Horizontal & SuHorizontal & Sump Pumpmp Pumps

CENTRIFUGAL PUMPS
A-5, Sector XXII, Meerut road,

Ghaziabad 201002, (U.P), India
Phone:+91-120-3015784
WPIL Limited
Trinity Plaza,3rd floor
84/1 a, Topsia road (south)
Kolkata 700046, India
WPE ES IOM Manual
WPIL designs are being regularly

improved and are thus subject to
changes.The pumps designed as
per customers requirement will
not exactly match data provided in
this manual.
WPE ES IOM Manual
The booklet covers the instructions for the following models of

Brg.Frame unit
11
15
12
18
22
pumps.
Pump models
32/130,40/130,50/130,65/130,32/200,40/200,50/200,65/200
32/160,40/160,50/160,65/160,80/160,32/260,40/260,50/260
80/200,100/200,65/260,80/260,100/260,125/260,40/320,50/320,65/320,80/320,100/320
150/260,125/320,150/320,100/400,125/400,150/400
This manual contains important and useful information for the proper
functioning and maintenance of this pump. It also contains important
instructions to prevent possible accidents and serious damage and to
ensure the safe and smooth functioning of this pump.
Read this manual carefully before commissioning the pump. Familiarize
your self with the operation of the pump and strictly obey the
instructions!
a
shall not be bound to any Guarantee other than the guarantee

accepted by
. In particular,
will not assume any liability for
explicit and/ or suitability of the articles supplied.
P
The guarantee shall forthwith and legally defunct in case:

Service and/ or maintenance has not been carried out strictly in
accordance with the instructions.
Installations and/ or commissioning has not been carried out in
accordance with the instructions.
Necessary repairs have not been carried out by our personal or have
been carried out without our prior written consent.
The articles supplied have been changed without our prior written
consent.
The spare parts used are not original WPIL Pump parts.
The articles supplied are used amateurishly, carelessly, improperly
and/or negligently.
The articles supplied become defective due to out side circumstances
beyond our control.
e
Furthermore, all deliveries are subject our

, which will be forwarded to you, free of charge and request.
G
Check the consignment immediately on arrival for damage and

conformity with the advice note.
In case of damage and/or missing parts, have a report drawn up by the
carrier at once.
3
WPE ES IOM Manual
If a pump or a complete pump unit has to be lifted, the slings should be fixed
as shown in figure 1. And figure 2.
N
p
WPE ES IOM Manual
In case the pump is not immediately being used, the pump shaft has to be
rotated manually twice a week.
E
Every WPIL pump has a name plate giving following details:

WPIL PUMPS
Ghaziabad
CENTRIFUGAL PUMP
SL.NO :
SIZE :
MM
SPEED:
RPM
DRIVE :
HP
TYPE :
TOTAL
HEAD
CAPACITY :
M/HR
JOB NO :
While you correspond with us for your

requirements of spare parts or for any
technical information, please always quote
this details in your letter.
WPIL water pumps are single volute casing pumps with axial suction branch and top
centre line delivery branch. All pumps supported by integrally cast foot in the casing
and all water pumps are centerline mounted.
Bearings are cooled when liquids are handled at temperatures above 100c
i
R
D
Clockwise, pump viewed from driven end.

