Water pump instruction manual. Instructions on labor protection during the repair and maintenance of pumps, pumping equipment, valves. Speed ​​changeover

Service Instruction centrifugal pumps

1. General part.

1.1. The mechanic (foreman) of the workshop is responsible for the operation of centrifugal pumps.

1.2. Responsible for timely and quality repair, according to the schedule of preventive maintenance and filling in the log of operating hours is the mechanic of the shop.

1.3. The operator is responsible for the operation of centrifugal pumps in shifts.

1.4. For all centrifugal pumps, passports, repair, operation and operating hours logs must be entered in accordance with the established form, PPR schedule and a plan of the premises with the drawing of pumps and pipelines on it.

1.5. All centrifugal pumps must be assigned a serial number. The number is applied with bright, indelible paint on the pump housing and electric motor, as well as at the pump starter.

1.6. Persons who have completed the training course and passed the exam are allowed to service the pumps.

2. Preparation for launch.

2.1. The pumps are kept clean and in good working order. Before starting, make sure that there are no foreign objects on the pump and electric motor. Check the grounding of the electric motor, the serviceability of the pressure gauges.

2.2. Check if there are any "jamming" in the pump (checked by turning the shaft by the coupling).

2.3. Check if the seal is well packed.

2.4. Check the presence and fastening of the guards of the coupling and the fan of the electric motor.

3. Pump start.

3.1. Close the valve on the discharge pipeline.

3.2. Open the valve on the intake pipeline.

3.3. Turn on the electric motor and make sure that the shaft rotates in the correct direction.

3.4. After pressure rises on the pressure gauge from the pump discharge line,

slowly open the valve on the discharge pipeline.

Note: To avoid overheating of the pump, do not work for a long time (more than five minutes) with the valve on the discharge pipeline closed.

4. Pump operation.

4.1. During operation of the pump, monitor the temperature of the bearings and the temperature of the motor.

4.2. Monitor the condition of the stuffing box (the stuffing box in normal mode should not pass more than 10-15 drops per minute).

4.3. Follow the readings of the manometers.

4.4. Stop the pump if:

a) the temperature of the electric motor exceeds 80 С;

b) there is a significant excess of the temperature of the pump housing compared to the temperature of the pumped liquid;

c) bearing temperature exceeds 70°C;

d) significant fluid leakage through the stuffing box;

e) the appearance of smoke from the stuffing box or electric motor;

f) increased noise and vibration in the pump, clutch and electric motor;

g) a significant pressure drop with a closed valve on the discharge pipeline.

5. Stop the pump.

5.1. Close the valve on the pump discharge pipe.

5.2. Switch off the electric motor.

5.3. In an unheated room during the cold season, drain the water from the pump housing and pipelines.

6.1. Pump operation without guard coupling and electric fan.

6.2. In the absence of grounding of the electric motor.

6.3. With a faulty pump seal.

6.4. With faulty gauges.

6.5. Clean and tighten the stuffing box while the pump is running.

Notify the mechanic of all pump malfunctions and record in a log

"Reception and delivery of change."

Developed

This manual has been developed for the organization safe conduct repair and maintenance of pumps, pumping equipment, stop valves

1. GENERAL REQUIREMENTS FOR LABOR PROTECTION

1.1. This Instruction provides for the basic requirements for the organization of safe work in pumping stations (hereinafter referred to as pumping stations) at oil product supply enterprises.
1.2. When performing work in pump rooms, in addition to the requirements set forth in this Instruction, the requirements of the instructions on labor protection when carrying out gas hazardous and hot work must also be met, and when working at a height of more than 1.5 m above the floor or ceiling, workers must comply with the requirements of the Instruction on labor protection when working at height.
1.3. Persons who have passed a medical examination, training, instruction and testing of knowledge on labor protection are allowed to service the pumping unit.
1.4. When working in pumping stations, in case of violation of labor protection rules, workers may be exposed to toxic substances, elevated temperatures, vibrations, electric current.
1.5. The head of the enterprise entrusts the technical supervision of the operation of pumping stations to a qualified specialist who is responsible for their safe maintenance, keeping a log of the operation of pumping units and pumping equipment, and taking measures to eliminate the detected malfunctions.
1.6. The pump room must be equipped with forced supply and exhaust ventilation, an emergency ventilation system interlocked with an automatic gas analyzer, stationary or portable lifting devices, a system automatic fire extinguishing.
1.7. In the pump room, instructions for labor protection and fire safety, for the operation of pumping units, a schedule for preventive maintenance of units, a scheme for piping pumps and connections with pipelines and tanks, and a diagram of the electrical part of pumps should be posted under glass.
1.8. Pump rooms must be kept clean and tidy. The trays and floors of the pump room should be regularly washed with water, the accumulation of oil products on the floors should be eliminated. Do not use flammable petroleum products for mopping.
1.9. Do not obstruct passages between pumps with materials, equipment or other objects.
1.10. Storage of lubricants in the pump room is allowed in an amount not exceeding the daily requirement. Lubricant should be stored in special metal or polyethylene containers with tightly closed lids. Storage of flammable liquids in pump rooms is not allowed.
1.11. All open and accessible moving parts of pumping equipment must be equipped with metal protective guards.
1.12. At night, the pump room should have lighting of at least 150 lux.
1.13. For local lighting at night, portable rechargeable lamps in an explosion-proof version with a voltage of no more than 12 V should be used. The lamps are turned on and off outside the pump room, at a distance of at least 20 m.
1.14. It is forbidden to use open fire and smoke in the pump room. Smoking must be provided in specially equipped areas.
1.15. In the pump room for pumping leaded gasoline, a supply of clean sand or sawdust, cleaning materials, bleach, as well as a tank of kerosene for washing hands and parts should be kept.
1.16. In the pump room, it is necessary to have a set of emergency tools, a supply of rechargeable lights, which must be stored in special cabinets in the operator's room.
1.17. Unauthorized persons (not serving the unit) are prohibited from entering the pump room.

