TM S6226-DN-MMA-010.pdf

TECHNICAL MANUAL

FOR

[SGML VERSION; SEE RECORD OF

REVISIONS ]

CENTRALIZED SEAWATER

COOLING PUMP

TYPE DH6080D

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

AGENCIES ONLY; THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR

ADMINISTRATIVE OR OPERATIONAL PURPOSES; (15 AUG 2006). OTHER REQUESTS

FOR THIS DOCUMENT MUST BE REFERRED TO THE NAVAL SEA SYSTEMS COM-

MAND (SEA-09T).

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, AS AMENDED, TITLE 50,

U.S.C., APP 2401 ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO

SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS

OF DOD DIRECTIVE 5230.25(D).

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-

SURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.

SUPERSEDURE NOTICE: THIS PUBLICATION SUPERSEDES S6226-DN-MMA-010

DATED 1 MAR 1988 AND ALL CHANGES THERETO.

S6226-DN-MMA-010

0910-LP-105-4420 REVISION 1

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

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

15 AUG 2006

TITLE-2

@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

REVISION

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

A 1 JANUARY 1997 503-01A-C004R1

B 15 DECEMBER

INCORPORATED CHANGED PIECE NUMBER FOR PILOT ON BEARING

COVER GASKET FROM 65C TO 65D FOR THE OUTBOARD END OF

PUMP.

C 1 DECEMBER

THIS CHANGE REFLECTS THE INSTALLATION OF MACHALT 256-78001

(ECP-587) WHICH REPLACED THE FLEXIBLE MECHANICAL COUPLING

WITH A MAGNETIC COUPLING.

CHANGED INFORMATION INCLUDES THE FOLLOWING:

1 15 JAN 2006 INCORPORATED TMDER C7B572-05-GH08. CHANGE AUTHORIZED BY

NSWCCD-SSES CODES 9442 AND 9234. THE FOLLOWING WAS

CHANGED; PARAGRAPH(S) , 1-1., 3-1.1.8A, 5-2. AND 8-5.

FIGURE(S) 3-3A. AND 6-1A.

NOTE

THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC

SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO LOEP.

ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT MATCH THE PAGINATION OF THE ORIGINAL PAPER TM. HOWEVER, THE CONTENT IS EXACTLY THE SAME.

ANY CHANGES RECIEVED AFTER RECEIPT OF THIS TM WILL ONLY FIT THIS PAGINATED VERSION.

S6226-DN-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 Centralized Seawater Cooling Pump, Type DH6080D. 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 TMDER BLDG 1388

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY

PORT HUENEME CA 93043-4307

on NAVSEA Technical Manual Deficiency/Evaluation Report, form NAVSEA 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom. One copy of form NAVSEA 4160/1 is included at the end of each separately bound technical manual 8-1/2 x 11 inches or larger.

Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency submittals via the Naval Systems Data Support Activity Web page located at:

http://nsdsa.phdnswc.navy.mil/tmder/tmder-generate.asp?lvl=1 Individual electronic TMs do not contain NAVSEA form 4160/1 but are linked to an electronic version on the resident CD-ROM. Therefore, we encourage the user to transmit deficiency submittals via the Naval Systems Data Support Activity Web page located above.

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

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

1-5. EQUIPMENT, ACCESSORIES, AND DOCUMENTS. . . . . . . . . . . . . . . . . . 1-3

1-6. WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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. . . . . . . 2-4

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

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

3-1. EQUIPMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

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

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

4-2. MAINTENANCE TASK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

5-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

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

TABLE OF CONTENTS - Continued

Chapter/Paragraph Page

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

SECTION I ADJUSTMENTS & ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

SECTION II REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-3. PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-4. PUMP MAINTENANCE AND REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-5. PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-6. MOTOR REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-7. MOTOR DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-8. MOTOR REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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

8-5. INITIAL STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 ii

LIST OF TABLES

Table Title Page

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

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

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

1-4. Weights (Actual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-5. Dimensions of Assembled Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-6. Equipment and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-7. Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

