AxFlow Aturia ND Series Manual

Single Stage
Mechanically Coupled
End Suction
Centrifugal Pump
built to
ISO 2858 –ISO 5199
standard
ND SERIES
OPERATION
&
MAINTENANCE
MANUAL

IMPORTANT NOTES
ND Series Operating & Instruction Manual Page i
Read these instructions before putting the pump into service.
Installation and operation should be carried out by qualified personnel only.
Danger of electrocution. Electric supply must be isolated before working on the pumpset.
Electrical work should only be carried out by qualified personnel

CONTENTS
ND Series Operating & Instruction Manual Page ii
GENERAL.................................................................................................................................................1
Construction features...........................................................................................................................1
Pump casing.....................................................................................................................................1
Shaft seal housing ............................................................................................................................1
Support ............................................................................................................................................1
Pump nameplate..............................................................................................................................1
Fields of applications............................................................................................................................2
Precautions during operation...............................................................................................................3
Noise levels ..........................................................................................................................................3
Operating limits ...................................................................................................................................5
Residual risks........................................................................................................................................5
In case of emergency............................................................................................................................6
Area of operation .................................................................................................................................6
Spare parts...........................................................................................................................................6
Transport .............................................................................................................................................7
Storage ................................................................................................................................................8
Storage for a period shorter than 3 months......................................................................................8
Storage for a period exceeding 3 months (but shorter than 12 months)...........................................8
Storage (after operation)..................................................................................................................8
Drivers..................................................................................................................................................9
INSTALLATION......................................................................................................................................10
Site installation ..................................................................................................................................10
Foundations .......................................................................................................................................10
Motor-pump units on baseplates....................................................................................................10
Pump and motor alignment ............................................................................................................... 11
Methods of checking alignment.........................................................................................................12
Straight edge..................................................................................................................................12
Dial gauge ("clocking") ................................................................................................................... 13
Optical methods............................................................................................................................. 13
Location and piping............................................................................................................................14
Admissible external forces and torques on pump flanges .................................................................. 17
Protecting the pump against dry running...........................................................................................18
Loss of liquid supply .......................................................................................................................18
Low inlet pressure ..........................................................................................................................18
`Dead-heading'...............................................................................................................................18
Electronic dry running protection.......................................................................................................18
Electrical connection..........................................................................................................................19
Connecting the electric motor........................................................................................................19
Oil lubricated......................................................................................................................................20
Bearings .........................................................................................................................................20
Oil type...........................................................................................................................................20
Direction of rotation...........................................................................................................................21

CONTENTS
ND Series Operating & Instruction Manual Page iii
OPERATION ..........................................................................................................................................22
Supervision ........................................................................................................................................22
Priming the pump ..............................................................................................................................22
Start-up..............................................................................................................................................23
Pump operation .................................................................................................................................24
MAINTENANCE .....................................................................................................................................26
Supply isolation..................................................................................................................................26
Maintenance schedule .......................................................................................................................26
Mechanical seal..................................................................................................................................27
Bearings .............................................................................................................................................27
Grease lubricated ...........................................................................................................................27
Oil lubricated..................................................................................................................................27
Oil type...............................................................................................................................................28
Pump stop for long period..................................................................................................................28
DISASSEMBLY.......................................................................................................................................29
Disassembling the pump....................................................................................................................29
Before disassembling .........................................................................................................................29
Pump disassembling ..........................................................................................................................30
Mechanical seal inspection.................................................................................................................30
Pump with integral mechanical seat site in stuffing box housing ...................................................30
Pump with integral mechanical seat site in mechanical seal cover .................................................30
Bearings inspection............................................................................................................................30
The shaft should come out complete with thrust bearings.................................................................30
REASSEMBLY .................................................................................................................................... 31
Before reassembling .......................................................................................................................... 31
Reassembling the pump..................................................................................................................... 31
Mechanical seal reassembling............................................................................................................32
Pump with integral mechanical seat site in stuffing box housing ...................................................32
Pump with integral mechanical seat site in mechanical seal cover .................................................32
TYPICAL CROSS-SECTION.................................................................................................................... 33
Support 24 –Mechanical seal standard .......................................................................................... 33
Support 24 –Mechanical seal cartridge.......................................................................................... 33
Support 32 –Mechanical seal standard –Impeller with back blades...............................................35
Support 32 –Mechanical seal standard ..........................................................................................36
Support 32 –Mechanical seal standard –Impeller with back blades...............................................36
Support 32 –Mechanical seal cartridge .......................................................................................... 37
Support 42 –Mechanical seal cartridge..........................................................................................39
Support 48 –Mechanical seal cartridge..........................................................................................40
Support 55 –Mechanical seal cartridge ..........................................................................................41
TROUBLESHOOTING ............................................................................................................................43
DECOMMISSIONING AND DISMANTLING ...........................................................................................48

