are repeated here for emphasis.

Prior to performing step a. on the equipment, deenergize the circuit and tag the unit ″Out of Service″. (Page 2-2) viii

The lifting lugs are designed for lifting the removable casing half (2A) only.

They should not be used for lifting the complete pump assembly. (Page 3-1)

Before performing any maintenance on a pump, isolate the pump from the sys-tem by closing and tagging or locking all valves closed. Tag all switches to motor and controller in the open position. (Page 6-1, page 6-17, page 8-11)

De-energize the equipment and tag the equipment properly before performing maintenance on the equipment. (Page 6-4, page 6-31)

Ensure proper lifting equipment is used to prevent possible equipment damage and injury to personnel. (Page 6-12, page 6-14)

Use insulated gloves to remove heated bearing to prevent burns. (Page 6-24)

De-energize the equipment and tag the equipment properly before performing removal procedures. (Page 6-27)

When lifting the motor, use a hoist rated for at least 2,000 pounds with a sling rated for the weight involved and in good condition. The motor weight is 803 (Welco) or 1018 (Reliance) lbs . (Page 6-27) ix

Motor endshields and rotor must be supported during disassembly as the weight of the rotor is 158(Welco) or 248 (Reliance) lbs. Otherwise, injury to personnel and damage to equipment can result. (Page 6-32)

Use insulated gloves to remove heated bearing to prevent burns. (Page 6-33)

De-energize the equipment and tag the equipment properly before performing removal procedures. (Page 6-34)

Motor endshields and rotor must be supported during disassembly as the weight of the rotor is 158 (Welco) or 248 (Reliance) lbs. Otherwise, injury to personnel and damage to equipment will result. (Page 6-35)

Handling bearings this warm with bare hands can result in burns. Use gloves or other insulation. (Page 6-35)

In order to prevent personnel injury, do not proceed with this task if power is on.

(Page 6-35) x

When lifting the unit, use a hoist rated for at least 2,000 pounds with a sling rated for the weight involved and in good condition. The assembled units ship weight is 1700 (Welco) or 1915 (Reliance) lbs. (Page 8-9)

Prior to performing step a. on the equipment, de-energize the circuit and tag the unit ″Out of Service″. (Page 8-12)

Do not run this pump dry. The pump may be damaged if the casing is not filled with liquid while the pump is running. (Page 2-1, page 8-12)

Do not run this pump without liquid. The pump will be damaged if the casing is not filled with liquid while the pump is running. Do not run this pump with dis-charge closed to prevent liquid in the pump from overheating. (Page 2-3)

Excessive piping forces on the pump flanges will cause pump and/or motor mis-alignment. (Page 6-10, page 8-11)

The magnetic coupling (68) is factory balanced. Ensure the pump hub (68B) and magnetic rotor (68E) are clearly matchmarked prior to disassembly. Failure to reassemble items in their original locations may cause coupling imbalance. (Page 6-12) xi

The magnetic coupling (68, Figure 6-6A) is factory balanced. Ensure the motor hub (68I) and conduct housing (68F) are clearly matchmarked prior to disassem-bly. Failure to reassemble items in their original locations may cause coupling imbalance. (Page 6-12)

Combined weight of conductor housing (68F) and magnetic rotor (68E) is approximately 74 lbs. Ensure adequate support of conductor housing (68F) is provided while removing hex head capscrews (68J). (Page 6-13)

Pump shaft nut (153, Figure 6-16) has left-hand threads. (Page 6-13)

Do not tighten hex head capscrews (68H) before installation. Inner ring of shrink disc (68G) and bore of motor hub (68I) can be permanently contracted even at relatively low tightening torques. (Page 6-13)

Before torquing hex head capscrew (68H, Figure 6-16) ensure there is 0.032-inch clearance between the shrink disc (68G) and the motor hub (68I). (Page 6-14)

