Related Manuals for truflo TSMP Series
Summary of Contents for truflo TSMP Series
- Page 1 I n s t a l l a t i o n , O p e r a t i o n , & Ma i n t e n a n c e Ma n u a l A N e w V i s i o n F o r Q u a l i t y P u mp s...
- Page 2 For special options, additional instructions are added. Please read complete manual before installation and maintenance. The quality design, materials, and workmanship used in the construction of all TRUFLO Pumps, gives these units long lasting service. The life and satisfactory service of any mechanical unit, however, is enhanced and extended by correct application, proper installation, inspection, monitoring and consistent maintenance.
- Page 3 PAGE SECTION Revision 8 – November 2011 3 ...
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Page 4: Important Safety Notice
Instruction, Operation, and Maintenance (IOM) manual. Current manuals are available at www.truflo.com or by contacting your nearest Truflo Pumps sales representative For additional information, contact your nearest Truflo Pumps sales representative or visit our Web site at www.truflo.com, or call us at 336-664-9225. 4 Revision 8 – November 2011 ... -
Page 5: Safety Warnings
Trapped liquid can rapidly expand and result in a violent explosion and injury. Truflo Pumps will not accept responsibility for physical injury, damage, or delays caused by a failure to observe the instructions for installation, operation, and maintenance contained in this Pump Safety Manual or the current IOM available at www.truflo.com. -
Page 6: Electrical Hazard
When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If there is any question regarding these requirements or if the equipment is to be modified, please contact a Truflo Pumps representative before proceeding. -
Page 7: General Precautions
Personal injuries will result if procedures outlined in this manual are not followed. Truflo Pumps will not accept responsibility for physical injury, damage or delays caused by a failure to observe the instructions in this manual and the IOM provided with your equipment. - Page 8 General Precautions Before beginning any alignment procedure, make sure driver power is locked out. NOTE Failure to lock out driver power will result in serious physical injury. Piping: Never pull piping into place by forcing at the flanged connections of the pump.
- Page 9 General Precautions Ensure pump is isolated from system and pressure is relieved before NOTE disassembling pump, removing plugs, opening vent or drain valves, or disconnecting piping. NOTE Shutdown, Disassembly, and Reassembly: Pump components can be heavy. Please lift properly to avoid physical injury and/or equipment damage. Steel toed shoes must be worn at all times.
- Page 10 T4 = Temperature class, can be T1 to T6 (see Table 1) The code classification marked on the equipment must be in accordance with the specified area where the equipment will be installed. If it is not, do not operate the equipment and contact your Truflo Pumps sales representative before proceeding.
- Page 11 Unpack the unit Remove packing materials from the unit. Dispose of all packing materials correctly. Inspect the unit to determine if any parts have been damaged or are missing. Contact your TRUFLO representative if anything seems out of order. Pump handling WARNING: Make sure that the pump cannot roll or fall over and injure people or damage property.
- Page 12 Examples Figure 1: Proper lifting method Figure 2: Proper lifting method 12 Revision 8 – November 2011 ...
- Page 13 You can purchase long-term storage treatment with the initial pump order or you can purchase it and apply it after the pumps are already in the field. Contact your local TRUFLO sales representative. ...