i
All the WPE models are suitable for the speed of 1450 rpm. Besides that the following
speeds are recommended.
Max speed
Upto 3600
rpm
Upto 2900
rpm
Upto 1800
rpm
Pump Models
32/130,40/130,50/130,65/130,32/160,40/160,50/160,65/160,32/200,40/200
50/200,80/160,80/200,100/200,32/260,40/260,50/260,65/260,80/260,100/260
125/260,150/260,40/320,50/320,65/320,80/320,100/320,125/320,150/320,
80/400,100/400,125/400,150/400
WPE ES IOM Manual
1.1 If the assembly of the pump with the driver on a common base plate is done in
our works, the whole set will be carefully mounted and aligned. It is necessary
to check once more the alignment of the coupling before putting the pump
into operation.
The eye bolts which may be fitted to the driver must never be used to lift the
complete set as they are meant to carry the weight of the driver only.
1.2. If you furnish the driver yourselves, the clearance between the motor and pump
coupling halves as shown on the arrangement drawing must be strictly observed.
Difference in level between the shaft centre lines of pump and driver must be
equalized by suitable pickings (plain parallel shims). When the pump and motor
holding down bolts are finally secured, care must be taken to avoid distortion.
l
Place a ruler (A) on the coupling. The ruler should touch both coupling halves
across the whole width( see figure ).
Do the same check against both sides of the coupling near the axis.
For all security the alignment is also checked with a pair of out side caliper (B) at
2 diametrically opposite points of the side surfaces of the coupling halves.
WPE ES IOM Manual
Construction with stuffing box: check whether the gland nuts have not been
over tightened. If necessary, loosen the gland nuts and retighten them by
hand.
Check whether the shaft turns freely. Do this turning the shaft end at the
coupling a few times by hand.
P
The bearings of pumps provided with grease-lubricated bearings are filled with
grease at the time of delivery.
Pump provided with oil lubricated bearings are supplied without oil. See the
enclosed chart for specifications of oil to be used.
Fill the oil sump through the oil filling orifice up to the bottom of the
constant level oiller.
After that fill the constant level oiller entirely.
P
Proceed as follows, both when the unit is put into operation for the first time
and after the pump has been overhauled.
Fully open the stop value in the suction pipe. Closed the delivery stop
value.
Fill the pump and the suction pipe with liquid to be pumped.
Turn the pump shaft a few times by hand and more liquid, if
necessary.
h
The sense of rotation of the pump is indicated the arrow. Check

whether the sense of rotation of the motor corresponds with that of
the pump.
Let the motor run for only a short time and check the sense of
rotation.
If the sense of rotation is not correct, change connecting wire of
motor so as to match with rotation of the pump.
Mount coupling guard.
t
Open the stop valve in the supply piping for flushing for flushing or
cooling liquid, if the pump is supplied with a flushing or cooling
system.
Start the pump.
7
WPE ES IOM Manual
As soon as the pump is under pressure, slowly open delivery stop

valve until the working pressure is attained.
d
After the pump is started, the stuffing box will show a certain amount
of leakage. Because of the expansion of the packing fibers, this
leakage will gradually decrease. Make sure that the packing never
runs dry. To prevent this, loosen that gland nut to the extent that the
stuffing box leaks drop wise. As soon as the pump has reached the
proper temperature (and leakage is still too much) the gland can be
adjusted permanently.
Tighten both gland nuts, one after the other, a quarter turn.
Wait 15 minutes after each adjustment before making the next
adjustment.
Continue in this way until an acceptable drop wise leakage has
been attained (20-30 drops/ minutes).
e
A mechanical seal may never show visible leakage.

o
If a pump is in operation pay attention to the following:

The pump should never run dry.
Never use a stop valve in the suction pipe to control pump capacity.
The stop valve should always be fully opened during operation.
Check whether the absolute inlet pressure is sufficient, so that no
vapour can be formed.
Check whether the pressure difference between suction and delivery
pressure corresponds with the specifications for the duty point of the
pump.
I
S
D
Since the pumps are offered of back pull out type of design. While
dismantling the pump, casing will remain in its place with the suction and
delivery piping. The rotating
Assembly can be pulled back easily. If spacer coupling is used, then the driver
also
Need not to be removed, enabling easy re-assembling of the pump without
affecting the alignment. We recommend to mach-mark the parts before
removing the spacer so as to ensure the original state of mounting when reassembling.
Drain the liquid handled by the volute casing(C 1) and oil from bearing
bed(C 27).
8
WPE ES IOM Manual
Remove spacer coupling or if there is no such coupling, loosen driver and

