Ingersoll-Dresser A Series Installation Operation & Maintenance

Centrifugal pumps

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A PUMP

INSTALLATION

OPERATION &

MAINTENANCE

Ingersoll-Rand

Pacific

Worthington

Pleuger

Scienco

Jeumont-Schneider Pumps

Ingersoll-Dresser Pumps

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Page 1 A PUMP INSTALLATION OPERATION & MAINTENANCE Ingersoll-Rand Pacific Worthington Pleuger Scienco Jeumont-Schneider Pumps Ingersoll-Dresser Pumps ™...
Page 3: Table Of Contents
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE TABLE OF CONTENTS 1. INTRODUCTION .........................1-1 1.1 SAFETY ............................1-1 1.2 SAFETY NOTICES ........................1-1 1.3 CONSTRUCTION ........................1-2 1.3.1 CASING ..........................1-2 1.3.2 IMPELLER ........................1-2 1.3.3 STUFFING BOXES......................1-2 1.3.4 SHAFT ..........................1-2 1.3.5 BEARING HOUSING .......................1-2 1.3.6 BEARINGS ........................1-2 1.3.7 COUPLING/COUPLING GUARD ...................1-3 1.3.8 MECHANICAL SEAL ......................1-3 1.3.9 STABILIZER ........................1-3...
Page 4 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE TABLE OF CONTENTS (CONTINUED) 3.2.6 HOT ALIGNMENT......................3-13 4. OPERATION ..........................4-1 4.1 TECHNICAL DATA ........................ 4-1 4.1.1 EFFECTS OF SPECIFIC GRAVITY................4-1 4.1.2 EFFECTS OF VISCOSITY....................4-1 4.1.3 CHANGING THE PUMP SPEED ..................4-1 4.1.4 NET POSITIVE SUCTION HEAD (NPSH)..............
Page 5 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE TABLE OF CONTENTS (CONTINUED) 5.4.4 CHECKING FIT BETWEEN IMPELLER BORE AND SHAFT ........5-6 5.4.5 CHECKING RUNNING CLEARANCES.................5-6 5.4.6 REPLACING STATIONARY WEAR RINGS ..............5-7 5.4.7 REPLACING IMPELLER WEAR RINGS ...............5-7 5.5 ASSEMBLY..........................5-8 5.5.1 PULL-OUT ELEMENT ASSEMBLY................5-8 5.5.2 PULL-OUT ELEMENT INSTALLATION..............5-12 6.
Page 7: Introduction
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 1. INTRODUCTION This manual contains instructions for the installation, operation, and maintenance of your Ingersoll- Dresser centrifugal pump. The instructions are written for the use of personnel with a general training in the operation and maintenance of centrifugal pumps. Your pump has been designed to provide safe and reliable service.
Page 8: Construction
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE NOTE An operating procedure, condition, etc., which is essential to highlight. 1.3 CONSTRUCTION The Type “A” pumps are horizontally mounted, vertically split, back-pullout, single-stage, single- suction overhung process pumps designed for continuous duty service in all process industries and industrial applications within its pressure and temperature limitations.
Page 9: Coupling/Coupling Guard
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 1.3.7 COUPLING/COUPLING GUARD Flexible spacer couplings are provided in various makes and models to suit customer preference. Couplings manufactured to API tolerances and dynamically-balanced couplings are optional. Fabricated heavy-gauge sheet metal, or aluminum hinged or non-hinged guards are provided to suit customer specified needs.
Page 11: Receiving And Storage
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 2. RECEIVING AND STORAGE 2.1 RECEIPT INSPECTION Your pump was carefully checked at the factory prior to shipment to ensure compliance with the requirements of your order. It is suggested that the pump be inspected upon arrival. As a minimum, the following items should be checked: 1.
Page 12: Lifting Driver
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE The coupling spacer must be removed from between pump and driver half couplings before lifting the complete unit. To lift the pump and baseplate without the driver or the baseplate alone, sling from all four eye bolts. The pump, driver and baseplate can be lifted as a complete unit.
Page 13: Storage
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Figure 2-2 Lifting Pump 2.3 STORAGE NOTE Unless otherwise agreed, full responsibility and cost associated with the storage and inspection of this equipment rests with the purchaser. During extended periods of storage prior to installation, precautions must be taken to protect the pump from deterioration.
