PUMPWORKS PW-PC Series User manual

TABLE OF CONTENTS
Introduction
Introduction INTRO-2
Safety INTRO-2
Warranty INTRO-4
Product Description
General Description DESIGN-2
Pumping Parts Description DESIGN-2
Ordering Information/Nameplate DESIGN-3
Nameplates DESIGN-4
Powertrain Description DESIGN-5
Figures
Figure 1: PW-PC pump package DESIGN-2
Figure 2: Nameplate on the Pump MotorAdapter
using English units DESIGN-4
Tables
Table 1: Hydraulicsizesperpipingsize DESIGN-2
Table 2: Nameplate Description DESIGN-4
Table 3: Definition of nameplate on the Pump Motor
AdapterEnglish units DESIGN-4
Table 4: Gearbox per PW-PC Model DESIGN-5
Handling
Delivery Inspection HANDLE-2
Transportation HANDLE-2
Pump Handling HANDLE-2
Lifting Methods HANDLE-2
Storage HANDLE-4
Pump Storage Requirements HANDLE-4
Frost Proofing HANDLE-5
Figures
Figure 1: Bare Pump Lifting HANDLE-3
Figure 2: Base Mounted Pump Lifting HANDLE-3
Figure 3: Base Mounted Pump with Gearbox
and Driver HANDLE-4
Tables
Table 1: Lifting Methods HANDLE-2
Table 2: Storage Requirements HANDLE-4
Table 3: Frost proofing HANDLE-5
Installation
Pre-installation INSTALL-2
Pump Location Guidelines INSTALL-2
Foundation Requirements INSTALL-2
Baseplate Mounting Procedures INSTALL-3
Install the Baseplate INSTALL-3
Install the pump, gearbox, and driver INSTALL-4
Piping checklists INSTALL-5
General piping checklist INSTALL-5
Suction-piping checklist INSTALL-6
Discharge piping checklist INSTALL-7
Figures
Figure 1: Sleeve Type Bolts INSTALL-2
Figure 2: J Type Bolts INSTALL-3
Figure 3: Baseplate Top View INSTALL-3
Figure 4: Baseplate Side View INSTALL-4
Figure 5: Coupling Details INSTALL-4
Tables
Table 1: Guidelines for Locations INSTALL-2
Table 2: Piping Guidelines INSTALL-5
Table 3: Suction Piping Guidelines INSTALL-6
Table 4: Suction Piping Guidelines –Liq. Below INSTALL-6
Table 5: Suction Piping Guidelines –Liq. Above INSTALL-7
Table 6: Discharge Piping Guidelines INSTALL-7
Startup, Operation, and Shutdown
Preparation for Startup STARTUP-2
Coupling Guard STARTUP-2
Pump Rotation STARTUP-3
Couple the Pump and Driver STARTUP-3
Install Coupling Guards STARTUP-4
Pump Priming STARTUP-5
Pump Operation Precautions STARTUP-6
Shut Down STARTUP-6
Figures
Figure 1: Guard Removal STARTUP-2
Figure 2: Required Guard Parts STARTUP-4
Figure 3: Pump Priming STARTUP-5
Maintenance
Schedule MAINT-2
Mechanical Seal Maintenance MAINT-2
Disassembly MAINT-3
Precautions MAINT-3
Required Tools MAINT-3
Drain Pump MAINT-3
Coupling Removal MAINT-4
Liquid End Removal MAINT-4
Motor Adapter Removal MAINT-5
Powertrain Disassembly MAINT-5
Driver Removal MAINT-5
Pre-Assembly Checks MAINT-6
Part Replacement Guidelines MAINT-6
Wet Components Inspection MAINT-6
Seal Chamber Inspection MAINT-8
Reassembly MAINT-9
Driver, Gearbox, and Driver Adapter MAINT-9
Case and Mechanical Seal tothe Skid MAINT-10
Couple the Rotor Assembly to the Gearbox MAINT-10
Stator Module Assembly to the Skid MAINT-11
Shaft sealing with cartridge mechanical seal MAINT-11
Post-Guard assembly checks MAINT-12
Coupling Guards MAINT-12
Spare parts MAINT-13
Figures
Figure 1: Liquid End Removal MAINT-4
Figure 2: Suction Case Removal MAINT-5
Figure 3: Motor Adapter Removal MAINT-5
Figure 4: Motor Removal MAINT-6
Figure 5: Case Inspection MAINT-7
Figure 6: Rotor Inspection MAINT-7
Figure 7: Stator Adapter Inspection MAINT-8
Figure 8: Seal Chamber Inspection MAINT-8
Figure 9: Driver/Gearbox Assembled to Skid MAINT-9
Figure 10: Motor Adapter Installation MAINT-9
Figure 11: Case and Seal Installation MAINT-10