5-2. Electrical Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

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

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

6-4. Driving Hub Runout Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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

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

6-7. Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-8. Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

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

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

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

7-4. Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-5. Flexible Coupling Parts List (Without MACHALT 256-78001 (ECP-587) installed) . 7-7

8-1. Site Selection Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 iii

LIST OF ILLUSTRATIONS

Figure Title Page

1-1. Centralized Seawater Cooling Pump, Type DH6080D. . . . . . . . . . . . . . . . . . 1-1

2-1. Pump Type DH6080D, Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3-1. DH6080D Pump Partial Disassembled to show Components. . . . . . . . . . . . . . 3-2

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

3-3. Flexible Coupling Components. (Without MACHALT 256-78001 (ECP-587) installed.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3A. Magnetic Coupling Components. (With MACHALT 256-78001 (ECP-587) installed.)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Volute-Type Centrifugal Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

6-1. Coupling Disassembly. (Without MACHALT 256-78001 (ECP-587) installed.) . . . 6-5

6-1A. Magnetic Coupling Disassembly. (With MACHALT 256-78001 (ECP-587) installed.)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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

6-3. Driving Hub Runout Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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

6-5. Angular Alignment Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-6. Offset Alignment Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-7. Mechanical Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-8. Packing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-9. Rotor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-10. Rotor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-11. Mechanical Seal Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-12. Back-to-Back Arrangement of Ball Bearings. . . . . . . . . . . . . . . . . . . . . . . 6-24

6-13. Pump Performance Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-14. Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-15. Centralized Seawater Cooling Pump, Type DH6080D Sectional Assembly Diagram Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

6-16. Centralized Seawater Cooling Pump, Type DH6080D Sectional Assembly Diagram.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 iv

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

6-17. Motor Cross-Sectional and Parts Identification Drawing (sheet 1 of 2). . . . . . . . . 6-37

7-1. Flexible Coupling Parts Identification Drawing. (Without MACHALT 256-78001 (ECP-587) installed.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-2. Centralized Seawater Cooling Pump, Type DH6080D Sectional Assembly Diagram Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-3. Motor Cross-Sectional and Parts Identification Drawing. . . . . . . . . . . . . . . . . 7-11

8-1. Installation Footprint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2. Removing Pump from Pallet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

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

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

8-5. Centralized Seawater Cooling Pump, Type DH6080D Diagram Outline Elevation. . 8-7 v

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.

Do Not Service Or Adjust Alone Never reach into the equipment for the purpose of servicing or adjust-ing 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.

WARNING

Prior to performing step a on the equipment, deenergize the circuit and tag the unit ″Out or Service″. (Page 2-1)

WARNING

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) vi

WARNING

Magnetic coupling is factory balanced. Do not paint. (Page 3-4)

WARNING

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

WARNING

Deenergize the equipment and tag the equipment properly before perform-ing maintenance on the equipment. (Page 6-3, page 6-28)

WARNING

Before performing any maintenance on a pump, isolate the pump from the system by closing and tagging or locking all valves closed. Tag all switches to motor and controller in the open position. (Page 6-12)

WARNING

Ensure proper lifting equipment is used to prevent possible equipment dam-age and injury to personnel. (Page 6-14, page 6-16)

WARNING

Deenergize the equipment and tag the equipment properly before perform-ing removal procedures. (Page 6-25)

WARNING

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 1,050 pounds. (Page 6-26) vii

Motor endshields and rotor must be supported during disassembly as weight of the rotor is 158 lbs. Otherwise, injury to personnel and damage to equip-ment can result. (Page 6-29)

WARNING

Handling bearings this warm with bare hands can result in burns. Use gloves or other insulation. (Page 6-30)

WARNING

When lifting the unit, use a hoist rated for at least 3,000 pounds with a sling rated for the weight involved and in good condition. The assembled unit weight is 2,523 pounds (dry). (Page 8-2)