2. SAFETY REQUIREMENTS BEFORE STARTING WORK

2.1. Turn on the supply and exhaust ventilation.
2.2. Check the condition of the workplace, serviceability of tools, fixtures, mechanisms, availability of funds personal protection and primary fire fighting equipment. It is forbidden to use faulty tools, devices, mechanisms, personal protective equipment.
2.3. Check the condition of the grounding of pumps, electric motors, electrical equipment, pipelines and other equipment of the pumping station. Casings of pumps pumping oil products must be grounded regardless of the grounding of electric motors located on the same frame with the pumps.
2.4. Before repair work related to the dismantling of the pumping unit or other equipment of the pumping station, it is necessary to turn off the electricity using the switching equipment and remove the fuses, hang the poster “Do not turn on - people are working!” on the control panel of the units, disconnect the pump from the pipelines by closing the valves.

3. HEALTH REQUIREMENTS DURING WORK

3.1. In the pumping station, reliable operation of natural and forced supply and exhaust ventilation. It is forbidden to put the pump units into operation when the ventilation is not working, as well as with the guards and safety covers removed, with faulty pressure gauges.
3.2. During the operation of pumping stations, supervision over the tightness of pumps and pipelines should be established. Leakage of oil products through the mechanical and stuffing box seals of pumps above the permissible standards established by the manufacturer must be immediately eliminated.
3.3. All moving parts of the pump must be lubricated regularly. When lubricating, there should be no spreading and splashing of lubricants.
3.4. In case of detection of violations in the pump operation mode (noise, increased vibration, overheating of bearings, leakage of seals, cracks and defects in individual parts, etc.), the pump must be stopped. For troubleshooting purposes, the pump must not be operated.
3.5. The temperature of bearings and seals should be checked at least once an hour. Overheating of bearings above 60 Co is not allowed. Do not cool the bearings or the shaft cold water, ice, etc.
3.6. When stopping the pump for repair, you must:
- Disconnect the motor from the power source and starting device hang a poster “Do not turn on - people are working!”;
- disconnect the pump from the pipelines by closing the valves and installing plugs;
- remove the remaining product from the pump;
- make an entry in the operation log indicating the time the unit was stopped for repair.
3.7. Dismantling and repair of the pump must be carried out by order of the head of the enterprise with the issuance of a work permit for the performance of work heightened danger.
3.8. Repair of pumps pumping leaded gasoline is allowed only after internal and external flushing of the housing and all components and parts of the pump with kerosene.
3.9. After washing, the pump housing and parts must be wiped dry with a cleaning cloth.
3.10. When repairing pumps and other work in the pump room, a tool made of a material that excludes sparking upon impact should be used.
3.11. It is not allowed to find people in front of knocked-out or pressed-out parts.
3.12. Workers using electric tools must have an electrical safety group of at least II and an appropriate certificate.
3.13. The change of electric lamps and safety caps in the pump rooms is carried out by an electrician.
3.14. During the operation of pumping units, it is prohibited:
- fix and repair any parts and equipment under pressure;
- remove the fence or its individual parts;
- slow down moving parts with your hands or with the help of other objects (crowbar, pipe, etc.);
- put cleaning material or any other objects impregnated with oil products on the hot parts of pumps and pipelines;
- leave the pumping unit unattended, in the absence of automatic control and alarm systems.

4. REQUIREMENTS FOR LABOR PROTECTION IN EMERGENCY SITUATIONS

4.1. During the operation of pumping stations, emergency situations are possible, including:
— significant leakage of oil products at the operating unit;
— sudden interruption of the supply of electricity or steam;
- strong vibration of the pumping unit;
- overheating and the appearance of smoke from bearings, seals, stuffing boxes in the separation wall;
- fire;
- increased gas content.
4.2. In the event of an emergency, as well as upon detection of any malfunction that disrupts the normal operation of the pump or poses a threat to workers, the pump must be stopped, the valves on the inlet and outlet lines are closed. The management of the enterprise must be notified of the emergency stop of the pump.
4.3. It is forbidden to put the pump into operation until all faults have been eliminated.
4.4. In case of an accident, the victim should be given first aid, call an ambulance by phone 103 and inform the management of the enterprise.
4.5. In the event of a fire or explosion in the pump room, immediately stop all types of pumping, call fire department by phone 101, inform the management of the enterprise, act according to the plan for the elimination of accidents.

5. HEALTH REQUIREMENTS ON COMPLETION OF WORK

5.1. After completion of work in the pump room, the workers who performed these works are required to clean the workplace, put in order the tools and working devices.
5.2. Oiled cleaning material should be placed in special metal boxes with covers with its subsequent regeneration or destruction.
5.3. After finishing work with toxic substances, it is necessary to comply with the requirements of personal hygiene.

The axial force is carried out by two angular contact ball bearings, and the radial load is carried out by a plain bearing.

Bearings are lubricated in an oil bath or with an oil scraper ring. The shaft seal is in the form of a mechanical seal.