Ensure matchmarks on magnetic rotor (68E) and pump hub (68B) are aligned before engaging studs (68C) with pump hub (68B). Ensure threads of studs (68C) are not damaged during the assembly procedure. (Page 6-14) xii

Before torquing hex head capscrew (68H) ensure there is 0.032-inch clearance between the shrink disc (68G) and the motor hub (68I). (Page 6-15)

Failure to ensure proper clearance exists between rotating parts will result in per-manent damage to the magnetic coupling (68). (Page 6-15)

Emergency packing should only be installed in the event of total mechanical seal failure (leakage rate in excess of 60 drops per minute). A mechanical seal with leakage rate in excess of 5 drops per minute is unsatisfactory. Replace as soon as possible. However, 5 drops per minute is not sufficient to provide adequate cool-ing and lubrication for the emergency packing. If leakage rates are too low to prevent overheating or emergency packing, loosen the gland nuts tightened in step (5) of this procedure until adequate leakage is obtained to prevent overheat-ing of the packing. Typical leakage rates for emergency packing is one drop per minute. (Page 6-20)

When disassembling the motor, care must be taken not to damage stator lamina-tions as other insulation may be injured by improper or rough handling. The bearings should not be allowed to become dirty through improper handling.

(Page 6-31)

CSE NECP 503–06A-N001 changes the manufacturers of the 60 hp drive motors from Welco Industries to Reliance Electric. Additionally, CSE NECP 503–06A- C003 modifies the configuration of the motors manufactured by Reliance Elec-tric to meet airborne noise requirements. Information in this manual specific to pre-CSE NECP 503–06A-C003 configuration will be noted as Group One, whereas information in this manual specific to post CSE NECP 503–06A-C003 will be noted as Group Two. The most recognizable differences between these xiii two groups are as follows; group One parts feature an aluminum Outer Fan (item

75) and a brass Balance Ring (item 71) whereas Group Two parts feature a black plastic Outer Fan (item 78) and a steel Balance Ring (item 75). These differences should be used to determine the correct ordering and replacement of parts. Group One and Group Two parts are not interchangeable therefore, care should be taken when ordering and replacing parts. (Page 6-34)

In order to prevent motor damage, record markers and location of wires before removing. Ensure wire markers are legible. (Page 6-36)

In order to prevent equipment damage, do not use a burn-out oven for stripping the winding from the stator core. (Page 6-38) xiv

CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. SAFETY PRECAUTIONS.

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 starting the equipment for the first time are listed in Chapter 2, Operation. Safety precautions to be followed prior to maintenance are listed in Chapter 4, Scheduled Maintenance, and safety precautions to be followed prior to and during disassembly and reassembly are listed in Chapter 6, Corrective Maintenance. General precautions and a summary of the Cautions and Warnings are listed in the Safety Summary, page iv.

1-2. INTRODUCTION.

This technical manual covers the description, operation, and maintenance of an Air Conditioning Chilled Water Pump Type DH5060M (see Figure 1-1), manufactured by Buffalo Pumps Inc., P.O. Box 156, North Tonawanda, New York 14210-0156.

1-3. FUNCTION OF EQUIPMENT.

The DH5060M Pump is used to distribute water from the air conditioning plant. This pump has two major components -- a centrifugal pump and its driver -- a 60 horsepower a.c. electric motor. The motor is connected to the shaft of the pump through an all-metal flexible coupling for ships without MACHALT 514-78001 (ECP-

Figure 1-1. Air Conditioning Chilled Water Pump, Type DH5060M.

1-1

547) or a magnetic coupling for ships with MACHALT 514-78001 (ECP-547). A guard covers this coupling to protect personnel during operation. The pump and motor are mounted on a welded steel subbase that is provided as part of the unit.

The pump is a horizontal, single-stage, double suction centrifugal unit of the volute type. The impeller dis-charges into a gradually widening channel in the casing. This channel is the volute which slows down velocity of the chilled water being pumped, transforming this energy into static head pressure.