WARNING

Prior to performing step a. on the equipment, deenergize the circuit and tag the unit ″Out of Service″. (Page 8-5)

CAUTION

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 2-2, page 8-5)

CAUTION

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

CAUTION

Do not disassemble conductor housing (68E) or coupling imbalance will result. If the conductor housing (68E) requires work, return the magnetic coupling (68) to the factory. (Page 3-4, page 6-14) viii

CAUTION

Excessive piping forces on the pump flanges will cause pump and/or motor misalignment. (Page 6-10)

CAUTION

The magnetic coupling (68) is factory balanced. Ensure the pump hub (68A) and magnetic rotor (68D) are clearly matchmarked prior to disassembly.

Failure to reassemble items in their original locations may cause magnetic coupling (68) imbalance. (Page 6-13)

CAUTION

The magnetic coupling (68) is factory balanced. Ensure the motor hub (68H) and conductor housing (68E) are clearly matchmarked prior to disassembly.

Failure to reassemble items in their original locations may cause magnetic coupling (68) imbalance. (Page 6-14)

CAUTION

Combined weight of conductor housing (68E) and magnetic rotor (68D) is approximately 85 lbs. Ensure adequate support of conductor housing (68E) is provided while removing hex head capscrews (68I). (Page 6-14)

CAUTION

Pump shaft nut with setscrew (153) has left-hand threads. (Page 6-15)

CAUTION

Do not tighten hex head capscrews (68G) before installation. Inner ring of shrink disc (68F) and bore of motor hub (68H) can be permanently con-tracted even at relatively low tightening torques. (Page 6-15)

CAUTION

Ensure matchmarks on magnetic rotor (68D) and pump hub (68A) are aligned before engaging studs (68B) with pump hub (68A). Ensure threads of studs (68B) are not damaged during the assembly procedure. (Page 6-16) ix

Failure to ensure proper clearance exists between rotating parts will result in permanent damage to the magnetic coupling (68). (Page 6-16)

CAUTION

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 considered unsatis-factory and should be replaced as soon as possible. However, 5 drops per minute is not sufficient to provide adequate cooling and lubrication for the emergency packing. If leakage rates are too low to prevent overheating of emergency packing, loosen the gland nuts tightened in step (5) of this pro-cedure until adequate leakage is obtained to prevent overheating of the packing. (Page 6-18)

CAUTION

When disassembling the motor, care must be taken not to damage stator laminations as other insulation may be injured by improper or rough han-dling. The bearings should not be allowed to become dirty through improper handling. (Page 6-28)

CAUTION

Excessive piping forces on the pump flanges will cause pump and/or motor misalignment. (Page 8-4) x

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 the planned maintenance requirements. 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.

1-2. INTRODUCTION.

This technical manual covers the description, operation, and maintenance of a Centralized Seawater Cooling Pump Type DH6080D (see Figure 1-1), manufactured by Buffalo Pumps Inc., P.O. Box 156, North Tonawanda, New York 14210-0156.

Figure 1-1. Centralized Seawater Cooling Pump, Type DH6080D.

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1-3. FUNCTION OF EQUIPMENT.

The DH6080D Pump is used to circulate cooling water. This pump has two major components -- a centrifu-gal pump and its driver -- a 50 horsepower a.c. electric motor. The motor is connected to the shaft of the pump through an all-metal flexible coupling. If MACHALT 256-78001 (ECP-587) is installed, the all-metal flexible coupling is replaced with a magnetic coupling. A guard covers this coupling to protect personnel during opera-tion. 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 seawater being pumped, transforming this energy into static head pressure.

1-4. REFERENCE DATA.

Table 1-1. Pump Characteristics

Service Centralized Seawater Cooling Pump

Type (Buffalo Pumps) DH6080D Pump Specification MIL-P-17639E Pump Classification C-2 Location of Discharge Bottom Horizontal Rotation (Driven End) Clockwise Capacity 1,450 GPM Total Head 35 PSI Suction Pressure Flooded Liquid Handled Seawater Specific Gravity of Liquid Pumped 1.03 Suction Temperature 28-85° F

RPM 1,800

Efficiency - % 75 Brake Horsepower at Rating 33 Maximum Brake Horsepower at any condition 41 Actual Shut - Off Head 125 ft.