Section 1. General Information

1-1 Introduction

Centrifugal pumps are designed by professionals to provide you with optimum performance equipment for continuous operation under the most severe conditions in the refinery, petrochemical, gasoline and LPG plants and other industries. The concept of this equipment was designed with mechanical and hydraulic characteristics that guarantee you reliable, economical and many years of trouble-free operation.

The purpose of this manual is to help you achieve just that with this equipment. To achieve this goal, it is necessary to familiarize with this manual those personnel who are directly responsible for the installation, operation and Maintenance pumps.

1-2 Equipment check

Immediately upon receipt of this equipment, it is necessary to check its compliance with the transport documents. If damage or shortages are found, the local agent must be notified immediately. transport company. In the event of a delay in notification, it may be difficult to satisfy a complaint about the equipment.

1-3 Protection during transport and storage

Pumps and drives must be protected from damage by dirt, sand and moisture, both during transport and during storage. After factory testing and prior to transport, the pump is thoroughly cleaned, dried and coated with anti-corrosion agents on the entire internal and on the entire external surface, which can be damaged by moisture. In order to prevent foreign materials from getting inside the pump, all suction and outlet openings, all pipeline openings are closed with metal plugs, which are securely bolted to the flanges. Protection pipe holes and pipes connected to the pump must be left until the pump unit is ready to start.

When installing the pump and drive for storage, it is necessary to check and fix the plugs for all openings of the pipeline or replace them if necessary with new ones. Shafts, ball bearings and other vital parts that may be exposed to moisture must be periodically checked and, if necessary, renewed their protective coating.

1. If pumps are stored on site in an assembled state, the following storage procedures must be observed.

See "Corrosion Protection Procedures" provided separately.

2. If pumps are stored on site in packaging, they should be stored as follows.

1. The packaging must not be exposed to rain water, etc.
2. Cover the packaging with vinyl sheet and protect from rain, etc.
3. If the storage period exceeds 6 months, check the condition of the equipment for corrosion and, if necessary, spray or fill the equipment with anti-corrosion oil

Section 2 Installation

2-1. Cleaning before installation

1. The bottom surface of the base plate must be free from dust, dirt, oil, grease, etc. in order to achieve proper adhesion between the cement mortar and the base slab.

2-2 Location of the pump.

1. Improper installation site and inadequate foundation preparation will adversely affect the life of the pump. Good foundations are of paramount importance, as they are the first factor in preventing the occurrence of vibration, which in most cases leads to rapid wear and failure of the pump.

2-3 Foundations

1. Foundations may be made of any material strong enough to provide rigid support over the entire surface of the baseplate and absorb all normal loads and shocks that may occur during operation.

The concrete foundation must be poured well in advance to allow proper curing time before the pump loads begin to act.

3. Place the base plate in position by supporting it with shims or set screws and securing it with anchor bolts. There must be a gap between the top of the notched concrete and the base slab for pouring. cement mortar about 50 mm in size.

4. The foundation bolts must fit into the holes and locations on the base plate, which are determined in accordance with the design installation drawing.

5. Each bolt should be surrounded by a collar, the diameter of which should be 3 times larger diameter foundation bolts.

After the concrete has been poured, the grommets must be held firmly in place and the bolts must fit into the holes in the base plate.

2-4. Leveling the base plate.

1. In addition to hand tools, the task of leveling and leveling the base plate is solved using the following tools and equipment:

1. Accurate straight edge
2. Foundation (or anchor) bolts
3. Gaskets and wedge gaskets
   Note: For heavy pumps, small metal leveling blocks (approx. 25 mm thick plates with spot-welded three M12 hex nuts) can be used. These blocks are used to install on each bolt hole in the base plate. See Fig. 2-a.
4. Accurate locksmith level or tooling equipment.
5. Optionally, alignment testing equipment such as an alignment laser or a clamping device capable of measuring to 0.02mm can be used.

2. The baseplate is level with the drive on a level surface prior to shipment.

The base plate simply needs to be installed on horizontally aligned foundations.

Thus, only the mounting surface of the base plate will need to be leveled.

Note: You need to make sure that the foundations have had enough time for the concrete to cure. Otherwise, the foundations may not support the weight of the pump.

3. Align the blocks according to the following methods shown in fig. 2b.

1. Align each block on the foundation using optical alignment equipment and a level.
   
2. Place blocks in four corners. Then proceed with the transverse alignment of the blocks by adjusting the adjusting bolts.
   Align one end of the blocks in A-B direction, using for this purpose the adjusting bolts on the anchor bolts (1) and (7)
   Then follow these steps step by step:
   • Align horizontally in direction A-D on anchor bolts (1) and (6).
   • Align horizontally to direction B-C on anchor bolts (7) and (12).
   • Align horizontally to direction C-D on anchor bolts (6) and (12).
3. Install blocks on both sides of the anchor bolts in longitudinal direction from (2) through (5) and (8) through (11)
   • Level the blocks on both sides in the longitudinal direction A-D and B-C on each anchor bolt.
   • Level the blocks at each end of the anchor block (2)-(8), (3)-(9), (4)-(10), (5)-(11)
   For horizontal pumps, the nominal level deviation is 0.1 mm/m.

4. When using gaskets or wedge gaskets, spot welding is used, and then building mixture. See Fig. 2d.

When using adjusting blocks, pour mortar around the blocks. See Fig. 2-c. After curing, the nominal deviation must be checked again.

5. Install the base plate with pump and drive and tighten the anchor nuts. If the baseplate level is measured for confirmation, the level tolerance for horizontal pumps is 0.3 mm/m.

Note: The measuring point must be the machined surface on the base plate.

