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WARMAN PUMPS ASSEMBLY, OPERATING AND MAINTENANCE INSTRUCTIONS
PART 2F
UNLINED SUMP PUMP TYPE ‘SP’
PC2F
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
WARMAN PUMPS ASSEMBLY, OPERATING AND MAINTENANCE INSTRUCTIONS
PART
2F
UNLINED SUMP PUMP TYPE ‘SP’
Issue Date: 1 November 2000
Information in this publication is subject to change without notice. This publication may not be reproduced in whole or in part by any process, electronic or otherwise, without the specific written consent of Research and Development Pty Limited.
Copyright © Research and Development Pty Limited 2000
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
SAFETY INFORMATION
The following safety information relating to pump operation and maintenance should be carefully observed, and correct procedures followed, to avoid injuries to personnel, and damage to equipment. All statutory requirements relating to this equipment must be complied with at all times.
DO NOT APPLY HEAT TO THE IMPELLER HUB OR INLET EYE TO ASSIST IMPELLER REMOVAL. APPLICATION OF HEAT MAY RESULT IN SHATTERING OF THE IMPELLER , RESULTING IN INJURY OR EQUIPMENT DAMAGE.
DO NOT OPERATE THE PUMP FOR AN EXTENDED TIME WITH ZERO OR VERY LOW FLOWRATE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OVERHEATING OF THE PUMP, AND VAPORISATION OF THE PUMPED FLUID, WITH GENERATION OF VERY HIGH PRESSURES. SERIOUS INJURY TO PERSONNEL, OR DAMAGE TO EQUIPMENT MAY RESULT FROM SUCH ACTION.
CHECK DRIVE MOTOR ROTATION PRIOR TO FITTING OF DRIVE BELTS OR COUPLINGS. INCORRECT MOTOR ROTATION MAY CAUSE PERSONNEL INJURY OR EQUIPMENT DAMAGE.
DO NOT FEED VERY HOT OR VERY COLD FLUID INTO A PUMP AT AMBIENT TEMPERATURE. THERMAL SHOCK MAY RESULT IN FRACTURE OF PUMP WET-END PARTS.
A WARMAN PUMP MUST BE REGARDED AS BOTH AN ITEM OF ROTATING MACHINERY, AND A PRESSURE VESSEL. ALL RELEVANT SAFETY PRECAUTIONS AND PROCEDURES FOR SUCH EQUIPMENT SHOULD BE OBSERVED DURING PUMP INSTALLATION, OPERATION AND MAINTENANCE.
WHERE AUXILIARY EQUIPMENT IS ASSOCIATED WITH A PUMP (eg MOTORS, DRIVE BELTS, DRIVE COUPLINGS, SPEED REDUCERS, VARIABLE SPEED DRIVES, ETC), ALL RELEVANT INSTRUCTION MANUALS SHOULD BE CONSULTED, AND RECOMMENDED PROCEDURES IMPLEMENTED, DURING INSTALLATION, OPERATION AND MAINTENANCE OF THE PUMP SYSTEM.
ISSUE DATE : 1 November 2000
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
CONTENTS - PART 2F Page 1.
INTRODUCTION ............................................................................................................................................................ 2 - 1
2.
APPLICATION AND FEATURES OF UNLINED TYPE ‘SP’ SUMP PUMPS
3.
IDENTIFICATION OF PARTS.............................................................................................................................. 2 - 2
4.
BEARING ASSEMBLY – ASSEMBLY, MAINTENANCE AND LUBRICATION
5.
..................................................................................................................................................
PUMP ASSEMBLY INSTRUCTIONS 5.1
............
..........................................................................................................
2-1
2-2
2-3
Frame Assembly .......................................................................................................................... 2 - 3 5.1.1
Standard Duty Bearing Assembly
5.1.2
Heavy Duty Bearing Assembly .................................................................... 2 - 5
..........................................................
2-3
5.2
Pump Casing Assembly ........................................................................................................ 2 - 8
5.3
Miscellaneous Fittings ............................................................................................................ 2 - 10
6.
IMPELLER ADJUSTMENT
7.
