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Veolia AS Series Installation, Operation & Maintenance Instructions Manual

Pumps with d, dm, g, gm, ht, hu, hw, hy, hz-bearing frame
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INSTALLATION, OPERATIONS, &
MAINTENANCE DOCUMENTATION PACKAGE
Project No.: N/A
TONKAFLO AS400, AS1600, AS2500, AS4000
TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing
frame
SYSTEM PART NO.: 1123174
*
Trademark of Veolia; may be registered in one or more countries.

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Summary of Contents for Veolia AS Series

  • Page 1 INSTALLATION, OPERATIONS, & MAINTENANCE DOCUMENTATION PACKAGE Project No.: N/A TONKAFLO AS400, AS1600, AS2500, AS4000 TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame SYSTEM PART NO.: 1123174 Trademark of Veolia; may be registered in one or more countries.
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  • Page 3 PERSONAL INJURY OR DEATH, BROKEN OR DAMAGED PARTS/EQUIPMENT, AND/OR WATER QUALITY ISSUES AND RESULTING HARM. Deviations or modifications of the IOM Package suggested by Veolia field personnel or other employees do not supersede the IOM Package unless stated in writing by Veolia.
  • Page 4 Veolia. Proprietary information The information contained in these manuals is Veolia proprietary information and is disclosed in confidence. It is to be used solely for the purpose for which it is furnished and returned upon request. This...

  • Page 5: System Provider Information

    Installation, Operations, & Maintenance Documentation Package Service information Service information It is recommended that owners complete the following fields upon receiving the system. This information will be helpful when requesting service and support. System provider information System provider Contact Phone Email System information Installation date...
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  • Page 7: Table Of Contents

    Installation, Operations, & Maintenance Documentation Package Contents Contents Service information System provider information System information BOOK 1: Overview & Design 1.1 Design and theory of operation 1.2 System design parameters 1.2.1 Pump nomenclature 1.2.2 Standard construction materials BOOK 2: Safety Manual 2.1 Personal safety 2.1.1 Personal protective equipment 2.1.2 Walking and working surfaces 2.1.3 Temperature extremes...
  • Page 8 Installation, Operations, & Maintenance Documentation Package Contents 3.2 Initial setup 3.2.1 Location 3.2.2 Foundation 3.3 Installing the flexible coupling 3.3.1 Coupling guards 3.4 Installing the piping 3.4.1 Orient the inlet housing 3.4.2 Piping specifications 3.4.3 Suction screen (strainer) 3.4.4 Discharge screen (strainer) 3.4.5 Pump piping connections 3.5 Belt drive operation BOOK 4: Operations Manual...
  • Page 9 Installation, Operations, & Maintenance Documentation Package Contents 5.3.1 Available services 5.3.2 Contact information 5.3.3 TONKAFLO service policy - liquid ends 5.3.4 TONKAFLO pump repair procedure 5.3.5 Motor warranty BOOK 6: Troubleshooting Manual 6.1 General precautions 6.2 Troubleshooting guidelines 6.2.1 Bearing frame temperature 6.2.2 Troubleshooting possible issues BOOK 7: Project Documents Standard Model Parts List - 1123174...
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  • Page 11: Book 1: Overview & Design

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame 1123174-WTS-OM-SYS-EN41-MA-001 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
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  • Page 13 Installation, Operations, & Maintenance Documentation Package BOOK 1: Overview & Design About this manual This manual provides an overview of the system and its design. It describes how the system works, how water flows through the system, and what the system parameters are. Use this manual in conjunction with the other manuals in the Installation, Operations, & Maintenance Documentation Package (IOM Package).

  • Page 14: Design And Theory Of Operation

    NOTICE Operating this system in a manner that deviates substantively from the Veolia instructions and best practices may render the warranty null and void. If an alternate mode of operation (example: revised...

