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PUMPWORKS PW-PC Series Installation, Operation And Maintenance Manual

Positive displacement pump
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Summary of Contents for PUMPWORKS PW-PC Series

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Introduction Introduction INTRO-2 Tables Safety INTRO-2 Table 1: Guidelines for Locations INSTALL-2 Warranty INTRO-4 Table 2: Piping Guidelines INSTALL-5 Table 3: Suction Piping Guidelines INSTALL-6 Product Description Table 4: Suction Piping Guidelines – Liq. Below INSTALL-6 General Description DESIGN-2 Table 5: Suction Piping Guidelines –...
  • Page 3 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...
  • Page 4 Introduction and Safety...
  • Page 5 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.
  • Page 6 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.
  • Page 7 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. ...

  • Page 8: Product Description

    Product Description...

  • Page 9: General Description

    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 Table 1 : Hydraulic sizes per piping size Piping size group Number of hydraulic sizes...
  • Page 10 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.

  • Page 11: Figure 2: Nameplate On The Pump Motor Adapter

    Nameplate types Table 2: Nameplate Description Nameplate Description Pump Motor Provides information about the hydraulic characteristics of the pump. Adapter 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.

  • Page 12: Powertrain Description

    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...
  • Page 13 Transportation and Storage...

  • Page 14: Table 1: Lifting Methods

    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.
  • Page 15 Examples Figure 1: Example of Proper Lifting – Bare Pump Figure 2: Example of Proper Lifting – Base Mounted Pump...
  • Page 16 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.
  • Page 17 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.
  • Page 18 Installation...

  • Page 19: Figure 1: Sleeve Type Bolts

    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...

  • Page 20: Figure 2: J Type Bolts

    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.

  • Page 21: Figure 5: Coupling Details

    1. Shims Figure 4: Side view 3. Lower the baseplate carefully onto the shims. 4. Set the machinist's levels across the mounting pads of the driver and the mounting pads of the pump. NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct level indication.

  • Page 22: Table 2: Piping Guidelines

    Piping checklists General piping checklist Precautions CAUTION:  Never draw piping into place by using force at the flanged connections of the pump. This can impose dangerous strains on the unit and cause misalignment between the pump and driver. Pipe strain adversely affects the operation of the pump, which results in physical injury and damage to the equipment.

  • Page 23: Table 3: Suction Piping Guidelines

    Fastening WARNING:  Only use fasteners of the proper size and material.  Replace all corroded fasteners.  Make sure that all fasteners are properly tightened and that there are no missing fasteners. Suction piping checklist Suction-piping checks Table 3: Suction piping guidelines Check Explanation/comment Checked...

  • Page 24: Table 6: Discharge Piping Guidelines

    This pump is not self-priming. Open the venting valve slow until all of the air in the suction casing is Make sure a venting valve is removed. Once product fluid starts installed in the top boss of the coming out of this valve, close the suction casing.
  • Page 25 Startup, Operation, and Shutdown...

  • Page 26: Figure 1: Guard Removal

    Preparation for startup WARNING:  Failure to follow these precautions before you start-up the pump could lead to serious injury and equipment failure.  Do not operate the pump below the minimum rated flow or with the suction or discharge valves closed. ...
  • Page 27 Check the pump rotation WARNING:  Operating the pump in reverse rotation (clockwise while standing at the driver and facing the direction of the pump stator) will result in reverse flow and building of pressure in the suction casing and ultimately out through the suction flange.

  • Page 28: Figure 2: Required Guard Parts

    Install the coupling guards WARNING:  Never operate a pump without a properly installed coupling guard. Personal injury will occur if you run the pump without a coupling guard.  Refer to driver and gearbox manufacturers IOMs for specific instructions and recommendations.

  • Page 29: Figure 3: Pump Priming

    Pump priming WARNING: Make sure to review MSDS regarding hazards for the pump process fluid. Personal Protective Equipment (PPE) should be worn during all activities around pump. Prime the pump with the suction case vent 1. Slowly open the suction case vent valve. 2.
  • Page 30 If the pump exceeds normal levels, then shut down the pump immediately and correct the problem. Repeat steps 5 and 6 until the pump runs properly. Pump operation precautions General considerations CAUTION:  Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side since this can result in decreased performance, unexpected heat generation, and equipment damage.
  • Page 31 Maintenance...
  • Page 32 Cartridge seals installed by the user require removal of the holding clips and engagement of the set screws prior to operation. If the seal has been installed in the pump by PumpWorks, these clips have already been removed.
  • Page 33 Other mechanical seal types For other types of mechanical seals, refer to the instructions provided by the seal manufacturer for installation and setting. Before you start the pump Check the seal and all flush piping. Disassembly Disassembly precautions WARNING:  This manual clearly identifies accepted methods for disassembling units.