CONTENTS
ND Series Operating & Instruction Manual Page iv
ATEX CLASSIFIED PUMPS.....................................................................................................................49
Introduction .......................................................................................................................................49
Pump installation in classified areas...................................................................................................50
Suitability of the pump in installation area .....................................................................................50
Areas where gas, vapour or flammable clouds are present.............................................................50
Plate data regarding safety ................................................................................................................51
Supplementary plate......................................................................................................................51
Notes..............................................................................................................................................52
Operational limits ..............................................................................................................................53
Contractual data.............................................................................................................................53
Processed fluid ...............................................................................................................................53
Prevention precaution and maintenance ...........................................................................................54
Cleaning .........................................................................................................................................54
Mechanical Seal..............................................................................................................................54
Misalignment .................................................................................................................................54
Dry running ....................................................................................................................................55
Safety devices ................................................................................................................................55
Earth connection ............................................................................................................................56
Coupling.........................................................................................................................................56
Periodical checks............................................................................................................................56
NOTES ................................................................................................................................................... 57

GENERAL
ND Series Operating & Instruction Manual Page 1
GENERAL
Construction features
AxFlow Aturia ND series pumps are single stage pumps with hydraulically balanced overhung impeller,
simple volute casing with end suction and top radial delivery.
The impellers, developed to be highly efficient, guarantee the most economic service.
Standardisation of the common parts to a very high degree simplifies spare parts storage.
UNI 2223/29 –ISO 7005 PN 16 flange nozzles are used for the standard construction (on request flanges
according to ANSI 150 RF).
Pump casing
The pump casing is back pull out, monobloc type, with casted feet fixed by 4 bolts to the common
Pump / motor baseplate.
Shaft seal housing
The shaft seal housing closes back the pump casing.
It is designed to allow mounting of mechanical seal (simple, balanced or double, according to pumped
liquid or as for plant requirements).
The shaft seal housing has a chamber for cooling or heating, if required, according to pump service or to
the type of pumped liquid.
Support
The support is back pull out type, fixed on the stuffing box by a set of screws.
The standard construction for pump with support size 24-32-42 is fitted with two ball bearings.
Heavy duty pumps, pumps with support size 55, and pumps with high suction pressure are fitted with
one roller bearing (pump side) and double thrust bearing (motor side) suitable to support a high axial
thrust.
The bearings are oil lubricated by a constant level oiler.
Pump nameplate
Details of the pump type and model, serial number and operating data are indicated on the pump
nameplate.
Pump nameplate reports the following data :
Manufacturer
Pump type
Serial number
Capacity (m³/h)
Head (m)
Shaft speed
Year of construction

GENERAL
ND Series Operating & Instruction Manual Page 2
The pump must be installed and operated in full compliance with these instructions. The pump may not
be operated outside the limits specified on the nameplate and within this manual. The pump should
only be operated by skilled trained personnel. The manufacturer will not accept liability if these
instructions are not followed.
This manual does not take into account any specific local regulations or bylaws that may be applicable,
and it is the responsibility of the installer to ensure compliance with such regulations.
Fields of applications
AxFlow Aturia ND series pumps are mainly employed in the following applications :
General Industrial services
Petrochemical plants
Chemical plants
Transfer of corrosive and/or dangerous fluids
Distribution
Marine
Hot pressurized water
Heat transfer oil
The operating limits are shown on the technical data sheet.