  • Page 15: System Design Parameters

    The TONKAFLO Pumps AS Series covers a flow range of 4 to 700 gpm (0.9 to 159 m /hr) with single unit pressures up to 630 psig (43.5 barg).
  • Page 16 Maximum recommended operating tem- 200 F (93 C) perature Note For high temperature applications, contact Veolia. The temperature stated in this table is for design flow and pressure. The maximum recommended temperature is stated on the pump case. NOTICE To prevent excessive heat buildup, ensure adequate flow through the pump at all times.

  • Page 17: Pump Nomenclature

    Installation, Operations, & Maintenance Documentation Package BOOK 1: Overview & Design 1.2.1 Pump nomenclature Table 1.3 - Pump name definitions Example model AS9022KZC Example model AS40415KTF-50 AS = all stainless steel AS = all stainless steel 90 = series 9000 40 = series 40000 22 = number of stages 4 = inlet size (4 in.
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  • Page 19: Book 2: Safety Manual

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-002 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
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  • Page 21 Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual About this manual This manual includes: general safety procedures and best practices, including those related to personal and environmental safety. They follow the Occupational Safety and Health Administration (OSHA) standards. However, it is the responsibility of the operator to follow their company policy regarding rules and regulations.
  • Page 22 General Hazard Veolia typically works with transportation carriers who understand the equipment and how to secure it properly. If transportation is required, work with Veolia to develop a procedure for transport. Topics in this manual 2.1 Personal safety 2.1.1 Personal protective equipment...

  • Page 23: Personal Safety

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual Personal safety The following sections provide general guidelines regarding personal safety and cleanliness. Refer to local codes and regulations for more detailed information. 2.1.1 Personal protective equipment The equipment listed here constitutes the minimum scope of protective gear that must be available to all operators.

  • Page 24: Walking And Working Surfaces

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual 2.1.1.3 Fall protection When working in a position where the possibility of falling a significant distance (approximately 1.2 m (4 ft)) is present, wear an approved safety harness in accordance with national and local safety requirements.

  • Page 25: Safety On Site

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual Safety on site The following sections provide information regarding general site safety and proper conduct during various procedures that may be performed onsite. This information is not intended to replace or override national or local codes and regulations. Hold pre-job inspections and meetings before each shift to discuss safety concerns before working.
  • Page 26 Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual Follow Confined Space entry rules when entering tanks, pits, vaults and other areas not designed for human occupancy. (See 2.3.2 Entering confined spaces) Personnel engaged in a procedure where the possibility of severe injury could be high (example: entering a confined space, lockout/tagout) must work under the supervision of a colleague prepared to provide assistance if required.

  • Page 27: Safety Inspections

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual 2.2.2 Safety inspections It is recommended that the following checks and inspections be completed before starting up the system for the first time: Check or inspection Know where evacuation meeting zones are located. Test all safety showers and eye wash stations.

  • Page 28: Electrical And Thermal Hazards

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual Check or inspection Store all required chemical protective gear near the chemical skids and in a clean, dry place. This includes, but is not limited to, full-face shields, rubber suits, and gloves. Ensure all components are clean and undamaged.

  • Page 29: Mechanical Hazards

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual the relevant manufacturer's instructions. (See BOOK 8: Supplier Data)(See BOOK 7: Drawings and BOMs) 2.2.4 Mechanical hazards TRAINING AND EQUIPMENT: Before working with any mechanical component or chemical, operators must be fully trained and equipped with all necessary protective equipment, as outlined in the relevant manufacturer's instructions.

  • Page 30: Chemical Hazards

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual After completing maintenance, replace any guards, interlock switches, or other safety components removed during the procedure. Personnel working on pumps used to transfer chemicals must be familiar with the safe-handling procedures associated with the chemicals involved.
  • Page 31 Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual chemicals give off vapors that also pose a health risk. In addition, events can occur that lead to contaminate off-gassing, which can cause hazardous conditions, posing a threat to personnel or equipment. It is recommended that airborne concentrations of chemical contaminates be assessed regularly to ensure permissible exposure limits are not exceeded.