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Page 14: Pump Description
PUMP DESCRIPTION NAMEPLATE INFORMATION RECEIVING THE PUMP PUMP DESCRIPTION with sleeve type journal bearings). When ball bearings are The Model TSMP is a high pressure, multi-stage, between used (standard), the outboard bearing (thrust bearing) is the bearings, horizontal centrifugal pump designed to meet shouldered and locked into place, thus enabling it to carry the rigorous demands of the petroleum and petrochemical both radial and axial thrust loads. -
Page 15: Nameplate Information
NAMEPLATE INFORMATION Our Pumps have a Truflo nameplate that provides all necessary pump information you will need to identify information about the pump. The nameplate is located on model, size, serial number, and the item number of the pump casing. -
Page 16: Receiving The Pump
File any claims with the transportation company as soon as possible. STORAGE REQUIREMENTS Short Term (Less than 6 months) Truflo normal packaging procedure is designed to protect pump during shipping. Upon receipt, store in a covered and dry location. -
Page 17: General Information
SITE/FOUNDATION GENERAL BASEPLATE INSTALLATION PROCEDURE BASEPLATE PREPARATION FOUNDATION PREPARATION SETTING AND LEVELING BASEPLATE ALIGNMENT AND ALIGNMENT CRITERIA GENERAL CONSIDERATIONS ALIGNMENT CRITERIA PUMP-TO-DRIVER ALLIGNMENT ALIGNMENT TROUBLESHOOTHING BASEPLATE GROUTING PROCEDURE GENERAL PROCEDURE ALIGNMENT CHECK PIPING SUCTION PIPING DISCHARGE PIPING BYPASS PIPING AUXILIARY PIPING FINAL PIPING CHECK SITE AND FOUNDATION... -
Page 18: Foundation Preparation
BASEPLATE INSTALLATION PROCEDURE Industry standard procedures, such as API RP 686/ PIP REIE 686, and/or the following procedure should be � followed prior to grouting the baseplate. The procedure CAUTION assumes the installer has a basic knowledge of baseplate and foundation design and installation methods. -
Page 19: General Considerations
Equipment mounting surfaces should be utilized to establish level. ALIGNMENT AND ALIGNMENT CRITERIA • After First Run -To obtain correct alignment when both pump and driver are at operating temperature. Alignment procedures must be followed to prevent Thereafter, alignment should be checked periodically in unintended contact of rotating parts. - Page 20 ALIGNMENT CRITERIA Good alignment is attained when readings as specified in this section have been achieved with pump and driver at operating temperatures (final alignment). Maximum allowable Total Indicator Reading (T.I.R.) for parallel and angular misalignment is .002 (0.05mm) for all Model TSMP pumps, regardless of the alignment method used.
- Page 21 After grouting the baseplate After grouting the baseplate This ensures that no changes have occurred during the grouting . After This ensures that no changes have occurred during the grouting . After connecting the piping connecting the piping This ensures that pipe strains have not altered the alignment. This ensures that pipe strains have not altered the alignment.
- Page 22 b) Attach the other indicator so that the indicator rod comes into contact with the inner end of the driver's coupling half. This indicator is used to measure angular misalignment. Rotate the pump's coupling half to check that the indicators are in contact with the driver's coupling half but do not bottom out.
- Page 23 Set the angular alignment indicator to zero on left side of the driver's coupling half, 90° from the top-center position (9 o’clock). Rotate the indicator through the top-center position to the right side, 180° from the start position (3 oClock) Record the indicator reading.
- Page 24 Shims Figure 7: Example of incorrect vertical alignment (side view) 5. Repeat the previous steps until the permitted reading value is achieved. Perform parallel alignment (horizontal correction) A unit is in parallel alignment when indicator P (parallel indicator) does not vary by more than 0.002 in.
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Page 25: Alignment Troubleshooting
Rotate the indicators through the top-center position to the right side (3 o’clock), 180° from the start position. Record the indicator readings. Make corrections according to the separate instructions for angular and parallel alignment until the TRUFLO permitted reading values are obtained. ALIGNMENT TROUBLESHOOTING Problem Probable Cause... -
Page 26: General Procedure
Maximum Allowable Parallel and Angular Misalignment Maximum Allowable Misalignment Size Parallel Angular 0.03 degrees [0.125 mm/cm (.0005 in. /in.) of coupling face 0.05 mm (.002 in.) diameter] NOTE For electric motors, motor shaft initial (cold) (0.05 -0.10 mm) lower than pump shaft, since thermal expansion will cause the motor shaft on foot mounted motors to "grow"... -
Page 27: Alignment Check
ALIGNMENT CHECK Re-check alignment before continuing, using criteria previously stated. PIPING Guidelines for piping are given in the “Hydraulic Institute 3-The piping should be arranged to allow pump flushing Standards,” available from: prior to removal of the unit on services handling hazardous liquids. -
Page 28: Suction Piping
(2) sizes larger than the suction pipe. NPSH must always exceed NPSH as shown on Truflo 6-The suction pipe must be adequately submerged below performance curves received with order. (Reference the liquid surface to prevent vortices and air entrainment at Hydraulic Institute for NPSH and pipe friction values the supply. - Page 29 AUXILIARY PIPING FINAL PIPING CHECK After connecting the piping to pump: The mechanical seal must have an appropriate seal flush system. Failure to do so will result in excess heat generation and possible seal failure. Rotate shaft by hand to ensure it rotates smoothly and there is no rubbing which could lead to excess heat Cooling systems such as those for bearing generation and or sparks.