DISMANTLING PUMP AND REMOVAL OF IMPELLER ............................................................ 2 - 12
..................................................................................................................................
2 - 12
APPENDIX - WARMAN BASIC PART NUMBERS ........................................................................ 2 - 13
ISSUE DATE : 1 November 2000
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
1.
PART 2F
INTRODUCTION
This publication, Part 2F, forms part of a set which together comprise the Assembly, Operating, and Maintenance Instruction Manual for the Warman Unlined Sump Pump, Type ‘SP’. Other publications in the set comprise the following: Part 1: Assembly, Operating and Maintenance Instructions – General Instructions for all Types of Warman Pumps. Part 3E: Vertical Bearing Assembly, Type ‘V’, Heavy Duty. Part 3F: Vertical Bearing Assembly, Type ‘V’, Standard Duty. Part 1 has been written to more specifically describe the horizontal Type AH pump, and hence sections not relevant to vertical sump pumps should be disregarded.
2.
APPLICATION AND FEATURES OF UNLINED TYPE ‘SP’ SUMP PUMPS
These pumps are of heavy-duty construction, designed for partially submerged mounting in pits or sumps. They are particularly suited to continuous pumping of highly abrasive slurries in the Mining, Chemical, and General Process Industries. They feature an unlined casing design, characterised by design simplicity, minimum number of parts, and light overall weight. Important design features of this range of Warman Slurry Pumps include: • • • • • •
Robust shafts Heavy duty bearing assemblies Heavy duty screw thread Impeller attachment Through-bolt design throughout Replaceable casing components No submerged bearings
Type ‘SP’ Sump Pumps may be supplied with either Standard Duty or Heavy Duty Bearing Assemblies. Standard Duty Bearing Assemblies are satisfactory for the bulk of sump pump applications. However for extreme operating conditions, involving high bearing loading, the longer bearing life yielded by the Heavy Duty Bearing Assemblies will often justify their use. All Standard Duty Bearing Assemblies are available in both Standard and High Head models, as indicated below. High Head models of the Heavy Duty Bearing Assemblies are available for a limited number of pump sizes only. Pumps fitted with Standard Duty Bearing Assemblies are characterized by a numeral representing PUMP SIZE (ie discharge pipe size in mms), immediately followed by FRAME TYPE (ie ‘V’), FRAME SIZE (eg ‘E’), and an optional IDENTIFIER for High Head models (ie ‘H’), followed by - PUMP TYPE (ie ‘- SP’), eg 100VE-SP, and 65VDH-SP Sump Pumps. High Head Sump Pumps (eg 65VDH-SP) are fitted with large diameter shafts for increased stiffness, which results in increase of critical vibration speeds, and corresponding maximum operating pump speeds, to higher values than for the equivalent standard Bearing Assembly.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
Pumps fitted with Heavy- Duty Bearing Assemblies are characterized by a numeral representing PUMP SIZE (ie discharge pipe size in mms), immediately followed by FRAME SIZE (eg ‘R’), FRAME TYPE (ie ‘V’), and an optional IDENTIFIER for High Head models (ie ‘H’), followed by - PUMP TYPE (ie ‘- SP’), eg 100RV-SP, and 100RVH-SP Sump Pumps.
3.
IDENTIFICATION OF PARTS
Each Warman pump part has a unique name and a three-digit Basic Part Number. Parts with the same name have the same Basic Part Number, regardless of pump size. For example, the Shaft of every Warman pump has the Basic Part Number 073. Additional letters and numbers are added before and after the Basic Part Number to further define a component part of a particular pump, as described in Part 1 of the Assembly, Operating, and Maintenance Instruction Manual. This expanded marking is identified as the Part Number, and represents a unique identification for each component part. The Part Number is normally cast or otherwise prominently marked on each part. For example, Part Number SP10092 identifies the Casing to fit the 100RV-SP, 100VE-SP, and 100VEH-SP Warman Sump Pumps. Refer to the Component Diagram of the appropriate size of Warman Pump for complete identification and description of component parts. Part names and Basic Part Numbers are used in assembly instructions throughout this instruction manual. Warman Basic Part Numbers for all component parts of Type ‘SP’ pumps are listed in the Appendix of this publication. In all communications with the C.H. Warman Group, or its representatives, and particularly when ordering spare parts, it is recommended that the correct component names and Part Numbers be used at all times to avoid supply of incorrect parts. The pump serial number should also be quoted if any doubt exists as to part identification.
