Pompetravaini TCTM User manual

(Rev. 2.0_10-2010)
DISASSEMBLY & ASSEMBLY
INSTRUCTIONS
SINGLE STAGE
CENTRIFUGAL PUMPS
TCHM & TCTM

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM
2
INTRODUCTION
These instructions are for the maintenance personnel for maintenance and/or repair of the indicated pump series.
Disassembly and assembly require expertise and knowledge of the procedures, therefore the work must be carried out
by qualified personnel.
These instructions must be carefully read and understood in conjunction with the section drawings and tables contained
in the manual and enclosed, prior to attempt any work on the pumps.
For safety, installation and maintenance instructions consult the manual “INSTALLATION & OPERATING
INSTRUCTIONS FOR CENTRIFUGAL PUMPS” attached to the pump at time of shipment. Consult also any other
attached instructions for accessories and/or components included with the pumps such as mechanical seals, heat
exchangers, flushing systems, instrumentation, etc.
Before operating or working on the pump it is recommended to adopt safety precautions wearing safety attire (hat,
glasses, gloves, shoes, etc.) and have ready the necessary tools required for the work to be done.
Do not subject the pump of its components to sudden mechanical impacts and /or distortions.
Do not damage or scratch the sealing faces. Pay particular attention not to damage flat gaskets and O-Rings.
Careful not to leave foreign matters such as moults, screws, washers, rags, etc. in the pump.
When requesting spare parts or technical information for the pump, always quote the pump model number and serial
number which is printed on the pump nameplate: therefore it is recommended not to remove the pump nameplate or, in
case this action will be necessary, write the serial number on the pump (for example on the flange).
Should additional information be required, please do not hesitate to contact POMPETRAVAINI or the closest
representative. Should there be any difficulties in repairing the pump, it is recommended to send the pump for repair to
POMPETRAVAINI or the local authorised representative.
Pump repairs and/or service carried out by customer or unauthorised personnel are not guaranteed by
POMPETRAVAINI or by its subsidiaries.
Note: Pump parts list identify all pump components by item number (VDMA) in connection with the sectional drawings.
All drawings are for reference purpose and not are certified for construction, however should additional
information be required, contact POMPETRAVAINI or its closest representative.
INDEX
1 - Steps to be followed prior to pump disassembly
2 - Disassembly and assembly
2.1- Disassembly
2.2- Assembly
3 - Spare parts
4 - Section drawings
5 - Nomenclature of pump parts
6 - Engineering tables
The liquids handled by the pumps and also their parts could be potentially dangerous for persons and
environment: provide their eventual disposal in conformity with the laws into force and a proper
environment management.
The present manual is not assigned for pumps subjected to the ATEX 94/9/CE directive. In case the
pump is assigned in environments subjected to the application ATEX 99/92/CE directive or in case the
pump is provided with a nameplate indicating the ATEX stamp, it strictly forbidden proceed to start up
the pumps but necessary to consult POMPETRAVAINI for clarifications.
For pumps subjected to the ATEX 94/9/CE directive it is available a dedicated integrative manual.
In preparing this manual, every possible effort has been made to help the customer and operator with the proper installation and operation of the
pump. Should you find errors, misunderstandings or discrepancies please do not hesitate to bring them to our attention.
1 - STEPS TO BE FOLLOWED PRIOR TO PUMP DISASSEMBLY
Should pump repairs be required, it is recommended to acquire full familiarity of the procedures to be followed by
studying these instructions and the “Operating Manual for Centrifugal Pumps”.
FOLLOW THE SAFETY INSTRUCTIONS LISTED UNDER CHAPTER 2 OF THE AFORE MENTIONED
OPERATING MANUAL.