  • Page 32: Pinch And Fall Hazards

    Refer to the chemical SDS for guidance on appropriate PPE. SDSs/MSDSs: Retain all SDSs/MSDSs for chemicals purchased from suppliers other than Veolia and file them alongside those that may have been provided by Veolia. (See BOOK 7: Drawings and BOMs)

  • Page 33: Noise Hazards

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual ROTATING COMPONENTS: Before operating components with rotating parts or other possible pinch hazards, ensure that all shields, guards, and emergency stop switches are in place. FALL HAZARDS: Fall hazards include any situation where the possibility of either personnel or equipment falling from a significant height (approximately 1.2 m (4 ft)) is present.

  • Page 34: Pressure And Rupture Hazards

    2.2.9 Environmental hazards The Veolia commitment to environmental management is to establish systems that meet or exceed environmental standards in all activities. It is the Owner’s responsibility to ensure that the environment is protected by taking ownership and enforcing environmental laws and regulations according to federal and local jurisdictions.

  • Page 35: High-Risk Procedures

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual High-risk procedures DANGER Follow the Manual The following procedures pose a significant risk to personnel involved. The possibility of severe injury or death will be significant if the instructions provided below, as well as in all relevant local government, industry, and facility regulations, are not followed.

  • Page 36: Locking Out Components

    Installation, Operations, & Maintenance Documentation Package BOOK 2: Safety Manual 2.3.1 Locking out components Components need to be locked out or tagged out to help prevent: contact with a hazard where safeguarding devices need to be temporarily bypassed, removed, or deactivated the unintended release of hazardous energy (stored energy) the unintended startup or motion of equipment, machinery, or processes.
  • Page 37 Veolia strongly recommends that any personnel required to enter a confined space first complete an official confined space entry training program. [Project Number]-WTS-OM-SYS-EN41-MA-002 | REV A...

  • Page 38: Safety Data Sheets (Sds)

    This can vary by jurisdiction and some countries may have set additional requirements on some sections of GHS SDSs. For chemicals supplied by Veolia, the latest SDSs can be found at https://www.watertechnologies.com/msds. If the chemicals are not Veolia branded products, the SDS is provided by the manufacturer or supplier of the product.

  • Page 39: Book 3: Installation Manual

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-003 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
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  • Page 41 (example: piping, external mechanical devices, anything else that connects to the system) that are outside of system specifications without first consulting with Veolia. Topics in this manual 3.1 Initial requirements 3.2 Initial setup 3.2.1 Location...
  • Page 42 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual 3.3.1 Coupling guards 3.4 Installing the piping 3.4.1 Orient the inlet housing 3.4.2 Piping specifications 3.4.3 Suction screen (strainer) 3.4.4 Discharge screen (strainer) 3.4.5 Pump piping connections 3.5 Belt drive operation [Project Number]-WTS-OM-SYS-EN41-MA-003 | REV A...

  • Page 43: Initial Requirements

    (See BOOK 7: Drawings and BOMs) WATER: Water introduced into the system during installation must be free of particulates. ELECTRICITY: Veolia is not responsible for supplying power to the system. NOTE Without proper bonding to earth, the UV system can generate nuisance ballast GFI alarms, causing lamps to randomly turn off.

  • Page 44: Initial Setup

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Initial setup All pumps are tested at the factory prior to shipment to ensure they meet requirements for the order. Check the pump upon receipt for possible damage due to shipping. Report any damage to the carrier immediately.
  • Page 45 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual strain on the pump from misalignment, do not bolt down the bearing frame. The pump mounting is to be horizontal and the pump leveled within 1/16 in/ft (4.5 mm/meter) both in the axial and side-to-side directions. The pump case and flat boss on the bearing frame are the best reference for leveling.

  • Page 46: Installing The Flexible Coupling

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Installing the flexible coupling If the pump has been supplied with the motor installed, the coupling is properly installed. If the pump has not been supplied as an assembled unit: 1. Install the coupling flange for the pump on the bearing frame shaft, flush with the end of the shaft.

