DOC. NO.

: VP-MM-VCP-03/0
MANUAL FOR
Instructions on Installations,
Operation and Maintenance of Type VCP
Pump applicable for 2+1 Bearing with
single driving head
Manufactured by :
Varat Pump & Machinery Pvt. Ltd.
20, NETAJI SUBHAS ROAD
KOLKATA 700 001
WEST BENGAL
INDIA
Page 2 of 21
DOC NO.:VP-MM-VCP-03/0
Contents
Point
No.
Description Page
No.
1.0 General 3
1.1 Model Coverage 3
1.2 Storage 3
1.3 Long Storage 3
2.0 Installation 3
2.1 Location 3
2.2 Foundation 3
2.3 Handling 4
2.4 Leveling 4
2.5 Flexible Coupling 4
2.6 Alignment 5
2.7 Misalignment 5
2.8 Grouting 8
2.9 Piping 8
2.10 Suction Pipe 8
2.11 Delivery Pipe 8
2.12 Vacuum Equalizing Line 8
2.13 Foot Valve 10
2.14 Stuffing Boxes and Packing 10
2.15 Lubrication 11
2.16 Ball Bearing 11
2.17 Priming 11
3.0 Preparation of Pump Starting 12
4.0 Starting and Stopping of the Pump 12
5.0 Bearing 13
6.0 Lubricant 13
7.0 Stuffing Box 14
8.0 Gasket 14
9.0 Coupling 14
10.0 Guide Ring / Wearing Ring 14
11.0 Shaft Sleeve 14
12.0 Spare Parts 14
13.0 Trouble Shooting 15
14.0 Maintenance 17
14.1 Daily Checks 17
14.2 Periodical Maintenance 17
15.0 Overhauling 17
15.1 Dismantling of Pump 17
15.2 Reassembling of Pump 18
Page 3 of 21
DOC NO.:VP-MM-VCP-03/0
1.1 The Operation & Instruction Manual is required to read carefully who will work on this Pump sets. The
working Instruction should be followed strictly so that damages to the equipment, specially for the Pump
is avoided. This book let covers instructions for following Models of VARAT Centrifugal Back Pull Out
Process Pump Model:
40VCP2, 40VCP3, 40VCP3N, 50VCP1, 50VCP2, 50VCP3, 65VCP3, 65VCP3M, 65VCP3N,
80VCP1, 80VCP1K, 80VCP2, 100VCP2,
1.2 When the pumps are received sometime before the use of the pump it should be located in dry place. The
coupling should be rotated once in a month to prevent pilling of bearing surfaces.
1.3 When the pumps kept idle for a period after one use, it should be cleaned properly and overhauling should
be made before long storage.
Unauthorized Modes of Operation
To ensure operational reliability and safety of the pump / unit supplied, the machine shall be used
exclusively in accordance with its designated use as described in the following sections. The limits
stated in the data sheet must not be exceeded under any circumstances.
Unauthorized Modification and Manufacture of Spare Parts
Modifications or alterations of the machine are only permitted after consultation with the manufacturer.
Original spare parts and accessories authorised by the manufacturer ensure safety. The use of other
parts can invalidate any liability of the manufacturer for consequential damage.
2.1 LOCATION
The pump should be located as near the liquid source as possible. This will minimise the suction lift and
pump will give better performance.
Ample space should be provided on all the sides so that the pump can be inspected while in operation and
can be serviced conveniently whenever required.
2.2 FOUNDATION
The foundation should be sufficiently substantial to absorb any vibration and to form a permanent rigid
support for the base plate. This is important in maintaining the alignment of a direct connected unit. A
concrete foundation on a solid base is advisable. Foundation bolts of the proper size should be embedded
in the concrete located by a drawing or template. A pipe sleeve about two and one-half diameter larger
than the bolt should be used to allow movement for the final position of the foundation bolts.
1.0 GENERAL
2.0 INSTALLATION
3.0
Page 4 of 21
DOC NO.:VP-MM-VCP-03/0
2.3 HANDLING
The pump set should be properly handled and slung for transport. Do not thread the ropes through the
eyebolt on the Motor or Pump during handling complete set. During handling do not remove the blank
rubber gasket provided on the suction and discharge nozzles. Lifting equipment must be able to
adequately support the entire assembly. Hoist bare pump using suitable slings under the outboard end of
the bearing frame and under the suction flange.