Hydrostatic Test Pressure 75 PSI Final Impeller Diameter 11-9/16 x 11-3/16 in.

NPSH Required 9.5 ft.

Table 1-2. Motor Characteristics

Manufacturer Welco Industries

Specification MIL-M-17060E Service Navy A Frame 365 TNS Horsepower 50 Design B RPM (Synchronous) 1,800 RPM (Full Load) 1,785 Phase/Hertz/Volts 3/60/440 Speed Class Constant Duty Continuous Ambient Temperature 50° C

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Table 1-2. Motor Characteristics - Continued

Manufacturer Welco Industries

Enclosure TEFC Rotor Type Squirrel-Cage Bearing Ball Mounting Horizontal Winding Single Insulation Class B with Sealed Insulation Calculated Full Load Amps 46

Table 1-3. Reference Drawings

Pump (Buffalo Pumps)

Outline Elevation CA15466 Sectional Assembly CA15467 Parts List PL. DH6080D-2 Certification Data NA1643

Motor (Welco Industries) Master Drawing and Parts List D1-021940 Certification Data D1-021940

Table 1-4. Weights (Actual)

Pump Weight

Pump (Dry) 865 lbs.

Pump (Operating) 907 lbs.

Motor 1,050 lbs.

Base 600.5 lbs.

Total One Unit (Dry) 2,515.5 lbs.

Total One Unit (Operating) 2,557.5 lbs.

Table 1-5. Dimensions of Assembled Unit

Overall Length 67 15/16 in.

Overall Width 32-9/16 in.

Height 40 in.

Figure 6-13 shows pump performance curve, Figure 6-16 shows clearance locations (indicated by letters) and the reference parts (indicated by numbers).

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 1-6. Equipment and Accessories

Qty. Item Name CID Number Overall Dimensions Weight

4 Pump DH6080D NA1643 Later 67-15/16″ x 32-9/16″ x 40″ 2,515.5 lbs.

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Table 1-7. Documents

Qty. Description Part No.

4 Technical Manual Centralized Seawater Cooling Pump, Type

DH6080D

S6226-DN-MMA-010/83130

1-6. 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 the 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.

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CHAPTER 2

OPERATION

2-1. INTRODUCTION.

The Centralized Seawater Cooling Pump, Type DH6080D 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 impeller within the casing. The pump is driven by a 50-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 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. Ensure that the pump bearings and the flexible coupling are properly lubricated in accordance with instruc-tions in the planned maintenance system requirements. If MACHALT 256-78001 (ECP-587) is installed, the flexible coupling is replaced with a magnetic coupling which does not require lubrication.

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.

WARNING

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

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a. 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. If MACHALT 256-78001 (ECP-587) is installed, the flexible coupling is replaced with a magnetic coupling. Ensure both the motor and pump shaft 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 valve to fill the pump with liquid. Close the vent valve when liquid begins to flow from the vent valve.

d. Return motor to service by removing ″Out of Service″ tag and reenergizing circuit.

e. Reinstall coupling guard.

CAUTION

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

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 hammering.

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

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2-4.2. NORMAL STARTING.

Do not run this pump without liquid. The pump will be damaged if the cas-ing is not filled with liquid while the pump is running. Do not run this pump with discharge 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. Open vent valve to release air trapped in pump casing. Fill pump completely with liquid until all air has been expelled from the casing. Close the vent valve.

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.

Figure 2-1. Pump Type DH6080D, Components.

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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. Do not run pump with discharge valve closed to prevent pump from overheating.

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 unit and familiarize themselves with normal pressures, temperatures, 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.

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.

c. Check the operation of all valves in the system.

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.