GENERAL
ND Series Operating & Instruction Manual Page 3
ATTENTION !
Precautions during operation
Always take the following safety precautions :
The coupling guard must be at its place on the baseplate.
If warm liquids are pumped, protect the pump to prevent contact with warm pump surfaces.
Never put your hands or any kind of object into pump openings where the shaft rotates
(see picture)
Protect motor and all
electric parts according to
current regulations

GENERAL
ND Series Operating & Instruction Manual Page 4
Noise levels
The following table reports the noise level produced by AxFlow Aturia ND Series pumps running with in
their operating limits and installed according to the instructions given in this manual (average values
measured in free field at 1 meter from the pump set and elaborated according to ISO standard R1680 –
curve A). The values are referred to groups with AxFlow standard electric motors. For other motors the
table values shall be compared to the actual used motors.
MOTOR
FRAME SIZE
MOTOR SPEED
2 Pole
4 Pole
63
65
65
71
67
65
80
71
65
90
73
67
100
77
69
112
79
70
132
80
71
160
81
72
180M
82
73
180L
82
73
200
83
74
225
84
75
250
85
77
280
86
80
315S
89
83
315M
90
84
355
91
87
400
93
89
If noise levels are to be guaranteed, add an allowance of 3 dB for measurement and manufacturing
tolerance.
Increase for 60 Hz operation :
3500 rpm +3 dB, 1750 rpm +1 dB, 1160 rpm +.--- dB

GENERAL
ND Series Operating & Instruction Manual Page 5
DON’T KICK THE PUMP
DON’T DAMAGE THE
PUMP BY MISHANDLING
DON’T PRESSURIZE THE
PUMP BEYOND
RECOMMENDED LIMITS
AVOID DRY RUNNING, OPERATION AT LOWER
CAPACITY THAN ALLOWED OR RUNNING
AGAINST A CLOSED DISCHARGE VALVE
AVOID THERMAL SHOCK
FROM COLD FLUIDS AGAINST
WARM SURFACES
ONLY USE THE PUMP WITH
FLUIDS SPECIFIED IN THE
ORDER DATASHEETS
Operating limits
The operating limits are the following :
Suction pressure max. 4 bar
Max. operating pressure at delivery max. 20 bar
Pumping liquid temperature max. 250 °C min. –50°C
Performances are described in the technical specification enclosed in the AxFlow order confirmation.
Residual risks
Inobservance of the safety instructions here reported or improper use of the pump may result in heavy
damage to things and/or injuries to the person.
Always keep to the following directions :

GENERAL
ND Series Operating & Instruction Manual Page 6
In case of emergency
Switch off line voltage
Warn service personnel responsible of the plant
Area of operation
AxFlow Aturia ND series pump sets may be installed within a building or externally. Wherever installed,
protect the pump from frost, snow and flooding.
Care must be taken to ensure that cold weather will not cause the pump or pipes to freeze, and
installers may wish to consider lagging or trace heating.
If supplied, standard electric motors are only suitable for operation in safe areas, free from the danger
of explosive liquids or gases.
Spare parts
Spare parts are available from AxFlow throughout Great Britain. Please quote the pump model and
serial number for all spares enquiries.
The pump user is strongly recommended to carry replacement spares for parts which are wearing items
as follows:
Radial ball bearing (3011 / 1)
Radial roller bearing (3012) if planned
Double thrust bearing (3032) if planned
Impeller (2200)
Casing wear ring (1500 –1520)
Gasket (4590.1 / 2)
Mechanical seal (4200)
Radial lip seal (43000.1 / .2)
O-Ring (4610)
If an electric motor is supplied as the drive then also include the following:
Pair of motor bearings

GENERAL
ND Series Operating & Instruction Manual Page 7
THE PUMP SHOULD BE TRANSPORTED BY
EQUIPMENT SUITED FOR ITS’ WEIGHT AND TO
THE SHAPE OF PACKAGE
LIFTING BY HAND IS ALLOWED ONLY FOR
LOWER WEIGHTS THAN 20 KILOGRAMS
Transport
Check the nameplate on the pump against the receiving and purchase order documents to be sure that the
correct size of pump and materials of construction have been supplied. If a motor has been supplied, check
that the power, speed, and voltage are correct.
Prior to unpacking, check for physical damage to the packing and the pump unit and notify the forwarding
agent IMMEDIATELY if any damage is found.
Check that the port covers are intact. If not, check whether foreign objects may have found their way into the
pump casing through the ports. Remove the port covers only when you are ready to connect the pipes to the
pump.
When shipped, the pumps are suitable for short-term storage only. If long-term storage is necessary
before the pump will be put into operation, we suggest that you contact your pump supplier for long-
term storage recommendations.
Check for free rotation of the pump. To check long-coupled pumps for free rotation, remove the coupling
guard and rotate the pump and motor shafts at the flexible coupling.