Warning : Pump and Components are heavy. Failure to properly lift and support equipment could
result in serious physical injury or damage to pumps
2.4 LEVELLING
When the unit is received with the pump and driver mounted on the base plate, it should be placed on the
foundation and the coupling halves disconnected. The coupling should not be reconnected until all
alignment operations have been completed. The base plate must be supported evenly and placed closed to
the foundation bolt. In each case, the supports should directly under the part base plate carrying the
greatest weight and spaced closely enough to give uniform support. A gap of about 25 to 50 mm should be
allowed between the base plate and foundation of grouting. Supporting will be such that it will not be
distorted or sprung by the uneven distribution of the weight. Adjust the wedges until the shafts of the
pump and driver are in level. Check the coupling faces, suction and discharge flanges for the horizontal
or vertical position by means of spirit level.
2.5 FLEXIBLE COUPLING
A flexible coupling will not compensate for misalignment of the pump and driver shafts. The purpose of
the flexible coupling is to compensate for temperature changes and to permit the movement of the shafts
without interference with each other while transmitting power from the driver to the pump.
Page 5 of 21
DOC NO.:VP-MM-VCP-03/0
2.6 ALIGNMENT
Pumps and drivers that are supplied by the manufacturers, mounted on a common base plate are
accurately aligned before despatch. All base plates are flexible to some extent and alignments are likely to
be disturbed during transit to some extent and therefore must not be relied upon to maintain the factory
alignment. Re-alignment is necessary after the complete unit has been leveled on the foundation and again
after the grout has set and foundation bolts have been tightened. The alignment must be checked after the
unit is piped up and re-checked periodically.
2.7 MISALIGNMENT
There are two types of misalignment between the Pump shaft and the driver shaft:
(a) Angular misalignment: Shafts with axis concentric but not parallel.
(b) Parallel misalignment: Shafts with axis Parallel but not concentric.
The unit can then be grouted by soft concrete under the edges.
DIAL GAUGE ALIGNMENT
An approved method for putting the coupling halves in final accurate alignment is by the use of a dial
indicator. Check the alignment by straight edge and fillers as accurately as possible as described above.
Fasten the indicator to the pump half of the coupling with the indicator button resting on the other half of
the coupling periphery (FIG 3). Set the dial to the 0 and chalk mark the coupling half beside where the
bottom rests. For any check, top or bottom or sides, rotate both shafts by the same amount i.e. all readings
on the dial must be made with bottom beside the chalk mark. The dials reading will indicate whether the
driver has to be raised or lowered or moved to either side. Accurate alignment of shaft center can be
obtained with this method.
Page 6 of 21
DOC NO.:VP-MM-VCP-03/0
ALIGNMENT OF SPACER TYPE COUPLING
Where a spacer type coupling is used between the pump and driver, it is may not be possible to align the
couplings to the pump and driver exactly as described above. To align unit with a floating coupling,
remove the spacer between the pump and driver. Use a magnetic stand and place the dial indicator as
given in FIG 4, make a chalk mark of the coupling half beside where the bottom rest and set the dial to
Zero. To check for parallel alignment, rotate both shafts be the same amount i.e. all readings are made
with the bottom beside the chalk mark. After parallel alignment has been obtained change the indicator so
it bears against the face of the same coupling half and follow the same procedure to check angular
alignment that were used for parallel alignment. The angular alignment may also to check by using inside
micrometer as shown in FIG 4. After final alignment is obtained, insert the spacer and bolt the coupling
halves.
ALIGNMENT CRITERIA
Good alignment is attained when readings as specified in this section have been achieved with pump and
driver at operating temperatures (final alignment). Table 1 shows maximum allowable Total Indicator
Reading (T.I.R.) for parallel and angular misalignment.
Maximum Allowable
Parallel and Angular Misalignment
Group
Maximum Allowable Misalignment
Parallel Angular
All
0.05 mm
(.002 in.)
0.03 degrees
[0.125 mm/cm (.0005
in. /in.) of coupling
face diameter]
NOTE A: For electrical motros, motor shaft initial (cold) parallel vertical alignment settings should
be 0.05-0.10mm (.002-0..4 in) lower than pump shaft.
NOTE B: For other drivers (turbines, engine etc.), follow driver manufacturers recommendation.
ALIGNMENT TROUBLESHOOTING
Problem Probable Cause Remedy
Cannot obtain horizontal (Side-to-
Side)
alignment, angular or parallel
Driver feet bolt bound.
Loosen pump hold down bolts and slide
pump and driver until horizontal lignment
is achieved.
Baseplate not leveled
properly, probably
twisted.
Determine which corner(s) of the
baseplate are high or low and adjust
leveling screws at the appropriate
corner(s) and realign.
Cannot obtain vertical (Top-to-
Bottom)
alignment, angular or parallel
Base plate not leveled
properly, probably
bowed.
Determine if center of baseplate should
be raised or lowered and correct by
adjusting leveling screws equally at the
center of the baseplate.