move it aside.
Loosen sealing liquid and coolant pipes if it is there and undo the
fastening bolt on the support foot.
Undo stud nuts on volute casing (C 1).
Using the 2 forcing screws on the stuffing box(C 11) with draw the volute
casing..
After undoing the impeller nut (C 6) withdraw the impeller with gasket.
After that undo the stuffing box studs from lantern(C 34), withdraw the
stuffing box along with packing, Lantern ring( C 4),Pressure Ring(C 33) and
Gland ( C 13) .
Remove the Shaft sleeve (C 14).
Remove the lantern from bearing housing.
Remove Deflector (C 31 ) and Inner Bearing Cap(C15) from bearing
housing.
Remove the Outer Bearing Cap(C 20).Remove pump shaft(C 24) with
Bearings towards drive side.
For assembly proceed with reverse sequence. After mounting the shaft,
check the axial flow of the rotor from 0.01mm to 0.7mm.
If new bearings are mounted on the shaft, they must first to be heated up to
80c in an oil bath. The bearings if installed in our works, have normal
clearances, however, use of bearings with C3 play is permissible.
L
The pump is furnished with two deep groove ball bearings (table 1.)
r
The grease lubricated bearing have been lubricated before shipment. For this
bearings following bearing greases are recommended which are available in
the market.
r
Name of the firm

Indian oil
Caltex
Hindustan petroleum
Speed 1450 rpm

Servo gem 3
Starfak 3
Natra 3
Speed 2900 rpm/3600 rpm

Servo gem 2
Starfak 2
Natra 2
WPE ES IOM Manual
Bearings
Amount
of oil in
liters
Qty of grease for relubr of each bearing

(g)
15
6305 2 Nos
0.550
100
18
6307 - 2 Nos
0.700
150
22
6309 - 1 No
3309 1 No
0.850
200
Frame
unit
Table 1
The lubrication in Table 1 apply if the temperature is below 70C.
Each temperature rise of 15C will reduce the lubrication interval to a half.
O
The bearing housing has been emptied of oil prior to shipment and must be
refilled before starting.
Pour oil in the bearing housing half way up the sight glass.
During operation the level may slightly fall. Refilling during operation.
When the pump is put into operation after prolonged shut down, flush
bearings and bearing housing with petrol or benzyl in order to remove
impurities. During the flushing procedure rotate the shaft slowly.
For lubrication of our pumps we recommend the lubricants shown on this lubrication table
L
Firm
Indian Oil
Hindustan Petroleum
Mobil
Speed up to 1500 rpm

Servo System 150
Esstic 55, Terresso 56
Mobil Vactra oil Heavy
Mobile D.T.E. oil Heavy
Vac HLP 49
Speed above 1500 rpm

Servo system 68, 46
Esstic 50, Terresso 52
Mobil Vactra oil Medium
Mobile D.T.E. oil Medium
Vac HLP 36
It is recommended that for a new pump the oil should be changed after 100
hours of operation for the first time and thereafter at intervals of 6-12 months add
oil when necessary.
10
10
WPE ES IOM Manual
When a new pump is being put into service or the stuffing box has just been
re-packed, watch the packing performance more closely than normal. Shut
off the cooling water to the gland (if applicable).
During the first hours, the stuffing box is allowed to leak quite a good deal,
about 100 drops a minute. If the leakage degreases, slack the packing gland.
If you want to reduce the leakage, tighten the packing stepwise at intervals of
about 10 minutes and continue until packing performance is satisfactory. A
small leakage of single drops should be allowed from the stuffing box for
ascertainment of lubrication and of the correct packing tightness. A suitable
leakage is 5 30 drops a minute. If the packing cannot be made to seal
without intense tightening, it is best to re-pack. When re-packing remove all
the old packing rings and cleans the stuffing box thoroughly. At the same
time check to see that the water channels are clear and the shaft is free of
warpage and score marks.
When selecting the packing type, observe the quality and temperature of the
liquid being pumped and the shaft sleeve material.
Carefully form the packing into the right shape over the shaft sleeve.
First insert the cut ends into the stuffing box and then push the whole ring to
the bottom of the stuffing box. Put the rings one by one in the stuffing box,
with the cut ends spaced 90 degrees apart. (See figure)
Frame unit
15
18
22
Packing ring
a x d / L in mm
8 x 8 x 150
10 x 10 x 188.5
10 x 10 x 220
:
No of packing
ring
4 (1 x L x 3)
4 (1 x L x 3)
4 (1 x L x 3)
Size in mm
8
10
10
Total length of
packing in mm
600
754
880
11
11
WPE ES IOM Manual
Frame
unit
DIN 3760
Because of design and

manufacturing tolerances it
is recommended to use
metric Oil seals according
to the following tables.
a
Size of Oil seal used in Bearing cap
15
Drive end
25 x 37 x 7
Non drive end