  • Page 34: Figure 1: Liquid End Removal

    Close the isolation valves on the suction and discharge sides of the pump. You must drain the system if no valves are installed. Always disconnect and lock out all potential energy sources (electrical, hydraulic, pneumatic, etc) before you perform any installation or maintenance tasks. Drain the pump.

  • Page 35: Figure 2: Suction Case Removal

    WARNING:  Never use heat to disassemble the pump due to the risk of an explosion from trapped liquid. Figure 2: Suction Case Removal Set the liquid end down and remove the bolts that hold the Suction Case to the Stator Adapter.

  • Page 36: Figure 4: Motor Removal

    Figure 4: Motor Removal Pre-assembly inspections Guidelines Before you assemble the pump parts, make sure you follow these guidelines:  Inspect the pump parts according to the information in these pre-assembly topics before you reassemble your pump. Replace any part that does not meet the required criteria.

  • Page 37: Figure 5: Case Inspection

    Casing areas to inspect The arrows point to the areas to inspect for wear on the casing: Figure 5: Case Inspection Rotor Assembly replacement Table 1: Rotor Inspection Inspection Area When to replace Rotor OD • When grooved deeper than 1/16 in. (1.6 mm), or •...

  • Page 38: Figure 7: Stator Adapter Inspection

    Stator Adapter replacement Table 2: Stator Adapter Inspection Inspection Area When to replace Stator Adapter ID - Grooved deeper than 1/16 in. (1.6 mm), or - Worn evenly more than 1/16 in. (1.6 mm) Stator Adapter O-ring OD - Either O-ring is torn or broken. - OD grooved deeper than 1/16 in.

  • Page 39: Figure 9: Driver/Gearbox Assembled To Skid

    Reassembly General Considerations NOTICE: Make sure that the pipe threads are clean, and that you apply thread sealant to the plugs and fittings. Failure to do so may result in equipment damage. Assemble the Driver, Gearbox, and Driver Adapter With gearbox secured in the upright positon, strap the driver to a crane and move drive in place for fastening.

  • Page 40: Figure 12: Coupling Details

    Assemble the Case and Mechanical Seal to the Skid 1. Hoist the Case to the installed Motor Adapter. 2. Fasten the Case to the Motor Adapter using four bolts and nuts, and hand tighten with and Engineers Wrench. 3. Using four studs and nuts lightly screw the Mechanical Seal to the sealing face of the Case.

  • Page 41: Figure 13: Stator Module Assembly Details

    Assemble the Stator Module Assembly to the Skid Lubricate entire Rotor with Molykote 55. Lubricate inner surfaces of the Stator with Molykote 55. Using a crane to lift the Stator Module Assembly and a fork lift to apply axial pressure, slide the Stator Module assembly onto the Rotor Assembly until it touches the Case.

  • Page 42: Figure 15: Coupling Guards Assembled

    Post-Guard assembly checks Perform these checks after you assemble the pump and prior to assembling the coupling guards, then continue with Guard assembly:  Rotate the shaft by hand in order to make sure that it rotates easily and smoothly and that there is no rubbing. ...

  • Page 43: Table 3: Spare Parts List

    Spare parts Pump Serial Number is REQUIRED for all Parts Orders. This ensures the correct material and design for your specific pump unit. Balloon Letter Part Number Description 517-00108-0000 COUPLING GUARD, LEFT, PLATE 517-00107-0000 COUPLING GUARD, RIGHT, PLATE 517-00111-0000 THERMOWELL ASSM, 100OHM, U2.0", DUAL 300-00109-1000 ADAPTER, MOTOR, 4X4 2S &...

  • Page 44: Parts List

    Parts Listings and Exploded Assembly Drawings...

  • Page 45: Table 1: Parts List

    Table 1 - Parts List Balloon Letter Part Number Description 517-00108-0000 COUPLING GUARD, LEFT, PLATE 517-00107-0000 COUPLING GUARD, RIGHT, PLATE 517-00111-0000 THERMOWELL ASSM, 100OHM, U2.0", DUAL 300-00109-1000 ADAPTER, MOTOR, 4X4 2S & 3X3 4S PC, CS 517-00110-0000 1/2"MNPT-1/2"MNPT PIPE COUPLING 517-00109-0000 1/2"FNPT-1/2"FNPT PIPE COUPLING 517-00105-0000...
  • Page 46 Figure 1: 3x3 4-Stage Pump Package Exploded View...
  • Page 47 Visit our website for more information and other products available. www.pumpworks.com ELECTRONIC PUMP ON DEMAND 65 Southbelt Industrial Drive Houston, TX 77047 U.S.A. Ph: (713) 892-5875 Fx: (713) 343-0765...

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