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM 3
It is important to adhere to the following before working on the pump:
- use the appropriate steps to stop the pump
- close the isolating valves at suction and discharge piping
- wear the safety clothing (hard hat, safety glasses, gloves, safety booths, etc.)
- disconnect the electrical power to the motor and all the electrical instrumentation and, if necessary, disconnect the
electrical cables
- if the pump is handling hot liquids, let it cool down to ambient temperature
- drain the pump casing through by removing the drain plugs, rinse the pump with neutral liquid, if required
- adopt all safety precautions when the pump handles hazardous liquids, pollutant or toxic; these liquids
as well as the liquid used for rinsing the pump must be collected and disposed of with the maximum caution
and always in compliance with the local safety regulations.
To remove the pump and the motor (if required) from the installation proceed as follows:
- remove the bolts on the suction and discharge flanges
- disconnect any flushing lines, accessories and/or instrumentation connected to the pump assembly
- remove the motor, if necessary, by removing the anchor bolts from the motor flange
- remove the pump by removing the bolts from the pump’s feet
- disconnect the pump from the installation with caution, do not damage any components
- refer to the “Operating manual for centrifugal pumps” for instructions on transporting the pump.
2 – DISASSEMBLY AND ASSEMBLY
2.1 – DISASSEMBLY
(Refer to sectional drawings fig. 1 and 2 of chapter 4).
To remove the impeller VDMA 230 from the pump casing VDMA 102 remove the nuts from the studs VDMA 902.2. Pumps
fitted with Vortex type impeller, series TCMT, remove spacer ring VDMA 110 from pump casing or casing cover VDMA 161.
Remove impeller nut VDMA 925, impeller VDMA 230 and impeller key VDMA 940.2 from shaft VDMA 210.
Measure (making a record) the location for seal locating ring VDMA 485, or mark its location on the shaft, then loosen the
set screw VDMA 904, remove the locating ring from the shaft and remove the seal rotating part VDMA 433.2.
In the event the mechanical seal is fixed on the shaft with its own set screws then the locating ring may not be in the pump
assembly.
Remove the nuts from studs VDMA 902.1, remove casing cover VDMA 161 from lantern flange VDMA 341.
Particular care should be given when removing the mechanical seal components from the pump, mechanical seals are
fragile and may easily get damaged when mishandled.
Remove the stationary mechanical seal face from the casing cover, replace if necessary.
For complete pump disassembly proceed as follows.
Remove bolts VDMA 901, remove motor from lantern flange, remove snap ring VDMA 932.1 and shaft complete with snap
ring VDMA 932 and ball bearing VDMA 320.
Remove snap ring VDMA 932 and the ball bearing from the shaft.
Finally remove the radial seal ring VDMA 421 from bushing VDMA 542.
2.2 – ASSEMBLY
Proceed with visual and dimensional inspections of the components to be replaced (use only original parts from
Pompetravaini), check the parts for wear and tear (for critical dimensions see tab.1 and 2 on chapter 6).
When in doubt, contact Pompetravaini or the closest representative.
To replace the wear rings (only for TCHM series) VDMA 502, it is necessary to remove the set screws VDMA 904 and
remove the wear rings with a gear puller or, if it is too difficult, machine them off with a lathe.
It is good practice to replace all gaskets even if they do not show any defects, replace also bearings and mechanical seals
that have excessive play or grooved faces.
Thoroughly clean the parts with suitable cleaning products that are also compatible with the pump materials.
The bearings should be washed with a solvent or Diesel fuel, let them dry and then oil them. To facilitate their installation
over the shaft it is required to pre-heat the bearings to about 800C.
If there are no complications and the components are free from defects, wear or markings over the sealing areas, the pump
assembly can be done proceeding with the sequences in the reverse of the disassembly.
Assembly of the pump wear ring should be done without force to prevent damages. To help keeping the gaskets firm in
their respective sealing faces, it is suggested the use of compatible liquids such as oil or equivalent fluid.
Fig. 3 in chapter 6 lists recommended torque values for various screws and bolts in relation to their diameter.
ONLY FOR TCHM
Insert and press the wear ring VDMA 502.1 (if it is being replaced) in the pump casing VDMA 102, drill and tap between
the wear ring and pump casing then install set screw VDMA 904 to secure the wear ring.