TABLE OF CONTENTS
Figure 12: Coupling Details MAINT-10
Figure 13: Stator Module Assembly Details MAINT-11
Figure 14: Mechanical Seal Installation MAINT-11
Figure 15: Coupling Guards Assembled MAINT-12
Tables
Table 1: Rotor Inspection MAINT-7
Table 2: Stator Adapter Inspection MAINT-8
Table 3: Spare Parts List MAINT-13
Parts List
Figures
Figure 1: 3x3 4-Stage Pump Package Exploded View PARTS-3
Tables
Table 1: Parts List PARTS-2

INTRO-1
Introduction and Safety

INTRO-2
Introduction
The purpose of this manual is to provide necessary information for installation, operation
and maintenance of the PumpWorks Model PW-PC
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages in this
manual before handling the product. They are published to help prevent these specific
hazards:
Personal accidents and health
Product damage
Product malfunction
Hazard criteria
DANGER:
A situation where a hazard, if not avoided, will result in serious bodily injury and/or death.
WARNING:
A situation where a hazard, if not avoided, could result in serious bodily injury and/or
death.
CAUTION:
A situation where a hazard, if not avoided, could result in less severe bodily injury.
NOTICE:
A potential situation, which if not avoided, could lead to product malfunctions.
Safety
WARNING:
The operator must be aware of safety precautions to prevent physical injury.
Any pressure-containing device can explode, rupture, or discharge its contents if it is over
pressurized. Take all necessary measures to avoid over-pressurization.
Operating, installing, or maintaining the unit in any way that is not intended could cause
death, serious personal injury, or damage to the equipment. This includes any
modification to the equipment or use of parts not provided by PW-IND. If there is a question
regarding the intended use of the equipment, please contact a PumpWorks representative
before proceeding.
This manual clearly identifies accepted methods for disassembling units. These methods
must be followed. Trapped liquid can rapidly expand and result in a violent explosion and
injury. Never apply heat to rotors or their retaining devices to aid in their removal unless
explicitly stated in this manual.
If the pump/motor is damaged or leaking, do not operate as it may cause an electric shock,
fire, explosion, release of toxic fumes, physical harm, or environmental damage.
Correct/repair the problem prior to putting the pump back in service.
Do not change the service application without the approval of an authorized PumpWorks
representative.

INTRO-3
User safety
General safety rules
These safety rules apply:
Always keep the work area clean.
Pay attention to the risks presented by gas and vapors in the work area.
Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
Safety equipment
Use safety equipment according to local regulations. Use this safety equipment
within the work area:
Helmet
Safety glasses
Protective shoes
Protective gloves
Gas mask
Hearing protection
Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety
devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local codes.
Precautions before work
Provide a suitable barrier around the work area, for example, a guard rail.
Make sure that all safety guards are in place and secure.
Make sure that you have a clear path of retreat.
Make sure that the product cannot roll or fall over and injure people or damage
property.
Make sure that the lifting equipment is in good condition.
Use a lifting harness, a safety line, and a breathing device as required.
Allow all system and pump components to cool before you handle them.
Make sure that the product has been thoroughly cleaned.
Disconnect and lock out power before you service the pump.
Check the explosion risk before you weld or use electric hand tools.
Precautions during work
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
Always wear Personal Protective Equipment (PPE).
Always lift the product as illustrated in the Transportation and Storage Section.
Beware of the risk of a sudden start if the product is used with an automatic control.
Clean all components thoroughly after pump disassembly.
Do not exceed the maximum working pressure of the pump.
Do not open any vent or drain valve or remove any plugs while the system is
pressurized.