GENERAL
ND Series Operating & Instruction Manual Page 8
Storage
The delivered pump is generally suitable for immediate installation.
Storage for a period shorter than 3 months
Store the pump in a dry and sheltered area.
Check that ambient temperature never falls below 5°C.
It is recommended that the pump shaft is rotated at regular intervals ( every 30 days ): this
prevents damage to the bearings and seizure of the rotating parts.
Storage for a period exceeding 3 months (but shorter than 12 months)
Raise the pump by means of wooden supports.
Open the package, if any, removing the protection from the pump nozzles and clean by
compressed air then carefully dry inside the pump, if necessary.
Protect the pump inside with anti-condensation products and close the flanges so that no
foreign objects can enter the pump.
Cover the pump with a plastic film and put inside some products the prevent water
condensation.
Check protections periodically.
It is recommended that the pump shaft is rotated at regular intervals ( every 30 days ): this
prevents damage to the bearings and seizure of the rotating parts.
Storage (after operation)
In case of long periods after operation, drain the pipes and the pump through the drain hole in
the lower part of the pump casing.
If an electric motor is supplied as the drive, then before putting into service, the motor winding
insulation should be tested. If the reading is below 10 Mega ohms, move to a warm dry place for a few
hours until the motor insulation value rises.

GENERAL
ND Series Operating & Instruction Manual Page 9
Drivers
AxFlow Aturia ND series pumps may be driven by an electric motor through a shaft-to-shaft coupling.
There are particular points which can affect the pump:
Shaft -to-shaft flexible couplings must be properly aligned, as poor alignment will
cause high loads on the pump bearings. Couplings must be suitably rated, and provide
sufficient flexibility to prevent shock forces and oscillating loads from being
transmitted to the pump shaft. This is particularly important for diesel engine drives.
When designing the drive system and prime mover, take into account that the pump
dismantles by removing the rotating element out from the back of the pump casing.
Sufficient space should be allowed to facilitate dismantling of the pump.

INSTALLATION
ND Series Operating & Instruction Manual Page 10
DURING SITE INSTALLATION AND
MAINTENANCE ALL COMPONENTS MUST BE
SAFELY TRANSFORTED
TRAINED PERSONNEL MUST USE PROPER
SLINGS IN ORDER TO AVOID ANY DAMAGE TO
EQUIPMENT AND / OR PERSONNEL
THE LIFTING EYEBOLTS OF PUMPING SET
COMPOUNDS MUST BE USED FOR LIFTING
EACH RELATED COMPONENT
INSTALLATION
Site installation
Foundations
The foundation should be substantial in order to reduce vibrations, and rigid enough to prevent flexing
which can result in misalignment. Foundation bolts of the correct size should be located by reference
to certified drawings if the baseplate is supplied with the pump.
The pump must be mounted horizontally on a level foundation, with the discharge port vertically
upwards.
The pumpset should be mounted on a level horizontal base. The base should be of sufficient rigidity to
prevent flexing. When bolting the pump down, insert shims as necessary under the pump feet to level
the pump using a spirit level on the suction and discharge flanges of the pump. Use all six bolt holes to
mount the pump.
Motor-pump units on baseplates
Level the baseplate accurately, using shims under the base-plate next to the foundation bolts. The
baseplate must sit firmly and evenly on its foundation: it must not be distorted by bolting to an uneven
surface, which will throw the pump and motor out of alignment.
Isolate the supply
before commencing
work on the pump.

INSTALLATION
ND Series Operating & Instruction Manual Page 11
COUPLING GUARD MUST
BE FITTED ON BASEPLATE
AFTER ALIGNMENT
CHECK THE ALIGNMENT OF
PUMP AND MOTOR PRIOR
TO START-UP
Pump and motor alignment
Long-coupled pumps have been pre-aligned with the motor prior to shipment. If pump units receive
rough treatment during shipment, they can become misaligned. The flexible coupling is not designed
to compensate for misalignment. Improper alignment will cause vibration and premature bearing
failure.