CSE NECP 503-06A-N001 changes the manufacturers of the 60 hp drive motors from Welco Industries to Reliance Electric. Additionally, CSE NECP 503-06A-C003 modifies the configuration of the motors manufac-tured by Reliance Electric to meet airborne noise requirements. Information in this manual specific to pre-CSE NECP 503-06A-C003 configuration will be noted as Group One, whereas information in this manual specific to post CSE NECP 503-06A-C003 will be noted as Group Two.

1-4. REFERENCE DATA.

Figure 6-14 shows pump performance curves and Figure 6-17 shows clearance locations (indicated by let-ters) and the reference parts (indicated by numbers).

Table 1-1. Pump Characteristics.

Service Air Conditioning Chilled Water

Type (Buffalo Pumps) DH5060M Pump Specification MIL-P-17639E Pump Classification C-2 Location of Discharge Bottom Horizontal Rotation (Driven End) Clockwise Capacity 900 GPM Total Head 70 PSI Suction Pressure Flooded Liquid Handled Fresh Water Specific Gravity of Liquid Pumped 1.0 Suction Temperature 44°F

RPM 3600

Efficiency - % 73 Efficiency - % (Ships with ECP 503-06D-C001 installed) 68.5% Brake Horsepower at Rating 54.25 Brake Horsepower at Rating (Ships with ECP 503-06D- C001 installed)

58.5%

Maximum Brake Horsepower at any condition 55 Maximum Brake Horsepower at any condition (Ships with ECP 503-06D-C001 installed)

59%

Actual Shut - Off Head 111 PSI/256 ft.

Actual Shut - Off Head (Ships with ECP 503-06D-C001 installed)

106 PSI/245 ft.

Hydrostatic Test Pressure 140 PSI Final Impeller Diameter 8-3/16 in. x 7-13/16 in. V-cut 22° angle

Table 1-2. Motor Characteristics

Manufacturer Welco Industries

1-2

Table 1-2. Motor Characteristics - Continued

Specification MIL-M-17060 and Amend 1 Service Navy A Frame 365 TNS Horsepower 60 Design B RPM (Synchronous) 3600 RPM (Full Load) 3550 Phase/Hertz/Volts 3/60/440 Speed Class Constant Duty Continuous Ambient Temperature 50°C Enclosure TEFC Rotor Type Squirrel-Cage Bearing Ball Mounting Horizontal Winding Single Insulation Class B with Sealed Insulation Calculated Full Load Amps 72 Manufacturer Reliance Electric Specification MIL-M-17060E & Amend 1 Service Navy A Frame 365 TNS Horsepower 60 Design B RPM (Synchronous) 3600 RPM (Full Load) 3575 Phase/Hertz/Volts 3/60/440 Speed Class Constant Duty Continuous Ambient Temperature 50°C Enclosure TEFC Rotor Type Squirrel-Cage Bearing Ball Mounting Horizontal Winding Single Insulation Class F with Sealed Insulation Manufacturer Ward Leonard Motor Type AC Motor, Single Speed, Reversible Part Number A/365TN/58 Drawing Number A/365TN/58, Sheets 1 through 4 Frame Size 365TNS Bearings Ball Bearing, Open, Low Noise (per MIL-B-17931E) Input Voltage 440 VAC, 60 Hertz, 3-Phase Horsepower 60 Duty Continuous Full Load Current 69.1 Amperes (Calculated) RPM at Full Load 3580 Stator Winding Wye Rotor Squirrel Cage Induction

1-3

Table 1-2. Motor Characteristics - Continued

Maximum Ambient Operating Temp. 50 degrees Centigrade Temperature Rise (max.) 70 degrees Centigrade (Res. method) Insulation Class F Speed Torque Characteristics Design B Efficiency 95 Percent Enclosure Totally Enclosed Fan Cooled Mounting Horizontal Mechanical Balance Less than 0.0002 Inch Dimensions, Inches L = 32.25; W = 21.75″; H = 20.0 Weight (Motor) 1010 Pounds Weight (Rotor) 306 Pounds Calculated Full Load Amps 65

Table 1-3. Reference Drawings

Pump (Buffalo Pumps).