  • Page 47: Installing The Piping

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Installing the piping The following sections describe the piping connections required for the TONKAFLO pump. 3.4.1 Orient the inlet housing The pump inlet housing is designed for either upright, or left/right horizontal positioning. The pump is shipped with the inlet in the upright position.
  • Page 48 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Table 3.2 - Suction inlet and discharge piping specifications Pump model Piping size - inlet Piping size - discharge 1.25 in. (3.175 cm) 1.25 in. (3.175 cm) 1600 1.25 in. (3.175 cm) 1.25 in.
  • Page 49 To prevent a vortex from forming, increase the size of the inlet pipe to reduce the velocity from forming. If necessary, consult the pump curve to reference the NPSHR. Contact Veolia for more information. Hot liquids within the temperature range of the pump must have sufficient positive head to prevent vaporization at the impeller inlet.

  • Page 50: Suction Screen (Strainer)

    24 in. (61 cm) away from the pump inlet. 3.4.3 Suction screen (strainer) An AS Series TONKAFLO pump is a precision multi-stage centrifugal pump with close tolerances to provide maximum efficiency. It is good practice to install a 30 mesh or finer screen (available as an accessory), or a cartridge filter, in the suction line, to collect any foreign objects or large particles.

  • Page 51: Discharge Screen (Strainer)

    Figure 3.2 - Discharge screen installation diagram 3.4.5 Pump piping connections The standard model TONKAFLO AS Series pumps have grooved ends, as shown in Figure 3.2 - Discharge screen installation diagram, to accept Victaulic-type couplings. The couplings with 1000 psi (69 bar) working pressure rating are available as an accessory and include a standard Buna-N gasket.
  • Page 52 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual NOTICE Petroleum grease, though suitable for most gasket materials, is not compatible with EPDM. 3-12 [Project Number]-WTS-OM-SYS-EN41-MA-003 | REV A...

  • Page 53: Belt Drive Operation

    Do not operate 60 Hz model pumps over 3600 rpm. Do not operate 50 Hz model pumps over 3000 rpm. Contact Veolia before operating a 50 Hz pump over 3000 rpm. Install a belt guard to prevent injury. Adjust the belt tension to achieve approximately 0.3 inch (7.6 mm) deflection with 5.5 lb (2.5...
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  • Page 55: Book 4: Operations Manual

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-004 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
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  • Page 57 Installation, Operations, & Maintenance Documentation Package BOOK 4: Operations Manual About this manual This manual outlines the procedures for starting up and operating the system as a whole. For detailed information regarding specific components included in this system, such as valves or instrumentation, refer to the manufacturer's instructions.

  • Page 58: Priming The Pump

    Installation, Operations, & Maintenance Documentation Package BOOK 4: Operations Manual Priming the pump NOTICE The inlet piping and pump must be filled with liquid (primed) before startup. If prime is lost, shut off the pump immediately to avoid overheating and possible damage to the internals of the liquid end.

  • Page 59: Pump Rotation

    Veolia for assistance. A motor starter is required for all three-phase motors. If required, contact Veolia for assistance. Install the proper size of wire between the power source and the motor controls/starter, and between the starter and the motor. To determine the correct wire size, refer to the motor installation manual or local electrical codes.
  • Page 60 Installation, Operations, & Maintenance Documentation Package BOOK 4: Operations Manual 3. Determine the difference between the current in each leg and the average of all three legs. 4. Take the difference with the largest value and divide it by the average current. Multiply by 100 to obtain the current imbalance percentage.

  • Page 61: Pre-Start Checks

    Installation, Operations, & Maintenance Documentation Package BOOK 4: Operations Manual Pre-start checks Before starting three-phase motors: 1. Prime the pump before applying power, to prevent damage. 2. Apply power for one (1) second to check the direction of the motor shaft rotation. The motor shaft turns in a clockwise direction as viewed from the motor end.

