Fire Pumps Data Book 2 IOM Section 3

8/11/2019 Fire Pumps Data Book 2 IOM Section 3

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Operating & Maintenance, FIRE PUMPS3.3 Operating & Maintenance, Main Pump IRON QH 20/3203.4 Operating & Maintenance, Feeding Pump DESMI DSL 400/430



IRON Pump A/S

Page 1

MOUNTING AND OPERATING INSTRUCTIONS

FOR PUMPS

YOUR REF.

PURPOSE : Fire fighting

ORDER NO.: 8505

PROJECT : Deres 8505

IRON REF.

PUMP NO. : FQV3370

ORDER NO.: 3572827

PUMP TYPE: QHGV-400-350/500

IMPORTANT: Read this manual before mounting and starting the pumps



IRON Pump A/S

Manual identification no. qhdv2870201eElleh

Page 2

Technical data..............................................................................................................4

Operating instructions for Centrifugal pumps.........................................................5

1.0 Product Description.................................................................................................................5

1.1 Capacities and Applications ....................................................................................................5

1.2 Construction and function .......................................................................................................5

1.3 Risks and leakages...................................................................................................................5

Demands for the mounting setup ...............................................................................6

2.0 Environment conditions...........................................................................................................6

2.1 Space requirements..................................................................................................................62.2 Foundation...............................................................................................................................6

2.3 Leakages..................................................................................................................................6

Transport and installation of pumps .........................................................................7

3.0 Condition on delivery ..............................................................................................................7

3.1 Transport and storage ..............................................................................................................7

3.2 Mounting on the foundation ....................................................................................................7

3.3 Installation of the pump...........................................................................................................7

3.4 Pipe installation .......................................................................................................................83.5 Installation of pipelines ...........................................................................................................8

3.6 Recommended accessories ......................................................................................................8

3.7 Safety arrangements ................................................................................................................8

3.8 Disassembling and transport....................................................................................................8

Running instructions for centrifugal pumps.............................................................9

4.0 Prevention of accidents............................................................................................................9

4.1 Start up.....................................................................................................................................9

4.2 During start up.........................................................................................................................94.3 Stand-by pump.........................................................................................................................9

4.4 Lubrication ............................................................................................................................10

Dismantling and Assembling instruction ................................................................11

5.0 Repairs...................................................................................................................................11

5.1 Disassembling and opening the pump...................................................................................11

5.2 Removing of the rotating element .........................................................................................11

5.3 Disassembling of the rotating element ..................................................................................11

5.4 Mounting ...............................................................................................................................115.5 Rotating element....................................................................................................................12

5.6 Assembling of the pump........................................................................................................12

5.7 Fastening of screws in the volute casing ...............................................................................12



IRON Pump A/S

Manual identification no. qhdv2870201eElleh

Page 3

Installation HUHNSEAL type HQB........................................................................13

Dimension drawing for HUHNSEAL type HQB....................................................14

Centrifugal pump wear ring clearances ..................................................................15

Instruction drawing for pump..................................................................................16

Parts list for pump.....................................................................................................17

Interruption of operations ........................................................................................19

6.0 Error finding ..........................................................................................................................19



IRON Pump A/S

Page 4

e.data

Technical data

Pump:

Type : QHGV-400-350/500

Capacity : 1.150,0/1.700,0 m3/h

Total head :

Head : 90,00

Suction head :

Inlet pressure :

Mech. seal : Carbon / Ceramics max 80 C

Gland packing :

Coupling type :

Weight kg. : 1700

Material:

Pump casing : Bronze RG10

Impeller : Ni.Al.Bronze

Casing wear ring : Ni.Al.Bronze

Shaft : AISI-329

Motor:

Type :

KW :

Power consumption kW : 370,00/470,00 max. 475,00

RpM : 1800

Voltage :

Weight kg :



IRON Pump A/S

Page 5

e0121

Operating instructions for Centrifugal pumps

1.0 Product Description

This description applies for centrifugal pumps from the pump factory IRON LTD.

The type and number of the pump together with the order no. is to be found in the technical data sheet.

1.1 Capacities and Applications

The maximum pressure, the permissible temperature and the pump media we have set the pump for is

stated in the technical data sheet. The performance of the pump can be seen in the graph.• IRON LTD. does not render any guarantee if the type of liquid or other important working conditions

have been insufficiently specified or omitted.

• If the working conditions differ from those given in the technical data sheet Contact us before putting

the pump into operation.

1.2 Construction and function

Type QHDV is a horisontal centrifugal pump with 2 external bearings and mechanical shaft sealings (can

also be supplied with a stuffing boxes) - for remaining details see the technical sheet.

In principal a centrifugal pump is built up in the following manner:

It consists of an impeller furnished with blades that are normally curved backwards in relation to its

direction of rotation. The impeller is situated in a spiral pump case (snail shell). The pump case is

equipped with a suction flange and a pressure flange.

Before the pump is started the pump case and the suction line must be filled with water (or other liquid

which is to be pumped).

When the impeller starts rotating the blades cause the liquid to rotate in relation to the pump case.

Centrifugal force will sling the liquid out of the impeller and into the spiral of the pump case. This causes

a vacuum in the centre of the impeller exactly where the entrance is situated. As atmospheric pressure

influences the surface of the water in the well (or in the tank from which one wishes to pump from) the

created vacuum (differential pressure) effects the fluid in the suction line and presses in into the centre of

the impeller.

When the water is slung out of the impeller and into the spiral of the pump case the velocity energy

which is created is changed to pressure energy. The pressure effects the amount of water in the pressure

line and starts this moving and hereby creates a continual flow (regular flow) from the suction line

through the pump to the pressure line.

1.3 Risks and leakages

IRON LTD: Products comply with the regulations for work safety and accident precautions.

