- Run a rope through eyebolt (910.01) of the bearing bracket and lift the assembly unit through a crane. Note: The eyebolt may not in the center of gravity.
- Insert assembly unit cautiously into the pump casing (102.01). Lubricate threads and support surfaces for nuts, screw on hexagonal nuts (920.01) and tighten evenly and crosswise.
- If present: Fasten support foot (183.01) at the bas eplate pedestal.
Final assembly
Coupling
- Mounting the coupling half: to do so, remove heat-sensitive parts
(e.g. rubber buffers and seal rings etc.) and heat up the coupling half to approx. 80 oC by means of uniform dry heat (e.g. oven or hot plate). Slide the coupling half onto the shaft and fit removed parts again after it has cooled down. Couplings with bores up to a diameter of 50 mm can also be fitted cold with an appropriate attachment.
The bearings must by no means be subjected to any pressure or shock
Ancillary equipment
- Install auxiliary lines and instruments.
Do not mix up connections. Carefully check piping system
.
Driver
- Couple the driving unit.
- Check coupling alignment (see 5.2), check free running of the rotor. - Fit the coupling guard.
Electrical connections for motors and controllers must only be produced by an electrician.
When re -commissioning, all steps described in Section 6.1 must be repeated. ATTENTION ATTENTION ATTENTION pump shaft coupling half bar nut stud Impeller Shaft Impeller nut Sketch 7.6-3 Securing screw
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8. OPERATING FAULTS
Hydraulic or mechanical causes can seriously affect the operation of a pump. There are other justifiable operating faults in the plant.
There is usually a certain connection between the different types of faults. It is, therefore, expedient to list and compare the symptoms as well as the possible causes. Assistance can be found for individual operating faults in virtually all cases.
8.1 Symptoms / Possible causes of faults / Remedies
Symptoms
Possible causes of faults
Remedies
Driver out of service, speed too low Check - refer to manufacturer‘s manual
Rotor blocked Check and correct
Wrong direction of rotation Check-refer to pump rotation arrow
Pump not primed Vent pump
Suction valve/line blocked Inspect and correct Foot valve blocked or damaged Inspect foot valve 1 Pump does not work.
No discharge pressure.
(Failure at startup)
Impeller passages blocked Inspect pump internals Suction pipe not completely full Fill the system Too much air or gas in the pumped
liquid
Check operating data (1.4) 2 Loss of discharge
pressure after startup
Leakage of air into pump suction Check and correct (seal) Suction or Discharge valve not fully
open
Check valve position and correct as required
Suction strainer blocked Disassemble and clean strainer Minimum flow line open, minimum
flow valve damaged or bypass orifice worn
Check minimum flow line, minimum flow valve, bypass orifice (5.4) Furring of the pump internals and/or
pipework
Clean and flush pipework. Disassemble and clean pump internals.
Impeller passages blocked Disassemble and inspect pump internals
3 Pump flow too small. Differential pressure too low.
Efficiency loss
Pump internals worn (gap clearances) Disassemble and inspect pump clearances (7.5)
Coupling alignment faults Check coupling alignment (5.2) Worn shaft coupling Check coupling condition and replace Suction valve not fully open Check and correct (open fully) Suction strainer blocked Disassemble and clean strainer Pump runs with cavitation Check operation data (1.4). Create
more pressure at the pump suction. Piping strain, excessive high nozzle
forces and moments
Piping should be properly supported to prevent strains from being imposed on the pump
Foundation too weak, base not or not correctly grouted
Inspect foundation bolt tightening and baseplate grouting (5.1)
Impeller damaged or blocked Inspect pump internals
Bearings damaged Disassemble and replace bearings (7.4 to 7.6)
Unbalanced rotor – causes vibration Check balance of coupling, driver and pump rotating parts
4 Pump vibrates or causes too much noise
Shaft bent Disassemble and check shaft runout
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Symptoms
Possible causes of faults
Remedies
Seal flush insufficient (flow rate) or missing
Check flow requirements Wrong orifice size or worn orifice Check size, flow requirements Solids block seal rings/springs Disassemble and remove solids,
review application
Vaporisation in the seal ring area Check circulation flow or cooling requirements (1.4, 7.2)
Seal fluid not suitable (abrasive) Review application, install filter or separator
Seal rings, auxiliary gaskets (O-rings) or springs damaged
Disassemble and replace damaged seal parts (7.4 to 7.6)
Dry operation of seal. Seal system not correctly filled or vented
Fill and vent shaft seal chamber/system
Seal face material inadequate Review application with seal manufacturer
5 High shaft seal temperature. High leakage of mechanical seal. Short shaft seal life
Pump shaft bent Check shaft runout at seal area Pump not running at operating point Review operating parameters (1.4) Coupling alignment faults Check coupling alignment (5.2) Too much grease or oil in the bearing Check and correct (7.3) Oil level too low or high Check and correct oil level (7.3) Wrong lube oil quality Verify that recommended lubricant is
used (7.3, T 3). Change lube oil. Bearings loaded during assembly Examine assembly and condition of
bearing and associated parts (7.4- 7.6)
Insufficient bearing cooling (air / water) Check air intake (environmental temperatures under noise hoods). Check cooling water requirement (1.4)
Bearings damaged Disassemble and replace bearings (7.4 to 7.6)
Excessive pump thrust Check hydraulic balance device, balance pipe. Disassemble and inspect pump internal clearances (7.4 to 7.6)
6 High bearing temperature. Short bearing life.
Shaft bent Disassemble pump and check shaft
runout (7.5)
Oil level too high Check and correct oil level (7.3) Labyrinth seal or shaft seal ring
improperly installed
Examine assembly (labyrinth leakage bore downwards)
7 Lube oil leakage
Bearing cover gasket or seal damaged Disassemble and replace gaskets/seal (7.4, 7.6) Pump not running at operating point
Insufficient suction pressure. Operating fluid differs from specified value (temperature, specif. gravity...) 8 Excessive wear of
pump internals - Corrosion - Erosion
- Loss of material
Materials of construction not compatible with medium delivered
Review pump operating parameters with a Sulzer representative, make necessary correction to unit design. Refurbish pump with correct parts, clean system. Assemble filter or separator.
9 Pump
overheating/seizure
Operating below minimum flow (pump dry running)
Review hints for minimum flow. (1.4, 5.4) In case of seizure disassemble and repair unit.