Page 7 of 21
DOC NO.:VP-MM-VCP-03/0
Page 8 of 21
DOC NO.:VP-MM-VCP-03/0
2.8 GROUTING
When the alignment is correct, the foundation bolts should be tightened evenly but not too firmly.
Working soft concrete under the edges can then grout the unit. Foundation bolts should not be fully
tightened until the grout is hardened, usually 48 hours after pouring.
2.9 PIPING
Both suction and delivery pipes and accessories should be independently supported near the pump so that
when the flange bolts are tightened no strain will be transmitted to the pump casing. It is usually advisable
to increase the size of both suction and delivery pipes at the pump nozzles in order to decrease the loss of
head from friction and for the same reason piping should be arranged with as minimum bends as possible,
as these should be made with a long radius wherever possible. The pipe lines should be free from scales,
welding residuals etc., and have to be mounted in such way that they can be connected to suction and
delivery flanges without any stress on the pump. Adequate supports should be given to pipe lines so that
the weight of the pipelines does not fall on the pump. The use of minimum number of the bends and other
fittings will minimise the friction losses.
2.10 SUCTION PIPE
The suction pipe should be as short as possible. This can be achieved by placing the pump close to the
liquid to be pumped. The suction pipe must be kept free from air leaks. This is particularly important
when the suction lift is high. A horizontal suction line must have a gradual rise towards the pump. Any
high point in the pipe will be filled with air and thus prevent proper operative of the pump. A concentric
taper piece should not be used in a horizontal suction line as it forms an air pocket in the top of the reducer
and the pipe. Use an eccentric per piece (FIG 5).
The end of the suction pipe must be well submerged to avoid whirlpools and ingress of air but must be
kept clear of any deposits of mud, silt grit etc. The pipe must be clear from any side of wall by at least
450mm. The end of the suction pipe should be provided with a strainer of sufficient open area.
2.11 DELIVERY PIPE
A check (non-return) valve and a gate or sluice valve (regulating valve) should be installed in the
discharge line. The check valve placed between the pump and the gate valve is to protect the pump from
excessive pressure and to prevent water running back through the pump in case of failure of the driving
machine i.e.-excessive backpressure.
Discharge piping should be provided with a sluice valve to control the discharge, if required. The valve is
used in primary, starting and when shutting down the pumps. If increaser is used on the discharge side to
increase the size of discharge piping they should be placed between the check valve and pump.
2.12 VACCUM EQUALIZING LINE (AND LIQUID LINE) (SEE FIGURE 6)
If the pump draws from system under vacuum a equalizing pipe min 25 NB must be carried from the
highest point of the suction line, however, as close to the suction flange of the pump as, to the top of the
feed tank to keep gas bubbles that might have been entrapped in the flow from entering the pump. The
line should be fitted with an isolating valve, which should be closed only for maintenance work on the
pump set.
Apply sealing liquid (external sealing) to the shaft seal cage to prevent entry of air and in the case of
pumps with packed stuffing box It is convenient to tap the sealing liquid from the delivery line above the
non-return valve.
Page 9 of 21
DOC NO.:VP-MM-VCP-03/0
Page 10 of 21
DOC NO.:VP-MM-VCP-03/0
2.13 FOOT VALVE
It is advisable to install a foot valve to facilitate priming of pump. Foot valve should have sufficient clear
passage for water. Care must be taken to prevent foreign matter from being drawn into the pump or
choking the foot valve and for this purpose an efficient strainer should be provided.
2.14 STUFFING BOXES AND PACKING
Stuffing boxes should be carefully cleaned and the packing placed in them. Be sure that sufficient
packing is placed at the back of the water seal cage. If the water to be pumped is dirty or gritty, sealing
water should be piped to the stuffing boxes from clean outside source of supply in order to prevent
damage to the packing and shaft. In placing the packing, each packing ring should be cut to the proper
length & ends at 45
0
so that ends come into correct contact with one another but do not overlap. The
following packing rings are then inserted into the packing compartment one by one making sure that the
butt joint of each ring is offset by 90
0
approx. in relation to the butt joint of the preceding ring. The
succeeding rings of packing should be placed in the Stuffing Box so that the joints of the several rings of
packing are staggered and cutting the shaft. If the stuffing box is not properly packed, friction in stuffing
box prevents turning the rotor by hand. On starting the pump, Stuffing Box Packing should be left slightly
loose without causing an air leak, and if it seems to leak instead of putting too much pressure on the gland,
put some heavy oil in the stuffing box until the pump works properly and then gradually tighten up the
gland. The packing should be occasionally changed. Cutting of the packing rings to correct length &
ends at 45
0
most important so that ends come into correct contact with one another.