Page 14: Storage Area
7. Document the results of the inspection and keep on file for later review. 2.3.3.1 Six Months Prior to Installation Six months prior to the scheduled installation date, an Ingersoll-Dresser service representative is to be employed to conduct an inspection of the stored equipment. This inspection should include, as a...
Page 15: One Month Prior To Installation
2.3.3.2 One Month Prior to Installation One month prior to installation of the equipment, an Ingersoll-Dresser Pumps representative is to be employed to conduct a final inspection. This inspection will be made to ensure that the requirements of the six month inspection report were satisfactorily completed and that the equipment is ready for installation.
Page 16 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Internal and unpainted external surfaces of the pump (as well as items ordered separately) are protected with a petroleum-based rust preventative. This can be removed by wiping or flushing with a petroleum-based solvent. Any painted surfaces that have been scratched or chipped should be touched-up with the appropriate paint.
Page 17: Installation
These units are furnished for a particular service condition. Changes in the hydraulic system may affect performance adversely. This is especially true if the changes reduce the pressure at the suction or if the liquid temperature is increased. When installing piping, Ingersoll-Dresser Pump recommends: 1.
Page 18: Bypass Line
The suction strainer should be installed between 5 to 20 pipe diameters upstream from the pump suction flange. The Ingersoll-Dresser standard for suction strainers consists of a conical shaped steel plate. The plate has 1/16” perforations and is of sufficient size and thickness for the required flow. The open area of the strainer should have a minimum of a 3 to 1 ratio to the area of the pump suction (see Figure 3-1 below).
Page 19: Leveling The Baseplate
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Allow bolts to project for grouting under baseplate Make this distance equal Bolt to flange on baseplate Pipe Washer Figure 3-2 Foundation Bolt Template Allow ample threaded bolt length above rough concrete Rough finish concrete for grout Stuff waste around bolt while pouring concrete...
Page 20 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Prepare sufficient steel blocks of at least 1 in. (25 mm) thickness to be placed below each baseplate jacking screw furnished with the baseplate. The purpose of the plate is to spread the load of the screw without crushing the concrete below, and to provide a minimum of 1 in.
Page 21: Grouting
When the grout is thoroughly hardened, remove the dam. If the leveling wedges are removed, fill the holes they leave with grout. 3.2 SHAFT ALIGNMENT Shaft alignment is critical to good performance of your pump. Should you require assistance with alignment of your pump and driver contact Ingersoll-Dresser Pumps for a service representative. DO2664-07...
Page 22: Alignment Frequency
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE NOTE Ingersoll-Dresser Pumps recommends the use of either a double-dial indicator procedure as outlined below or a laser alignment procedure for coupling of this pump. If a laser alignment procedure is used, follow the procedures supplied by the laser alignment equipment manufacturer for alignment of the pump.
Page 23 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE SLEEVE BEARING (TYPICAL) TOTAL LATERAL MOVEMENT 0.5 in. THRUST COLLAR (TYPICAL) ADJUSTED LATERAL MOVEMENT 0.37 in. 0.13 in. Figure 3-6 Motor Shaft Running Clearance 1. Set motor on driver pads. 2. If the motor manufacturer has provided information on setting shaft end space in their manual in the back of this manual, use those instructions to set the motor shaft end space.
Page 24: Tapping Driver Mount Pads
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Figure 3-7 Measuring Distance Between Pump and Motor Shafts 4. If hold down bolt holes have not been tapped in driver mount pads, you should now proceed with task (see paragraph 3.2.4 below); otherwise, you may begin cold alignment (see paragraph 3.2.5 below).
Page 25: Cold Alignment
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE c. repeat steps a and b until 0.002 in (0.05 mm) TIR in horizontal plane is not exceeded. 3. Reverse position of dial indicator and bracket and repeat step 2. 4. Remove dial indicator and bracket. 5.