4.
BEARING ASSEMBLY – ASSEMBLY, MAINTENANCE AND LUBRICATION
The Bearing Assembly is assembled and maintained, generally as described in the separate publications, Part 3E, and 3F of the Instruction Manual as listed in Section 1. Part 3E describes the Heavy Duty, and Part 3F describes the Standard Duty, Type ‘V’, Bearing Assembly, each of which fits a range of different types of Warman Series ‘A’ pumps. It is recommended that grease used for lubricating the rolling bearings should have the following characteristics: Lithium soap base grease with EP additives and oxidation inhibitors. N.L.G.I. Consistency No: Drop Point Work penetration 25°C A.S.T.M.
2 > 170° C 265 – 295
RECOMMENDED GREASE:
SHELL ALVANIA EP GREASE 2, CASTROL EPL2, or equivalent.
For detailed description of lubrication requirements for the rolling bearings, refer to the separate publications, Part 3E, and Part 3F of the Instruction Manual as listed in Section 1.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
5.
PART 2F
PUMP ASSEMBLY INSTRUCTIONS
Reference to a Component Diagram for the particular pump being assembled will be of assistance in following the instructions outlined in the following sections. All parts dismantled during pump overhaul should be inspected to assess suitability for reuse, and identification of new parts should be checked. Parts suitable for re-use should be cleaned and painted. Matching faces should be free of rust, dirt, and burrs, and have a coating of anti-seize compound applied prior to assembly. Small fasteners should preferably be replaced, and all threads coated with graphite grease before assembly. Replacement of all elastomer seals is recommended at major overhauls, as these materials tend to deteriorate with use. Exposure to direct and continuous sunlight will accelerate material degradation. 5.1
FRAME ASSEMBLY
Type ‘SP’ Sump Pumps may be fitted with either Standard Duty or Heavy Duty, Type V, Vertical Bearing Assemblies. 5.1.1
Standard Duty Bearing Assembly - Fitting of Column and Mounting Plate - Refer Figs 1 and 2
For Pump Sizes:
40VC-SP, 40VCH-SP, 65VD-SP, 65VDH-SP, 100VE-SP, 100VEH-SP
(i) Fully assemble BEARING ASSEMBLY (005) in accordance with instructions in Warman Manual Part 3F. (ii) With Bearing Assembly mounted horizontally, and lubrication block uppermost, fit MOUNTING PLATE (019) to Bearing Assembly, ensuring that they are aligned as indicated in Figs 1 and 2. Carefully note orientation of Grease Nipples, and Grease Tubes. Take particular care during pump assembly to avoid damage to the exposed Grease Tubes. (iii) Fit four SPACERS (290) between Bearing Assembly mounting flange, and top of Mounting Plate flange at each bolt hole. Fit BEARING HOUSING BOLTS and tighten evenly. (iv) Fit DISCHARGE PIPE SUPPORT (293) angle bar to Mounting Plate channel members, aligning corresponding holes in each. Upturned flange of Discharge Pipe Support should be positioned remote from Bearing Assembly, as shown in Fig 1. Fit two DISCHARGE PIPE SUPPORT SCREWS to fasten Discharge Pipe Support to Mounting Plate, and tighten firmly.
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PART 2F
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
(v) If upper mesh STRAINER (116-4) to be fitted - Fit STRAINER (116-4) inside drive-end of COLUMN (102), and slide to other end, with end of Strainer resting on end flange of Column. Intake openings of Column should be fully covered by Strainer mesh. If elastomer or cast metal upper STRAINERS (116-1, 116-2, 116-3) to be fitted, in lieu of mesh STRAINERS (116-4) – These will be fitted at a later stage in the assembly, refer Section 5.3 (vi)(a). (vi) Fit COLUMN (102) around Shaft and engage with lower flanges of Mounting Plate, ensuring that bolt holes are aligned. (vii) Fit four COLUMN BOLTS to fasten Column to Mounting Plate, and firmly tighten.