If the workers are exposed to danger due to the media used having for example too high temperatures,

they must ensure that the necessary protection precautions are made.



IRON Pump A/S

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Demands for the mounting setup

2.0 Environment conditions

Standard pumps are intended for installing in dry rooms free from aggressive atmosphere and having a

temperature between + 10 and 40 deg.C. Mounting under other conditions (e.g. outdoors, in damp rooms

etc.) is only allowed if it stated in the technical data sheet and is therefore suitable for these conditions.

2.1 Space requirements

The space required for the pump and the positions of the foundation holes are given in the dimension

print.

2.2 Foundation

The foundation with its mass must counteract vibrations, take up small outside stresses such as hydraulic

strain and “fitting in” forces from the pipelines.

• Damages due to insufficient or faulty foundation is not covered by the guarantee.

2.3 Leakages

Leaking can arise from the mechanical shaft seals so it is recommended to fit a drainpipe to them.

When the pump is supplied with a stuffing box, it is always leaking from the gland.



IRON Pump A/S

Page 7

e0300Elleh

Transport and installation of pumps

3.0 Condition on delivery

IRON LTD. products are inspected for perfect condition and function before leaving the factory. The

pump has been tested with water complying with the capacity ratings that are given in the technical data

sheet and shown in the graph.

3.1 Transport and storage

Standard packing protects the pump against corrosion by land transport and storage in dry rooms for atleast 3 months. For longer storage it is necessary to make special protection measures.

Seaworthy packing protects the pump for land and sea transport and dry storing (under cover or in closed

rooms) for at least 3 years. On arrival at its destination, the packing must be examined to ensure that it is

in a condition to guarantee protection in storage.

• The cases can be opened when:

• Large damage is found.

• The goods are to be stored for a longer period than originally planned.

• In all other cases the goods must not be opened until the pump is to be installed. When unpacking

check that the order is complete and correct.

3.2 Mounting on the foundation

If the pump and motor are delivered separately, they must be assembled on a base , see instructions for

fitting the couplings. After being assembled the unit can be mounted directly on to a suitable foundation.

3.3 Installation of the pump

The whole pipeline system must be pressure tested and examined for leakages and rinsed out before con-

necting to the suction and delivery flanges of the pump. If the pump has been installed before the pres-

sure test care should be taken to ensure that the test pressure does not exceed the test pressure of thepump (stamped in the pump, usually in the suction flange) otherwise damage can be caused to the pack-

ing or the mechanical shaft seals of the pump. When connecting the pipelines to the pump, do not use

force as this can damage the alignment of the pump.

Precautions must be taken to support the pipelines so as prevent inadmissible strain being transferred to

the pump due to expansion.

Check all connections to the pump e.g. lubrication, priming, heating, cooling media drainage etc. and

various measuring instruments are all properly connected. Make sure that nothing prevents access to the

pump for inspection or replacing parts. adequate room must be made for axial split case pumps in order

to disassemble the upper half of the casing.



IRON Pump A/S

Page 8

3.4 Pipe installation

Points to be considered:

Loss of pressure in the suction line must be kept at a minimum in order to avoid cavitation in the pump.

Static suction height + loss of pressure in the suction line + NPSH value for the pump + steam pressure

must not exceed 10 mWC at sea level. Long suction pipes making air pockets possible should be

avoided.

3.5 Installation of pipelines

Suction and pressure lines must be connected to the flanges of the pump free from strain, as eventual

stresses are taken up at fixed points and therefore suitable compensators should be installed in the pipe

system. The flanges in between which the pump is installed must be absolutely parallel.

3.6 Recommended accessories

As the pump, especially the mechanical shaft sealing, is designed to run with clean water without sludge

a suitable filter must be installed in the suction line, and if the mechanical shaft seals are not furnished

with external cooling a filter must be installed in the circulation pipe. A filter having a large area and

which can be cleaned is recommended.

IRON LTD. can supply suitable filters.

3.7 Safety arrangements

If the pump should run with closed valves for a longer period of time, it should be furnished either with

temperature control equipment or recirculation, otherwise it will run hot.

3.8 Disassembling and transport

• Before sending the pump for repair, Please note the following:

• All media remains to be removed from the pump.

The sender is liable for damage inflicted to the pump or other goods caused by media remains leaking.



IRON Pump A/S

Page 9

e0463

Running instructions for centrifugal pumps

4.0 Prevention of accidents

Ensure that the pump and motor are mounted according to instructions, all connections are right and the

necessary screens and guards are in order.

If the workers should be exposed to danger e.g. the media having high temperatures, the user must take

the necessary precautions such as periodic examination for leakages from all packings.

Air escape valves are to be opened very carefully.

The pump must be emptied before it is opened.

4.1 Start up

Before starting, make sure that there is grease in the bearing houses - see next page.

Carefully fill the pump with water and let the air escape as follows:

• Unscrew the plug on the top of the pump and make sure that the water does not come too quickly as

this can cause pressure thrusts which can destroy the mechanical shaft seal.

• When the pump is full and all the air is out, screw the plug on.

• This air escape operation is very important because otherwise the shaft seal can be destroyed.

• Check the coupling.

• Ensure that the pump can be turned by hand.

• Start the motor for a short period and check the direction of rotation - Remember that the pump must

be filled with water, or the coupling removed, so as not to destroy the shaft seals.

4.2 During start up

Normally the pump is started with discharge valve closed and filled with water.

After starting, the discharge valve is slowly opened until the working point is reached.

Immediately after start, check for noise and vibrations. At the normal head of the pump and after running

for about a minute it should have a very steady motion without unusual noise and vibrations.

Check bearing temperature - max. 105 deg.C.

Check seal housing for leakages.

4.3 Stand-by pump

If the pump is not used frequently it must started or rotated at least once a week to avoid damaging the

shaft seals.