MECHANICAL SEAL (MOSTLY APPLICABLE FOR SINGLE BALANCE SEAL)
Since mechanical seals are made in a wide variety of designs, the instruction for the specific seal must be
carefully studied and followed exactly. A Mechanical Seal is a precision device and must be treated
accordingly. If any leakage is found, observe carefully whether it is found from:-
1) Between shaft & sleeve or
2) Between stuffing box flange and sleeve or
3) Between stuffing box and seal cover
For clause no.1 PTFE gaskets & O ring (Item no. 03 & 17) are to be replaced. For clause no.2 if
adequate leakage from the sleeve surface is found then after inspection of the seal face damage,
compression of the seal is to be increased. Unscrewing 4 nos.align screws for holding rotary part on the
sleeve, you have to slide the seal rotary part towards the stationary part and tightening the 4 nos. align
screw can do this. You have to keep the compression of the seal about 3 to 4 mm. If the leakage is little
then it is normally through the O Ring provided inside the rotary seal. The ring may be required to be
replaced. For clause no.3 tighten the 4 nos. gland nut (No. 35), if any further leakage found then seal
cover O ring/gasket (No.13) is to be replaced.
Page 11 of 21
DOC NO.:VP-MM-VCP-03/0
2.15 LUBRICATION
Pump is usually provided with a special auto feed oil lubrication pot. Initially fill up oil at the driving
head through the breather port. The oil pot provided at the side of driving head, is to be removed, during
initial filling. When oil just comes out from the port then replace the oil pot and stop the oil filling
through the breather part. Lift the oil pot as explained in the figure 7 and fill up oil at the pot. Release the
pot and find that due to spring action pot will take its place. Oil level inside the pot will decrease
automatically until the pre-determined required level is reached. The repetition of the process of oil pot
filling is required if you find the pot empty. Never fill up oil through others part of oil pot, which may
cause excess filling of lubricating oil. This will result in excess rise of temperature of the bearing.
Bearings are normally oil lubricated. Bearing temperature is permissible to rise 40 degree Centigrade
above ambient temperature. For oil lubrication, oil should be maintained in the oil pot. Explained with
below figure. The Bearing Housing should be filled with oil of any one of the following types and
specification :
Indian Oil Servosystem 46
Hindustan Petroleum Enklo 46
Bharat Petroleum Bharat Hydrol 68
2.16 BALL BEARING
Correct maintenance of ball bearings is essential. The bearing manufacturers give the following as guide
to relubrication periods under normal conditions.
Quarterly when on continuous duty.
Half yearly when on eight-hour per day duty.
The bearings and housings should be completely cleaned and recharged with fresh oil after 2500 hours or
the nearest pump overhaul time.
2.17 PRIMING
No pumping action occurs unless the pump casing is filled with liquid. Pump casing and suction pipe must
therefore be completely filled with the liquid and thus all air removed before the pump is started. Several
different priming methods can be used depending on the kind of installation and service involved.
(1) Liquid level above pump level.
Pump is set below liquid level of source of supply so that liquid always flows to pump under
positive head.
(2) Priming with Foot Valve.
(a) When pump is installed on suction lift with foot valve at the end of suction line, fill pump
with water from some outside source till all air is expelled and water flows through air
vent or filled up up to Delivery flange of Pump.
(b) When there is liquid under some pressure in the discharge pipe, priming can be effected
by bypassing the pressure liquid around the check and gate valve. Provide one stop cock
at bypass line. Of course, the initial priming must be effected from some outside source.
NOTE: In this case, the foot valve must be capable of withstanding pump pressure and possible
surge.
Page 12 of 21
DOC NO.:VP-MM-VCP-03/0
(3) Priming by ejector: An ejector operated by steam, compressed air or water under pressure and
connected to air vent on top of casing can be used to remove air from and prime the pump on
suction lift installations.
(4) Priming by dry vacuum pump: A hand or power pump sucks in all the air from the casing and the
suction pipe, and thus primes the system
After the pump and the drive are mounted, the plant should be prepared for starting. The following
rules should be observed before starting the pump:
The pins or pad should be inserted into the coupling or placement of spacer for spacer coupling not before
making sure of the correct rotation of drive motor. In case of the drive rotating in the wrong direction, the
connection of two cable conductors supplying the current to the motor should be interchange in case of
DOL starting.
Check presence of oil in bearings and correct location of water deflector on shafts that ensure flashing,
quenching, and lubrication in case of mechanical seal as well as if required as per design.
Gland packing should be tightly stuffed, but not over tightened. The sealing packing should be tightened
to such an amount as to allow the pumping liquid to seek to the outside. Over tightening of sealing
packing causes quick wear out of shaft sleeves, increases its friction and lowers the efficiency factor of the
whole plant.