5.1.2
Heavy Duty Bearing Assembly - Fitting Upper Strainer, Column, and Mounting Plate - Refer Figs 3 and 4
For Pump Sizes:
40PV-SP, 65QV-SP, 100RV-SP, 150SV-SP, 200SV-SP, 250TV-SP, 300TV-SP, 100RVH-SP
(i) Fully assemble BEARING ASSEMBLY (005) in accordance with instructions in Warman Manual Part 3E.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
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PART 2F
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
(ii) If upper mesh STRAINER (116-4) to be fitted – Fit STRAINER (116-4) inside drive-end of COLUMN (102), and slide to other end, with end of Strainer resting on end flange of Column. Intake openings of Column should be fully covered by Strainer mesh. If elastomer or cast metal upper STRAINERS (116-1, 116-2, 116-3) to be fitted, in lieu of mesh STRAINERS (116-4) – These will be fitted at a later stage in the assembly, refer Section 5.3 (vi)(a). (iii) Fit Bearing Assembly to COLUMN (102), ensuring that they are aligned as indicated in Fig 4. Carefully note the orientation of the Grease Nipples. (iv) Fit four SPACERS (290) between Bearing Assembly feet, and top flange of Column. Fit COLUMN BOLTS and tighten evenly. (v) Screw COLUMN STUDS into tapped holes in two sections of MOUNTING PLATE (019) (vi) Place two sections of split Mounting Plate around Column, below top flange, orienting to suit discharge pipe position, and engage studs with holes in flange, as shown in Fig 4. (vii)
Fit Nuts to Studs, and firmly tighten to fix Mounting Plate to Column.
ISSUE DATE : 1 November 2000
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
5.2
PART 2F
PUMP CASING ASSEMBLY - Fitting Back Liner, Impeller, Casing and Suction Strainer - Refer Fig 5 (i) It is recommended that the partly assembled unit be inverted for assembly of pump casing components, by supporting the assembly on a hoist with the impellerend upwards. (ii)
Fit BACK LINER SEAL (125) to matching groove in end face of Column.
(iii) Place BACK LINER (041) over impeller-end of Shaft, and engage Liner spigot with bore of Column end face, ensuring that the Back Liner contacts the Seal evenly. (iv) Fit IMPELLER O-Ring (064) to groove on end of Shaft. Apply heavy grease to O-Ring groove to hold the O-Ring which seals against the back face of the Impeller. (v)
Apply anti-seize compound liberally to Shaft thread.
(vi) Select the appropriate IMPELLER required for the pump assembly, and fit as follows: (a) Place impeller (thread up) on a flat surface, apply anti-seize compound to thread, and screw Impeller to Shaft. (b) Fit SHAFT KEY (070) in Shaft keyway at drive-end, and bolt SHAFT WRENCH (306) to Shaft over key. While restraining Shaft with Wrench, and turning Impeller with a bar between vanes, firmly screw Impeller to Shaft, but do not overtighten. (vii) Fit STRAINER (LOWER) (116L) to CASING (092), and bolt together using INTAKE FLANGE BOLTS. (viii) Lift Casing, using a hoist, and position on end of Column, with orientation as shown in Fig 4. Check that Impeller turns freely, without contacting Casing surfaces. If necessary, add or remove SPACERS (290) between Column flange and Bearing Assembly. Fit three COLUMN BOLTS to fasten Casing to Column flange, and tighten evenly. NOTE: Column bolts should be tightened only sufficiently to compress Backliner Seal, and bring Casing and end face of Column into contact. DO NOT OVERTIGHTEN COLUMN BOLTS (ix) Check again that Impeller turns freely, without contacting surfaces of Casing. Adjust Spacers between Column flange and Bearing Assembly if required.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
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PART 2F
WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
5.3
PART 2F
MISCELLANEOUS FITTINGS - Refer Figs 6 and 7
(i)
Position pump horizontally with discharge pipe upwards.