IRON Pump A/S

Page 10

4.4 Lubrication

The pump bearings are greased with Mobiltemp SHC 100 or similar grease.

Lubricating intervals are 1000 hours at 1500 - 1800 rpm.

The bearing are greased while the pump are running until new grease is comming aut.

• Check every 3 months:

Unusual noise, vibrations and leakages.

Pumps with mechanical shaft seals must not leak either during standstill with inlet pressure on the pump

or when running. Circulation pipe to the mechanical shaft seal must be intact and not blocked. If any of

these points are lacking, they must immediately be put right, otherwise any defects can have great impor-

tance to the function of the pump and its lifetime.

• Check every 12 months:Take the pump apart (see instruction).

The rotating parts are checked and repaired of necessary. Normal clearance between the impeller and

sealing ring is 0,45-0,50 mm. Maximum clearance is 0,8-1,0 mm. depending on the size and capacity.

The pump is lubricated in accordance with the following table:

Grease lubricated bearings

Pump type All types

Nato code / DIN G 395

BP ENERGREASE LS-EP2

CASTROL SPHEEROL AP 2/3

CHEVRON DURA LITH GREASE EP2

ESSO BEACON EP2

MOBIL MOBILTEMP SHC 100

Q8 REMBRANDT EP2

SHELL ALVANIA GREASE EP2

TEXACO MULTIFAK ALL

PURPOSE EP2



IRON Pump A/S

Page 11

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Dismantling and Assembling instruction

5.0 Repairs

If you undertake repairs your self, you are requested to follow these instructions or contact our service

department.

• When ordering spare parts state the following:

• Pump type.

• IRON LTD. order No. (is normally stamped in the suction flange and on the nameplate situated on the

support).

• Pos. No. Name and No. of part (Instructions drawing and parts list).

For gasket, use non-asbestos 1 mm thick.

5.1 Disassembling and opening the pump

• Mechanical seal covers pos. 471 are carefully unscrewed. To protect the seat of the shaft seal put a

piece of paper or such round the shaft and under the seat

• Various connections, such as cooling pipes, temperature feelers are unscrewed and removed from the

upper half of the pump casing.

• After removing all the nuts from the studs in the pump casing, the upper part can then be lifted off.

5.2 Removing of the rotating element

• The coupling is disassembled - see instruction for coupling.

• The clamp for the bearings on the bearing pedestals are removed.

• The entire rotating element, incl. the bearing housing and the seal ring, is lifted out of the pump.

5.3 Disassembling of the rotating element

• The coupling is pulled off.

• The bearing covers are removed.• The bearing nut pos. 923 is removed - after the lockwasher has been bent free.

• The bearing housing with bearings is removed from the shaft, and the bearings removed from the

bearing housing.

• The shaft seals, the spacer sleeves pos. 525.2 and the casing wear rings are removed from the shaft.

• The impeller nuts are removed.

• The impeller can now be pulled off / pressed out.

5.4 Mounting

To make disassembling of the pump easy next time and to avoid damages all joints and bolts must begreased with “Never Seez” before assembling.



IRON Pump A/S

Page 12

5.5 Rotating element

• The impeller is pulled / pushed on shaft after cleaning of the shaft for possible flashes, the place for

the impeller is cleaned as well. The impeller nuts pos. 922 are mounted but not fastened.

• After cleaning the shaft, the spacer sleeves pos 525.2, the mech. seals and the seal covers pos. 471 are

mounted on the shaft, remember the gaskets for the seal covers.

• The casing wear rings pos. 502 are mounted on the impeller.

• The bearing housing - with the shaft seal ring pos. 420.2 mounted - are mounted on the shaft.

• The bearings are heated to 80 degree C. and are mounted on the shaft. Bearing nuts with lockwashers

are put on, fastened and locked.

• The bearing cover pos. 360 with the shaft seal ring pos. 420.1 mounted, and the bearing end cover

pos. 361, are mounted.

• The coupling half is heated max. 80oC. put on the shaft and the coupling mounted.

5.6 Assembling of the pump

• Before the pump is assembled the pump casing is cleaned inside and may be painted (e.g. with Apex-

ior No.3) or treated with more resistant products (e.g. Hempadur No.15/3 “Hempel Marine Paints”).

• The complete rotating element is put in the bottom part. The bearing closest to the coupling is guiding

the shaft axially. Place the casing wear rings correct in the volute casing.

• The clamps and the bearing housings are fastened in the bearing bracket lantern.

• The impeller nuts pos. 922.1+2 are fastened and secured so the impeller is correct placed in the volute

casing. Secure the spacer sleeves with the headless screws. Place the shaft seals correct - see instruc-

tion for mech. seal.• The volute casing top part is put on, all bolts are greased with “Never Seez” before screws and nuts

are mounted and fastened.

• All connections, i.e. cooling pipe, sensor and the like are mounted.

5.7 Fastening of screws in the volute casing

• When the pump is assembled and all screws are mounted they can be fastened.

• The bolts in the casing joint surfaces are fastened by appr. 60% of the specified moment, in order for

the gasket to “fall in” and then fastened 100%. See torque table below.

The chart is valid for bolts greased with “Never Seez”

Designation

Fastening Moment Nm

BoltStainless steel Steel

Bolt for volute casing 470 650 M 24

Bolt for clamp 220 M 16

Bolt for bearing cover 45 M 10

Bolt for seal cover 150 220 M 16

Bolt for bearing housing 90 M 12



IRON Pump A/S

Page 13

Installation HUHNSEAL type HQB

Installation

When installing a seal, the following points need to be taken into

consideration:

Working with seals should only take place if the system is turned of

and pressure free.

Insure that the place of fitting is clean.

Build-in dimensions (± 0.2mm) and tolerance (concentricity

tolerance and seal chamber bore) have to be followed.