25 x 37 x 7
18
35 x 47 x 7
35 x 47 x 7
22
45 x 60 x 10
45 x 60 x 10

Regularly check the outlet pressure.

Bearing Temperature.
Noise and Vibration.
Voltage and Current.
Check the pressure of the flushing liquid. This pressure must be 1.5
bar higher than the pressure at the impeller hub.
Do not tighten the gland nuts any more after the running in period and
adjustment.
If in time in gland packing starts to leak excessively, new packing rings have to
be mounted instead further tightening the gland nuts.
e
A mechanical seal generally requires no maintenances. However, it should

never be allowed to run dry. If there are no problems it is not advisable to dismantle
the seal as the facing surfaces are running one another. Dismantling always means
replacement of the mechanical seal.
When the mechanical seal is leaking it has to be replaced.
L
Bearing housings with grease packed deep groove ball bearings require no
maintenance.. The bearings are filled with grease during assembly. In case the pump
is overhauled, the bearing housing and the bearings have to be cleaned and provided
with new grease.
12
12
WPE ES IOM Manual
During operation the constant level oiler should never be empty, so take care to top
up timely. The oil should be changed once a year. If the oil temperature is higher
than 80 C, the oil should be change more often.
E
R
D
13
13
WPE ES IOM Manual
R
D
W1
W2*
W3 *
W4*
W5*
W6 *
W7*
W8 *
W9
W 10 *
W 11 *
W 12
W 13 *
W 14
W15
W 16
W 17
W 18
W 19
W 20 *
W 21
W 22
W 23
W 24 *
W 25 *
W 26
W 27 *
W 28
W 29 *
W 30
W 31
W 32 *
W 33
e
Volute Casing
Impeller
Stuffing Box
Gasket Shaft/ Sleeve
Impeller Nut
Impeller Key
Lantern Ring
Wear Ring
Casing Drain Plug
Gasket - Stuffing Box/Casing
Sleeve
Stud Gland/Stuffing Box
Oil Seal Inner Bearing Cap
Plug Oil Drain
Bearing Bed
Oil Level Sight Glass
Support Foot
Hex Bolt Support Foot
Outer Bearing Cap
Oil Seal Outer Bearing Cap
Key Coupling
Shaft
Hex Bolt Outer cover/Bed
Gaskets Outer Bearing Cap
Bearing - Coupling End
Vent
Bearing Pump End
Bearing Cap Inner
Deflector
Gland
Stud Bed/Stuffing BOx
Gland Packing
Stud Stuffing Box / Casing.
s
14
14
WPE ES IOM Manual
In general failures in a pump unit are attributable to the following causes:

Failures in the pump

Failures or faults in the piping systems
Faults due to a wrong installation or commissioning
Faults due to a wrong pump selections
A number of the most frequently occurring failures as well as their possible causes
are set forth in the below table.
o
Pump doesn't deliver any liquid

Volume flow of the pump is
insufficient
The discharge head of the pump is
insufficient
Pump stalls after it has been put into
operation
The power consumption of the pump
is higher than normal
The power consumption of the pump
is lower than normal
The stuffing box is leaking excessively
Shaft packing or mechanical seal have
to be replaced to often
Pump vibrates or makes noise
Bearings wear too soon or gets hot
Pump runs with difficulty, gets hot or
stuck
P
1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20
21 29
1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20
21 28 29
2 4 5 13 14 17 19 28 29
1 2 3 4 5 6 7 8 9 10 11
12 15 16 17 18 22 23 24 25 26 27 32 34
38 39
13 14 15 16 17 18 20 21 28 29
6 7 23 25 26 30 31 32 33 43
6 7 23 25 26 30 31 32 33 34 35 36 41
1 9 10 11 15 18 19 20 22 23 24 25 26 27
29 37 38 39 40
23 24 25 26 27 37 38 39 40 42
23 24 25 26 27 34 37 38 39 40 42
1.
2.
3.
4.
5.
6.
7.
8.
9.
Pump or suction pipe not sufficiently filled or de-aerated.

