1. Manuals
  2. Brands
  3. Veolia Manuals
  4. Water Pump
  5. AS Series
  6. Installation, operation & maintenance instructions manual

Veolia AS Series Installation, Operation & Maintenance Instructions Manual

Pumps with kz- & kt-bearing frame
Hide thumbs Also See for AS Series:
Table of Contents

Advertisement

Quick Links

Download this manual
INSTALLATION, OPERATIONS, &
MAINTENANCE DOCUMENTATION PACKAGE
Project No.: N/A
TONKAFLO AS9000, AS14000, AS22500, AS40000
TONKAFLO pumps with KZ- & KT-Bearing frame
SYSTEM PART NO.: 1125317
*
Trademark of Veolia; may be registered in one or more countries.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AS Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Veolia AS Series

Summary of Contents for Veolia AS Series

  • Page 1 INSTALLATION, OPERATIONS, & MAINTENANCE DOCUMENTATION PACKAGE Project No.: N/A TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame SYSTEM PART NO.: 1125317 Trademark of Veolia; may be registered in one or more countries.
  • Page 2 This page has been left blank intentionally...
  • 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...
  • Page 6 This page has been left blank intentionally...

  • 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 Lubricating the KZ-bearing frame pumps 3.5.1 Setting the KZ-bearing frame oil level...
  • Page 9 Installation, Operations, & Maintenance Documentation Package Contents 5.2.1 Mechanical seal leakage 5.2.2 Removing and installing the liquid end assembly 5.2.3 Replacing the mechanical seal 5.2.4 High-pressure mechanical seal replacement 5.2.5 KZ- and KT-bearing frame maintenance 5.2.6 Oil seal replacement 5.2.7 Maintenance during long-term storage 5.3 Service and support 5.3.1 Available services 5.3.2 Contact information...
  • Page 10 This page has been left blank intentionally...

  • Page 11: Book 1: Overview & Design

    TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame 1125317-WTS-OM-SYS-EN41-MA-001 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
  • Page 12 This page has been left blank intentionally...
  • 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 Operating temperature for standard steel stages Maximum recommended operating temperature 200 F (93 C) 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 Table 1.2 - Maximum developed boost pressure AS series 60 Hz 60 Hz 3500/3565 rpm 50 Hz 50 Hz 2900/2950 rpm Model Stages Developed pressure Stages Developed pressure Up to 640 psig (44.1...

  • Page 18: Standard Construction Materials

    Installation, Operations, & Maintenance Documentation Package BOOK 1: Overview & Design 1.2.2 Standard construction materials Impellers, diffusers, wetted casting, pump shaft, and casing are 304 stainless steel. The standard mechanical seal has a carbon rotating face and a ceramic stationary face. The secondary sealing element of the mechanical seal is Buna-N.

  • Page 19: Book 2: Safety Manual

    TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-002 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
  • Page 20 This page has been left blank intentionally...
  • 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 AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-003 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
  • Page 40 This page has been left blank intentionally...
  • 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 Lubricating the KZ-bearing frame pumps 3.5.1 Setting the KZ-bearing frame oil level 3.5.2 Maintaining the oil level 3.5.3 Oil change/maintenance...

  • 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 The pump case and flat boss on the bearing frame are the best reference for leveling. NOTICE Do not force the pump case into a horizontal position. Level the pump by shimming the bearing frame base (KZA) or the motor base (KZB, KZC, KTE, and KTF).

  • 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 on the motor shaft. Do not tighten the set screws until after the pump and motor are assembled.

  • Page 47: Coupling Guards

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Table 3.2 - Coupling Gap Specifications Coupling Size 1 - 7/16 in 36.5 mm 1 - 5/8 in 41.3 mm 3.3.1 Coupling guards Coupling guards are available for all TONKAFLO pumps. Check plant safety requirements.

  • Page 48: 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 49 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Table 3.3 - Suction inlet and discharge piping specifications Piping size - Piping size - dis- Pump model inlet charge AS9000, AS14000 pumps 3 in. (7.6 cm) 3 in. (7.6 cm) AS22500, AS30000, 40400 boost 4 in.
  • Page 50 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 51: 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 52: Discharge Screen (Strainer)

    Figure 3.3 - Discharge screen installation diagram 3.4.5 Pump piping connections The standard model TONKAFLO AS Series pumps have grooved ends, as shown in Figure 3.3 - 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 53 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual NOTICE Petroleum grease, though suitable for most gasket materials, is not compatible with EPDM. [Project Number]-WTS-OM-SYS-EN41-MA-003 | REV A 3-13...

  • Page 54: Lubricating The Kz-Bearing Frame Pumps

    THE BEARING FRAME IS SHIPPED WITHOUT OIL. Two quarts (1.9 L) of oil are provided with each new TONKAFLO pump. Additional oil can be purchased from Veolia (See Book 5 - Maintenance manual/RSPL). The bearings are lubricated by maintaining a static oil level within the bearing frame.
  • Page 55 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual 1. Vent/breather 3. "Full line" oil level sight guage 2. Leveling boss 4. Drain plug Figure 3.4 - Initial cold setting of oil level for KZ-bearing frame pumps NOTICE The bearing frame oil reservoir capacity is approx- imately 37 ounces [1 quart, 5 ounce (1.1 L)].