Concentricity tolerance:

Diameter < 50mm:

=> max. 50 µm

100mm < Diameter <

100mm:

=> max. 80 µm

Diameter > 100mm:

=> max. 100 µm

Seal chamber bore:

Sliding velocity vg < 25 m/s

=> max. 0,2 mm

Sliding velocity vg > 25 m/s and

double seal with buffer fluid

=> max. 0,1 mm

Soapy water, soap or glycerine can be used to ease installation.

Grease containing silicone may not be used.

Mineral oil or grease may not be used together with EPDM O-Rings.

Sliding rings should not come in contact with lubricant, they should

be installed dry, dust-free and clean.

The installation of the seals must be done carefully and the

installation notes should be considered.

After the seal is installed, the buffer space (seal chamber) must be

carefully vented to prevent damage to the sliding faces from dryrunning.



IRON Pump A/S

Page 14

Dimension drawing for HUHNSEAL type HQB

D D1 D2 D3 L1 L2 L3

65 85 77 90 49 12,0 11,0

68 90 81 94 49 12,5 11,3

70 92 83 97 49 12,5 11,3

75 97 88 102 52 12,5 11,3

80 105 95 109 56 13,0 12,085 110 100 116 56 15,0 14,0

90 115 105 125 59 15,0 14,0

95 120 110 131 59 15,0 14,0

100 125 115 132 62 15,0 14,0



IRON Pump A/S

Page 15

Centrifugal pump wear ring clearances

22531e



IRON Pump A/S

Page 16

Instruction drawing for pump



IRON Pump A/S

Page 18

931 Lockwasher 2 Steel

940.1 Key for coupling 1 Steel

940.2 Key for impeller 1 AISI 316

Parts list for pump

Pump type: QHDV 400-350/630

Pos no Description Production no Pcs Material



IRON Pump A/S

Page 19

e0500

Interruption of operations

6.0 Error finding

This list below shows possible trouble sources if the pump does not function correctly.

If you are unable to find the source of interruption or if you cannot repair the fault, Please contact our

service section.

Faults Possible causes

• Pump and motor cannot be actuated:

Impeller or shaft blocked.

Motor fault.

• Motor running but no pumping effect:

Motor rotation is not transmitted through coupling.

Discharge valve closed.

Non-return valve or other valves are closed.

Suction line closed.

Air in pump casing.

Suction line leaking.

Shaft seal leaking.Bottom valve defective.

Suction lift too high.

Priming pump defective.

• Insufficient capacity:

Wrong direction of rotation.

Number of revolutions too low.

Counter-pressure too high.

Suction line or impeller partly clogged.

Air in pump casing.

Air in pumping medium.Suction lift too high (inlet pressure too low).

Cavitation.


Shaft seal leaking.

Pump worn out.



IRON Pump A/S

Page 20

• Pump pressure too high:

Number of revolutions too high.

Impeller oversized.

Too many pressure stages.Specific gravity of pumping medium too high.

Viscosity of pumping medium too low.

Inlet pressure too high.

Manometer defective.

• Capacity too large:


Impeller diameter too big.

Counter-pressure too low.

• Discharge head too low:


Impeller diameter too small.

Too few pressure stages.

Specific gravity of pumping medium too low.

Viscosity of pumping medium to high.


• Power consumption too large:

Motor too small.

Motor fault.Capacity too large.


Stuffing-box tightened too much.

Shaft ends out of alignment.

Electricity supply incorrect.-Volt-amp-frequency.

• Pump output decreases or stops:


Shaft seal leaking.

Increasing suction lift.

Filter clogged.Cavitation.

• Irregular running:

Bearings defective.

Motor fault.

• Increasing noise level:

Beginning cavitation.

Air in pumping medium.

Capacity too large.

Clamping to base loosened.

Base bolts loosened.

Influences from pipe connections or base.



IRON Pump A/S

Page 21

• Leaks:

Cracks in pump casing.

Faulty assembly of pump.

Pipe connections leaking.Shaft seal leaking (in case of soft stuffing-box pack-

ing minor leaks are necessary).

• Bearing temperature too high:

Faulty lubrication or wrong lubricant.

Deficient pump alignment.

Influences from pipe line.

Coupling distance wrong.

Shaft bent.

Foreign bodies or impurities in bearings.

• Pump wears out quickly:

Wrong materials in relation to pumping medium

Cavitation.


Shaft bent.

Deficient alignment.

Influences through pipe line.

• Strong vibrations:

Impurities in pump.Motor not properly balanced.

Influence from other factors.



IRON Pump A/S

Page 1

MOUNTING AND OPERATING INSTRUCTIONS

FOR PUMPS

YOUR REF.

PURPOSE : Fire fighting

ORDER NO.: 8505

PROJECT : Deres 8505

IRON REF.

PUMP NO. : FQV3371

ORDER NO.: 3572828

PUMP TYPE: QV 16/400

IMPORTANT: Read this manual before mounting and starting the pumps



Maskinfabriken IRON A/S

Page 2

Manual identification No.: qv22272e.bog

List of content

Technical data..............................................................................................................4

Mounting and operating instructions for pumps......................................................5

1.0 Before start ..............................................................................................................................5

1.1 General instructions.................................................................................................................51.2 Mounting instructions..............................................................................................................5

1.3 For pumps delivered without motor - mounting of coupling parts .........................................5

1.4 Alignment of couplings ...........................................................................................................5

1.5 Installation of the pump...........................................................................................................6

1.6 Motor wiring............................................................................................................................6

1.7 Motor-driven pumps (diesel)...................................................................................................6

1.8 Starting of the pump ................................................................................................................6

1.9 Pumps with priming device.....................................................................................................7

1.10 Self-priming pumps...............................................................................................................7

1.11 All pumps ..............................................................................................................................7

1.12 Maintenance - lubrication......................................................................................................7

1.13 3 months’ check.....................................................................................................................8