2-5. Pouring with cement mortar

1. The recommended mortar mix consists of one part cement and one part pure river sand by weight. Usually 6.6 to 7.6 liters pure water for every 45 kg of the mixture is enough to prepare a normal solution.
2. Carry out the appropriate wooden formwork to hold the solution. See Fig. 2-e.
3. Remove water and debris that may have accumulated in the foundation bolt holes.
4. Pour grout through the grout injection holes in the baseplate and direct it between the foundation and the baseplate.
5. Pour mortar until all space between the top of the foundations and the top of the grout holes is completely filled with no air pockets.
6. Verify that the base plate is firmly bonded with mortar by tapping the pan with a steel rod and listening for resonance. A dull sound indicates a solid pour, and a drum sound indicates voids that need to be filled with epoxy mortar.

You need to take the following actions:

1. Drill and enlarge a hole (6.4mm) that should fit the grease fitting.
2. Install the fitting and fill with epoxy grout using a hand gun compatible with the fitting.
3. Tap the plate again and listen to the sound.
4. Remove fittings, plug holes with epoxy grout and level epoxy grout.

2-6. Mounting the drive on the base plate (if removed)

1. Install the drive on the drive feet in such a way that the distance between the ends of the pump shaft and the drive shaft would correspond to the data given on the installation drawing.
2. Install the pump and drive shafts in the position shown on the installation drawing. The actuator must be about 3 mm lower before adjustment.

2-7. Alignment of pump and drive alignment. (See Fig. 2-f)

1. Install a dial indicator on the drive coupling half.

The dial indicator bracket must be rigid in order to ensure the accuracy of the dial indicator readings.

2. Set the indicator button to outside diameter pump coupling hubs and adjust the hubs with an accuracy of 0.05 mm of the total reading of the dial indicator.

3. Install the indicator button on the end of the pump coupling hub and adjust the parallelism of the ends at all points with an accuracy of 0.05 mm of the total reading of the dial indicator.

4. To check alignment, install a dial indicator on the pump coupling half and take readings on the outside diameter and on the end of the drive coupling hub. Readings must be accurate to 0.05 mm of the total dial indicator reading.

Note: If a steam turbine is used and alignment is done with a cold turbine, the turbine must be centered 0.5 mm below the pump shaft center, or to within 0.1 mm of the total dial indicator reading. Alignment must be done with a hot turbine.

2-8. Suction and discharge pipeline.

The piping must be adequately supported close to the pump in order to prevent unforeseen loads from being transferred to the pump once the flange bolts have been tightened and the required temperature has been reached.

1. Suction pipeline

1. The piping at the suction end must be short, straight and in no case be smaller than the suction port of the pump. If it is impossible to avoid the use of long pipelines, the diameter of the pipeline should be the same or, better, twice the pump inlet. Suction lines must be free from any sudden reductions in size that can cause turbulence, gases or vapors, and pockets or projections where gases or vapors can collect must be avoided.
   A properly designed suction line should be as follows:
   I. Have a slight slope from the pump to the source of the fluid being supplied. See Fig. 2-g and 2-h.
   II. Provide bends with a large radius or bends with a large radius. See fig. 2-i.
   III. Provide eccentric adapters for changing the size of horizontal lines. See Fig. 2-i, 2-j and 2-k. The length L of the adapters must be equal to at least twice the diameter of the widest pipe.
2. It is recommended that temporary filters be installed in the suction line to collect scale or other foreign material. See Fig. 2-1.

2. Outlet pipeline

Outlet piping must be of the appropriate size with a minimum number of fittings and bends. There are no fixed rules for determining the diameter of the outlet pipeline, since the diameter depends on the length of the line and on the applied pressure.

Section 3 Operation

3-1. Preparation for work.

1. Fill the bearing housing with oil to the specified level. See section. four.
2. Disconnect the pump and drive and check the direction of rotation of the drive.
3. Open all valves if cooling, flushing (sealing) and quenching of the pipeline is provided.
4. Fully open the valve at the suction end.
   If the temperature of the pumped liquid exceeds 177°C, the pump must be thoroughly heated up to this temperature.
   Note: Before starting the pump, it is recommended that all points of the pump housing are heated to a temperature that is 30-40°C lower than the temperature of the pumped liquid. If the pump is started at room temperature, the liquid temperature must be raised gradually over 3-4 hours. If this is not possible, the hot liquid must be circulated in the pump for 3-4 hours in order to ensure that the pump heats up before it starts.
   Excessive thermal shocks must be avoided.
5. After the pump has warmed up, try to turn the pump rotor by hand and check the alignment of the pump and drive again.
6. After checking, connect the pump and drive.
7. Open the bleed valve installed on the pump to prevent dry running in any case. The pump body and suction pipe must be filled with liquid.
   Check the opening or closing of the valves installed on the auxiliary pipeline.

3-2. Start

1. Make sure the valves in the suction line are fully open and the valve in the discharge line is fully closed.
   If the pump is above the liquid level, the discharge valve must be closed. If the pump is below the liquid level, the discharge valve must be opened 1 ½ -2 turns.
2. If a minimum flow line is installed, its valve must be opened.
3. Open the outlet valve again (if supplied). After checking the release of gases or air, the exhaust valve must be closed.
4. Start the drive according to the drive instructions and quickly bring the pump speed up to the required speed.
5. As soon as the pump reaches the required speed, slowly open the valve on the discharge line. The pump must not be allowed to operate with a closed valve in the discharge line. The pump must not be allowed to operate at a flow rate below the minimum set value.
6. The temporary suction line filter should be checked periodically to ensure that it is not clogged so as not to cause voids in the pump. It must remain on line for at least 24 hours after the pump is started.
7. The following items should be periodically checked and recorded during operation:

Note: If the pump is unstable, it must be stopped. Find out the causes of unstable work.