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CHAPTER 3

FUNCTIONAL DESCRIPTION

3-1. EQUIPMENT DESCRIPTION

(See 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. If MACHALT 256-78001 (ECP-587) is installed, the all-metal flexible coupling is replaced with a magnetic coupling. 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 pump.

3-1.1.2. Casing. The casing (2, 2A) is a 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 half casing (2A) is fitted with a vent valve (67) at the highest part of the pump casing. Two vent plugs 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 liquid from the discharge volute to the pump stuffing boxes to cool and lubricate the mechanical seals in the stuffing boxes. Tapped openings are located on the suc-tion 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).

WARNING

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

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

3-1.1.3. Impeller (3). The double suction impeller (3) is a machined casting. The impeller is positioned by a pin (71), and is prevented from rotating on the shaft (7) by a feather key (17B). Impeller nuts (15, 15A) on either side of the impeller (3) ensure positioning on the shaft.

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 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.

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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). If MACHALT 256-78001 (ECP-587) is installed, the all-metal flexible cou-pling is replaced with a magnetic coupling. The shaft (7) is supported by ball bearings (26) 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 (18) prevent pos-sible gland leakage from traveling along the shaft to the ball bearings or flexible coupling (68). If MACHALT 256-78001 (ECP-587) is installed the all-metal flexible coupling is replaced with a magnetic coupling (68).

3-1.1.6. Ball Bearings (26). The pump is provided with a set of two angular contact ball bearings mounted back-to-back at the inboard and outboard which serve as guide bearings. Both bearing pairs (26) at the inboard end serve as thrust bearings and bearings (26) at the outboard are secured to the 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 Packing Co., Chicago, Illinois. These seals, when properly installed, reduce leakage from the stuffing boxes to almost nil. The non-repairable mechanical seals (82), (see Figure 3-2), prevent leakage by pressing a rotating car-bon washer against a stationary tungsten carbide seat. The seal is held in place by gland (12) which bolts to the

Figure 3-1. DH6080D Pump Partial Disassembled to show Components.

3-2 casing. The stuffing boxes are provided with liquid pumped at discharge pressure for lubrication and cooling of the mechanical seal faces. The liquid used to lubricate the seal flows through tubing from the discharge volute to tube fittings (78) to glands (12), through the stuffing boxes and back into the pump suction. Glands (12) con-tain 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.

NOTE

Ships without MACHALT 256-78001 (ECP-587) installed refer to paragraph 3-1.1.8. Ships with MACHALT 256-78001 (ECP-587) installed refer to paragraph 3-1.1.8A.

3-1.1.8. Coupling. (See Figure 3-3.)

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 is pressed onto the straight motor shaft and secured by a key (17C) and setscrews (68L). A spring type gridmember (68E) con-nects 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.

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3-1.1.8A Magnetic Coupling (With MACHALT 256-78001 (ECP-587) installed). (See Figure 3-3A.)

Magnetic coupling is factory balanced. Do not paint.

CAUTION

Do not disassemble conductor housing (68E) or coupling imbalance will result. If the conductor housing (68E) requires work, return the magnetic coupling (68) to the factory.

Figure 3-3. Flexible Coupling Components. (Without MACHALT 256-78001 (ECP-587) installed.)

3-4

The motor shaft is connected to the pump shaft (7) by a magnetic coupling (68). The pump hub (68A) is mounted on the tapered pump shaft (7) and is secured with a key (17A) and pump shaft nut (153). The magnetic rotor (68D) is rigidly fastened to the pump hub (68A). The motor hub (68H) is mounted on the straight motor shaft and is secured with a shrink disc (68F). The conductor housing (68E) is rigidly fastened to the motor hub (68H). As the conductor housing (68E) rotates around the magnetic rotor (68D), electromotive forces generate a voltage in the conductor housing (68E). The resulting current from this generated voltage produces its own mag-netic field which applies an attractive force to the magnetic rotor (68D). The magnetic attraction between the conductor housing (68E) and the magnetic rotor (68D) is translated into rotational torque, causing the pump shaft

(7) to rotate.