INTRO-4
Make sure that the pump is isolated from the system and that pressure is relieved
before you disassemble the pump, remove plugs, or disconnect piping.
Never operate a pump without a properly installed coupling guard.
Product Warranty
Basic Coverage
PumpWorks will remedy faults in products under these conditions:
The faults are due to defects in design, materials, or workmanship.
The faults are reported to a PumpWorks representative within the warranty period.
The product is used only under the conditions described in this manual.
All service and repair work is done by PumpWorks authorized personnel.
Genuine PumpWorks parts are used.
Limitations to Warranty:
Except where noted above, the warranty does not cover faults caused by these situations:
Deficient maintenance
Improper installation
Modifications or changes to the product and installation made without consulting
PumpWorks
Incorrectly executed repair work
Normal wear and tear
PumpWorks assumes no liability for these situations:
Bodily injuries
Material damages
Economic losses
Environmental damage

DESIGN-1
Product Description

DESIGN-2
General Description PW-PC
The PW-PC is a positive displacement pump that utilizes a rotor and stator to move fluid through various
stages. The pressure built in each stage is twice that of its previous stage.
Figure 1: PW-PC pump package
Table1: Hydraulicsizes per pipingsize
Pipingsize group
Number of hydraulic sizes
3X3
2
4X4
2
Pumping Parts Description PW-PC
Seal
Single Cartridge Seal (RBX1) in 3.250”, 4.000”, or 5.625” shaft sizes.
Dual Tandem Cartridge Seal (79X) in 3.250”, 4.000”, or 5.625” shaft sizes.
Is located on the non-oscillating plugin shaft portion of the Rotating Assembly.
Pilots with the bore of the Case.
Case
ANSI class 300# raised-faced serrated suction flange.
Suction flange is axially rotatable in 90 degree increments.
Material is either ASTM A216 WCB (Carbon Steel) or ASTM A351 GR CF3M (Stainless Steel)
¾” FNPT Vent and drain port accommodations.
Sealed at the back end with a mechanical seal and at the front end with a double o-ring.
Fully suspended between the stator module and the motor adapter.

DESIGN-3
Stator Adapter
Seals to the case with double OD o-rings.
Counter bore on front end mates and seals with back end of stator.
Material is carbon steel.
Stator Housing
Material is carbon steel.
Contains Stator elastomer at all times.
Dedicated location for installation of temperature sensing mechanism.
Stator
Even Wall geometry to allow for higher pressures.
Material is either HNBR elastomer (FF) or Fluoroelastomer Terpolymer (H5)
Takes shape and extends out both ends of the stator housing which creates a sealing face to the
Stator Adapter and the Discharge Casing.
Rotating Assembly
Includes two universal joints with a plug in shaft on one end and a rotor on the other.
Rotor is inserted into and makes contact with inner surfaces of the stator.
Plugin shaft is locked into the gearbox shaft by a high tolerance coupling pin and rubber sleeve.
Rotor material is either AISI 4140 with Duktil coating or 316L Stainless Steel.
Plugin shaft and coupling pin is either AISI 420 or 316L Stainless Steel.
Discharge Casing
ANSI class 600# raised-faced serrated discharge flange.
Counter bore on back end mates and seals with front end of stator.
Material is carbon steel.
Important Information for Ordering PW-PC
Every pump package has nameplates that provide information about the pump and powertrain. The
nameplate for the pump is located on the Pump Motor Adapter.
When you order spare parts or replacement packages, identify this pump information:
Model
Size
Serial number
Item or Tag numbers of the required parts
Purchase Order Number
Refer to the nameplate on the Pump Motor Adapter for most of the information. See Parts List for
item numbers.