3-3. Stop

1. Gradually close the valve in the discharge line.
2. Stop the drive immediately.
3. If a minimum flow line is provided, fully close the valve on the discharge line, fully open the valve on the line minimum flow, then immediately stop the drive.
4. After the pump has completely stopped, it is necessary to completely close the valve in the discharge line and in the minimum flow line.
5. Close all valves once in auxiliary pipelines such as cooling, flushing (sealing) and quenching lines.
6. Completely close the suction valve.

Note:

1. If there is a risk of frost, the cooling piping and seals must be completely drained.
2. When pumping a liquid that can thicken and become solid when stopped, it is necessary to clean it thoroughly after stopping the pump. inner part.

3-4. Backup pump.

In order to be able to immediately start the standby pump, the following operations must be performed:

1. Carry out the same work as for the main pump. See points 3-1.
2. In case the pump starts automatically, it is necessary to open the valve in the discharge line and the valve in the minimum flow line, if any.
3. Check weekly that you can freely turn the pump rotor by hand.
4. It is recommended to run the pump at least once a month to make sure it is working properly.

Section 4: Pump Lubrication

4-1. Type of lubricating oils

High quality turbine oil must be used.

4-2. Oil change

1. Drain the oil from the bearing housing and flush with light oil.
2. Unscrew the drain plug and install the permanent grease fitting horizontally.
3. Fill in oil through the vent hole on the bearing housing so that the oil level reaches the center of the grease fitting connection point. See fig. 4-a.
4. Fill the oiler cap with oil and then quickly insert it into the lower housing.

Repeat the operation until the oil reaches required level. See Fig. 4b.

Note:

1. Make sure that the oil from the oiler comes down when the oil is supplied by the oiler cap. If the oil in the oiler does not go down, the oil level is sufficient.
2. When the oil level goes down to half the level of the oiler, it is necessary to add oil with the oiler cap.

4-3. Oil change interval.

The oil should normally be changed every 8500 hours of operation or annually.

After one month has passed since the start of operation, the oil must be changed. See list of oils.

4-4. Grease Fitting Method

1. If the oiler is supplied with a wire gauge, the level adjuster must be installed as shown in Fig. 4-c.
2. If the lubricator is supplied without a wire gauge, the lubricator does not need to be adjusted.

Section 5 Maintenance

For mechanical seals and actuators, refer to the relevant instructions.

5-1. Disassembly.

1. Disconnect the auxiliary piping and remove the coupling spacer.
   When dismantling the pump, it is not necessary to disconnect the suction and discharge pipes.
2. Remove the coupling half using the coupling ejector.
3. Rotate the set plate attached to the sealing cover of the mechanical seal into the groove on the shaft sleeve and lock it in this position. Loosen the drive collar of the shaft sleeve.
4. Loosen the set screws holding the deflector ring.
5. Remove the bearing housing as follows:

   Note:

   The ball bearing must be removed with a puller. The ejector must be hooked onto the inner race of the ball bearing.

   (1-1) If the pump is equipped with a thrust ball bearing, disassemble according to the following sequence:

   1. After the bearing housing cover is shifted, it is necessary to remove the bearing housing cover, the bearing housing.
   2. Then the bearing lock nut and washer, bearing thrust washer, thrust ball bearing and bearing spacer.
   3. Bearing housing cover and deflector ring.

   (1-2) If the pump is equipped with plain bearing and thrust ball bearing, disassemble according to the following sequence:

   1. Bearing housing cover, upper bearing housing half, plain bearing upper half and oil ring.
   2. Bearing lock nut and washer, bearing thrust washer, bearing race, thrust ball bearing and bearing spacer.
   3. Plain bearing lower half, oil ring and bearing housing lower half.

   (2-2) If the pump is equipped with a radial plain bearing, disassemble according to the following sequence:

   1. upper part of the bearing housing and top part bushings
   2. Plain bearing lower part, oil ring and bearing housing lower part.
   3. reflective ring.
6. Remove the nut holding the stuffing box and slide the stuffing box including the mechanical seal assembly, shaft sleeve and removed shaft.

   Note:

   The sealing surface of the mechanical seal is mirror polished and optically flat. These surfaces must be cleaned with the utmost care.

7. Remove the body nut and slide the top half of the body.
8. Remove the rotating element and disassemble according to the following sequence.
9. Impeller lock nut, impeller, impeller key and casing wear rings.

Note:

1. Observe the direction of the bend of the impeller vanes in relation to the shaft in order to properly install the impeller on the assembly.
2. The following parts should not be removed without the need for replacement:
   1. Impeller wear ring
   2. Packing gland bush
   3. Stationary oil slinger - excluding plain bearing if used

5-2. cleaning

After dismantling, clean all parts according to the following sequence:

1. Remove scale or similar deposits with a cleaning solvent.
2. Rinse and blow air through the inside of the housing (2 and 3).
3. Wash the bearings and the inside of the bearing housing in solvent. Use a clean cloth for cleaning.

5-3. Examination

Carefully check all parts according to the following sequence.

1. Check all parts for dirt, wear or damage. The adjacent surfaces of each part must be clean and undamaged.
2. Check shaft for straightness. The shaft must be straight to within 0.025 mm of the total indicator reading.
3. Replace parts that cannot be repaired. If the diametral clearance of rotating parts has reached the limit value, it is necessary to replace them.