Page 26 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 6. Securely attach the bracket to a length of rigid pipe, and install the indicator at the distance determined in step 5 above. (see Figure 3-9). Dial Indicator Bracket Pipe Bracket Span Figure 3-9 Determining Bar Sag 7.
Page 27 (example: an indicated -0.003 would be set in as a +0.003) while in the upright (12 o'clock) position. NOTE Use of a shaft alignment graph, such as Ingersoll-Dresser Pump Shaft Alignment Calculator (see Figure 3-11) aids and simplifies the alignment process. It graphically shows the...
Page 28 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 17. Measure the distance between dial reading points, and between dial reading point on fixed unit hub or shaft and each hold down bolt on movable unit (see Figure 3-12). Record these readings on the graph or by other suitable means. Movable Unit Fixed Unit Figure 3-12 Alignment Measurement Points...
Page 29: Hot Alignment
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 20. Tighten hold down bolts, then repeat steps 11 through 19. 21. Remove dial indicators and brackets and detach lifting equipment. 22. See paragraph 3.1.2, “Piping”, on page 3-3, and connect piping, as required. 23.
Page 30 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE be opposite signs. Total angularity must not exceed 0.001 inch per 12 inches (0.03 mm per 305 mm). 3. Check hold down bolt positions on the graph or otherwise determine the amount of shims to be added or subtracted for the vertical correction, and the movement required for the horizontal correction.
Page 31: Operation
The pump is designed to deliver rated capacity and rated head for a liquid with a particular viscosity. When contemplating operation at some viscosity other than for which the pump was originally designed and/or applied, the changed conditions should be referred to Ingersoll-Dresser for our recommendations.
Page 32: Minimum Continuous Stable Flow
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 4.1.5 MINIMUM CONTINUOUS STABLE FLOW For “A” type pumps up to 3600 RPM, the Minimum Continuous Stable Flow (MCSF) can be obtained from below and the margin of NPSH available vs. the NPSH required at the Best Efficiency Point (BEP).
Page 33 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE CAUTION In no case is a MCSF of less than 10% of flow at BEP to be used. Water Hydrocarbon Figure 4-1 Minimum Flow Correction Factor for NPSHA Margin 1.20 1.00 Percent of Design R.P.M. Figure 4-2 Correction of MCSF for Speeds Other Than Design Speed DO2664-07...
Page 34: Control Notes
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 4.2 CONTROL NOTES 4.2.1 MINIMUM FLOW CONTROL In all cases, it is the customer’s responsibility to supply a system and/or control which assures that any pump within a system is not operated below its minimum flow condition. In many cases, this is not a problem because the system is operating within its own flow range to assure product delivery.
Page 35: Lubrication
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Total Minimum Flow Minimum Flow + (Total No. Pumps - 1) × (Strong Pump Flow) of Pumps in System of Weakest Pump Sample: (see Figure 4-3) 1. Assume the minimum flow for a single pump is 27 GPM. 2.
Page 36: Lubrication Specifications
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 4.3.1 LUBRICATION SPECIFICATIONS The ideal bearing lubricant is mineral oil, preferably of the turbine type. It should be corrosion, oxidation, and foam inhibited, and should not contain free acid, chlorine sulfur or more than a trace of free alkali.
Page 37: Oil Change
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Reservoir Thumb Screw Leveling Rod 0.86 to 0.90 in. (21.8 to 22.8 mm) Adjusting Nut Oiler Body Side Port Locknut Plugged Port Figure 4-4 Trico Oiler 4.3.6 OIL CHANGE Frequency of oil change is dependent on pump service and environmental conditions. As a general guide, the oil in the bearing housing should be changed at least every six months.
Page 38: Pre-Operational Checks
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Do not allow sparking, flames, or hot surfaces in the vicinity of equipment which handles volatile or flammable liquids. Do not perform any maintenance on or around the pump when it is rotating. If unusual noise or vibrations occur, secure the pump as soon as possible.