Check the free rotation of pump rotor, turning it by hand to verify any major obstruction or friction with
wearing parts.
Check the proper order of suction and pressure pipelines, tightening of flanges, fittings of inlet valve and
presence of drain plug.
Check the correct direction of rotation of pump and drive. The pump rotor should rotate according to
direction of rotation marked on pump.
Getting reasonably sure of the proper order of the whole plan and its readiness for operation, the suction
pipe should be primed with water / liquid. Arrangement for priming funnel and three ways connection of
pressure gauge with air-cock after delivery flange but before delivery sluice valve is required.
The pump is being filled up (Primed) until the air-cock produces water jet without air bubbles. Then the
primary funnel, air-cock and sluice valve is required to be closed. After all these operation and checking,
the pump is ready for starting.
The pump should be loaded gradually, when the drive is engaged. When the prime movers attain full
speed, the regulating sluice valve should be smoothly opened. This will avoid overloading of the drive.
On the other hand it should be kept in mind that a lengthy operation with completely close sliding valve is
likewise to be avoided, since this causes unnecessary heating of the liquid in the pump.
3.0 PREPARATION OF PUMP STARTING:
4.0 STARTING AND STOPPING OF THE PUMP:
Page 13 of 21
DOC NO.:VP-MM-VCP-03/0
By controlling the sliding valve the required flow and head may be obtained. After setting of pressure
gauge at required point, check ampere consumption. If found value exceeds required value, pump should
be stopped
Generally the pump is supplied with 2 nos. anti-friction ball bearings or angular contact ball bearing at DE
and 1 no ball or self align roller bearing at NDE according to the load factor of pump. Bearings are of
SKF/NBC/RHP/ equivalent make.
Bearings are normally oil lubricated. Bearing temperature is permissible to rise 40 degree Centigrade
above ambient temperature. For oil lubrication, oil should be maintained in the oil pot. Level is maintain
in bearing housing. Explained with below figure. The Bearing Housing should be filled with oil of any
one of the following types and specification :
Indian Oil Servosystem 46
Hindustan Petroleum Enklo 46
Bharat Petroleum Bharat Hydrol 68
Procedure :
Unscrew vent plug. Pour in oil through the vent plug aperture after having hinged down the reservoir of
the constant level oiler until oil appears in the vertical portion of the connection elbow of the constant
level oiler (see figure below). Then fill the reservoir of the constant level oiler with oil and snap it back
smartly into the operation position. Screw vent plug in again. After a short time has elapsed, check
whether the oil level in the reservoir has sunk. The reservoir should always remain filled.
6.0 LUBRICANT:
5.0 BEARING:
Page 14 of 21
DOC NO.:VP-MM-VCP-03/0
Stuffing Boxes are extra deep and suitable soft packing and/or for single balance mechanical seal.
Mechanical seal must be over oiled before starting the pump after long time storage. Soft-packing stuffing
boxes reduce the flow of leakage liquid at the clearance gap between casing and shaft protection sleeve
when the pressure inside the pump is higher than atmospheric. Conversely, on pumps which operate on
suction lift, the soft-packed stuffing box prevents the ingress of air into the pump.
Compressed asbestos packing gasket for joining of volute casing is used. However, packing gasket
suitable to handle corrosive liquid and high temperature fluid is supplied against specific requirements.
Normally star type spider coupling with spacer is used. Other type of coupling may be supplied against
specific requirements.
Replaceable throat bush as guide ring and wearing ring for protection of both side of impeller provided at
casing cover (optional) and Volute Casing of pumps.
Replaceable sleeve for protecting the shaft and for Balance seal step sleeve is being provided. Sleeve is
extended beyond seal cover or gland flange.
One set Anti-friction bearing, Wearing Ring, Shaft Sleeve, Gland Packing/ Mechanical seal, Sleeve
gasket, Gasket for Impeller nut, Lantern ring, and Gasket & O ring set must always be kept with the
actual users of the pump to ensure uninterrupted service from the pump.
7.0 STUFFING BOX:
8.0 GASKET
9.0 COUPLING
10.0 GUIDE RING / WEARING RING
11.0 SHAFT SLEEVES
12.0 SPARE PARTS
Page 15 of 21
DOC NO.:VP-MM-VCP-03/0
SL.NO. DEFECTS CAUSES REMEDY
1. Pump does
not deliver
liquid.
(1)Insufficient quantity of
water/water not filled in pump
casing
(1) Fill up pump casing with
clear water or liquid to be
pumped.
(2) Incorrect direction of
rotation.