3-1.1.9. Lubrication.(Without MACHALT 256-78001 (ECP-587) installed), (See Figure 3-3.)

Lubrication of pump bearings, mechanical seals, and coupling is as follows. Ball bearings (26) are lubricated by grease in the reservoir of the bearing housing. Mechanical seals (82) are lubricated by the liquid pumped. The coupling is grease lubricated from grease contained in the coupling halves.If MACHALT 256-78001 (ECP-587) is installed, the all-metal flexible coupling is replaced with a magnetic coupling which does not require lubrica-tion.

Figure 3-3A. Magnetic Coupling Components. (With MACHALT 256-78001 (ECP-587) installed.)

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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 the casing. A series of radial curved vanes are cast on the face of the impeller, with a suitable means of entry for the liquid at the center or eye of the impeller. When a positive supply of the liquid being pumped is introduced at the impeller eye, the high-speed rotation of the impeller throws the liquid outward giving a high velocity head (pressure due to speed). The pres-sure head of the liquid at this stage is relatively low as compared with that at discharge and most of the energy of the liquid is due to its speed. Upon leaving the curved vanes of the impeller, the liquid enters the casing where the curved volute passage leads the liquid to the discharge piping. In the volute, the energy imparted from the liquid’s speed is gradually changed to a static pressure head by reducing the speed of the liquid as it passes through the volute. (See Figure 3-4.)

3-1.2.2. Reference Manual. For complete principles of operation of centrifugal pumps, see Naval Ships Techni-cal Manual, S9086-RH-STM-010, Chapter 503, paragraph 503-3.7.

3-2. MOTOR.

3-2.1. GENERAL CONSTRUCTION. The Centralized Seawater Cooling Pump, Type DH6080D is driven by a 50-horsepower, 3 phase, 60 cycle, 440 volt squirrel-cage induction motor. Polyphase induction motors have two kinds of windings, one kind on the stationary part, or stator; and one kind mounted on the revolving part, or rotor.

The stator windings consist of a number of slotted electrical sheet steel laminations welded into the frame with coils inserted in the slots. The three rotor windings consist of a number of slotted, electrical sheet steel lamina-tions pressed directly on the shaft.

3-2.2. PRINCIPLE OF OPERATION. The induction motor differs from other types of motors in that there is no electrical connection from the rotor winding to any source of electrical energy. Three phase AC power applied to the stator induces a rotating field across the gap in the rotor. Opposing electromotive force (EMF) produced by the rotor forces the rotor to turn at a rate proportional to that of this rotating field.

3-2.3. REFERENCE MANUAL. For complete principles of operation of induction motors, see Naval Ships Technical Ships Technical Manual S9086-KE-STM-010, Chapter 302.

Figure 3-4. Volute-Type Centrifugal Pump.

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CHAPTER 4

SCHEDULED MAINTENANCE

4-1. INTRODUCTION.

This chapter contains preventive maintenance and cleaning procedures to be used at the intervals specified in the instructions. The scheduled maintenance instructions in this manual are not intended to duplicate those fur-nished in the Planned Maintenance System (PMS). Maintenance procedures in this manual are intended for the user when PMS procedures do not exist or do not apply. Shipboard users of this manual will disregard these pro-cedures and perform maintenance in accordance with PMS.

4-1.1 PLANNED MAINTENANCE SYSTEM. Required preventive maintenance procedures to be performed on a scheduled basis are provided in Planned Maintenance System (PMS) documentation. OPNAVINST 4790.4 describes this system which also covers departmental and work center recordkeeping, as well as the Maintenance Index Page (MIP) and Maintenance Requirement Cards (MRCs). MRCs cover scheduled inspection, testing, and lubricating procedures for the (NOUN NAME OF EQUIPMENT) covered by this manual.