Outline Elevation CA15464 Sectional Assembly CA15465 Parts List PL. DH5060M-1 Certification Data NA1644 Motor (Welco Industries).

Master Drawing and Parts List D1-022278 Certification Data D1-022278 Motor (Reliance Electric).

Master Drawing and Parts List 801635-514B Certification Data 801635-514CD Motor (Ward Leonard) A/365TN/58

Table 1-4. Weights (Actual)

Unit with Welco Motor

Pump (Dry) 452 lbs.

Pump (Operating) 485 lbs.

Motor 803 lbs.

Base 445 lbs.

Total One Unit (Dry) 1700 lbs.

Total One Unit (Operating) 1733 lbs.

Unit with Reliance Motor Pump (Dry) 452 lbs Pump (Operating) 485 lbs.

Motor 1018 lbs.

Base 445 lbs.

Total One Unit (Dry) (for ships without MACHALT 514-

78001 (ECP-547))

1915 lbs.

Total One Unit (Dry) (for ships with MACHALT 514-

78001 (ECP-547))

1973 lbs.

Total One Unit (Wet) (for ships without MACHALT 514-

78001 (ECP-547))

1948 lbs.

1-4

Table 1-4. Weights (Actual) - Continued

Total One Unit (Wet) (for ships with MACHALT 514-

78001 (ECP-547))

2006 lbs.

Ward Leonard Motor 1010 lbs.

Table 1-5. Dimensions of Assembled Unit

W/Welco W/Ward Leonard W/Reliance

Overall Length 64-1/2 in. 32.23 in. 63-5/8 in.

Overall Width 22 in. 21.75 in. 22 in.

Height 30-13/16 in. 20.00 in. 32-1/8 in.

Table 1-6. Clearances

Part Clearance - Inches

Radial Axial A Impeller (3) and Casing Wearing Rings (9) .013-.015 - B Impeller (3) and Casing Wearing Rings (9) - 1/8″ Nominal C Impeller (3) and Casing (2, 2A) - 1/32″ Nominal D Shaft Sleeve (8) and Gland (12) .0165-.018 - E Shaft Sleeve (8A) and Casing (2, 2A) .015-.022 - G Spacer Ring (121, 121A) and Bearing Cap (23) .0075-.0011 - H Shaft (7) and Bearing Cover (24) .0075-.0011 - J Guide (Outboard) Bearing Pair (26) and Outboard Bearing Cover (25) -

5/32″

Nominal K Guide (Outboard) Bearing Pair (26) and Outboard Bearing Bracket (33) - 3/32″ Nominal L Thrust (Inboard) Bearing Pair (27) and Inboard Bearing Cover (24) .003″ .005″ -

1-5. EQUIPMENT, ACCESSORIES, AND DOCUMENTS.

The pump and motor are assembled at the factory, mounted to the base, aligned, mounted on a skid and packaged for shipment. No other equipment, or documents are supplied.

Table 1-7. Equipment and Accessories

Qty. Item Name CID No. Overall Dimensions Weight

4 Pump 64-1/4″ x 22″ x 1760.3 lbs.

DH5060M 31-13/16″ (Welco) Welco NA1644 63-5/8 x 22 x 1915

32-1/8 (Reliance) Reliance

Table 1-8. Documents

Qty. Description Part Number

4 Technical ManualAir Conditioning Chilled Water Pump,Type DH5060M

S6226-C9-MMA-010/83130

1-6. EQUIPMENT REQUIRED BUT NOT SUPPLIED.