  • Page 62: Initial Operation

    Installation, Operations, & Maintenance Documentation Package BOOK 4: Operations Manual Initial operation The bearings were lubricated at the factory. Do not add grease to new or factory rebuilt pumps. Add the specified grease type, the correct quantity and at the specified intervals noted on the label on the bearing frame to ensure reliable pump operation.

  • Page 63: Book 5: Maintenance Manual

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
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  • Page 65 BOOK 5: Maintenance Manual About this manual The information provided in this section is intended as a general maintenance guide for the TONKAFLO Pumps AS Series. Use this manual in conjunction with the other manuals in the Installation, Operations, & Maintenance Documentation Package (IOM Package).
  • Page 66 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.3 High-pressure mechanical seal replacement 5.2.4 D, G and H-bearing frame maintenance 5.2.5 Maintenance during long-term storage 5.3 Service and support 5.3.1 Available services 5.3.2 Contact information 5.3.3 TONKAFLO service policy - liquid ends 5.3.4 TONKAFLO pump repair procedure 5.3.5 Motor warranty [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A...

  • Page 67: Preparing For Maintenance Or Service

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual Preparing for maintenance or service Before performing maintenance, test the following for proper functioning: all safety critical switches (example: interlocks) any pressure gauges that will be used applicable pressure relief valves. 5.1.1 Locking out and tagging out equipment When a machine or a piece of equipment is being prepared for...

  • Page 68: Securing The Electrical Cabinet

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual equipment. 4. LOCKOUT/TAGOUT: Lock and tag out the machine. Attach lockout and/or tagout devices to each energy-isolating device in such a way that it stays in a "safe" position and cannot be moved to the unsafe position except by the person who placed it in the "safe" position, and if tagged out, includes a tag that indicates the name of the person who performed the lockout,...

  • Page 69: Tonkaflo Pumps Field Maintenance

    CAUTION General Hazard Be careful not to damage the pump shaft. If the leak persists, the mechanical seal is damaged and needs to be replaced. Contact Veolia for replacement information. [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A...

  • Page 70: Replacing The Mechanical Seal On D, G, H Bearing Frames

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.2 Replacing the mechanical seal on D, G, H bearing frames To replace the mechanical seal, the following tools are required: one (1) 3/16 in. Allen (hex) wrench to remove the bearing frame shaft set screw 1/2 in.
  • Page 71 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 1: Key (PN 1120062) 5: O-ring 2: Pump shaft 6: Stationary portion mechanical seal 3: Cone point set screw (PN 7: Rotary portion mechanical seal 1113769) 4: Mechanical seal holder 8: Retaining ring Figure 5.1 - Removing the mechanical seal 4.
  • Page 72 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual pushing the rotary portion down the pump shaft until it is lightly seated against the spring. 7. Remove the stationary portion of the mechanical seal from the cavity in the seal holder (see Figure 5.1 - Removing the mechanical seal).