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Page 30: Preparation For Start-Up
PREPARATION FOR START-UP CHECKING ROTATION COUPLING PUMP AND DRIVER LUBRICATING BEARINGS SHAFT SEALING PRIMING PUMP START-UP PRECAUTIONS STARTING PUMP OPERATION GENERAL CONSIDERATIONS OPERATIONAL CHECKS OPERATING AT REDUCED CAPACITY OPERATING UNDER FREEZING CONDITIONS SHUTDOWN FINAL ALIGNMENT DOWELING PUMP CASING MOTOR INSTALLATION COLD SERVICE APPLICATION HOT SERVICE APPLICATION PREPARATION FOR START-UP... -
Page 31: Lubricating Bearings
If specific directions are not indicated in the motor instructions, the following is applicable. NOTE: If the driver is mounted at Truflo, the setting LUBRICATING BEARINGS for the coupling will already have been determined. -
Page 32: Shaft Sealing
If the seal has been installed in the pump by Truflo, these clips have already been disengaged. For other types of mechanical Figure 14 shows the supply above the pump suction. -
Page 33: Start-Up Precautions
START-UP PRECAUTIONS Running a new or rebuilt pump at slow speeds may � not provide enough flow to adequately flush and cool the CAUTION wear ring and throat bushing close running surfaces. Pumped fluid temperatures in excess of 200°F Ensure that pump and systems are free of foreign (93°C) will require warm-up of pump prior to operation. -
Page 34: Operation
OPERATION GENERAL CONSIDERATIONS AND REVIEWS � � CAUTION CAUTION The following are minimum operational checks for the pump only. Consult driver and auxiliary equipment Always vary capacity with regulating valve in the manufacturers’ literature for additional information. discharge line. NEVER throttle flow from the suction side. -
Page 35: Final Alignment
OPERATING UNDER FREEZING CONDITIONS Exposure to freezing conditions while pump is idle could cause liquid to freeze and damage the pump. Fluid inside pump, if supplied, should also be drained. 1-Slowly close discharge valve. 2-Shut down and lock out driver to prevent accidental rotation. -
Page 36: Motor Installation
Two (2) separate the pump cannot be moved on its pedestals after it has methods are used by Truflo, depending on whether the been doweled. pump is used in a cold application or a hot application (see COLD SERVICE APPLICATION below). - Page 37 Revision 8 – November 2011 37 ...
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Page 38: General Comments
GENERAL COMMENTS MAINTENANCE SCHEDULE ROUTINE MAINTENANCE ROUTINE INSPECTIONS QUARTERLY INSPECTIONS ANNUAL INSPECTIONS MAINTENANCE OF BEARINGS RING OIL LUBRICATED BEARINGS PURE OR PURGE OIL MIST LUBRICATED BEARINGS (OPTIONAL) MAINTENANCE OF SHAFT SEALS MECHANICAL SEALS TROUBLESHOOTING GENERAL COMMENTS A routine maintenance program can extend the life of your pump. Well maintained equipment will last longer and require fewer repairs. -
Page 39: Maintenance Of Bearings
MAINTENANCE OF BEARINGS Do not insulate bearing housings as this can result in excess heat generation, sparks, and premature failure. RING OIL LUBRICATED BEARINGS Ring oil lubricated ball bearings are standard on Model TSMP pumps. High quality turbine oil with rust and oxidation inhibitors should be used. -
Page 40: Mechanical Seals
PURE OR PURGE OIL MIST LUBRICATED BEARINGS (OPTIONAL) NOTE: Oil mist is recommended for use on ball bearing arrangements only (See Appendix I). The same oil requirements applicable to ring oil lubricated bearings also apply to oil mist lubricated bearings. The steps necessary for oil mist lubrication are as follows: Follow oil mist system supplier’s instructions. -
Page 41: Troubleshooting
TROUBLESHOOTING Issue Probable Cause Remedy � Pump not primed. Check that pump and suction line are full of liquid. Reprime pump. � Suction line clogged/not filled with liquid Remove obstructions/fill line. � Impeller clogged with foreign material. Back flush pump to clean impeller. �... - Page 42 TROUBLESHOOTING Problem Probable Cause Remedy � Improper pump/driver alignment. Align shafts, recheck piping stability. Backflush pump to clean impeller, remove � Partly clogged impeller causing imbalance. rotating element to inspect if necessary. � Broken or bent impeller or shaft. Replace as required.