4-1.2 EXTENT OF COVERAGE. The extensive and comprehensive scheduled maintenance provided by MRCs eliminates the need for any coverage within this chapter. Specific corrective maintenance is covered in Chapter 6 of this manual.

4-2. MAINTENANCE TASK.

This paragraph is deleted with Change C.

Table 4-1. DELETED

Figure 4-1. DELETED

Figure 4-1. DELETED

Figure 4-2. DELETED

Figure 4-2. DELETED

Figure 4-3. DELETED

Figure 4-3. DELETED

4-1

Figure 4-4. DELETED

Figure 4-5. DELETED

4-2

CHAPTER 5

TROUBLESHOOTING

5-1. INTRODUCTION

(See Figure 7-2.)

Table 5-1 lists troubles that may be encountered during pump operations with their probable causes and rem-edies. Table 5-2 provides electrical troubleshooting information. The following checks shall be made prior to starting troubleshooting procedures in Tables 5-1 and 5-2.

a. Verify all operating procedures have been performed correctly. Refer to paragraphs 2-4 through 2-4.4.

b. Ensure all wiring between electrical components is intact.

c. Ensure that pump internals and attached piping are free of foreign material.

d. Verify pump has been operating properly prior to malfunction. Refer to operating log.

5-2. 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 the Planned Maintenance System requirements. Safety precautions to be followed prior to and during disas-sembly 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.

Table 5-1. Pump Troubleshooting Chart

Trouble Probable Cause Remedy

No Discharge Pump not primed or vented. Prime pump per instructions. Open vent valve (67) and ensure that the casing is filled with liquid.

Close the vent valve.

Speed too low or pump not running. Check driver.

Discharge head too high. Obstructions in pump or piping.

Open all valves in the discharge line. Inspect pump and piping and remove any obstructions.

Impeller (3) clogged or locked. Disassemble to inspect impeller and remove any obstructions or replace defective parts. (Refer to paragraph 6-3.)

5-1

Table 5-1. Pump Troubleshooting Chart - Continued

Trouble Probable Cause Remedy

Insufficient Discharge Discharge head higher than expected. Ensure that all valves are open. Check for installa-tion according to design specifications.

Obstructions in pump or piping. Inspect pump and piping. Be sure all valves are completely open. Remove any obstructions.

Clogged suction line or screen. Clean thoroughly.

Speed too low. Inspect motor and controller for proper power sup-ply and correct as necessary.

Wrong direction of rotation. See that pump shaft turns in direction of arrow on pump casing. If necessary, rewire motor by alter-nating any two of the three leads to correct motor rotation. Verify proper direction rotation.

Mechanical defects: Impeller ring turns and casing wearing rings worn or dam-aged.

Check clearance and renew if necessary using pro-cedures in paragraph 6-4.3.

Bent shaft. Straighten or replace defective parts. (Refer to paragraph 6-4.6.)

Impeller damaged. Repair or replace as required. (Refer to paragraph 6-4.5.)

Pump Discharge Speed too low. Check driver for low speed.

Pressure Low Air or gases in liquid. Be sure pump is vented. (See Figure 8-3.)

Obstruction in suction line. Suction clogged or closed.

Clean line and open suction valves.

Wrong direction of rotation. See that pump shaft turns in direction of arrow on pump casing. If necessary, rewire motor to correct motor rotation by alternating any two of the three leads. Verify proper direction of rotation.

Impeller partially clogged. Disassemble and remove any obstruction in the impeller.

Delivering excess capacity. Reduce capacity by adjusting valve in the dis-charge line.

Pump Discharge Pres-sure Low Mechanical defects: Impeller ring turns and/or casing wearing rings worn or dam-aged.

Check clearances. Renew clearance using proce-dures in paragraph 6-4.3.

Impeller (3) damaged. Repair or replace as required. (Refer to paragraph 6-4.5.)

Bent shaft. Straighten or replace.

Pump Loses Prime After

Starting Incomplete venting (air or gases in liq-uid).

Be sure pump is vented.