1.14 12 months’ check...................................................................................................................8

1.15 Disassembling instructions....................................................................................................8

1.16 Assembling instructions ........................................................................................................9

1.17 The following packings are used...........................................................................................9

1.18 Mounting of motors in direct-coupled pumps.......................................................................9

1.19 Pumps with split casing.........................................................................................................9

1.20 Maintenance (storage instructions) - General instructions....................................................9

1.21 Preservation of bearings ........................................................................................................9

1.22 Preservation of interior parts of the pumps .........................................................................101.23 Preservation of gear wheel pumps and gearboxes...............................................................10

1.24 Preservation procedure ........................................................................................................10

1.25 Restarting of the pumps.......................................................................................................10

Installation and maintenance instructions for EFLEX-R coupling type RA.......11

2.0 Safety precautions .................................................................................................................11

2.1 Mounting ...............................................................................................................................11

2.2 Alignment ..............................................................................................................................11

2.3 Possible misalignments .........................................................................................................112.4 Operation ...............................................................................................................................11

2.5 Maintenance ..........................................................................................................................12

2.6 Replacing of flexibles............................................................................................................12




Page 3

2.7 Table .....................................................................................................................................12

2.8 Instruction drawing for EFLEX-R coupling type RA ...........................................................13

Lubricants ..................................................................................................................14

Instruction drawing for pump..................................................................................15

Instruction drawing for mech. seal/constant level oiler .........................................16

Fitting instruction for mech. seal .............................................................................17

Centrifugal pump wear ring clearances ..................................................................18

Parts list for pump.....................................................................................................19

Interruption of operations ........................................................................................21

3.0 Error finding ..........................................................................................................................21



IRON Pump A/S

Page 4

e.data

Technical data

Pump:

Type : QV 16/400

Capacity : 1.150,0/1.700,0 m3/h

Total head : 24,00 mVs

Head :

Suction head :

Inlet pressure :

Mech. seal : Carbon / Ceramics max 80 C

Gland packing :

Coupling type :

Weight kg. : 770

Material:

Pump casing : Bronze RG5

Impeller : Ni.Al.Bronze

Casing wear ring : Ni.Al.Bronze

Shaft : AISI-329

Motor:

Type :

KW :

Power consumption kW : 110,00, max 112,00

RpM : 1500

Voltage :

Weight kg :



IRON Pump A/S

Page 5

manual.e

Mounting and operating instructions for pumps

1.0 Before start

Check direction of rotation (marked with an arrow).

• Check that there is liquid in the pump (might have been emptied by standstill).

• Check that the pump is turnable by hand.

• Check that the pump has been lubricated with grease.

• Check the pump for noises and vibrations immediately after starting.

• Check priming pump (if any). See special instructions.

1.1 General instructions

Check the pump immediately after receipt. In case of damages or defects - complain immediately.

All pumps are marked with indication of type and number, stamped into the plate as well as into the

pump itself - as for centrifugal pumps, usually in the suction flange - as for other pumps, at an easily

visible place.

If the pump is not mounted immediately after receipt it should be protected during storage (see storage

instructions).

1.2 Mounting instructions

When calculating the piping system, special regard should be paid to minimizing pressure losses in the

suction line (short pipe lengths, large diameter, few bendings, no valves). If valves are necessary, then

use valves with min. pressure losses, e.g. slide valves, butterfly valves, flap non-return valves etc.

Static suction lift + total pressure losses in suction line + NPSH value of the pump + steam pressure of

the liquid must not exceed 10 mWC at sea level (and 760 mm Hg.).

1.3 For pumps delivered without motor - mounting of coupling parts

Before mounting, shaft and coupling parts must be carefully cleaned. Grease shaft ends and check that

key fits. Heat coupling parts to 80oC. and push them on to the shaft ends by hand or by a light pressure.

By dismounting a puller will have to be applied.

1.4 Alignment of couplings

Flexible couplings will absorb small deviations in the relative positions of the shaft ends to be connected,

however, a careful and accurate alignment will prolong the life of the coupling flexibles - see instructions

for coupling.



IRON Pump A/S

Page 6

1.5 Installation of the pump

The entire piping must be pressure and leakage tested and flushed clean before it is connected to the suc-

tion and discharge side of the pump. If the pressure test takes place with the pump installed the testing

pressure must not exceed the testing pressure of the pump, which is stamped into the pump, usually in the

suction flange. Otherwise, the pump packings or flanges for the mechanical shaft seal might be dama-

ged. Connection of the pipes to the pump must take place without using force as this might interfere with

the alignment of the pump.

Precautions must be taken to ensure that the pipe connections to the pump are supported in a way that

prevents tensions from being transmitted to the pump, e.g. owing to thermal expansion. Check that all

other connections to the pump are in working order, such as lubrication, priming, heating, cooling med-

ium outlet, etc., and that the various measuring equipment has been correctly connected. Take care that

no parts obstruct the easy access to the pump for inspection or replacement of important parts. For pumps

with axially split casing there should be sufficient space for dismounting the top part of the pump casing.

1.6 Motor wiring

Electric motors should be connected by means of sufficiently long cables to permit the motor to be

moved a little without dismantling the connections. A control unit (emergency stop) should be installed

close to the pump.

1.7 Motor-driven pumps (diesel)

When using pumps driven by internal combustion engines vibrations may occur in the system. It is re-

commendable to mount the unit on vibration dampers and to install compensators between pump and

pipelines. The calculation of vibration dampers should be left to specialized companies.

1.8 Starting of the pump

When the preceding preparations and installations have been completed the pump can be started. To cen-

trifugal pumps it applies that the pump must be provided with a bypass if it is operating for long periods

with closed valve on the discharge side as, otherwise, a too strong heating and expansion of the pump

medium will occur. When starting positive pumps (e.g. piston pumps, type BDV - BDHV, gear pumps,

type ON - ONV, and others), the valve on the discharge side must be open as, otherwise, the pump may

burst, in spite of the fact that a bypass valve to the suction side is incorporated in these pumps. Pumps

provided with mechanical priming pump should be checked for supply / contents of liquidbefore starting.