  • Page 73: High-Pressure Mechanical Seal Replacement

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual lock washers. 15. After fastening the inlet housing to the bearing frame assembly, line up the set screw hole in the bearing frame shaft with teh access hole in the bearing frame. Place the set screw in the bearing frame shaft.
  • Page 74 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.4.1 Lubricating the bearing frame Bearing frames were lubricated prior to delivery. Do not add grease when initially putting the pump into service. Regrease the bearing frame every lubrication interval, or once a year, whichever occurs first.
  • Page 75 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.4.2 Disassembling pumps with D, G, and H-bearing frames To remove the pump from its installation: 1. Disconnect the motor from the power source. 2. Remove the inlet and discharge plumbing. 3.
  • Page 76 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 1: Pressure relief plugs 4: Set screw - PN 1113769 threaded - PN 1120578 2: Bearing frame shaft 5: Pump shaft 3: Bearing frame Figure 5.2 - Disassembling the liquid end from the bearing frame To disassemble the motor and motor adapter from the bearing frame: 1.
  • Page 77 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.4.3 Bearing frame overhaul tools Two (2) 6-32 bolts for removal of grease seal holder (HT-, HU-, HW-, HY-, HZ- and G-Frame pumps). One (1) 3/8-16 bolt for D-Frame pumps to hold bearing frame shaft when removing lock nut.
  • Page 78 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 1. Remove the lock nut and lockwasher from the bearing frame shaft. To help with removing the lock nut, place a 3/8-inch bolt into the set screw hole in the shaft to hold the shaft while unthreading the bolt.
  • Page 79 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual not use excessive force or damage will result. 1: Pressure relief plug - PN 8: 1.900 inch+ .006 inch (148.26 mm 1120578 + 0.15 mm) 2: Grease fitting - PN 9: Bearing cone #1 - PN 1120491 1120060 3: Pressure relief plug - PN 10: Washer - PN 1120252...
  • Page 80 5. Repeat Step 4 two to three times to verify end play accuracy. NOTICE End play of 0.006 inch or less is difficult to read by hand. Veolia recommends using a dial indicator to measure end play. Readily noticeable end play requires the lock nut to be tightened.
  • Page 81 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual may be removed simultaneously with bearing cone #3, (proceed to Step 4). The bearing frame can be disassembled without removing retaining ring #1. 2. Remove retaining ring #2, the shims, and the back-up washer. 3.
  • Page 82 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual the shims. Press the shaft to force bearing #2 back against the shim pack. Again, apply just enough force to set the bearing against the washer, shim, and retaining ring. Do not apply excess force or damage may result.
  • Page 83 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual At this point of the overhaul procedure, check the end play of the shaft. 1. To ensure that the bearing cone is completely seated in the bearing race, grasp the shaft on the motor side of the bearing frame while turning the shaft as far as it will go.
  • Page 84 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual NOTICE Ensure the face of the grease seal holder with the threaded holes is exposed and is not facing the bearings. 5. Reshim the low profile socket head cap screw as needed (see Figure 5.4 - Pump bearing frame types G and H).

  • Page 85: Maintenance During Long-Term Storage

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 1. Attach the motor adapter to the bearing frame with four (4) 5/16-inch bolts and lockwashers. 2. Check that key is fully seated in the keyway of the motor shaft. With a chisel, put two small indentations along the shaft key slot near the shaft end.
  • Page 86 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual In addition to the general instructions provided above, ensure that the manufacturer’s instructions for each individual component (example: valves, instrumentation) are also followed. (See BOOK 8: Supplier Data)(See BOOK 7: Drawings and BOMs) 5-22 [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A...

  • Page 87: Service And Support

    5.3.1 Available services Veolia delivers a comprehensive range of services beyond system design and installation. Contact the Service Department to inquire about the following services: site visits and component audits...

  • Page 88: Contact Information

    Training Customized training packages are available. Contact Veolia for more information. 5.3.2 Contact information To contact Veolia for TONKAFLO pump service or support, see the following information: Address: (Minnetonka office) 5951 Clearwater Drive, Minnetonka, MN 55343-8995 Phone: 952-933-2277 Fax: 952-933-0141 Toll free: 1-800-848-1750 email: technicalsupport@veolia.com...

  • Page 89: Tonkaflo Service Policy - Liquid Ends

    (pump liquid end, bearing frame, and motor adapter) less the motor and flexible coupling pieces. If the motor adapter is not returned, Veolia will connect a new motor adapter to [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A 5-25...