(2) Change the direction of
rotation of prime mover.
(3) Pump is clogged. (3) Check up Impeller may
clog. Clean Suction pipe and
Strainer.
(4) Pump speed too low. (4) Check up speed of prime
mover and adjust.
(5) Suction Lift too high. (5) Reduce Suction Lift.
(6) Leakage in Suction Pipe. (6) Prevent leakage in suction
Pipe.
(7) Incorrect layout of Suction
Line.
(7) Correctly install the
Suction Line.
(8)Valve in Suction Line not
open properly.
(8) Check up the opening of
line valve.
(9) Shaft Sleeve & Gland
packing worn and air leaks.
(9) Replace Shaft-Sleeve &
Gland Packing.
(10) Delivery liquid too viscous. (10) Liquid viscosity to be
checked & corrected.
(11) Incorrect selection of pump
for operating condition.
(11) Replace the pump with a
suitable designed capacity.
2. Flow not
adequate.
(1) Speed too low. (1) Check up speed of prime
mover and adjust.
(2) Leakage in Suction side
fitting and piping
(2) Prevent leakage in suction
pipe and fittings.
(3) Discharge Head too high.
Excessive high back pressure.
(3) Check up vertical head
obstruction of frictional
losses. Adjust duty point.
(4) Pump Casing or Piping are
not vented carefully.
(4) Fill up the pump casing/
vented pressure pipe.
(5) Rubber Flap Valve clogged. (5) Check up rubber Flap
assembly & leakage from
pump casing.
(6) Leakage through seal and air
leaks.
(6) Check Mechanical Seal
unit and rectify/replace if
required.
(7) More clearance between
Impeller and Wearing Plate.
(7) Measure the clearance
between Impeller and Wearing
Plate and adjust by using
proper Packing.
(8) Suction lift too high or
suction pipe too long.
(8) Avoid High Suction lift
and Suction piping.
(9) formation of air pocket (9) After piping layout fit a
vent valve
(10) Supply line or Impeller
passage obstruction
(10) Remove deposit in piping
and inside of Impeller
13.0 TROUBLE SHOOTING
Page 16 of 21
DOC NO.:VP-MM-VCP-03/0
SL.
NO.
DEFECTS CAUSES REMEDY
3. Pump
takes more
Power.
(1)Opening Voltage is too low. (1) Provide required voltage
(2) Specific gravity of liquid is
higher than specified.
(2) Reduce speed if possible.
(3) Motor running on two phase (3) Rectify defective phase
(4) Speed too high. (4) Check and correct the speed.
(5) Head/Back pressure less than
rating.
(5) Provide minimum head. Adjust
duty point
(6) Shaft Bent (6) Check and replace the Shaft.
(7) Misalignment of the set. (7) Correct the alignment.
4. Rated
pressure
not
developed.
(1) Prime mover not running at rated
speed.
(1) Check the speed of Prime mover
and correct it.
(2) Leakage through Gland Packing. (2) Replace Gland Packing.
(3) Too much clearance between
Impeller and Wearing plate.
(3) Measure the clearance between
Impeller and Wearing plate and
adjust by using proper packing.
5. Pump
vibrates
and makes
more
noise.
(1) Pump casing not filled with
Water/Liquid (it is only possible
only during priming time).
(1) Fill up the pump casing.
(2) Suction lift too high. (2) Reduce the suction lift or install
the Foot valve.
(3) Mis- alignment (3) Correct the alignment.
(4) Foundation not rigid (4) Check up the foundation bolt.
(5) Shaft bent (5) Replace the shaft
(6) Bearing Worn out (6) Check & replace Bearing.
(7) Lack of Lubrication (7) Lubricate the Bearings.
(8) Pump operating at very low
capacity.
(8) Reduce total head.
6. Bearings
have short
life.
Increase in
Bearing
Temperatu
re
(1) Misalignment (1) Correct the alignment.
(2) Shaft bend (2) Check the shaft condition.
(3) Excessive Oil or lack of oil. (3) Check up lubrication.
(4) Dirty water getting into Bearings. (4) Protect bearing neatly.
(5) Pump is on vibration in the pipe
line
(5) Check pipe line & ensure proper
fixing of pipe line. Reduce distance
of piping support. Fix pipe line
using anti vibration material.
7. Excessive
pressure
(1)Speed is too high than rated RPM (1) Adjust speed to the rated RPM
Page 17 of 21
DOC NO.:VP-MM-VCP-03/0
Preventative maintenance schedule are the periodical checks and precautions by which possibilities of
failures and breakdowns are made very remote.
14.1 Daily Checks
Pressure gauge reading
Bearing temperature
Leakage through stuffing box
Noise and vibration
Voltage and current
Constant flow of cooling water.