Gas or air coming from the liquid.
Air lock in the suction pipe.
Suction pipe leaks air.
The pump sucks in air through the stuffing box.
The sealing or flush water pipe to the stuffing box is not connected or blocked.
The lantern ring in the stuffing box has been mounted wrongly.
The manometric suction head is too high.
Suction pipe or suction strainer is blocked.
15
15
WPE ES IOM Manual
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Insufficient immersion of foot valve or suction pipe during operation of the pump.
NPSH available too low.
Speed too high.
Speed too low.
Wrong sense of rotation.
Pump doesn't work at the right duty point.
Liquid density differs from the calculated liquid density.
Liquid viscosity differs from the calculated liquid viscosity.
Pumps works when the liquid flow is too low.
Wrong pump selection.
Obstruction in impeller or pump housing.
Obstruction in the piping.
Wong installation of the pump unit.
Pump and motor nor well alignment.
Rotating part running out of true.
Imbalance in rotating parts (for instance impeller, coupling).
Pump shaft is running out of true.
Bearing faulty or worn out.
Seals rings faulty or worn out.
Damaged impeller.
Pump shaft or shaft sleeve at shaft packing or running surfaces of the mechanical
seal are worn out or damaged.
31. Worn or dried up shaft packing.
32. Not well packed stuffing box or bad mounting of the mechanical seal.
33. Packing type of the mechanical seal not suitable for the operation liquid or
operation circumstances.
34. Gland of seal cover has been tightened too much or crookedly.
35. No water cooling of stuffing box at high temperatures.
36. The sealing or flushing liquid to the stuffing box or the mechanical seal is polluted.
37. Axial retaining of impeller or pump shaft is defective.
38. The bearings have been mounted wrongly.
39. Too much or too little bearing lubrication.
40. Wrong or polluted lubricant.
41. Impurities in the liquid get into the stuffing box.
42. Too high axial force because worn dorsal blades or excessive inlet pressure.
43. Excessive pressure in packing space due to much play in the smothering bush,
blocked by-pass pipe or worn dorsal blades.
16
16
WPE ES IOM Manual
For any correspondence / ordering spares , please quote the

following
CUSTOMER :
PROJECT :
WPIL REF. :
PUMP MODEL :
PUMP SERIAL NO. :
Contact WPIL
For any complaints and suggestion regarding Pumps
Email us: service@wpil.co.in
Phone: +91-120-3015784
Fax : +91-120-3015740
Factory Address :
WPIL LIMITED
A-5, Sector XXII, Meerut road,
Ghaziabad 201002, (U.P), India
Corporate office address :

WPIL limited
Trinity Plaza, 3rd Floor,
84/1 a, Topsia Road (South)
Kolkata 700046, India
P: +91.33.3021.6800
F:+91.33.3021.6835
17
17
WPE ES IOM Manual
WPIL PUMP BASKET
18
18
INSTALLATION, OPERATION AND

MAINTENANCE MANUAL
CENTRIFUGAL PUMPS
TYPE U
Factory Address:
Corporate Address:
A-5, Sector XXII, Meerut Road,
WPIL Limited
Ghaziabad - 201002, (U.P.), India
Phone:+91-120-3015784
84/1 A, Topsia Road (South)

Kolkata 700 046, India
WPIL LTD.
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19
What do you want to do?
Foreword & safety regulations

Receiving & Checking
Storage & Shifting
Preparation for installation
Installation Procedure
Pump start-up and operation
Maintenance of the pump
Contact Us
Click on the option you need above,

for any further assistance, contact WPIL on
service@wpil.co.in
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20