(ii) Apply contact cement to face of DISCHARGE PIPE GASKET (204) and to end face of Casing discharge flange. Fit Gasket to Casing discharge. (iii) Fit DISCHARGE PIPE (154), and secure with DISCHARGE PIPE BOLTS. Tighten bolts.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
(iv) Only Sump Pump with Standard Duty, Type ‘V’, Bearing Assembly Refer Fig 6. Fit U-BOLT (421) around top end of DISCHARGE PIPE (154) with ends projecting through matching holes in DISCHARGE PIPE SUPPORT (293). Fit two Nuts and firmly tighten to secure Discharge Pipe to Discharge Pipe Support. (v) Only Sump Pump with Heavy Duty, Type ‘V’, Bearing Assembly. Refer Fig 7. Fit DISCHARGE PIPE RETAINING SCREW AND NUT to fasten top end of Discharge Pipe to Mounting Plate. Firmly tighten Nuts.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
(vi)
PART 2F
All Type ‘SP’ Sump Pumps – Refer Figs 6 and 7 (a) If elastomer or cast metal upper STRAINERS (116) to be fitted, in lieu of mesh STRAINERS (116-4) described in 5.1.1 (v) or 5.1.2 (ii) - Fit three (3) upper STRAINERS (116) as follows. Bend elastomer Strainer slightly, and fit into cut-out in Column so that the four Strainer lugs clip into sides of Column cut-out, and hold Strainer firmly. (b) If applicable, fit SUCTION PIPE (231), with or without STRAINER (LOWER) (116L), according to requirements. (c) Fit elastomer NUT COVERS (430) to all external nuts to prevent fouling of threads with slurry.
The pump assembly is now substantially complete, and ready for fitting of drive components.
6.
IMPELLER ADJUSTMENT
No provision is made for periodic adjustment of Impeller end clearances in Type ‘SP’ Sump Pumps, as is provided in horizontal Warman Pumps to compensate for effects of wear on pump performance. During pump assembly, Spacers are fitted between the Bearing Housing and Column upper flange to provide satisfactory Impeller end clearances in the Casing, and compensate for manufacture tolerances. When wear of the Impeller and casing progresses to the stage that pump performance is reduced to an unsatisfactory level, the pump casing should be dismantled and worn parts replaced.
7.
DISMANTLING PUMP AND REMOVAL OF IMPELLER
The procedure for dismantling the pump is generally the reverse of that described for pump assembly. Access to the IMPELLER requires removal of the CASING (092). This may be removed after hoisting the Pump from the sump to give access to the wet-end. Impellers are fitted to Shafts with a right hand screw thread attachment on all Warman pumps. Impeller removal generally involves applying an impulsive torque loading to the Impeller, while separately restraining the Shaft from rotation.
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WARMAN PUMPS — Assembly, Operating, and Maintenance Instructions
PART 2F
APPENDIX WARMAN BASIC PART NUMBERS
WARMAN BASIC PART No. 005 019 041 064 070 092 102 116-1 116-2 116-3 116-4 116L 125 154 204 231 290 293 306 430 A05A -
STANDARD WARMAN MATERIAL CODE E02 A05A S18 E05 A05A E02 R10A G01 U02A C23 U01A R08A E02 R00 E02 E02 E02 E02 U04A -
PART NAME Bearing Assembly Mounting Plate Back Liner Impeller O-Ring Shaft Key Casing Column Strainer – Upper (Rubber) Strainer – Upper (Cast Iron) Strainer – Upper (Urethane) Strainer – Upper (SS Mesh) Strainer – Lower Back Liner Seal Discharge Pipe Discharge Pipe Gasket Suction Pipe Spacer Discharge Pipe Support Shaft Wrench Nut Covers Bearing Housing Bolts Column Studs Column Bolts Discharge Flange Bolts Discharge Pipe Bolts Discharge Pipe Retaining Screws Discharge Pipe Support Screws Impeller Intake Flange Bolts
NOTE: For details of specific Warman Material Codes, refer to Assembly, Operating and Maintenance Instructions, Part 1 – General Instructions for all Types of Warman Pumps, Appendix B.
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