Torishima Pump ETA-N User manual

Operation and Maintenance Manual
1/13
ETA-N
PT TORISHIMA GUNA INDONESIA
End Suction Volute Pump

Operation and Maintenance Manual
2/13
CONTENTS
Description Page
0 General
0.1 Before starting initial operation
0.2 Quality control
0.3 Name plate
0.4 Handling
1 Pump Installation
1.1 Installation of common baseplate
1.2 Direct coupling
1.3 Piping
2 Operation
2.1 Starting
2.2 Shutdown
2.3 Operation and Maintenance
2.3.1 General
2.3.2 Shaft seal
1) Gland packing without lantern ring
2) Gland packing with lantern ring
2.3.3 Gauges
2.3.4 Bearing
3 Dismantling and reassembling
3.1 General
3.2 Dismantling
3.3 Reassembling
4 Mechanical seal
4.1 General Cautions
4.2 Type
5 Trouble shooting
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Operation and Maintenance Manual
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0. General
0.1. Before starting initial operation
CEN type pump is the general purpose single-stage single suction centrifugal pump conforming to JIS
B8313-81 "End Suction Centrifugal Pumps". Each pump model fully satisfies the specified requirements of the
said JIS Standard. If installed properly and operated correctly, the pump can perform its specific performance
in satisfactory condition throughout a long term. Before putting the pump into initial operation, carefully read
this Instruction Manual to handle, operate, and maintain the pump properly. Keep this Manual all the times
where operator or main tenance personnel can have access to it easily for study any time when required.
All the pump parts and components are so manufactured under severe quality control that they can
fulfil their functions to entire satisfaction. But any fault or trouble attributed to one of the causes described
below shall be out of our guaranty.
1. The ordered pump is used to handle the liquid of a different nature, density, temperature, or others than
those clearly specified in the order specification, or operates outside the operating range specified there in.
2. Pump damage is caused as a result improper handling and operation, faulty installation, the use of
unsuitable material, faulty or unskilled piping, etc.
3. Pump damage is caused by natural disaster
When repair is required, it is recommended to repair the pump by our skilled serviceman as far as possible or
to return it to our factory.
0.2. Quality Control
All inspection and test for material, dimensions, performance, etc, are performed in the manufacturing process.
Only pump that have fully satisfied the specified performance value upon inspection and test are allowed for shipment.
0.3. Name plate
Any pump is provided with a name plate. Please inform us of the followings when ordering spare parts and
replacement parts.
(1) Pump type, Mfg. No. (Indicated in TS), date of production, etc. (identified on the name plate).
(2) Parts name, material, quantity, etc. described in Sectional Drawing and Spare Parts List.
0.4. Handling
When handling the pump directly coupled with the driver, hook a lifting rope on the pump and its driver as
illustrated below. (Absolutely avoid to hook a lifting rope on the eye bolt of the driver).
Fig. 1
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Operation and Maintenance Manual
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1. Installation
1.1. Installation of common baseplate
Installation and centering of the pump should be performed by skilled workers. Improper installation and
centering would cause various troubles during the pump running. When the pump and its driver are shipped as directly
coupled on the common baseplate, they have already been leveled and centered completely at our fabrication shop
before shipment.
However, install the common baseplate (with pump and driver properly in the sequence given below and recheck
the level and centering of pump and its driver).
(1) Prepare packers (steel wedges) and several kinds of 1 mm ~ 0.1 mm thick levelling shims.
(2) After complete cure-up of the pump foundation, place and position packers on the foundation at the both sides
of each anchor bolt seat so that the common bed can be put on the packers later on. Thereafter, grout
concrete on the foundation floor at each packer position and re-place and reposition the packers on the
concrete. In this case, don't fail to keep each packer right horizontal after adjusted by use of a level. The
height of each packer is to be fine-adjusted by insertion of shim(s) when the common bed is installed thereon.
Accordingly, at this stage only horizontality adjustment of the packers is sufficient.