Page 39: Initial Start Up Procedure
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 4.4.3 INITIAL START UP PROCEDURE 1. Close discharge valve if valve is not already closed, and then crack it open to ensure minimal flow. (Do not start pump with a fully closed discharge valve). On first starts care must be taken not to cause a system water hammer.
Page 40: Normal Start-Up
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE CAUTION If pump stops abruptly when driver is shut down, investigate for pump binding. Take necessary remedial action before resuming operation. 10. Start the driver in accordance with the manufacturer’s instructions and bring it up to speed quickly.
Page 41: Securing The Pump
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 1. Check suction and discharge pressure gauges. 2. Check pressure gauges on each side of suction strainer. CAUTION Excessive tightening of the packing gland increases packing wear which in turn is apt to result in burned packing and a scored shaft sleeve.
Page 42: General Maintenance
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 4. Turn off cooling liquid. 5. If pump is subjected to freezing temperatures, it must be drained of liquid to prevent damage to the pump. 4.5 GENERAL MAINTENANCE These pumps have been designed to simplify maintenance and make service easy. Preventative maintenance and overhauls before serious troubles occur will reduce operating costs.
Page 43: Troubleshooting
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 4.5.2 TROUBLESHOOTING This chart presents the probable troubles that can occur to the pump along with the probable causes and remedies for the troubles. Table 4-3 Troubleshooting Table TROUBLE CAUSE REMEDY Insufficient capacity and/or Suction pressure or speed too Open suction valve wide.
Page 44 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE TROUBLE CAUSE REMEDY Specific gravity too high. Check rated conditions. Pump bearings seized or Dismantle pump and replace rotating element binding. part or parts causing seizures or binding. Pump stops abruptly. Pump binding at running fits. Dismantle pump and realign rotor in casing.
Page 45: Maintenance
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 5. MAINTENANCE 5.1 GENERAL Avoid serious or troublesome problems by systematic maintenance checks. Study Table 4-3, “Troubleshooting Table”, as an aid to your maintenance program. Your pump is a precision machine. Take every precaution to avoid damage or even slight burrs to the shaft bearing areas, as well as any other ground finished surface when dismantling your pump.
Page 46: Packing Rings
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 1. Tag driver controls in the OFF position. 2. Isolate pump from the suction and discharge system and any other auxiliary systems. 3. Drain all operating fluids from the pump as follows: a. Open the casing drain valve, or remove the casing drain plug, and allow the casing to drain.
Page 47: Disassembly
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 5.3 DISASSEMBLY 5.3.1 PULL-OUT ELEMENT REMOVAL NOTE This is a pull-out element design. It is not necessary to remove the casing from the baseplate, or to remove the suction and discharge piping from the casing in order to remove the pull-out element.
Page 48 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 8. With unit suspended in a vertical position, carefully remove the shaft sleeve (8A) with the complete mechanical seal assembly (3213) and gland (68) intact from the pump shaft (0001). Remove gasket (2986) from shaft sleeve (8A). If packed box is provided, remove shaft sleeve (21) and gasket (2986).
Page 49: Inspection And Renewal Of Parts
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE NOTE When removing bearings (3036A/B) exert pressure on the inner bearing race only. Do not exert any pressure on the outer bearing race. 18. Remove oil rings (2889) and oil throwers (3237) from the shaft (0001). 5.4 INSPECTION AND RENEWAL OF PARTS After the pump has been disassembled for repair or overhaul, each part should be cleaned and inspected.
Page 50: Checking Shaft Straightness
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 6. The mechanical seal (3213A) should be disassembled and inspected in accordance with the manufacturer’s instructions located in the back of this manual. Specifically, the stationary and rotating seal faces should be inspected for wear or cracking and replaced as necessary. When reassembling the seal, all old gaskets and O-rings should be discarded and replaced with new parts.
