Instructions on Installation, operation and maintenance : Monoblock Centrifugal Pumps
 

Installation:

Location :
The Pump should be located as near the water source as possible. This reduces the suction lift and permit the use of the long suction pipe, reduces friction and gives better performance.
A clear space to be provided surrounding the pump operations for free access to service the pump and free air circulation to keep the motor cool.
If the unit is not put in to service immediately, it should be stored in a warm, clean, dry atmosphere. The insulation resistance of the winding should not be less than 1 M Ohms.
If the resistance is less than that the stator winding should be dried out by surrounding with Electric Lamps or Electric Heaters up to temperature of 6CPC and maintain slow air circulation until the resistance figure is obtained.
Do not install the pump in damp locations. Take adequate precautions around the motor by providing wire mesh to protect the motor from insects.


Foundation:

For satisfactory operation, suitable firm foundation is essential. The surface on which the unit is mounted should be flat and leveled, so that the pump set is bolted down without distortion. It should be seen that the foundation do not obstruct the air circulation to the motor. Do not tightenltne bolts until the grouting is properly set.


Piping :

In order to reduce the friction losses, use minimum numbers of bends and other fittings on suction and delivery side, suction pipe should be as short as possible with the long bend, adequate support should be given to pipe lines, so that the weight of the pipe line should not fall on the delivery casing.
A good quality of Foot Valve should be used whose open area is 2 Vi times the pipe area to have the smooth flow of the water. Other wise the foot valve acts like a throttle valve, thus reducing the flow of the water.

Before starting the pump ensure the following points :

  • Check up the foundation bolts, tighten them fully.
  • The gland is properly tightened at stuffing box position.
  • Fill the suction and the delivery pipe with water.
  • The valve on the delivery side should be kept open.
  • Check the direction of rotation by giving the electrical kick to motor. It should be as shown by arrow marked on casing. Change the phase sequence. F Check the suction line after priming. There should not be any leakage of water in the static position. Tighten all joints. Any leakage on the line will affect the discharge of the pump. G The starter should be checked before connection, the electric supply particulars should agree with the stamped readings on the name plate.


Check - Points during running conditions :

  • Leakage through the stuffing box is 5/6 drops per minute.
  • The pump is running smooth.
  • The ball bearing do not get excessively hot.


Ball Bearings :

For all our pumps pre-greased, double shielded bearings are used.


Stuffing box packing :

The Stuffing Boxes are packed with standard graphited cotton / asbestos packing for handling clear cold water. Whenever excessive leakage is observed, replace the packing.
Mechanical Seal for 2 HP & above can also be provided in place of stuffing box packing on request, at extra cost.


Bearing numbers and gland packing mech./oil seal size :