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM
4
Fill radial seal VDMA 421 with grease and press it in the bushing VDMA 542.
Place shaft VDMA 210 in a vice with the threaded end upward, slide the ball bearing VDMA 320 over the shaft until it rests
against the shaft shoulder and lock the bearing with snap ring VDMA 932. Do not to scratch the face of the radial seal ring.
Slide shaft with bearing in the lantern face VDMA 341, careful not to damage the radial seal ring, then install the snap ring
VDMA 932.1.
Place the motor vertically with the flange facing the top, place the pump shaft assembly on the motor flange guiding its
shaft to engage the hallow pump shaft VDMA 210, then tighten bolts VDMA 901. Motor shaft and the key must slide
precisely without being forced into the pump shaft.
Clean the seal cavity in cover VDMA 161 where the stationary seal part VDMA 433.2 will fit. Remove any incrustations,
oxidations and deposits created by the flushing fluid.
Lubricate seal cavity and seal O-Ring with oil compatible with the materials.
Press the stationary part of the mechanical seal in the cavity lining up the driving pin VDMA 562 if there is one.
When considering a new mechanical seal, different than the original, it is very important to compare the major working
dimensions with those of the original seal and the materials of construction must be compatible with the pumped liquid. It
is recommended to read the mechanical seal instructions if supplied with the seal. For further information and working
dimensions see tab. 1 in chapter 6 or contact Pompetravaini or the nearest representative.
Install the housing cover on the lantern face and tighten it with bolts VDMA 902.1.
The position should be so that the internal lubrication bore in the housing cover is pointing to the right hand and lined up
with the arrow on the lantern frame cast; in the event tapped holes for the pump foot are drilled on the lantern frame,
they should be directed downward.
Lubricate the seal rotating part and pump shaft with compatible oil, clean the seal faces with a soft non-abrasive tissue
and slide the seal rotating part over the shaft until it rests against the face of the stationary seal face. Seal must be
suitable for clockwise rotation unless it is a bi-directional type.
Slide and locate the seal locating ring in the original location which had been marked or at the measured location, then
tighten the two set screws.
To prevent seal damages and breakdowns it is recommended not to use excessive force when fitting the seals, their
components can be fragile
ONLY FOR TCHM
Slide impeller VDMA 230 over the shaft and lock it in place with impeller nut VDMA 925.
Place the gasket VDMA 400.1 on casing cover.
ONLY FOR TCTM
Place the proper gasket VDMA 400.1 on the casing cover and position casing spacer VDMA 110.
Slide impeller VDMA 230 over the shaft and lock it in place with impeller nut VDMA 925.
Place the gasket VDMA 400.1 on casing spacer.
Install pump casing VDMA 102; fix it in place with nuts and washers.
Pump casing should be positioned in such a way that, with the pump feet pointing downwards, the bore for internal
lubrication in the casing cover is positioned on the right.
Place the pump in the horizontal position and make sure it turns freely by hand.
Following the pump assembly it is recommended to hydrotest the pump to make sure there are no outward leakages.
The recommended pressure test should be at least 1,2 times the maximum working pressure but in any case not less
than 4 bar.
3 - SPARE PARTS
When ordering the pump it is good practice to also order the necessary spare parts, especially when there are no stand-
by pumps in the installation. This will minimise unnecessary down times in the event of pump failure or routine
maintenance. Following spare parts are suggested for each pump size:
1 Impeller
1 Wear ring (only for TCHM)
1 Shaft assembly
1 Ball bearing
1 Mechanical seals
2 Sets of gaskets
However for proper parts management, consult the VDMA 24296 standard that recommends the quantity of spare parts
to be stocked in relation to the number of pumps installed.
On the pump nameplate are printed the pump model, the year of manufacture and the pump serial number: always
provide this information when requesting spare parts.
Specify also the VDMA number of the required part, as seen on the pump sectional drawing and parts list for proper
identification of spare parts.
We recommend the use of original spares: in case this is not respected, POMPETRAVAINI declines any responsability
for eventual damages caused by not original spare parts.

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM 5
4 - SECTION DRAWINGS
421
925
940.2
502.1
230
161102 903.3 562400.1
904 903.1 485 902.2 183902.1
904
320
433.2
932 932.1
542
901.1
341 901
210
Fig. 1 - Pump series TCHM gr. 1 and 2 design /1-C = Single mechanical seal and motor frame 80 and 90
421
925
940.2
230
161
102
903.3 562400.1
903.1 485 902.2 932.1902.1
904
320
433.2
932 183
542
901.1
341 901
210
110
Fig. 2 - Pump series TCTM gr. 1 and 2 design /1-C = Single mechanical seal and motor frame 80 and 90

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM
6
5 - NOMENCLATURE OF PUMP PARTS
VDMA
N° DESCRIPTION
VDMA
N° DESCRIPTION
102 Suction casing 485 Seal locating ring
110 Spacer ring 502.1 Wear ring
161 Casing cover 542 Mechanical seal bush
183 Support foot 562 Pin
210 Shaft 901... Screw
230 Impeller 902... Stud
320 Ball bearing 903... Plug
341 Lantern 904 Grub screw
400.1 Gasket 925 Impeller locking nut
421 Radial seal ring 932... Circlip
433.2 Mechanical seal 940... Key
6 - ENGINEERING TABLES
Fig. 3 - Torque values for various bolt sizes
Torque values
(Nm)
300
200
100
20
50
15
30
40
60
70
80
150
4 6 8 10 12 14 16 18 20 22 24 26
MAX
MIN
Bolt diameter (mm) at threaded area