Further information see operation instructions for priming pumps.

Check also that the pump shaft can be turned by hand. Pumps with mechanical shaft seal must be pro-

tected against impurities and dry running. Supply of liquid or oil to the mechanical shaft seal is

imperative. Please note that clogged filters will cause considerable friction losses, which may decisively

affect the suction capacity and output of the pump. Check also when starting the pump that the direction

of rotation is correct (shown with an arrow on the pump), and open slowly the valve on the discharge side

of the pump. At normal discharge head the pump should run smoothly without abnormal noises and

vibrations after abt. 1 minute of operation.



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1.9 Pumps with priming device

The valve on the discharge side of the pump must be closed during priming. The operating instructions

for the priming system should be strictly followed, see instructions for the system in question

(mechanical system with pump or ejector system driven by compressed air). After priming of the pump,

open the valve on the discharge side slowly and adjust it in such a way that permissible vacuum is not

exceeded.

1.10 Self-priming pumps

Type RS - RSM this type of pump is provided with integral air separation in pump casing. If there is not

free access on the discharge side the pump must be provided with air relief cocks to be opened during

priming. Fill the pump casing with liquid before the first start. By subsequent operation of the pump the

pump casing will be filled with liquid.

1.11 All pumps

It is an absolute requirement that pumps are not operating unnecessarily long without liquid, nor-

mally max. 5 min. During the first hours of operation bearings, packings and mechanical shaft (seal(s)

should be checked for heating and leakage. Normal bearing temperature is 40-75 gr.C. Max. temperature

for normal ball and roller bearings is up to 105 gr.C.

1.12 Maintenance - lubrication

To pumps directly coupled on motor shaft it applies that only the bearings of the motor require

lubrication.

Pumps executed with bearing bracket and grease lubricated bearings should be lubricated every 3rd

month with ball bearing grease (Lithium soap grease) Check that not too much grease is pressed into the

bearings as this will cause generation of heat. All bearings are provided with sealing rings in order to pre-

vent humidity and impurities from entering. The grease must no be pressed through these sealing rings.

For bearings which are exposed to higher pressures or humidity a heat resisting and water-repelling

grease will apply (Molypan LT-1 or similar quality).

For pumps executed with oil lubrication, lubricating oil (Mobilgear 682 or similar quality) can be used

for normally loaded bearings. For more heavily loaded bearings Mobil SHC 626 or similar quality

should be used.

In case of oil sump lubrication the oil level should be checked by means of screw-plug, oil level glass, oil

indicator or other control equipment - see instructions for the pump in question.



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1.13 3 months’ check

Check the pump for false noises, vibrations and leakage. Pumps with mechanical shaft seal must not

leak, neither during standstill with inlet pressure on the pump, nor during operation. The bypass pipe to

the mechanical shaft seal must be intact and permit free flow. Likewise, the piping system and filter of

the priming device must be intact and permit free flow. In case of defects they must be corrected

immediately as they may greatly influence the operation and life of the pump.

1.14 12 months’ check

Disassemble the pump (see instructions). Check the components of the rotary element and perform all

necessary. Normal clearance between impeller and sealing rings is 0,2 - 0,3 mm, and max. clearance is

0,5 - 0,8 mm, according to size and capacity. Clean the pump casing inside and paint it if necessary (e.g.

with Apexior No.3 or with more corrosion-resistant products, e.g. Hempadur No.1513 - “Hempel Marine

Paints”).

1.15 Disassembling instructions

Before starting the disassembly of the pump the sectional drawings of the various pump parts should be

studied closely. All pumps are designed for easy disassembly, and no special tools should be required.

The pumps consist of standard components, which means a large number of the components are used in

various pump sizes, for which reason it is necessary to keep a small stock of spares for various sizes of

the same pump type.

Pumps with split casing, e.g. type QV and type QH, can be disassembled without dismantling motor and

pipe connections. After dismounting of coupling bolts (triparted coupling), bearings housing top part and

pump casing top part, the rotating element consisting of shaft with impellers(s), bearings, casing wear

rings, mechanical seal(s) and coupling half can be lifted out for inspection, repair or replacement.

In-line pumps type CNH with spacer coupling, can also disassembled without removing motor and pipe

connections. First the intermediate piece between the coupling elements is dismounted, then the pump

cover with the rotating element can be lifted out for inspection. In the smaller types of these pumps, CNL

and CNLB, the motor with pump cover and rotating elements is removed as one unit. In horizontal, self-

priming pumps type RSM and RS, the impeller can be inspected after removing the inspection cover. In

type RSM the rotating element can be taken out after removing the rear cover with motor, and in type RSafter removing the rear cover and the bearing bracket. To both pump types it applies that it is not

necessary to dismount the pipe connections.

As for other pump types, it is necessary to remove the pipe connections in order to inspect the interior

parts of the pump.



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Page 9

1.16 Assembling instructions

When assembling the pump the mechanical seal must be treated with the greatest care. Take care that the

various parts are placed correctly. For further information see instructions for mechanical seal.

1.17 The following packings are used

Between pump casing top part and bottom part - 1,00 mm Klingerit.

Between pump casing and cover 1,00 mm Klingerit.

In such places where liquid packing has once been used this type of packing must be used again when

remounting the pump, as other types of packing would produce wrong spaces.

1.18 Mounting of motors in direct-coupled pumps

If the pump is delivered without motor a distance ring is mounted between the packing flange and the

shaft. This ring must not be removed until the motor has been mounted and the pump shaft screwed

together with the motor shaft. Do not forget to remove the ring before starting the pump.