  • Page 90: Tonkaflo Pump Repair Procedure

    2. When contacting Veolia’s Customer Service Center, have the original sales order or invoice available. All equipment must be shipped to Veolia with the freight prepaid by the customer. Call the Customer Service Center with any questions or issues concerning freight claims and a representative will discuss the situation.
  • Page 91 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.3.5.1 Liquid end pump warranty Warranty information can be found in the sales quote or invoicing information. Contact Veolia or technical support for more information. [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A 5-27...
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  • Page 93: Book 6: Troubleshooting Manual

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-006 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
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  • Page 95 Several training courses related to troubleshooting techniques and skills are available upon request. For more information, contact Veolia (see 5.3 Service and support). Use this manual in conjunction with the other manuals in the Installation, Operations, & Maintenance Documentation Package (IOM Package).

  • Page 96: General Precautions

    NOTICE Address any questions about the cause or response to a system problem to Veolia field services. Completed daily operating logsheets will be necessary to help determine the cause. Observe the following precautions at all times while attempting to...
  • Page 97 Installation, Operations, & Maintenance Documentation Package BOOK 6: Troubleshooting Manual attempting repairs. (See BOOK 8: Supplier Data)(See BOOK 7: Drawings and BOMs) Wear suitable protective equipment when working with pumps, piping, or other components that may have contained caustic or acidic chemicals. In the event of a contradiction between information provided in this section and that supplied by the manufacturer, the manufacturer’s information will always take precedence.

  • Page 98: Troubleshooting Guidelines

    Installation, Operations, & Maintenance Documentation Package BOOK 6: Troubleshooting Manual Troubleshooting guidelines This section provides general troubleshooting guidelines and information related to operation of the TONKAFLO Pumps AS Series. The tables in 6.2.2 Troubleshooting possible issues provides a quick-reference guide to help identify causes for common issues associated with pump operation.
  • Page 99 Installation, Operations, & Maintenance Documentation Package BOOK 6: Troubleshooting Manual Table 6.1 - Low flow Potential cause Solution If TONKAFLO pumps are "lifting" or "pulling" fluid from a tank, Inlet suction lift they must be fed with positive pressure as specified by the too high NPSH curve.
  • Page 100 Send to Veolia for repair. Specific gravity or viscosity of liquid TONKAFLO pumps are designed to pump water. Contact higher than Veolia for liquids other than water. design conditions Three-phase Ensure the three legs of the three phase power are current imbalance balanced within ±...
  • Page 101 Installation, Operations, & Maintenance Documentation Package BOOK 6: Troubleshooting Manual Table 6.3 - Motor does not run Potential cause Solution Blown fuse or Verify a fuse has not blown, a circuit breaker has not been tripped circuit tripped and the heater has not overloaded. Check the breaker or breaker for the controls.
  • Page 102 Table 6.5 - Pump vibration Potential cause Solution Pump shaft bent Send to Veolia for repair. Confirm the pump liquid end and the motor are firmly Improper secured to a bedplate or other rigid structure and that the mounting/leveling pump and motor are not misaligned.
  • Page 103 Mechanical seal Maintenance Manual. needs replacing Send to Veolia for repair. O-rings in pump Contact Veolia to arrange the return of the pump for repair. casing damaged Perform bearing frame maintenance as described in BOOK Oil seals need 5: Maintenance Manual.
  • Page 104 Clean vent on bearing frame. Vent/breather Replace vent on bearing frame. dirty or plugged Send to Veolia for repair. Drain appropriate amount of oil from the bearing frame and adjust the oil level to a correct level. Oil bottle too full Perform an oil change on the bearing frame.

  • Page 105: Book 7: Project Documents

    TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-007 | REV A SYSTEM PART NO.: 1123174 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.

  • Page 106: Standard Model Parts List - 1123174

    Standard Model Parts List - 1123174 Item # Part Description Part # All HZ All G All D Inlet housing Specify model Specify model Specify model number number number Discharge housing Specify model Specify model Specify model number number number Mechanical seal holder 1122731 1122731...
  • Page 107 Standard Model Parts List - 1123174 Accessories - Standard Models Part Description Part # All HZ All G All D Liquid end assembly Specify model Specify model Specify model number number number Bearing frame assembly 1120742 1120740 1120327 Mechanical seal kit - standard (<...

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