INSTALLATION
ND Series Operating & Instruction Manual Page 12
A final alignment check should be made after the baseplate has been grouted and set, and the
foundation bolts have been tightened.
TYPE
DISPLACEMENT
GAP
Short flexible coupling
(3000 rpm)
0.05 mm
0.04 mm per 100 mm
coupling diameter
Flexible spacer coupling
(3000 rpm)
0.07 mm per
100 mm spacer length
0.04 mm per 100 mm
coupling diameter
Methods of checking alignment
Straight edge
Using a straight edge, check the distance from the shaft at several points on the circumference of the
coupling. The distances d1 and d2 should each remain constant.
IMPORTANT NOTE: The straight edge method checks static coupling alignment, not shaft alignment.
It relies for its accuracy on the accurate alignment of each coupling half on its shaft. The straight edge
method is a useful preliminary check, but should not be seen as an effective final alignment method.

INSTALLATION
ND Series Operating & Instruction Manual Page 13
Dial gauge ("clocking")
There are several methods, using one or two dial gauges. The lost accurate is the reverse indicator
method, using two gauges, which overcomes errors due to `sag' of the gauge bars.
Place the ruler in positions 1-2-3-4 ( see below picture ) and check radial offset “a” it should not exceed
0.1 mm.
Measure then the distance “ b “ with a thickness gauge at positions 1-2-3-4.
The difference between readings in positions 1-3 and 2-4 should not exceed 0,1 mm.
Group alignment can be checked more accurately by using a millesimal comparator (millesimal dial
indicator).
Optical methods
Several proprietary systems are available, such as the `OPTALIGN' system (INA Linear Systems).
Mechanical errors are eliminated by optical alignment techniques. On request, AxFlow can provide
further information about suitable alignment methods, including allowances for THERMAL
EXPANSION IN HIGH TEMPERATURE USE.

INSTALLATION
ND Series Operating & Instruction Manual Page 14
ATTENTION !
Location and piping
The correct pipework sizes should be selected according to the allowable limits of liquid velocity and
pressure drop at the required flow rate. Check the NPSH required by the pump at its specified duty
point, and ensure that the minimum NPSH available exceeds that required.
This is particularly important for liquids near their boiling temperature (or bubble point).
Check that the pipework is THOROUGHLY CLEAN before the pump is installed.
Pipework connections must be accurately aligned with the pump ports, so that they can be connected
to the pump without forcing. Maximum allowable bending moments are set out in the Table overleaf.
These moments must not be exceeded, otherwise the pump may distort internally, or the pump and
motor may become misaligned.
Pipework must be fully and independently supported as close as practicable to the pump.
Locate the pump as close as possible to the liquid source.
The suction line should be as short and straight as possible, with a minimum number of bends. Bends
should be large radius type: avoid sharp elbows. Bends and fittings should be no closer than 20 pipe
diameters to the pump suction, to allow undisturbed flow to the pump impeller. Liquid velocity in the
suction line should normally be between 0.7 and 2.0m/sec. If the liquid is near its boiling temperature
(or bubble point), its velocity may need to be reduced to 0.5-1.0m/sec. If the suction line is oversized,
the reducer at the pump inlet port should be ECCENTRIC, not concentric.
Generally, suction piping should be one or two sizes larger than the inlet bore of the pump, to keep
liquid velocity low and friction losses to a minimum. This becomes more important as the distance
between the pump and the liquid supply increases.
The suction line should slope so as to avoid air pockets.

INSTALLATION
ND Series Operating & Instruction Manual Page 15
Valves on the suction side should be mounted with stems horizontal, or vertically downwards. All joints
in the suction line must be tight, to prevent air from entering into the system, with the risk of vapour
locking.
If the pump is installed with a negative static inlet head (lower diagram), the foot valve/ strainer must
always be immersed at a sufficient depth to avoid entry of air into the pump. Take suitable precautions
to prevent vortexing in the supply vessel. A pressure gauge should be installed in the suction line, as
close as possible to the pump.
If the supply vessel is under vacuum, a pressure balancing line should connect the supply vessel and the
pump inlet port.
The discharge line should be as short and direct as possible to minimize friction losses. An air vent (if
permissible) should be installed at the first high point in the discharge line.
Leave enough space for motor ventilation.