1.19 Pumps with split casing

When mounting the rotating element in the pump, take care that the tongue of the case wear rings fits

correctly in the groove of the pump casing. The bolts of the pump casing must be tightened with a torqueof 6,0 kgm, the bolts of the bearing housings with a torque of 3,0 kgm.

When reassembling pumps, take care that impellers, as regards the vanes, have the same direction of

rotation as before the disassembling.

1.20 Maintenance (storage instructions) - General instructions

All pumps which are taken out of operation for some time should be protected against corrosion and frost

and kept in a dry place. The following directions should be observed:

1.21 Preservation of bearings

Both ball / roller bearings and slide bearings should be lubricated all over with their normal lubricant.



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Page 10

1.22 Preservation of interior parts of the pumps

The interior parts of the pumps should be protected against aggressive pumping media, for instance by

using a water-repelling solvent containing at the same time corrosion inhibiting nitrides. We recommend

“Mobil oil - Arma 245” or similar quality.

1.23 Preservation of gear wheel pumps and gearboxes

Gear wheel pumps do not need any protection if they have been operating with oil products. If not, they

should be lubricated all over with a neutral oil.

Gearboxes should be completely filled with the oil specified. If the standstill lasts longer than 12 months

the oil should be emptied and replaced by “Mobil Arma 25” or similar quality or the gearbox should be

flushed with this oil.

1.24 Preservation procedure

Flush the pump with pure. hot water (does not apply to be screw pumps and gear pumps) and let it airdry.

Close the valves on both sides of the pump and flush the pump with “Mobil Arma 25” or similar quality.

Flushing can take place through the manometer connections.

1.25 Restarting of the pumps

When restarting pumps it is advisable to fill the pump with hot water through the manometer connections

(does not apply to screw pumps and gear wheel pumps) and to turn the pump shaft by hand before

starting the pump. Watch the operation of the pump for abt. 10 minutes and open the valve in the normal

way. Bearings, gearboxes etc. should be lubricated with normal oil or grease if a change of oil has taken

place.



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Installation and maintenance instructions for EFLEX-R coupling type RA

2.0 Safety precautions

• Rotating parts should be guarded by the buyer to prevent accidents, taking account of applicable local

accident prevention regulations.

2.1 Mounting

• Before mounting the hubs, carefully clean shaft ends and coupling parts.

• Inside hubs to be flushed with the shaft ends. Tighten set screw to secure hubs axially.

• Tighten set screw only with hexagon socket wrench according to DIN 911 without extension piece.

• Heating of coupling parts till approx. 80oC. will facilitate mounting, but the flexible elements must be

removed first from the female part.

• Be shure the flexible elements are turned correct when they are mounted again - se instructions draw-

ing.

• Bring the coupling hubs together, taking care to observe dimension S1 according to the table.

• Check all screw connections with screw tightening torques of the table.

2.2 Alignment

• EFLEX-R couplings will absorb deviations in the relative position of shafts to be connected (see pos-

sible misalignments).

• When aligning the coupling halfs , the angular and parallel offset misalignments of shaft relative to

each other should be as small as possible. Alignment to be carried out in two planes as shown in fig.1

with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dail indicator will

give greater accuracy.

• The gap dimension S1 must be within the limits listed in the table.

2.3 Possible misalignments

• The permissible axial distance Ka (fig.2) must be within the limits for S1 (see the table).

• Angular misalignment Kw (fig.3) is measured as the difference between Smax. and Smin. possible val-

ues are calculated with values from the table.

• Parallel offset misalignment Kr (fig. 4) see the table.

• Angular and parallel offset misalignment can occur at the same time. The sum of both alignments

should not exceed the values Kr respectively Kw.

• Kw and Kr apply in a shock free operation at ambient temperature - 30oC to 80oC.

2.4 Operation

• Before commencing initial operatings check alignment and gap dimension S1and if necessary make

corrections. Further check screw connections.



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Page 12

2.5 Maintenance

• EFLEX-R couplings do not require any regular maintenance except for an occasional check on the

• torsional play or backlash between the driving and driven halves. When EFLEX-R couplings are used

in drives which do not require a minimum of torsional play or backlash in the coupling, the coupling

flexibles can be allowed to wear down 2/3 of their original thickness before they need replacing.

2.6 Replacing of flexibles

• Uninterrupted torque transmission and reliability of operation cannot be guaranteed unless original

• EFLEX-R flexibles are used.

• After fitting new flexibles, be shure they are turned correct.

• Before starting up control the mounting.

2.7 Table

Table

Coupling size

RN/RA /

outside diam.mm

S1

mm

Angular

Misalignment

Kw

Smax. - Smin

mm

Offset

Misagnment

Kr

mm.

1800 RPM 3600 RPM 1800 RPM 3600 RPM

2 / 80

3 / 94

4 / 110

3 - 4,5

3 - 4,5

4 - 6

1,4

1,6

1,9

0,28

0,32

0,38

0,26

0,30

0,36

0,05

0,06

0,07

5 / 125

6 / 140

7 / 1658 / 180

4 - 6

5 - 7,5

5 - 7,55 - 7,5

2,2

2,4

2,93,1

0,44

0,48

0,580,62

0,42

0,50

0,600,70

0,08

0,10

0,120,14

9 / 210

10 / 240

11 / 260

6 - 9

6 - 9

7 - 10,5

3,7

4,2

4,5

0,76

0,84

0,95

12 / 300

13 / 325

14 / 360

8 - 12

8 - 12

10 - 15

5,2

5,7

6,3

1,00

1,15

1,30



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2.8 Instruction drawing for EFLEX-R coupling type RA