Sr. No. Pump Model DE Bearing * NDE Bearing * Mechanical seal / Oil Seal / Gland Packing (Size X Length) mm
1 0.5AM25C 6203 6203 Mech. seal DR L-12
2 1AM32 6204 6204 Mech. Seal DRL-18
3 1AM40 6204 6204 Mech. Seal DRL-18
4 1AL50 6204 6204 Mech. Seal DRL-18
5 1.5AM40 6304 6304 Mech. Seal DRL-18
6 2AH50HH 6305 6304 Oil Seal 30-52-10
7 2AH50LH 6305 6304 Oil Seal 30-52-10
8 2AM65 6305 6304 Oil Seal 30-52-10
9 3AH50HH 6206 6206 Oil Seal 30-52-10
10 3AH50LH 6206 6206 Oil Seal 30-52-10
11 3AH50LHE 6305 6304 Oil Seal 30-52-10
12 3AM60HH 6206 6206 Oil Seal 30-52-10
13 3AM60/3AS60 6206 6206 Oil Seal 30-52-10
14 3AM60HHE 6305 6304 Oil Seal 30-52-10
15 3AH50DS 6305 6304 Oil Seal 30-52-10
16 3AM60E 6305 6304 Oil Seal 30-52-10
17 3AM80E 6305 6304 Oil Seal 30-52-10
18 5AH50DS 6306 6306 Gland Packing 6X6X800
19 5AH60/5AS60 6306 6306 Oil Seal 30-52-10
20 5AH60HHE 6306 6306 Oil Seal 30-52-10
21 5AH50HH 6306 6306 Oil Seal 30-52-10
22 5AM75/5AS75 6306 6306 Oil Seal 30-52-10
23 5 AM 80 E 6206 6206 Oil Seal 30-52-10
24 5AH50HHDR 6306 6306 Gland Packing 6X6X800
25 5AH65DR 6306 6306 Gland Packing 6X6X800
26 5AH80DR 6306 6306 Gland Packing 6X6X800
27 5AH90DR 6306 6306 Gland Packing 6X6X800
28 7.5AH50HHDR 6308 6308 Gland Packing 6X6X800
29 7.5AH65DR 6308 6308 Gland Packing 6X6X800
30 7.5AH80DR 6308 6308 Gland Packing 6X6X800
31 7.5AM90DR 6308 6308 Gland Packing 6X6X800
32 7.5AH50HHB 6306 6306 Gland Packing 8X8X800
33 7.5AH65B 6306 6306 Gland Packing 8X8X800
34 7.5AH80B 6306 6306 Gland Packing 8X8X800
35 7.5AH90B 6306 6306 Gland Packing 8X8X800
36 10AH65DR 6308 6308 Gland Packing 6X6X800
37 10AH80DR 6308 6308 Gland Packing 6X6X800
38 10AH90DR 6308 6308 Gland Packing 6X6X800
39 12.5AH65DR 6308 6308 Gland Packing 6X6X800
40 12.5AH80DR 6308 6308 Gland Packing 6X6X800
41 12.5AH90DR 6308 6308 Gland Packing 6X6X800
42 15AH65HH 6309 6309 Gland Packing 6X6X800
43 15AH65DR 6309 6309 Gland Packing 6X6X800
44 15AH80DR 6309 6309 Gland Packing 6X6X800
45 15AH90DR 6309 6309 Gland Packing 6X6X800
46 20AH65 6309 6309 Gland Packing 8X8X800
47 20AH80 6309 6309 Gland Packing 6X6X800
48 20AH80DSDR 6309 6309 Gland Packing 8X8X900
49 20AH100DR 6309 6309 Gland Packing 8X8X900
50 20AH90 6309 6309 Gland Packing 6X6X800
51 3BM65 6206 6206 Gland Packing 8X8X800
52 5BM80 6306 6306 Gland Packing 8X8X800
53 5BL100 6306 6306 Gland Packing 8X8X800
54 7.5AH65DS 6308 6308 Gland Packing 6X6X900
55 10AH65DS 6308 6308 Gland Packing 6X6X900
56 15AH65DS 6309 6309 Gland Packing 6X6X900
57 20AH65DS 6309 6309 Gland Packing 6X6X900
58 25AH80DS 6309 6310 Gland Packing 8X8X1000
59 25AH100 6309 6309 Gland Packing 8X8X900
60 30AH80DS 6310 6310 Gland Packing 8X8X1000
61 30AH100 6310 6310 Gland Packing 8X8X900
62 25AH100DR 6310 6310 Gland Packing 8X8X900
63 25AH80DSDR 6310 6310 Gland Packing 8X8X1000
64 12.5AH65DSDR 6310 6310 Gland Packing 6X6X1000
65 15AH65DSDR 6310 6310 Gland Packing 6X6X1000
66 20AH80DSDR 6310 6310 Gland Packing 8X8X1000
67 5BM90 6306 6306 Gland Packing 8X8X1000
67 7.5BM90 6308 6308 Gland Packing 8X8X1000
69 10AH90HF 6308 6308 Gland Packing 8X8X1000
70 12.5AH90HF 6308 6308 Gland Packing 8X8X1000

Note : * bearigs are double shielded (ZZ)


Storage and handling needs :

If the pump is stored for a longer duration, then it is advised, to run it once in a month and store it in a dry place. Pump should be handled carefully during installation, dismantling and reassembly stages to avoid damages to the windings and other components. Improper handling may reduce the life of the pump.


Defects and their possible causes :

Defect Possible Causes
No Discharge 1. Pump not properly primed.
2. Leakage in Footvalve, Suction Pipe or Gland.
3. Hump in suction line.
4. Wrong direction of rotation.
5. Blockage in strainer, Pipes or in pump.
6. Low drive speed (Low voltage).
7. Head too high for the pump.
8. Suction lift too high.
Loss of delivery or Insufficient Discharge 1. Leakage in suction pipe and glands.
2. Footvalve uncovered or inadequately submerged.
3. Suction lift high.
Excess Power 1. Too high speed.
2. Pump strained by pipes.
3. Head too low.
Noise & Vibration 1. Too high delivery.
2. Too high suction ift.
3. Blocked suction tine or impeller.
4. Air entrained in the water.
5. Worn or defective Bearing.