5-4. Repair

1. Impeller wear rings.

1. Remove worn wear rings using appropriate tools.
2. Install new rings and tighten set screws.
3. Check diametrical clearance of new wear rings.

2. Stationary oil deflector.

1. Remove worn parts by pushing the plate and tapping with a hammer.
2. Install the new part with a hammer.
3. The stationary oil slinger must be installed in such a way that its drain hole is located at the bottom.

3. Plain bearing

1. Repair, if possible, worn journal bearings by scraping away surface defects on the babbitt-faced side of the pads.
2. If it is not possible to repair worn plain bearings, they must be replaced.

5-5. Reassembly

1. Mount the rotating elements and check the concentricity following the following sequence.

1. Insert the impeller key onto the shaft and push the impeller in.
   Note: The direction of bending of the impeller blades in relation to the shaft must be the same as during disassembly.
2. Install the impeller lock nut and adjust the lock nut to align the impeller and impeller key.
3. Check the concentricity of the rotating element by centering and measuring with a dial indicator. Turn the shaft slowly by hand and take readings on the impeller wear rings and on the shaft. If the total indicator reading does not exceed 0.05 mm, then the assembly was carried out accurately.
4. Outer ring housing.

2. Install the inner assembly on the bottom half of the housing.

Install housing wear rings.

• Check the concentricity and squareness of the rotor, observing the following sequence:
  (1) Install the upper body half (2) with the body gasket and tighten the body nut (926) firmly to prevent leakage at the connector surfaces.
  1. Assemble the thrust bearing and housing as directed in the thrust bearing assembly section.
  2. Assemble the radial bearing and housing as directed in the Radial Bearing Assembly section.
  3. Install the dial indicator firmly on the pump shaft. Check the concentricity of the stuffing box bore and the squareness of the end ends of the stuffing box and bearing housing.
  4. Disassemble both bearing housings.
• Insert the grooved mechanical seal drive-in collar mounting plate onto the shaft sleeve and secure in position. Slide the mechanical seal shaft sleeve assembly and flinger onto the shaft.
• Assemble the bearing housing according to the following sequence:
  Note: Lubricate all surfaces of the bearing when assembling. Ball bearings must be heated in an oil bath to a temperature of 120°-150° and quickly mounted on the shaft.
  1. Thrust bearings
     1. If the pump is equipped with thrust ball bearings, assembly is carried out in accordance with the following sequence:
        1. Install bearing housing cover with gasket. The oil drain hole must be on the underside.
        2. Bearing spacer, thrust ball bearing, bearing thrust washer and bearing lock nut with washer.
        3. Bearing housing and bearing housing cover with gasket. Tighten the nuts holding the bearing housing to the housing evenly.
     2. If the pump is equipped with a sleeve bearing and a thrust ball bearing, assembly is carried out in the following sequence:
        1. The lower half of the bearing housing, the lower half of the sleeve bearing, the oil ring and the lower half of the stationary oil slinger with an oil drain hole.
           Tighten the nuts holding the bearing housing to the housing evenly.
        2. Bearing spacer, thrust ball bearing, bearing race, bearing thrust washer, bearing lock nut and washer and oil ring.
        3. Upper sleeve bearing half, upper bearing housing half with stationary oil slinger upper and gasket, and bearing housing cover with gasket.
        4. Check play in axial direction. Axial play should be within 0.05-0.15 mm.
  2. Radial bearings
     1. If the pump is equipped with deep groove ball bearings, assembly is carried out in the following sequence:
        1. Install bearing housing cover with gasket. The oil drain hole must be on the underside.
        2. Bearing spacer, deep groove ball bearing and bearing retainer.
        3. Bearing housing, outer bearing housing cover with gasket. The oil drain hole of the bearing housing cover must be on the underside. Tighten the nuts holding the bearing housing to the housing evenly.
     2. If the pump is equipped with a radial plain bearing, assembly is carried out in the following sequence:
        1. Lower half of the bearing housing, lower half of the stationary oil slinger with oil drain hole, lower half of the plain bearing and oil ring. Tighten the nuts holding the bearing housing to the housing evenly.
        2. Upper sleeve bearing half and bearing housing upper half with stationary oil slinger upper half and gasket.
• Install the deflector ring with the set screws. The gap between the flinger and the stationary oil slinger should be about 2 mm.
• Bolt the stuffing box cover to the housing. Install the drive-in sleeve of the shaft sleeve, unscrew the mounting plate from the groove of the shaft sleeve and secure in this position.
• Rotate the shaft by hand to make sure that the wear rings and bushings are free and clean.
• Install flexible coupling
• Check alignment of pump and drive. Make appropriate adjustments if necessary.

These replacement periods should be considered as a guideline in order to ensure the minimum number of spare parts required for field service.

Section 6 Troubleshooting

Malfunctions, their possible causes and corrective actions

The installation of a circulation pump in dwellings with an individual heating system ensures uniform and high-quality distribution of heat throughout all the premises of the house.

In closed heating systems, forced circulation of hot water is required. This function is performed by circulation pumps, which consist of a metal motor or a rotor attached to a housing, most often made of stainless steel. The ejection of the coolant is provided by the impeller. It is located on the rotor shaft. The entire system is driven by an electric motor.

Circulation pump

Also in the design of the described installations there are the following elements:

• shut-off and check valves;
• the flow part (usually it is made of a bronze alloy);
• thermostat (it protects the pump from overheating and ensures the economical operation of the device);
• work timer;
• connector (male).