  • Page 56: Maintaining The Oil Level

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual 3.5.2 Maintaining the oil level When cold, maintain the oil level at the “FULL” line on the sight gauge (see Figure 3.4 - Initial cold setting of oil level for KZ-bearing frame pumps).

  • Page 57: Lubricating The Kt-Bearing Frame Pumps

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Lubricating the KT-bearing frame pumps NOTICE The bearing frame is shipped without oil. The trico oiler bottle is not installed when shipped. The automatic oiler is provided and used to maintain the static oil level inside the bearing frame.

  • Page 58: Setting The Kt-Bearing Frame Oil Level

    Two quarts (1.9 L) of oil is provided with each new TONKAFLO oil lubricated bearing frame pump. Additional oil can be purchased from Veolia (see Book 5 - Maintenance manual - RSPL).

  • Page 59: Maintaining The Oil Level On Kt-Bearing Frames

    Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual The oil level sight gauge is provided with the bearing frame so the oil level may be viewed before start-up as a check for proper installation of the automatic oiler. 3.6.2 Maintaining the oil level on KT- bearing frames When cold, the oil level can be set 1/8 in.
  • Page 60 Installation, Operations, & Maintenance Documentation Package BOOK 3: Installation Manual Under extreme temperature variations, high, humidity, or dusty/dirty conditions oil changes should be more frequent. Clean the breather and vent/breather between oil changes. 3-20 [Project Number]-WTS-OM-SYS-EN41-MA-003 | REV A...

  • Page 61: Book 4: Operations Manual

    TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-004 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
  • Page 62 This page has been left blank intentionally...
  • Page 63 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 64: 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 65: 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 66 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 67: 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 68: 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 69: Book 5: Maintenance Manual

    TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
  • Page 70 This page has been left blank intentionally...
  • Page 71 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 72 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.4 High-pressure mechanical seal replacement 5.2.5 KZ- and KT-bearing frame maintenance 5.2.6 Oil seal replacement 5.2.7 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 73: 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 74: 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 75: 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 76: Removing And Installing The Liquid End Assembly

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.2 Removing and installing the liquid end assembly 5.2.2.1 Removing the liquid end assembly It is necessary to remove the liquid end assembly to replace the mechanical seal, or perform maintenance work on the pump bearing frame.
  • Page 77 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual screw. Remove the set screw. 3. Loosen the clamp on the discharge end of the pump case . 4. Remove the liquid end assembly (liquid end of the pump shaft) by pulling the liquid end away from the bearing frame. Ensure that the discharge end of the liquid end assembly is supported so the pump shaft is not bent when removed.

  • Page 78: Replacing The Mechanical Seal

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual or local industrial supply house. 3. Align the keyed pump shaft with the bore of the bearing frame shaft, and insert the pump shaft such that the key on the pump shaft fits into the key way on the bearing frame shaft.
  • Page 79 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 2. Remove the pump shaft key and slide the mechanical seal holder off the pump shaft (see Figure 5.3 - Removing the mechanical seal). 1: Liquid end assembly 5: O-ring 2: Retaining ring - Do Not 6: Seal holder Remove 3: Pump shaft...
  • Page 80 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual a. To protect the rubber bellows from damage, deburr the set screw dimple and shaft key way, and wrap thin plastic tape over the shaft key way. b. Wrap 1-1/4 turns to cover the end of the key way opposite the shaft end.

  • Page 81: High-Pressure Mechanical Seal Replacement

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 11. Install the liquid end assembly onto the bearing frame assembly (see 5.2.2.2 Installing the liquid end assembly). 5.2.4 High-pressure mechanical seal replacement High-pressure mechanical seals have the same basic design as standard mechanical seals.
  • Page 82 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual WARNING Burn Hazard If there is a bearing failure or inadequate lubrication, the bearing frame assembly will become very hot: Before performing any maintenance, allow the bearing frame to cool to room temperature. Always put on protective gloves before handling hot components.
  • Page 83 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 1: Bearing cups 10: Oil chamber bulkhead 2: Bearing #1 11: Oil drain plug 3: O-ring 12: Oil seal #2 4: Retaining ring #1 13: O-ring 5: Oil seal #1 14: Adapter, motor bearing frame 6: Retainer ring #2 15: Bolts (4) 7: Oil seal holder...
  • Page 84 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5. Inspect the bearing cups and cones for any rough surface conditions and replace both cup and cone when necessary. Pitted and galled rollers and/or bearing cap indicates replacement is necessary. Very light marks from the bearing cage may form around roller during “break-in period”.
  • Page 85 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual correct, place the shaft into the bearing frame and measure 2.772 to 0.010in. (70.41 to 0.025 mm) recess. Refer to Figure 5.5 - Setting the bearing frame shaft end play. Apply only enough press force to fully seat the bearing against the washer and retaining ring.
  • Page 86 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.5.5 Checking the end play of KZ- and KT-bearing frames 1: Dial indicator 3: Bearing frame shaft 2: Move shaft to check end 4: Set tang into slot play Figure 5.5 - Setting the bearing frame shaft end play To check the end play of the KZ- and KT-bearing frames: 1.
  • Page 87 NOTICE End play of 0.011 to 0.014 in. (0.28 to 0.36 mm) or less is difficult to read by hand. Veolia recommends using a dial indicator to measure end play. 6. If further adjustment is necessary, press bearing cone #2 to reseat it against the bearing cup.