IRON Pump A/S

Page 14

Lubricants

Grease lubricated

bearingsOil lubricated bearings Gear box

Pump type All type Only QHGV Only QVP

Nato code / DIN G 395 DIN 51524.1.2 DIN 51517.3

BP ENERGREASE LS-EP2 ENERGOL GR-XP 320

CASTROL SPHEEROL AP 2/3 ALPHA SP 320

CHEVRON DURA LITH GREASE EP2 MECHANISM LPS 68 NL GEAR COMP.320

ESSO BEACON EP2 SPARTAN EP 320

MOBIL MOBILTEMP SHC 100 SHC 626 MOBILGEAR 634

Q8 REMBRANDT EP2 GOYA 320

SHELL ALVANIA GREASE EP2 OMALA OIL 320

TEXACO MULTIFAK ALL

PURPOSE EP2

MEROPA 320

ELF EPEXA 2 BARELF CH 68 EPONA Z 320

e0401



IRON Pump A/S

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Instruction drawing for pump



IRON Pump A/S

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Instruction drawing for mech. seal/constant level oiler



IRON Pump A/S

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Fitting instruction for mech. seal



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Page 18

Centrifugal pump wear ring clearances

22531e




22272-1e

Parts list for pump

Pump type: QV-16/400 + QV-18/400 - Drawing No.: 22272-1

Pos No Description Productions No. Pcs Material

102 Volute casing 1 Bronze

181 Pump stool 185610102 1 Bronze

210 Shaft - keys and bearing nut 266377124 1 AISI 329

234 Double entry impeller 1 Bronze

321 Radial ball bearing 217632309 1

322 Radial roller bearing 217662509 1

341 Motor stool 1 Cast iron

343 Pump bearing lantern 218960102 1 GG-25

360.1 Bearing cover 218990102 1 GG-25

360.2 Bearing cover 219390102 1 GG-25

381.1 Bearing cartridge 218980102 1 GG-25

381.2 Bearing cartridge 219330102 1 GG-25

382 Bearing carrier 1

400.1 Gasket for cover 217480247 1 SIL C-4400

400.2 Gasket for cover 217480247 1 SIL C-4400

400.3 Gasket for pump volute casing 217470644 1 SIL C-4400

402 Plastic gasket 217681080 1

420.1 Shaft seal ring 217518540 1

420.2 Shaft seal ring 217517640 1

420.3 Shaft seal 217517640 1

420.2 Shaft seal ring 217517040 1

433 Mech.seal 1

471 Seal cover 1 Aluminium bronze

502 Casing wear ring 2 Aluminium bronze

506 Retaining ring 96081626 1 Aluminium bronze

507 Thrower 218540240 1

524 Shaft wearring sleeve 210490118 1 Aluminium bronze

525 Spacer sleeve 1 DT-11

545 Bearing bush 1




636 Grease nippel 217520409 2

638 Constant level oiler 217680128 1

731 Pipe union 218513332 /

225541323

2 Bronze /

Stainless steel

861.1 Coupling half 1 Cast iron

861.2 Coupling half 1 Cast iron

867 Coupling flexibles 1 set

923 Bearing nut 218552509 1 Steel

931 Lockwasher 218552609 1 Steel

Parts list for pump

Pump type: QV-16/400 + QV-18/400 - Drawing No.: 22272-1

Pos No Description Productions No. Pcs Material



IRON Pump A/S

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e0500

Interruption of operations

3.0 Error finding

This list below shows possible trouble sources if the pump does not function correctly.

If you are unable to find the source of interruption or if you cannot repair the fault, Please contact our

service section.

Faults Possible causes

• Pump and motor cannot be actuated:

Impeller or shaft blocked.

Motor fault.

• Motor running but no pumping effect:

Motor rotation is not transmitted through coupling.

Discharge valve closed.

Non-return valve or other valves are closed.

Suction line closed.

Air in pump casing.


Shaft seal leaking.Bottom valve defective.

Suction lift too high.

Priming pump defective.

• Insufficient capacity:

Wrong direction of rotation.


Counter-pressure too high.

Suction line or impeller partly clogged.

Air in pump casing.

Air in pumping medium.Suction lift too high (inlet pressure too low).

Cavitation.


Shaft seal leaking.

Pump worn out.



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• Pump pressure too high:


Impeller oversized.

Too many pressure stages.Specific gravity of pumping medium too high.

Viscosity of pumping medium too low.

Inlet pressure too high.


• Capacity too large:


Impeller diameter too big.


• Discharge head too low:


Impeller diameter too small.

Too few pressure stages.

Specific gravity of pumping medium too low.

Viscosity of pumping medium to high.


• Power consumption too large:

Motor too small.

Motor fault.Capacity too large.



Shaft ends out of alignment.

Electricity supply incorrect.-Volt-amp-frequency.

• Pump output decreases or stops:


Shaft seal leaking.

Increasing suction lift.

Filter clogged.Cavitation.

• Irregular running:

Bearings defective.

Motor fault.

• Increasing noise level:

Beginning cavitation.

Air in pumping medium.

Capacity too large.

Clamping to base loosened.

Base bolts loosened.

Influences from pipe connections or base.



IRON Pump A/S

• Leaks:

Cracks in pump casing.

Faulty assembly of pump.

Pipe connections leaking.Shaft seal leaking (in case of soft stuffing-box pack-

ing minor leaks are necessary).

• Bearing temperature too high:

Faulty lubrication or wrong lubricant.

Deficient pump alignment.

Influences from pipe line.

Coupling distance wrong.

Shaft bent.

Foreign bodies or impurities in bearings.

• Pump wears out quickly:

Wrong materials in relation to pumping medium

Cavitation.


Shaft bent.

Deficient alignment.

Influences through pipe line.

• Strong vibrations:

Impurities in pump.Motor not properly balanced.

Influence from other factors.

Fire Pumps Data Book 2 IOM Section 3

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Transcript of Fire Pumps Data Book 2 IOM Section 3