The pump, when installed in a heating system, draws in water, and then supplies it to the pipeline due to centrifugal force. The indicated force is generated when the impeller produces rotational movements. The circulation pump will work efficiently only if the pressure it creates can easily cope with the resistance (hydraulic) of the various components of the heating system (radiator, pipeline itself).

Various circulation units can be mounted in the heating system of a private house. They are divided into two large groups. The circulation pump can be "dry" or "wet". When installing devices of the first type with your own hands, it should be borne in mind that their motor is separated from the working part by sealing rings. They are made from stainless steel. During the start-up of the installation, the process of movement of these rings begins, which leads to the sealing of the connection with a water (very thin) film. The latter is located between the seals.

Circulation pumping unit

High quality sealing this case It is ensured due to the fact that the pressure in the external atmosphere and in the heating system itself is characterized by different indicators. A “dry” pump makes quite loud sounds during operation. In this regard, its installation is always carried out in a specially soundproofed room. separate room private house. Index useful action of such a circulation unit is at the level of 80%.

There are three types of "dry" devices for connection to the heating system: horizontal, vertical, block. The electric motor in the units of the first type is placed horizontally. The discharge pipe is attached to them on the body of the apparatus, and the suction pipe is mounted on the shaft (on its front side). AT vertical installations nozzles are on the same axis. And the engine in this case is located vertically. In block circulating units, heated water exits radially, and enters the system in an axial direction.

Caring for a "dry" unit is objectively difficult. Its elements need to be lubricated regularly. special composition. If this is not done, the end seals will quickly fail, causing the pump to stop. In addition, in a private house, “dry” devices should be placed in rooms where there is no dust. Its turbulence during equipment operation often causes pump depressurization.

In "wet" units, the coolant itself performs the function of lubrication. The impeller and rotor of such installations are immersed in water. "Wet" devices are much less noisy, they are easier to mount with your own hands. And their maintenance is simpler compared to "dry" pumps.

The body of the "wet" installation, as a rule, is made of brass or bronze. Between the stator and the rotor there must be a special separator made of stainless steel. It is called a glass. It is necessary to give the required tightness to the engine (more precisely, its elements under electrical voltage). It is the “wet” units that are most often mounted in a private house in the heating system.

They do a good job of heating relatively small areas. For large objects, such devices are not suitable, since their performance usually does not exceed 50%. The low efficiency of "wet" installations is due to the impossibility of high-quality sealing of the glass placed between the stator and the rotor.

The key indicator that determines the efficiency of the circulation pump is its power. For household system heating, you do not need to try to purchase the most powerful installation. It will only hum strongly and waste electricity.

Mounted circulation pump

• indicator of hot water pressure;
• section of pipes;
• performance and throughput heating boiler;
• coolant temperature.

The flow of hot water is determined simply. It is equal to the power heating unit. If, for example, you have 20 kW, no more than 20 liters of water will be consumed per hour. The pressure of the circulation unit for the heating system for every 10 m of pipes is about 50 cm. The longer the pipeline, the more powerful the pump must be purchased. Here you should immediately pay attention to the thickness of tubular products. The resistance to the movement of water in the system will be stronger if you install small pipes.

In pipelines with a diameter of half an inch, the flow rate of the coolant is 5.7 liters per minute at the generally accepted (1.5 m / s) speed of water movement, with a diameter of 1 inch - 30 liters. But for pipes with a cross section of 2 inches, the flow rate will already be at the level of 170 liters. Always select the diameter of the pipes in such a way that you do not have to overpay extra money for energy resources.

The flow rate of the pump itself is determined by the following ratio: N/t2-t1. Under t1 in this formula is understood the temperature of the water in the circulation pipes (usually it is 65–70 ° С), under t2 - the temperature provided by the heating unit (at least 90 °). And the letter N indicates the power of the boiler (this value is available in the equipment passport). The pump pressure is set according to the standards accepted in our country and Europe. It is believed that 1 kW of power of the circulation unit is quite enough for high-quality heating of 1 square of the area of ​​a private dwelling.

Installation circulation pumps produced in two ways. The first connection scheme of the unit is two-pipe. This connection method is described by a high temperature difference in the system and variable flow coolant. The second scheme is one-pipe. In this case, the temperature difference in will be insignificant, and the carrier flow rate will be constant.

Installed circulation pump

Do-it-yourself connection of the pump is carried out according to the instructions that are attached to the unit. It also indicates the installation procedure for a functional reinforcing chain. Be sure to drain all water from the system before installing the pump. Often there is a need to clean it. During the operation of the heating boiler, a lot of debris is collected on the inner surfaces of the pipes, which worsens the technical performance of the system.

Experts advise placing the circulation unit in front of the boiler - on the return line. This is done in order to eliminate the risk of boiling. heating system open type due to the vacuum that is created when the pump is installed on the supply. In addition, if you install the circulation unit on the return, its trouble-free operation will be significantly increased due to the fact that it will operate at lower temperatures.

The procedure for installing the pump itself looks like this:

1. You make a bypass (in professional slang - a bypass) in the area where the pump will be placed. The bypass diameter is always taken slightly smaller than the cross section of the main pipe.
2. Mount (strictly horizontally) the shaft pumping device, place the terminal box on top.
3. Install ball valves on both sides of the pump.
4. Install a filter. It is not recommended to operate the equipment without this device.
5. Place an automatic (optionally manual) vent valve above the bypass line. This device will allow you to clean the air pockets that regularly form in the system.