- Page 43 Disassemble / Assemble 1. Unbolt hexbolt(9A) and remove bearing housing cover(9G‐D/N) and bearing housing cover gasket( 9D‐E) from both side (DE : Drive end, NDE : Non Drive End) 2. For DE side, untighten set screw on deflector (6H2) and then remove deflector before step ...
- Page 44 12. Untighten set screw on deflector(6H1) 13. Unbolt hexbolt from bearing housing cover inboard(9F‐D/N) 14. Remove bearing housing cover gasket 15. Remove bearing housing cover 16. Remove Delfector(6H1) 17. Release nut from Stud(Seal Cover) (8E) 18.
- Page 45 21. Remove upper casing(1‐2) by using proper equipment like overhead crane. 22. Remove Rotor assembly from lower casing(1‐1). Refer to following picture. 23. Remove Sleeve nut(7A) from the shaft. 24. Remove Throat Bush(2F) 25. Remove Suction Adjust Sleeve(7H). 26.
- Page 46 Assemble is reverse sequence of disassemble. 46 Revision 8 – November 2011 ...
- Page 47 INSPECTIONS Model TSMP parts must be inspected to the 1. Localized wearing or grooving greater than following criteria before they are reassembled 3.2mm. to ensure the pump will run properly. Any part 2. Pitting greater than not meeting the required criteria should be 3.
- Page 48 Table 5 — Diametrical Clearance (in) Pressure Impeller Wear Ring Reducing Pump Size Sleeves Center Impeller Rings Truflo Truflo Standard API 610 Ring Diameter Standard Truflo Standard 3x4-8B 0.010 0.010 0.015 4.00 0.016 0.030 4.87 0.017 5.50 3x6-9/10 0.010 0.015...
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Page 49: Bearing Housings
Clean and check impeller bore diameter. BEARING HOUSINGS (9) Check impeller balance. It should be rebalanced if it Make sure bearing housings are very clean -no burrs. exceeds the criteria of ISO G1.0 (4W/N). Check bearing housing bores to values in Table 6 for the ball bearing arrangement. - Page 50 SHAFT (6) NOTE: DO NOT use shaft centers for runout check as they may have been damaged when removing bearings. Table 7 Shaft and Rotor Runout Requirements (Abstracted from Table 15 in API-610 10th Edition) Flexibility factor, L/D, mm >1.9x10 (3.0x10) (in)
- Page 51 Inspect seats. They must be smooth and free of physical defects. If remachining is necessary to restore surface, contact a Truflo PRO Services Center for service. Dimensional relationships must be maintained with other surfaces. Replace parts if seats are defective beyond reasonable repair.
- Page 52 Installation of Wear Rings (2C, 2C-1)) Clean wear ring seats thoroughly, ensuring they are smooth and free of scratches. Heat new impeller wear rings to 180° -200°F (132° -143°C) using a uniform method for heating e.g. -oven) and place on impeller (2) wear ring seats.
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Page 53: Post Assembly Checks
For the rarely-supplied sleeve/Kingsbury arrangement, refer to the included sleeve/ball arrangement for sleeve bearing assembly and disassembly, and see the included instructions from Kingsbury for specific instructions regarding this tilting pad hydrodynamic bearing. POST ASSEMBLY CHECKS All checks and procedures listed under Safety, Installation, Operation, and Preventive Maintenance sections must be followed. - Page 54 SECTIONAL Drawing of Typical TSMP 54 Revision 8 – November 2011 ...