(3) After complete cure-up of the concrete with packer on, temporarily install the common baseplate (with pump
and driver) on the packers and check the center height of the pump. Furthermore, hold a level on the
discharge flange to make fine-adjustment of the pump horizontality in both axial and crosswise directions by
inserting previously prepared levelling shims between the baseplate and each packer.
(4) After the pump was positioned and levelled, make pre-center alignment between the pump and the driver
using a centering jig (refer to 1.2 for the detail). In this case, recording the numeral date on pre-alignment will
be helpful when the direct coupled condition is checked.
(5) After pre-centering, grout concrete in each anchor bolt holder.
(6) After complete cure-up of the concrete in each anchor hole, tighten each anchor bolt nut with uniform
tightening torque. In this case, check and readjust the center alignment between coupling halves, based on
the recorded numeral pre-alignment data.
(7) After the above check, grout mortar under the common bed till it reaches entirely all the corners of the bed so
that no cavity exists under the bed.
(8) After completion of all the above items, connect the suction pipe and discharge pipe to the respective flanges
of the pump.
1.2. Direct Coupling
The pump shaft and the driver shaft must be centered in line. Therefore, make centering in the following
procedure without fail.
(1) For centering of the coupling, put a straightedge on the both coupling halves and insert a wedge gauge in
the axial clearance between the coupling halves, as illustrated in Fig. 2, to check run-out of the coupled
shafts.
Fig. 2 Aligning a non-spacer type flexible coupling
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2
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Operation and Maintenance Manual
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(2) In this case, measure the concentricity and parallelism of the coupling halves (the both shafts) respectively at
4 points spaced at 90°. The specified accuracy shall be within 0.1 mm respectively.
(3) Check the driver’s rotating direction without fail, before connecting one coupling half (pump side) and other
coupling half (driver side) together. The correct rotating direction of the pump is shown with an arrow mark on
the side face of the bearing pedestal, that is, clockwise direction viewing from the driver side.
(4) If the rotating direction is correct, connect two coupling halves together.
(5) Further, if the temperature of pumping liquid exceeds the normal temperature range of changes widely during
pump running, the direct coupling will possibly deviate a little. In such case, therefore, use the coupling with
large flexibility.
1.3. Piping
After completion of the direct coupling work, the suction and discharge pipes must be connected to the
respective flanges of the pump. Perform the piping connection with good care for the following items.
(1) When connecting the suction and discharge pipes, take proper measure to prevent piping load from directly acting
on the pump. Direct load to the pump by piping would cause trouble.
(2) The suction line must be installed in upward slope (about 1/50) toward the pump prevent air leak and air pocket in
the case of suction lift. And it must be installed in downward slope reversely in the case of forced suction.
(3) Take to minimize various losses of the suction pipe and avoid sudden changes of cross-section and use of abrupt
bends in the suction piping. Select the pipe size such that the flow velocity in the pipe does not exceed 3 m/s.
(4) When the suction pipe size is different from the pump suction nozzle size, use an eccentric tapered pipe to connect
the suction pipe and pump suction nozzle and to prevent air pocket. (Fig. 3)
(5) When a sluice valve is installed on the discharge line, located the valve as close as possible to the discharge
nozzle of the pump. Further, when a check valve and a sluice valve are provided o the discharge line, locate the
check valve between the pump discharge nozzle and the sluice valve.
(6) In case of starting operation of a plant for the first time, various foreign matters remain in its pipe line and may
possibly flow into the pump. In such case, therefore, provide a strainer on the suction line for complete removal of
foreign matters. The strainer used shall have the passing area equal to 3 ~ 4 times the sectional area of the suction
pipe. If the strainer is clogged with foreign matters during the pump running, readings of the suction line pressure
gauge will fluctuate. Sometimes, clean the strainer to remove foreign matters.
(7) When external flushing water piping is provided, clean adequately the flushing water pipe before connecting.
(8) The temperature of pumping liquid significantly different from the atmospheric temperature would cause the pipe
line to shrink or expand. In such case, install a flexible pipe, etc. on the pipe line to prevent the load by shrinkage o
the pump.
(9) After completion of the piping work, recheck that the pump is free from abnormal load by piping as well as free from
alignment deviation, and make re-adjustment when required upon rechecking.
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