Equipment required but not supplied with the contract include:

1-5

Item Qty. Purpose

Magnetic Controller One Control ON/OFF function of Pump.

Pressure Gauges Two For monitoring suction and discharge pressures. Tapped

9/16-18 standard thread connections are provided. See Figure 8-5 for location.

Subbase Mounting Hardware 12 Sets Mounting resilient mounts to foundation. Mounts require 1/2-inch bolts and hardware per MIL-S-1222, Grade 8.

Suction Piping and Mounting Hardware

As Required Connect pump suction to ships chilled water system. Size 6, 6-1/2 inch bore, 10-1/8 inch diameter flange with 12 11/16 holes. Mounts with 5/8 inch Grade 5 minimum bolts and hardware sets. See Figure 8-5.

Discharge Piping and Mounting Hardware

As Required Connect pump discharge to ships chilled water system.

Size 5, 5-1/2 inch bore, 9-1/16 inch diameter flange with 10 11/16 holes. Mounts with 5/8 inch Grade 5 minimum bolts and hardware. See Figure 8-5.

1-7. WARRANTY.

A. Notwithstanding inspection and acceptance by the BUYER of the Contract Product(s) or any part thereof fur-nished under this Purchase Order or any provision concerning the conclusiveness thereof, the SELLER war-rants the Contract Product(s) shall be new, suitable for its intended purpose, and constructed strictly in accor-dance with the drawings, specifications, rules and regulations referred to in this purchase order.

B. The SELLER also warrants the Contract Product(s) shall operate satisfactorily as specified and will be and remain free of any weakness, deficiency, defect, failure, breaking down or deterioration in design, material or workmanship. At any time during the performance of this Purchase Order, but within nine months, as extended by Article 15, Additional Warranty Period, after preliminary acceptance of the ship by the U.S.

Government, the BUYER may require the SELLER to remedy, by correction or replacement, as directed by the BUYER, any failure by the SELLER to comply with the requirements of this Purchase Order. Any time devoted to such correction or replacement shall not be included in computation of the period of time speci-fied in the preceding sentence. The SELLER shall not be responsible for the cost of correcting any such fail-ure or noncomformance of the Contract Products to the extent that it is due to ordinary wear and tear or to the extent increased by the negligence or improper act of the BUYER or the Government.

C. During warranty period, and at the election of the BUYER and/or the Government, the SELLER shall correct any SELLER responsible defects defined in paragraph B above as directed by the BUYER pursuant to the Article of these General Provisions entitled ″Inspection″.

D. The same warranty as described herein will extend to any Contract Products corrected or furnished as replacements pursuant to this Article. The warranty Period with respect to such replacement Contract Prod-ucts shall be nine months from the date of delivery of such replacement Contract Products or until the expi-ration of the original warranty period (whichever is longer).

E. In the event of the breach of this warranty, the BUYER shall be entitled to a correction of the defect: (i) by the SELLER; or (ii) at the SELLER’S expense, in accordance with the ″Inspection″ Article of the Purchase Order, notwithstanding any expiration of the warranty period as it may be extended pursuant to paragraph B of this Article.

F. The rights and remedies of the BUYER provided in this Article are in addition to and do not limit any rights afforded to the BUYER by any other Article of this Purchase Order.

1-6

CHAPTER 2

OPERATION

2-1. INTRODUCTION.

The Air Conditioning Chilled Water Pump Type DH5060M is a volute-type centrifugal pump that depends on centrifugal force for its operation. The centrifugal force is generated by the high-speed rotation of the impel-ler within the casing. The pump is driven by a 60-horsepower, squirrel-cage induction motor, which is started and stopped by pressing the start-stop pushbutton on the A.C. magnetic controller. This controller is not provided with the contract.

2-2. GENERAL.

The operating procedures 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.

2-3. SAFETY PRECAUTIONS.