Further, valves (shut-off) are installed at the inlet-outlet section of the circulation unit. For an open heating system, an additional expansion tank(not placed in closed complexes). Final stage installation work- treatment with a good sealant of all, without exception, the connection points of various elements of the system.

Although centrifugal pumps are reliable devices used for pumping liquid, they may also need repair. Not always the cause of malfunctions of centrifugal pumps is improper operation, this may be due to the quality of the pumped medium, and a number of other factors. If there are violations in the operation of the centrifugal pump, then you must first eliminate external causes and only after that to carry out diagnostics of the equipment itself.

Proper operation

In order to significantly extend the life of the centrifugal pump and face the repair of such equipment as rarely as possible, this device should be used correctly. The operating instructions for a centrifugal pump require compliance with the following rules.

1. Before turning on the centrifugal pump, check that working chamber was completely filled with liquid.
2. In front of the suction pipe, it is necessary to install strainer, which will protect the inside of the device from ingress of solid insoluble inclusions contained in the pumped liquid medium.
3. Overload protection of the drive motor is provided by a special valve installed on the suction pipe, which limits the flow of liquid entering the pump.
4. When starting the pump, make sure that the drive motor shaft and the impeller rotate clockwise.
5. The depth of the tank from which the liquid medium is pumped out must not exceed the allowable level specified in the technical passport.
6. The pipe through which the suction of the liquid medium from the tank is carried out should have as few bends and connecting points as possible, and its internal diameter should be as large as possible.
7. The pipe through which the liquid medium is transported from the pump to horizontal plane, it is desirable to arrange with a slope in relation to the place of liquid supply. If it is not possible to fulfill this requirement, then the pump should be installed as high as possible relative to the ground.

During the operation of this pump, a depressurization of the cable entry was allowed, as a result of which the motor winding burned out

The most common causes of breakdowns

The first thing to do if malfunctions are noticed in the operation of pumping equipment is to stop its operation and proceed with a thorough check of all components. A fairly common situation in which pumping equipment requires maintenance or even repair is the wear of seals. A number of reasons can contribute to a more active course of the process of wear of stuffing box elements of pumping equipment:

• uneven rotation and beating of the drive motor shaft;
• too much tightening of the bolts that secure the pump cover (the seals do the best job of sealing if they are sufficiently moistened);
• overheating of the drive motor;
• incorrectly performed maintenance or repair of a centrifugal pump (replacement of not all sealing rings, etc.).

Another common cause of incorrect operation and even breakdown of pumping equipment is inaccurate alignment of the drive motor shaft with the pump housing. The consequences in this case can be both the destruction of stuffing box elements and the failure of bearing assemblies.

The bearing units of a centrifugal pump are the elements that require the most careful attention and regular care. To minimize the risk of failure of such units and provide them with the most optimal operating conditions, it is necessary to control the amount of lubricant.

Repair of centrifugal pumps, like any other technical devices, requires certain knowledge and skills. Meanwhile, if you follow the instructions for performing such a procedure and follow the recommendations below, then there should be no difficulties with its implementation.

Experts with experience in working with pumping equipment recommend that it be repaired in the following sequence:

1. Disassemble the device and carefully inspect the elements of the internal structure.
2. Verify technical condition rotor, measure the gaps in the seats of the sealing elements.
3. Replace worn and failed bearings with new ones.
4. Verify geometric parameters necks of the shaft and, in case of defects, perform their turning and grinding.
5. After correcting all the identified defects, assemble the pump, check the condition of its housing and the correctness of the assembly.

According to the algorithm described above, a scheduled repair of centrifugal pumps is carried out, which, according to the manufacturers' recommendations, should be carried out every 4500 hours of its operation.

More complex in technical terms repair is required for pumping equipment after every 26,000 hours of operation. As part of such a repair with centrifugal pumps, the following actions are carried out:

• replace the wheel and the working shaft;
• replace the seal rings of the pump housing, spacer and pressure bushings;
• in some cases, sections of sectional pumps are completely replaced;
• perform surfacing and boring seats in the body of the device;
• after the pump is assembled, it is hydraulically tested.

If a seasonally operated pump is left for the winter with moisture inside, then in the spring it may jam. The problem is solved by disassembling and cleaning

The following procedures cause the greatest difficulty in the process of repairing a centrifugal pump according to the above scheme:

• disassembly of bearing units;
• removal of liners;
• removal of the coupling half using a special puller supplied with the pumping equipment;
• dismantling of the unloading disc (hydraulic feet);
• removal of the pressure flange.

When disassembling a centrifugal pump, the impellers should be very carefully removed from the shaft, it is important not to bring them to jamming. This procedure is performed in turn with each section. In the event that the impeller cannot be removed or is difficult to remove, you can warm it up a little.

Assembling a centrifugal pump is a rather complicated procedure, during which it is necessary to perform the following steps:

1. check how accurately the new parts correspond to those that have already been installed in the pump, as well as the drawings of the repaired pumping equipment;
2. precisely fit new parts to the dimensions of the places in which they will be installed;
3. perform grinding and lapping of surfaces of mating parts;
4. tighten threaded fasteners evenly using torque wrench, which allows you to accurately control the force applied to such elements;
5. when installing the impeller on the shaft, check the accuracy of the formed axial clearance;
6. make sure that the perpendicularity error of the end side of the unloading disk during its installation does not exceed 0.02 mm.

If during the operation of a centrifugal pump you are faced with such a breakdown of the device as the destruction of the impeller or casing, then you should not try to restore them using, for example, welding. A wheel or housing restored in this way will not last long and may cause even more serious damage.

These dry-running pump parts cannot be repaired and must be replaced.