Page 51: Replacing Stationary Wear Rings
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 5.4.6 REPLACING STATIONARY WEAR RINGS NOTE For replacement of the case wear ring (26A) it is recommended that the case be removed from the system and transported to a suitable work area. To replace a stationary wear ring (26A/B), proceed as follows: CAUTION Ensure that the parent part is not damaged during removal of the wear ring.
Page 52: Assembly
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE To replace an impeller wear ring (200A/B) proceed as follows: CAUTION Ensure that the parent part is not damaged during removal of the wear ring. 1. Remove the wear ring set screws (259A). 2. Remove the old wear ring by placing the impeller in a lathe and turning off the wear ring. If this is not feasible, grind through the wear ring in two places and break the ring off of the impeller.
Page 53 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Ensure that the thrust bearings (3036B) are assembled as illustrated below with the wide flanges of the outer race in contact in-between the two bearings. 2. Heat radial bearing (3036A) and thrust bearing (3036B) to 200 to 230°F (95 to 110°C) and slide them up against their shoulders on shaft.
Page 54 If you need help, contact your nearest Ingersoll-Dresser Pump Sales Office (see PART ORDERING AND SERVICING INFORMATION). 12. Install impeller key (2966A) and impeller (0034). Install washer (3151B), tab washer (3151A), and impeller cap screw (530A).
Page 55 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE NOTE If runout is excessive, check fit of impeller on shaft and wear ring installations (see paragraphs 5.4.4 and 5.4.7 above). 14. Remove impeller cap screw (530A), tab washer (3151A), washer (3151B), impeller (0034), and impeller key (2966A).
Page 56: Pull-Out Element Installation
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE POSITION 1 POSITION 2 Figure 5-2 Checking Rotor Concentricity b. Slowly rotate shaft and note readings at 12, 3, 6, and 9 o'clock points; total indicator reading (TIR) for 12 to 6 o'clock points and 3 to 9 o'clock points should not exceed 0.002 in (0.05 mm) and the shaft shall turn smoothly.
Page 57 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE CAUTION Use care when installing the pull-out element into the casing (0037) to prevent damage to the casing cover to casing gasket (2988). 2. Rig pull-out element with lifting straps to an overhead hoist and carefully install the pull-out element into the casing (0037).
Page 59: Parts Ordering And Servicing Information
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 6. PARTS ORDERING AND SERVICING INFORMATION Ingersoll-Dresser Pump sales offices and other facilities are located throughout the world. Contact the sales office nearest you for sales and service or for assistance with parts and repairs. Your computerized parts list follows the addresses listed below.
Page 60: Customer Service
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Cleveland Repair Center Houston Parts Manufacturing Center 6250 Halle Drive 1251 Lumpkin Road Cleveland, OH 44125 Houston, TX 77043 Phone: (216) 524-6155 Phone: (713) 827-7736 Fax: (216) 524-3830 Fax: (713) 932-4374 Greenville Repair Center Fairfield Repair Center 2431 S.
Page 61: International Offices
A PUMP INSTALLATION, OPERATION, AND MAINTENANCE 6.4 INTERNATIONAL OFFICES Algeria Chile Ingersoll-Dresser Pompes Ingersoll-Dresser (Chile) Ltd. 4 rue de berry El Mouradia 16070 Casilla (P.O. Box) 1704 Algiers, Algeria Correo Central Phone: 256 2138 Santiago, Chile SA Phone: (56-2) 236-14-55...
Page 62 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Hong Kong Mexico Ingersoll-Dresser Pompes Industrias Medina S.A. de C.V. c/o Ingersoll-Rand (India) Ltd. Carratera Panamericana Km 402 19th Floor, Malaysia Building Apartado Postal E 29 50 Gloucester Road C.P. 37280 Leon GTO, Mexico...
Page 63 A PUMP INSTALLATION, OPERATION, AND MAINTENANCE Spain United Kingdom Cia Ingersoll-Dresser Pumps, S.A. Ingersoll-Dresser Pumps (UK) Ltd. Ctra. N-III, Km 24, 300 Queensway Team Valley Trading Estate 28500 Arganda Del Rey Gateshead Tyne & Wear NE11 0QB Madrid, Spain Phone: 091 487 5051...