The following safety precautions and operating checks shall be made before starting the unit after initial installation, after an overhaul, or after a long period of idleness (three months or more).

a. Prior to remaking the ship system piping, check to ensure that exposed pump internals and attached piping are free of foreign matter. Ensure that all blank flanges are removed.

b. 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 freely without noise or binding.

c. Ensure that the motor rotates in the correct direction. The correct direction of rotation is indicated by an arrow on the pump casing. When rotation is reversed, rewire as necessary.

d. Ensure that the ship system arrangement and valve line up provides a flow path to the pump.

e. Ensure that the unit is properly aligned in accordance with instructions in Chapter 6.

f. For ships without MACHALT 514-78001 (ECP-547), ensure that the pump bearings and the flexible coupling are properly lubricated in accordance with instructions in Chapter 4. For ships with MACHALT 514-78001 (ECP-547), lubrication is not required for the magnetic coupling.

2-4. OPERATING PROCEDURES.

2-4.1. INITIAL START-UP INSTRUCTIONS. This section lists procedures for starting the pump for the first time after installation or overhaul.

Do not run this pump dry. The pump may be damaged if the casing is not filled with liquid while the pump is running.

2-1

To start the pump, refer to Figure 2-1 and:

Prior to performing step a. on the equipment, deenergize the circuit and tag the unit ″Out of Service″.

a. For ships without MACHALT 514-78001 (ECP-547), remove the coupling guard, grasp the coupling and rotate a full turn clockwise with respect to motor end to check that the motor and pump shafts are free to rotate. For ships with MACHALT 514-78001 (ECP-547), remove the coupling guard and rotate both the pump and motor shaft separately, a full turn clockwise to check both the motor and pump shafts are free to rotate.

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

c. Prime the pump by opening the vent cock to fill the pump with liquid. Close the vent cock when liquid begins to flow from the vent cock.

d. Return motor to service by removing ″Out of Service″ tag and re-energizing circuit.

e. Reinstall coupling guard.

f. Check that sealing liquid is flowing to the mechanical seals by loosening the tube fittings on the seal line and noting the presence of water. Tighten the fitting.

g. Start the pump.

h. Open the discharge valve slowly when discharge pressure is reached.

i. Check that the pump is properly vented to prevent cavitation.

j. Check all connections for leaks and correct any that are found.

2-4.2. NORMAL STARTING.

Figure 2-1. Pump Type DH5060M, Components.

2-2

Do not run this pump without liquid. The pump will be damaged if the casing is not filled with liquid while the pump is running. Do not run this pump with dis-charge closed to prevent liquid in the pump from overheating.

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

b. Vent pump casing of entrapped air by opening vent cock. Fill pump completely with liquid until all air has been expelled from the casing. Close the vent cock.

c. Check for liquid flow through the seal lines.

d. Start the pump motor.

e. Open the pump discharge valve slowly as pump discharge pressure reaches the rated discharge pressure.

f. Check all connections for leaks and correct any that are found.

2-4.3. RUNNING.

a. Check motor bearing and pump operating temperatures and pressures hourly or as required. If values vary from normal or change suddenly, investigate and correct the trouble immediately.

b. The mechanical seal stuffing box is lubricated with liquid from the seal line. If the stuffing box appears to be running hot, check for fluid flow through the seal line by loosening the seal line tube fittings.

c. Periodically check for rubbing sounds, unusual noise, or vibration. If found, secure the pump. Do not resume operation until the cause of trouble has been found and corrected.

d. Watch for oil, grease, or liquid leakage and correct cause if found. If there is visible leakage at the stuffing box, the mechanical seal should be replaced at the earliest opportunity.

2-4.4. SECURING.

a. Stop the pump motor.

b. Shut the pump discharge valve.

c. Close the pump suction valve only if necessary. If possible, leave this valve open at all times to prevent acci-dental starting without suction.