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM 7
Tab. 1 BEARINGS TYPE RADIAL SEAL RINGS TYPE for SHAFT
Motor frame Motor frame
PUMP
MODEL 80
90 100 112 132 160 180 200 80 90 100 112 132 160 180 200
* MECHANICAL
SEAL
Ø (mm)
25-125
25-160
25-200
32-125 
32-160 
32-200 
40-125 
40-160 
40-200 
50-125 
50-160 
Group 1
50-200 
6208.2RS
(40x80x18) 6011.2RS (55x90x18) --- AS40527 (40x52x7) AS55708 (55x70x8) --- 30
32-250
40-250 
40-315
50-250 
65-125
65-160 
65-200 
65-250 
80-160 
80-200 
80-250 
Group 2
100-200 
6011.2RS
(55x90x18)
6214.2RS
(70x125x24)
AS55708
(55x70x8)
AS709010
(70x90x10)
45
100-250
125-250 --- 6214.2RS
(70x125x24) --- AS709010 (70x90x10)
Group 3
150-250 ---
6214.2RS
(70x125x24) --- AS709010 (70x90x10)
55
Available on TCTM design * According to DIN 24960 standards
Tab. 2 DIAMETRAL CLEARANCE in mm
BETWEEN IMPELLER NECK AND WEAR RING
NOMINAL DIMENSIONS
OF WEAR RINGS DESIGN
PUMP
MODEL A B H F - RA A3
IMPELLER
MINIMUM
BALL SIZE
mm
25-125 72 84 13 0,33 - 0,48 0,43 - 0,58 6
25-160 72 84 13 0,33 - 0,48 0,43 - 0,58 6
25-200 72 84 13 0,33 - 0,48 0,43 - 0,58 5
32-125 72 84 13 0,33 - 0,48 0,43 - 0,58 6
32-160 72 84 13 0,33 - 0,48 0,43 - 0,58 5
32-200 72 84 13 0,33 - 0,48 0,43 - 0,58 5
32-250 85 97 13 0,44 - 0,59 0,74 - 0,89 6
40-125 85 97 13 0,34 - 0,49 0,44 - 0,59 10
40-160 85 97 13 0,34 - 0,49 0,44 - 0,59 7,5
40-200 85 97 13 0,34 - 0,49 0,44 - 0,59 6
40-250 95 110 16 0,44 - 0,59 0,74 - 0,89 6,5
40-315 95 110 16 0,44 - 0,59 0,74 - 0,89 8
50-125 95 110 16 0,34 - 0,49 0,44 - 0,59 16
50-160 95 110 16 0,34 - 0,49 0,44 - 0,59 13
50-200 95 110 16 0,34 - 0,49 0,44 - 0,59 9
50-250 105 120 16 0,44 - 0,59 0,74 - 0,89 5
50-315 105 120 16 0,44 - 0,59 0,74 - 0,89 7,5
65-125 105 120 16 0,44 - 0,59 0,74 - 0,89 20,3
65-160 120 135 16 0,44 - 0,59 0,74 - 0,89 18
65-200 120 135 16 0,44 - 0,59 0,74 - 0,89 14
65-250 120 135 16 0,44 - 0,59 0,74 - 0,89 12
80-160 135 150 16 0,44 - 0,61 0,74 - 0,91 25
80-200 135 150 16 0,44 - 0,61 0,74 - 0,91 21
80-250 135 150 16 0,44 - 0,61 0,74 - 0,91 15
100-200 150 170 18 0,44 - 0,61 0,74 - 0,91 27
100-250 150 170 18 0,44 - 0,61 0,84 - 1,01 18
125-250 180 200 20 0,44 - 0,61 0,84 - 1,01 30
150-250 215 235 20 0,45 - 0,62 0,85 - 1,02 48
H
Ø
A
ØB

Disassembly & assembly instructions single stage centrifugal pumps series TCHM & TCTM
8
NOTES
PUMP model
.........................................................................
Serial Number
......................
Computer Number
........................................................
Year of manuf.
......................
LIQUID handled
.........................................................................
Capacity
...............m3/h
Suction Pressure
........................m
Discharge Press.
........................m
Temperature
..................°C
Lethal Toxic Noxious Corrosive Irritant Malodorous ...................
Clean Dirty With suspended parts Spec. Gravity........... Viscosity.............. PH..........
TOTAL WEIGHT
...................KGs.
MAXIMUM DIMENSIONS
X =................cm
Y =................cm
Z =................cm
NOISE (measured at 1 m)
Pressure =...................dB(A)
Power =...................dB(A)
INSTALLATION SERVICE
Inside Outside Continuous Intermittent
Explosive area ............................. ......................................................................
MOTOR type / Frame
..................................
No Poles
................................
No Revolutions
........................RPM
Absorbed power
.........................Amp
Installed Power
...............kW / ..............HP
Frequency
.............................Hz
Supply
..........................Volt
Enclosure
IP............................
Insulation class
...............................
Absorbed Power
..............kW / ..............HP
COMMENTS
NA5.SM.TCHM.GB00 / PRINTED IN ITALY
Smontaggio TCHM-TCTM Inglese
POMPETRAVAINI’S continuing research results in product improvement, therefore any specifications may be subject to change without notice.
S.p.A.
20022 CASTANO PRIMO (Milano) ITALY
Via per Turbigo, 44 – Zona Industriale
Tel. [phone] – Fax [phone]
www.pompetravaini.it