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Page 55: Recommended Spare Parts
RECOMMENDED SPARE PARTS When ordering spare parts, always state Truflo serial number, and indicate part name and item number from relevant sectional drawing. It is imperative for service reliability to have a sufficient stock of readily available spares. ... - Page 56 TSMP Parts List With Materials Of Construction for Sleeve/Ball Bearing Arrangement Construction -API Designation Item Part Name Qty. Casing Carbon Steel Chrome 316L SS Duplex (2) 101/101M Impeller (3) – Chrome 316L SS Chrome 316L SS Duplex (2) Bearing End Cover (Thrust) - 109A Carbon Steel Outboard)
- Page 57 TSMP Parts List With Materials Of Construction for Ball Bearing Arrangement Construction -API Designation Item Part Name Casing Chrome 316L SS Duplex (2) 101-101 Impeller (3) Chrome 316L SS Chrome 316L SS Duplex (2) Bearing End Cover (Thrust) - 109A Carbon Steel Outboard)
- Page 58 CONSTRUCTION CROSS REFERENCE CHART API Designation Materials (Case/Trim) Steel / 12% Chrome Steel / SS Impeller & Trim 12% Chrome 316LSS Duplex SS MATERIAL CROSS REFERENCE CHART Truflo Pumps Material Material Code ASTM Other Carbon Steel 1212 A216 Grade WCB 12% Chrome...
- Page 59 1/2" to 1/4" bushing, and insert an oil Construction Only) mist fitting by the oil mist manufacturer. Truflo has designed the TSMP bearing housing to accept Pure Mist Lubrication: Constant oil mist in oil mist lubrication. The radial and thrust end bearing housing.
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Page 60: Installation
INSTALLATION AND DISASSEMBLY INSTRUCTIONS FOR TRUFLO ANSI B15.1/OSHA COUPLING GUARDS The coupling guard used in an ATEX classified environment must be constructed from a non- sparking material. If the coupling hub diameter is larger than the diameter of the opening in the end plate (234B), remove the coupling hub. - Page 61 The annular groove in the guard is located around the end plate as indicated in Fig. II-D. NOTE: Locate opening (flange) so that it will not interfere with piping but will allow access for installing bolts (Step 8). Spread opening of remaining coupling guard half (501B) slightly and place over installed coupling guard half so that annular groove in remaining coupling guard half faces the driver as indicated in Fig.
- Page 62 Repeat steps 8-10 for rear end of coupling guard half (501B), except that nut should be finger tightened only. Adjust length of coupling guard to completely cover shafts and coupling as shown in Fig. II-H by sliding rear coupling guard half (501B) towards motor. Repeat steps 8-10 for center slots in coupling guard.
- Page 63 Revision 8 – November 2011 63 ...
- Page 64 Replace coupling guard before resuming normal operation of the pump. TRUFLO Pumps, Inc., assumes no liability for avoiding this practice. WARNING DO NOT resume normal pump operation with the coupling guard removed.
- Page 65 DIAL INDICATOR (RIM-AND-FACE) ALIGNMENT PROCEDURE This will eliminate any measurement problems due to Alignment procedures must be followed to prevent runout on coupling half Y. unintended contact of rotating parts. Follow coupling Take indicator measurements with driver foot hold manufacturer's installation and operation procedures.
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Page 66: Parallel Alignment
NOTE A: When adjusting leveling screws, nuts on PARALLEL ALIGNMENT foundation bolts should be tightened only enough to A unit is in parallel alignment when indicator P (parallel hold firmly. Final tightening is done after the unit is indicator) does not vary by more than 0.05 mm (.002 in.) as grouted and the grout has set for at least 48 hours. - Page 67 Horizontal Correction (Side-to-Side) COMPLETE ALIGNMENT Zero indicator P on left side of coupling half Y, 90° from A unit is in complete alignment when both indicators A top dead center (9 o’clock, Fig. III-E). (angular) and P (parallel) do not vary by more than 0.05 Rotate indicator/coupling hubs through top dead center to mm (.002 in.) as measured at four points 90°...
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