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

2-5.1. GENERAL AND DAILY OPERATIONAL CHECKS.

a. Personnel should frequently check the operating pump and familiarize themselves with normal pressures, tem-peratures, and operating sounds. Any deviation from normal should be reported and investigated.

b. Listen carefully for any unusual sound. A peculiar sound could be a sign of potential pump failure and there-fore should be checked out.

2-5.2 WEEKLY TEST AND INSPECTIONS.

2-3

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 zero.

Excessive leakage indicates a defective mechanical seal which should be replaced as soon as possible. Maxi-mum acceptable leakage rate is 5 to 7 drops per minute.

2-6. EMERGENCY OPERATION.

In the event of mechanical seal failure, emergency packing (66) may be installed in the auxiliary gland. Fol-low instructions in paragraph 6-4.2.

2-4

CHAPTER 3

FUNCTIONAL DESCRIPTION

3-1. EQUIPMENT DESCRIPTION (refer to Figure 3-1).

3-1.1 PUMP. The pump is a horizontal, single stage, double suction, volute-type centrifugal unit coupled directly to an electric motor by an all-metal flexible coupling (for ships without MACHALT 514-78001 (ECP- 547)) or by a magnetic coupling (for ships with MACHALT 514-78001 (ECP-547)). The pump and motor are mounted on a welded steel subbase which is provided as part of the unit.

3-1.1.1 Subbase. The subbase (1) forms the rigid mounting platform necessary to maintain alignment between pump and motor. It is constructed from rectangular steel tubes, welded for rigidity. Reinforced bolt holes are pro-vided for mounting the subbase and also at motor and pump mounting locations. The nameplate is located on the subbase between the motor and the pump.

3-1.1.2 Casing. The casing (2, 2A) is a nickel-aluminum-bronze casting split horizontally for access to internal parts without breaking the suction or discharge piping connections. These openings are located in the lower or stationary half casing (2). The removable casing half (2A) is fitted with a vent cock (67) at the highest part of the pump casing. Two vent plugs, with ″O″ rings (74C) on the suction chambers, are used to remove trapped air from the casing. The casing is also provided with two seal lines which are complete on the pump and take liq-uid from the discharge volute to the pump stuffing boxes to cool and lubricate the mechanical seals in the stuff-ing boxes. Tapped openings are located on the suction and discharge nozzles for gauge connections. Casing halves (2, 2A) are accurately positioned with taper pins (144) and bolted together. Casing wearing rings (9) are fitted into the casing to minimize wear and provide close running clearances with the impeller hubs. Lifting lugs are cast in the removable casing half (2A).

The lifting lugs are designed for lifting the removable casing half (2A) only.

They should not be used for lifting the complete pump assembly.

3-1

3-1.1.3 Impeller (3). The double suction impeller (3) is a machined nickel-copper alloy casting. The impeller is positioned by a pin (71), and it is prevented from rotating on the shaft (7) by a feather key (17B).

3-1.1.4 Wearing Rings. The pump is fitted with replaceable labyrinth type wearing rings in the casing halves.

Casing wearing rings (9) are valve bronze castings located in the casing by a tongue and groove. The rings are prevented from turning in the casing by an enlarged projection on the ring tongue and a mating groove in the stationary casing half.

3-1.1.5 Shaft (7). The shaft (7) is machined from nickel-copper alloy and is connected to the driving unit by an all-metal flexible coupling (68) (for ships without MACHALT 514-78001 (ECP-547)), or by a magnetic cou-pling (68) (for ships with MACHALT 514-78001 (ECP-547)). The shaft (7) is supported by ball bearings (26,

27) at the inboard and outboard ends. Two sets of sleeves (8, 8A) are installed on the shaft to protect the shaft from wear and corrosion. The shaft sleeves (8) provide shoulders for positioning the mechanical seals (82).

Deflectors (18A) prevent possible gland leakage from traveling along the shaft to the ball bearings or flexible coupling (68). Spacer rings (121, 121A) are also fitted on the shaft to provide a shoulder for the ball bearings (26, 27).