  • Page 88: Oil Seal Replacement

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 1. Install the liquid end on the bearing frame (See 5.2.2.2 Installing the liquid end assembly.). 2. Mount the pump on the motor or other mounting position and tighten the clamp on the discharge support. 3.
  • Page 89 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual provided. (Select bolt length as needed to engage coupling nuts). d. Tighten the two (2) bolts uniformly to pull the seal holder out straight. 4. Remove the oil seal from the seal holder and install a new oil seal.
  • Page 90 Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 8. Install the motor adapter onto the bearing frame. Take care not to damage the oil seal lip. 9. Reinstall the bolts and lock washers to fasten the motor adapter to the bearing frame. 10.

  • Page 91: Maintenance During Long-Term Storage

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual 5.2.7 Maintenance during long-term storage While the pump is in storage, ensure that the following maintenance tasks are performed regularly, as applicable: Rotate the pump shaft by hand (under 15 rpm) for approximately 10 rotations every three(3) months.

  • Page 92: 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 93: 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 94: Tonkaflo Service Policy - Liquid Ends

    They are typically characterized by a “KZ” or “KT” in the model number (e.g., AS9023KZ or AS40415KT). To return an oil-lubricated bearing frame pump to the factory, Veolia requires the whole unit (pump liquid end, bearing frame, and motor adapter) less the motor and flexible coupling pieces.

  • Page 95: Tonkaflo Pump Repair Procedure

    Installation, Operations, & Maintenance Documentation Package BOOK 5: Maintenance Manual adapter is not returned, Veolia will connect a new motor adapter to the repaired pump liquid end/bearing frame and the client will be billed for it. The original bearing frame is essential for the rebuilding of the pump liquid end on the 9000, 14000, 225000, 30000 and 40000 Series pumps based on the pump design (locked impellers).

  • Page 96: Motor Warranty

    Motors must be sent to the nearest authorized motor service center for repair, replacement, and warranty disposition. 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. 5-26 [Project Number]-WTS-OM-SYS-EN41-MA-005 | REV A...

  • Page 97: Book 6: Troubleshooting Manual

    TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-006 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.
  • Page 98 This page has been left blank intentionally...
  • Page 99 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 100: 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 101 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 102: 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 103: Troubleshooting Possible Issues

    Installation, Operations, & Maintenance Documentation Package BOOK 6: Troubleshooting Manual 6.2.2 Troubleshooting possible issues Table 6.1 - Low flow Potential cause Solution Pipe the pump inlet to induce minimal pressure drops through Inlet/discharge piping diameter changes, elbows, instrumentation, and so on. restricted Never throttle TONKAFLO pumps at the inlet.
  • Page 104 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 105 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 106 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 107 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 108 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 109 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 110 This page has been left blank intentionally...

  • Page 111: Book 7: Project Documents

    TONKAFLO AS9000, AS14000, AS22500, AS40000 TONKAFLO pumps with KZ- & KT-Bearing frame [Project Number]-WTS-OM-SYS-EN41-MA-007 | REV A SYSTEM PART NO.: 1125317 *Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.

  • Page 112: Standard Model Parts List

    Standard Model Parts List - 1125317 Part Description Part Description Part # Item # Part # Item # Clamp, Pump Shell Support Nut, Lock 3/8-16 flanged 1121469 AS9000 & AS14000 Discharge Support Assembly 1114375 AS22500 / 30000 (With #s 23 & 24, Center line) 1122957 AS40000 6.25, AS9000/14000/ 225000...

  • Page 113: Pump Cutaway Drawing

    Pump Cutaway Drawing – Replacement Parts (Refer to Standard Model Parts List)

  • Page 114: Pump Accessories

    Pump Accessories - 1125317 Part Description Part # Retaining Ring Pliers for K Mechanical Seal Retaining Ring 1120717 Set Screw for Pump Shaft for K-Bearing Frames 1113769 Allen Wrench, 3/16-inch, for Set Screw P/N 1113769 1113770 Pump Discharge Screen (3-inch Victaulic) 1120501 Royal Purple Synfilm 68, synthetic oil: 1 Quart...
  • Page 115 Recommended Spare Parts - 1125317 Spare Parts for Mechanical Seal Replacement and General Bearing Part Description Part # Quantity Installation, Operation, and Maintenance Manual for AS9000, AS14000, AS22500, AS30000, and AS40000 Series High-Pressure Pumps with KZ and KT Bearing Frames 1125317 1-inch, Type 21, BF 1C1-316SS Mechanical Seal Kit.

This manual is also suitable for:

As9000 seriesAs14000 seriesAs22500 seriesAs40000 series

Table of Contents