14.2 Periodical Maintenance
Replace the oil for bearing lubrication.
Change of stuffing box packing.
Check the alignment of the pump set.
Calibrate the measuring instruments.
Check the sealing and cooling connections etc.
Normally the pump will be due for overhauling after about 3000 working hours. Pump dismantling and
assembling should be done by skilled personal. Special attention should be given to continuous running
pumps & advice is to keep stand by pump for emergency services.
15.1 DISMANTLING OF PUMP: (Refer cross section drawing with list of component.)
1. Remove Coupling Guard, Pressure Gauge, Oil Pot, Cooling Pipe, Flash Pipe and other fittings as
applicable. Drain out pumping liquid by removing casing drain plug (Item.26) and drain out oil from
Bearing Housing by removing plug (Item.42)
2. The Design advantage of this BPO pumps is, dismantling of pump can be done without disturbing the
pipe line connected to suction or delivery flange. If spacer type coupling is provided than remove both
side spacer bolt (Item.21) by unscrewing it and then remove the spacer of the coupling (Item. 24).
Remove support foot (Item 45) by unscrewing the bolt (Item.46) and removing bolt & nut of base
frame fixed with it the support leg.
3. Unscrew and remove the nut from the stud (Item 29) for casing and take out the Driving Head
assemble with impeller and shaft along with bearing housing without disturbing the pump casing.
Take assistance of forcing screw if provided for removal of Casing Cover from Casing(Item no.03).
Special care may be taken during removal of casing cover to save the casing gasket.
4. To dismantle dynamic assembly, first unlock the lock washer (Item no.03) of impeller lock nut (if
applicable) and remove impeller lock nut (Item 01) by unscrewing it. Remove lock washer (Optional).
Now pull out the Impeller (Item 04) from shaft and take out the Impeller key (Item no.05).
5. In case of mechanical seal dont disturb the gland nut (Item 35). After removal of impeller take out the
guide ring/throat bush (Item no.08) unscrewing 4 numbers screw(Item 07). For gland packed pump
remove gland flange (Item no.34) and then take out Stuffing Box Packing (Item 31) and Lantern Ring
(Item 30) one by one after removal of Throat Bush for Mechanical Seal application, take out sleeve
with mechanical seal rotating assembly from non-driving end. This is major advantage of our
14.0 MAINTENANCE
15.0 OVERHAULING
Page 18 of 21
DOC NO.:VP-MM-VCP-03/0
mechanical seal design that you can remove the rotating part of seal without disturbing the stuffing
box. Remove key for sleeve (optional) before removal of the sleeve.
6. Remove Casing Cover (Item no.28) with stuffing Box (Item no.11) (along with gland flange for
mechanical seal pump) from the driving head by removing the bolt (Item 33). In special case for few
model casing cover and stuffing box are integrally casted.
7. For mechanical seal pumps remove seal cover fitted with stationary parts of mechanical seal from
stuffing box by unscrewing 4 Nos. gland nut (Item no.35). Take out the mating rings (stationary seal)
from the seal cover along with seal secondary O ring for inspection of stationary face & Oring
condition.
8. Remove align screw (Item no.22) provided at coupling, take out pump coupling half & Key for
coupling (Item no.23).
9. Remove both side baring cover (Item 39&53) by unscrewing bolt (Item no.38&49) provided for it.
Remove both side oil seal (Item no.41&52) from bearing covers.
10. Carefully take out the pump shaft (Item no.20) together with bearings (item no.43) towards driving
end. In few model NDE bearing provided self align cylindrical rotter type instead of ball bearing
providing a cieclip inside NDE housing. Check the condition of NDE bearing housing circlip and
replace it if required (Applicable for self align cylindrical bearing if provided at NDE.) Remove
NDE roller case of cylindrical roller bearing from housing.
11. Unlock bearing lock washer (Item no.51) and remove bearing lock nut (Item no 50) by unscrewing it
before removal of the bearing from the shaft. Pull out D.E. bearings (Item no 47) from the shaft and
take out NDE bearing (Item no.43) or the inner race of the cylindrical roller bearing as applicable.
12. Check wearing ring provided at casing and casing cover (optional) (Item no. 02 & 06) and if required
replaced it. Wearing ring may be provided with cod screw. Pull out the wearing rings after removing
the cod screw if provided.
13. After removal of all above pump parts it is necessary to check up properly for any wear and tear and if
any part is found to be worn out, the same should be replaced or rectified. Special care should be
taken for check up of Wearing ring, Sleeve, Throat Bush, Mechanical Seal, Lantern Ring, Bearings
Gasket & O Ring.