3-1.1.6 Ball Bearings (26, 27). The pump is provided with a set of two angular contact ball bearings mounted back-to-back at inboard and outboard bearing housings. Bearings (27) at inboard end serve as thrust bearings and bearings (26) at outboard end are guide bearings. Both bearing pairs are secured to shaft (7) by lockwashers (28) and locknuts (29). Grease lubrication is provided. Each bearing cover (24, 25) has a grease cup (32A) through which grease in the bearing housing can be replenished.

3-1.1.7 Stuffing Boxes. An inboard and outboard stuffing box is cast into the casing. The bottom is formed by a shoulder on shaft sleeves (8). The pump stuffing boxes contain mechanical seals (82) manufactured by Crane

Figure 3-1. DH5060M Pump Partial Disassembled to show Components.

3-2

Packing Co., Chicago, Illinois. These seals, when properly installed, reduce leakage from the sniffing boxes to almost nil. The non-repairable mechanical seals (82), (refer to Figure 3-2), prevent leakage by pressing a rotat-ing carbon washer against a stationary tungsten carbide seat. The seal is held in place by gland (12) which bolts to the casing. The stuffing boxes are provided with liquid pumped at discharge pressure for lubrication and cool-ing of mechanical seal faces. The liquid used to lubricate the seal flows through tubing from discharge volute to tube fittings (78) to glands (12), through the stuffing boxes and back into the pump suction. Glands (12) contain an auxiliary stuffing box that can be packed with compression packing as an emergency measure in the event of seal failure or excessive seal leakage.

3-1.1.8 Coupling (refer to Figure 3-3.). For ships without MACHALT 514-78001 (ECP-547) the driving shaft is connected to the pump shaft by an all-metal flexible coupling (68). The driven hub (68B) is mounted on pump shaft (7). It is secured with a key (17A) and locknut (153). The driving hub (68A) is pressed onto the straight motor shaft and secured by a key (17C) and setscrew (68L). A spring type gridmember (68E) connects the hubs.

The hubs are housed in a coupling guard (125). The coupling is lubricated by grease contained in the coupling covers (68C, 68D).

Figure 3-2. Mechanical Seal Cutaway.

3-3

Figure 3-3. Flexible Coupling Components.

3-4

Figure 3-3A. Magnetic Coupling Components.

3-5

3-1.1.8A Magnetic Coupling (see Figure 3-3A). For ships with MACHALT 514-78001 (ECP-547) installed, a magnetic coupling (68) is used between the pump and motor. The coupling consists of a magnetic rotor (68E) and conductor housing (68F). The magnetic rotor (68E) is rigidly fastened to the pump hub (68B). The conduc-tor housing (68F) is rigidly fastened to the motor hub (68I). As the conductor housing (68F) rotates around the magnetic rotor (68E), electromotive forces generate a voltage in the conductor housing (68F). The resulting cur-rent from this generated voltage produces its own magnetic field which applies an attractive force to the mag-netic rotor (68E). The magnetic attraction between the conductor housing (68F) and the magnetic rotor (68E) is translated into rotational torque causing the pump shaft (7, Figure 7-2) to rotate. The hubs are housed in a cou-pling guard. Lubrication of this coupling is not required.

3-1.1.9 Lubrication. Lubrication of pump bearings, mechanical seals, and coupling is as follows. Ball bearings (26, 27) are lubricated by grease in the reservoir of the bearing housing. Mechanical seals (82) are lubricated by the liquid pumped. For ships without MACHALT 514-78001 (ECP-547), the coupling is grease lubricated from grease contained in the coupling halves.

3-1.2. PRINCIPLE OF OPERATION.

3-1.2.1. General. A centrifugal pump is a hydraulic machine that depends on centrifugal force for its operation.

This force is generated by the high-speed rotation of the impeller within…