DESIGN-4
Nameplate types
Table 2: Nameplate Description
Nameplate
Description
Pump Motor
Adapter
Provides information about the hydraulic characteristics of the pump.
Discharge x Suction, Number of stages.
(Example: 3X3 4S)
ATEX
If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the
baseplate, or the discharge casing. The nameplate provides information about the ATEX
specifications of this pump.
Figure 2: Nameplate on the Pump Motor Adapter using English units
Table 3: Definition of nameplate on the Pump Motor AdapterEnglish units
Nameplate field
Definition
TAG
Pump package part number
SIZE
3X3 4S
FLOW
Rated pump flow, in Barrels Per Day
SG
Specific gravity of rated product fluid
HYDRO
Hydrostatic test pressure
PO#
Package purchase order number
MOD
Pump package model
SPEED
Rotational speed of the pump in RPM
SN
Serial number of the pump package
MOC
Material of which the pump is constructed
MAWP
Maximum pressure at 100ºF according to the pump design
PUMP WT
Total pump package weight

DESIGN-5
Powertrain Description PW-PC
Gearbox
Manufacturer: Nord Gear Corporation.
Uses a disposable auto greaser and grease catch mechanism.
Fastens directly to the Motor Adapter.
Inserts directly into the Rotating Assemblies plugin shaft and is installed by coupling pin and sleeve.
Suspended between the feet mounted Motor and Motor adapter.
Table 4: Gearbox per PW-PC Model
PW-PC Model
Gearbox Model
Gear Ratio
4X4 4-Stage
Nord SK92F_VL-N400TC
3.51
4X4 2-Stage
Nord SK72F-N360TC
4.12
3X3 4-Stage
Nord SK72F-N320TC
4.12
3X3 2-Stage
Nord SK52F-N280TC
4.38
Motor
Manufacturer: ABB Baldor.
Feet mounted.
Various horsepower in 280TC, 320TC, 360TC, and 400TC frame C-Faced configurations.

HANDLE-1
Transportation and Storage

HANDLE-2
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company immediately if anything is out of order.
NOTE: Contact your local PumpWorks sales office if any items are missing or for
replacement components.
Inspect the pump unit
1. Inspect the product to determine if any parts have been damaged or are missing.
2. Note and report any evidence of damaged paint to your PumpWorks
representative. This might be evidence of impact damage during shipment that could
result in reduced product performance.
Transportation guidelines
Pump handling
WARNING:
Make sure that the unit cannot roll or fall over and injure people or damage
property.
PumpWorks pumps contain sensitive parts that can be damaged if dropped or
subjected to impact. Handle the equipment with care and do not attempt to
install or operate a pump unit that is damaged.
Lifting methods
WARNING:
All lifting must be done in compliance with all applicable regulations/standards.
Assembled units and their components are heavy. Failure to properly lift and
support this equipment can result in serious physical injury and/or equipment
damage. Lift equipment only at the specifically identified lifting points.
Crush hazard. The unit and the components can be heavy. Use proper lifting
methods and wear steel-toed shoes at all times.
Do not lift any pump or motor by attaching lifting equipment to shaft ends.
Table 1: Lifting Methods
Pump type
Lifting method
A bare pump without lifting
handles
Use a suitable sling attached properly to solid points like the
casing, the flanges, or the stator housing.
A baseplate-mounted pump
Use shackles and chains (or straps) in the provided lifting pad
eyes on the baseplate. Never lift the pump package by the motor
or gearbox lifting eyes.