15.2 Reassembling of Pump:
1. The pump should be reassembled in accordance with the rules of sound engineering practice. Before
reassembling all parts are to be cleared and it is advised to paint all the parts which are without
machined faces. Paints should be dry before reassembling. Bearings are to be cleaned with petrol.
All machined faces should be rubbed with suitable Lubricant, Lubricant to be applied on screwed
components also.
2. Reassembly proceeds in reverse sequence to dismantling. Fit driving end bearings (Item no.43) with
the pump shaft (2 nos. Bearing to be fitted back to back if supplied with angular contact ball bearings
as applicable) lock with lock washer clip after slipped on lock washer (Item no.50) and screwed on
bearing lock nut (Item no.51) firmly fix up of lock washer. After tightening of bearing fold the lock
washer peak to lock the nut . NDE ball bearing (Item no.43) or inner ring of self-align bearing for
non-driving end is to be fitted with the shaft. For oil lubrication dont apply any grease to the
Bearings. If bearings are not replaced then provide few drops of oil at bearings. For NU series self
align bearing only outer ring of N.D.E. roller bearing to be inserted at N.D.E. bearing housing after
providing the circlip at inside bose of NDE housing.(Bearing & Inner ring may be preheated on oil
Page 19 of 21
DOC NO.:VP-MM-VCP-03/0
bath to 80
0
C before fixing at shaft).
3. Insert the pump shaft with bearing assembly from driving end inside bearing housing keeping proper
direction of shaft. Fixed up bearing at its position by a press fit.
4. Fix up bearing cover at driving end (Item no.53) and other bearing cover (Item no.39) at non-driving
end. Dont forget to replace Bearing Cover Gasket (Item no.40&48) and the Oil Seal inside Bearing
Cover (Item no.41&52) before insert it. Put coupling key (Item no.23) at shaft, fit pump half coupling
and tighten the coupling grub screw (Item no.21).
5. For balance mech. seal pump gland flange is to be fitted with stationary part (Item no.15) of the seal
by hand press fit providing O ring (Item no.14) for it. At first stuffing box(Item no.11) is to be fitted
with Casing Cover (Item no.28). Then the gland flange (Item no.34) along with the stationary seal is
to be fitted with stuffing box tightening the Gland Nut (Item no.35). Provide gasket /O ring (Item
no.13) before placement of seal cover. Also check for O ring (item no.36) and if required replace it.
6. Now fixed up casing cover (Item no.28) with bearing housing (Item no.18) i.e. driving head-shaft
assembly and tighten the stud-nut/bolt (Item no.33) as applicable.
7. Before mounting the seal on the sleeve measure the distance of seal face from setting face of throat
bush and additional compression to be required at about 3 to 4mm. Sleeve may be provided with a
separate key / lock screw (Item no.36) for locking it. Provide key if applicable after placement of the
sleeve. Provide guide ring /Throat Bush (Item no.08) and tight 4nos screw (Item no.07) to fix up
throat bush from NDE.
8. Put impeller key(Item no.05) to shaft and PTFE gasket(if applicable) between sleeve and impeller and
fix up the impeller on the shaft. Tighten the impeller lock nut. Provide a lock washer (if applicable)
between impeller and nut and lock the nut by lock it by folding the tooth of washer after full tight.
9. Now the assembly is ready to fit with volute casing providing one recommended ring gasket(Item
no.27).
Fit all oil pot, seal flash pipe, pressure gauge and other fittings applicable. This completes the re-
assembling.
10. While ordering the spares please inform us your pump sl. No. along with item no. and Cross Section
drg. no.
Recommended Stock of Spare Parts for two years of Operation
Item No. Designation
Number of Pumps (including standby pumps)
2 3 4 5 6 8 10 and more
Quantity of spares parts
42 Pump Shaft 1 1 2 2 2 3 30%
01 Impeller 1 1 1 2 2 3 30%
37 Bearing (DE) 1 1 2 2 3 4 50%
34 Bearing (NDE) 1 1 2 2 3 4 50%
12 Guide Ring 1 1 2 2 2 3 30%
19 Stuffing Box Packing/Mechanical
Seal
2 2 3 3 3 4 40%
06 Wearing Ring 2 2 3 3 3 4 50%
08 Wearing Ring 2 2 3 3 3 4 50%
14 Shaft Sleeve 2 2 3 3 3 4 50%
09 Casing Gasket 4 6 8 8 9 12 150%
11,13,16,26,29 Other secondary seal like O Ring 4 6 8 8 9 12 150%
Page 20 of 21
DOC NO.:VP-MM-VCP-03/0
Page 21 of 21
DOC NO.:VP-MM-VCP-03/0