In the event of Break down of the motor, Please check the following points:

1 See that there are no breaks in the cables or wires and all terminals are clean & tight
2 Make sure that the rated supply voltage is reaching the motor terminals


Dismantling procedure for LHP monoblock :

  • Remove the suction and delivery pipe lines from the Monoblock. Remove the foundation bolts of the pump and take out the pump from the well.
  • Take out the pump casing ( 3 ) by removing four nuts on studs.
  • Pull out the impeller ( 2 ) after removing lock nut.( 38 ).
  • Take out backplate ( 9 ) after unscrewing the four nuts of the studs.
  • Take out the gland packing ( 39 ) Lantern ring ( 32 ) from the stuffing box of the backplate (9).
  • Pull out the shaft sleeve ( 36 ) by puller.
  • Take out the fan cover ( 40) after unscrewing the four bolts .
  • Pull out fan ( 22 ) after removing the locking pin.
  • Take out three screws from bearing cover on End Shield(20)
  • Unscrew the four bolts on the pump bracket (13 ) of the frame (14 ).
  • Hammer lightly on rear end of the shaft (18 ) till the pump bracket (13) along with shaft (18 ) comes out of frame (5).
  • Remove the end shield ( 20 ) from the frame (14) after unscrewing four bolts.
  • Take out the shaft ( 18 ) along with 2 bearings from pump bracket ( 13 ) after unscrewing three screws from bearing cover
  • Remove both ball bearings from shafts by puler or hydraulic press.

Note :

  • Before assembling, all parts should be thoroughly cleaned in kerosene to remove dirt & dust. after cleaning, remove burrs from all parts, use new paper packing during assembly.
  • In case of ds series pumps (two stage pumps) there are two casings and impellers. these are to be removed one by one. also there is an additional sleeve which is to be removed.


Reassembly of the Monoblock :

  • Press the front and rear ball bearings on both the ends of the shaft (18 ) with the inner bearing covers.
  • Locate pump bracket ( 13 ) on front ball bearing and press it in to the bore by light hammering.
  • Locate the bracket ( 13 ) along with rotor shaft assembly on to the frame (14 ) and tighten it by four bolts.
  • Locate end shield (20 ) on rear ball bearing (19) and hammer lightly on end shield to take the location of frame (14). Tighten end shield (20) on frame (14) with the four bolts.
  • Slide fan ( 22 ) on the shaft and lock it with pin.
  • Locate the fan cover ( 40 ) on end shield ( 20 ) and fix it by four screws.
  • Push shaft sleeve ( 36 ) on shaft ( 18 ) with light hammering by mandrel up to the shaft step.
  • Locate backplate ( 9 ) on pump bracket (13 ) and fix it by four bolts.
  • Put seal plain washer ( 34 ) first in the bore then insert oliseal ( 33 ) by light hammering up to 1" to 1.5" deep, then put seal back washer (32 ) on the seal, now locate gland ( 28 ) and tighten it slowly by two nuts on the studs.
  • Slide impeller (2) on the shaft (18) and lock it by lock nut (38). Do not forget to put key (37).
  • Locate pump casing ( 3 ) along with gasket ( 8 ) on the back plate ( 9 ) and tighten it by studs already fitted on pump casing
Now the pump is ready for installation.
Note : in case of ds series pumps (two stage) ii stage impeller shall be fitted first and then ii stage casing with gasket shall be fitted. after this i-stage impeller shall be fitted and then i-stage casing with gasket shall be fitted. check the freeness of pump shaft after assembly.


Part List :

Part No Description Part No Description
1 Suction Flange 21 Wave Washer
2 Impeller 22 Fan
3 Volute Casing 23 Split Pin
4 Air Cock 24 Foundation Leg
5 Fiber Washer 25 FT. Bolt
6 Delivery Flange 26 Bearing D.E.
Gasket 27 Water Deflector
7 Delivery Flange 28 Gland (O.S./G.R)
8 Gasket 29 Stud
9 Back Plate (O.S./G.R) 30 Nut
10 Spring Washer 31 Spring Washer
11 Hex Nut 32 Al. Ring Coller
12 Stud 33 Oil Seal
13 Bracket (O.S./G.P) 34 Al. Ring Plain
14 Motor Frame 35 Suction Flange
15 Eye Hook Gasket
16 Stator 36 Sleeve
17 Rotor 37 Key
18 Shaft 38 Lock Nut
19 Bearing NDE 39 Gland Packing
20 End Cover 40 Fan Cover