HANDLE-3
Examples
Figure 1: Example of Proper Lifting –Bare Pump
Figure 2: Example of Proper Lifting –Base Mounted Pump

HANDLE-4
Figure 3: Example of Proper Lifting –Base Mounted Pump with Gearbox and Driver
Storage guidelines
Pump storage requirements
Storage requirements depend on the amount of time the pump unit will be stored
prior to installation and start up. The normal packaging is designed only to protect the
unit during shipping.
Table 2: Storage
Length of time in storage
Storage requirements
Upon receipt/short-term (less than six months)
• Store in a covered and dry location.
• Store the unit free from dirt and vibration.
Long-term (more than six months)
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and
vibration.
• Rotate the shaft by hand several times at
least every month ensuring that the shaft
is not in the same position each time.
NOTICE:
Risk of damage to the mechanical seal on units supplied with cartridge
mechanical seals. Follow seal manufacture’s recommendations for long term
storage.
Treat bearing and machined surfaces so that they are well preserved. Refer to
motor and gearbox manufacturers for their long-term storage procedures.
Long term storage preparation is available as part of initial product purchase or after
your pump has been delivered. Contact your local PumpWorks sales representative.

HANDLE-5
Frost proofing
Table 3: Situations when the pump is or is not frost proof
Situation
Condition
Operating
The pump is frost proof.
Not Operating
The pump internals might be subject to frost damage.
Protect non-operational units with climate control or
an anti-freeze solution in the casing.

INSTALL-1
Installation

INSTALL-2
Precautions
WARNING:
When installing in a potentially explosive environment, make sure that
the motor and other electrical equipment are properly rated for the area
of classification.
You must ground all electrical equipment. This applies to the pump
equipment, the driver, the gearbox, and any monitoring equipment.
Test the ground lead to verify that it is connected correctly.
Electrical connections must be made by certified electricians in
compliance with all international, national, state, and local rules.
NOTICE:
Supervision by an authorized PumpWorks representative is recommended to
ensure proper installation. Failure to do so may result in equipment damage.
Pump location guidelines
Table 1: Guidelines for locations
Guideline
Explanation/comment
Keep the pump as close to the liquid source as
possible.
This minimizes friction loss and keeps
the suction piping as short as possible.
Make sure that the space around the pump is
sufficient.
This facilitates ventilation, inspection,
maintenance, and service.
If you require lifting equipment such as a hoist or
tackle, make sure that there is enough space above
the pump.
This makes it easier to properly use the
lifting equipment and safely remove and
relocate the components to a safe
location.
Take into consideration the occurrence of unwanted
noise and vibration.
The best pump location for noise and
vibration absorption is on a concrete
floor.
Foundation requirements
Requirements
The foundation must form a permanent, rigid support for the unit.
The location and size of the foundation fasteners should be in
accordance with those shown on the construction drawing provided
with the pump data package.
The foundation must weigh between three and five times the weight of
the entire pump package.
Ensure foundation is level and free of discontinuity to prevent
distortion when foundation bolts are tightened.
1. Baseplate
2. Shims or wedges
3. Foundation
4. Sleeve
5. Form
6. Bolt
Figure 1: Sleeve-type bolts

INSTALL-3
1. Baseplate
2. Shims or wedges
3. Foundation
4. Form
5. Bolt
Figure 2: J-type bolts
Baseplate mounting procedures
Prepare the baseplate for mounting
1. Remove the pump, gearbox, and driver from the baseplate.
2. Clean the underside of the baseplate completely.
3. If applicable, coat the underside of the baseplate with a re-coatable epoxy
primer. Use an epoxy primer only if you will be using an epoxy-based grout.
4. Remove the rust-proof coating from the machined mounting pads using an
appropriate solvent.
5. Remove water and debris from the foundation-bolt holes.
Install the baseplate using shims
Required tools:
Two sets of shims for each foundation bolt
Two machinist's levels
This procedure is applicable to rolled steel baseplates.
1. If you use sleeve-type bolts, fill the bolt sleeves with packing material or
rags to prevent grout from entering the bolt sleeves.
2. Set shims on each side of each foundation bolt.
The shims should have a height of between 0.75 in. (19 mm) and 1.50 in
(38mm).
1. Shims
Figure 3: Top view
1.