1.
Foreword
2.
Safety regulations
3.
Safety instructions
4.
Manufacturers regulations
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1. Unloading & inspection.
2. Shortages & damages.
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Storage & Shifting
Storage & Shifting

1. Environmental briefing.
2. Recommended storage procedure.
3. Recommended shifting procedure.
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23

1. Required tools, material & equipment.
2. Installation drawings.
3. Preparing the pump foundation.
4. Layout & inspection of pump parts for installation.
5. Hoisting instructions.
6. Layout of pipe work valves and accessories
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5.1
Leveling & grout type

5.1.1 Leveling of base plate
5.2
Installing the pump assembly
5.3
Couplings
5.3.1 Flexible coupling
5.3.2 Coupling alignment
5.4
5.3.2.1
Radial Alignment
5.3.2.2
Angular Alignment
5.3.2.3
Alternative Method for Alignment
Installing the accessories

5.4.1 Priming connection
5.4.2 Air vent connection
5.4.3
5.4.4
5.4.5
Pressure gauge connections

Stuffing box packing
Mechanical seal
WPIL LTD.
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1. Pre-start checks.
2. Important operating instructions.
3. Trouble shooting chart.
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7.1
Preventive maintenance table.
7.2
Recommended spare parts & ordering procedure.

7.2.1 Procedure for Odering Spare Part
7.2.2 Recommended list of spare parts subject to most wear
7.2.3 Recommended list of spare parts to be stocked if down time is critical
7.3
Major maintenance of pump.

7.3.1 Packing box assembly/Mechanical Seal
7.3.2 Bearings
7.3.3 Pump assembly (U) removal
7.3.3.1
Complete rotating assembly removal
7.3.3.2
Dismantling of rotor shaft
7.3.3.3
Method of removing dowel bushing
7.3.3.4
Re-Assembly of the rotor assembly
7.3.4
Re-Assembly of the pump unit
7.3.5
Dismantling of Re-Assembly of U pumps
7.3.6
Lubrication chart
WPIL LTD.
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27
7.4
7.3.6.1
Recommended grease lubricants
7.3.6.2
Recommended oil lubricants
Reference drawings, material of construction & technical details.

WPIL LTD.
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2011
28
FOREWORD
1.1 FOREWORD
This manual provides instructions for installing, operating and maintaining WPIL Horizontal
Centrifugal Pumps. These instructions are written only for those who have a working knowledge of
Horizontal
pumps and a familiarity with both the terminology and proper field practices used in
pump industry. Cautions and warnings are included, but they are not substitutes for the careful
work of the experienced.
If installation & maintenance work is neglected, or carried out incorrectly, we will not be able to
fulfill our warranty obligations as agreed and documented in the purchase contract.
Although we used the most current information available at the time this manual was published, all
information contained herein is subject to change without notice. We have made every effort to
avoid errors, but we cannot guarantee that this manual is error-free.
We appreciate your interest in our product. If you have questions about the contents of this manual,
please contact our field service department.
By furnishing this manual, WPIL does not

accept liability for successful pump installation,
operation or maintenance; that liability belongs
to those who actuallyinstall, operate and
maintain the pump.
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SAFETY REGULATIONS
1.2. SAFETY REGULATIONS
WARNING
We wish to point out that we accept no liability for
damage and operatrional faults arising from nonadherence to the instructions in the operating and
maintenance manual.
This section contains safety regulations which must be always followed when operating our pumps.
The regulations are highlighted in the text using the following symbols:
=Working safety symbol = WARNING

For working and operating procedures which is must.
= CAUTION
To prevent damage to the EQUIPMENT.
The words WARNING and CAUTION are always in front of the text to which they refer. The word
NOTE is after the associated text.
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SAFETY REGULATIONS
It is essential to observe the regulations highlighted this way.
Particular attention must be paid to the safety equipment installed in the pump. If the safety
equipment is not working or malfunctioning, the pump must not be operated.
The following instructions for guaranteeing protection at work and safety must be observed:
Operators must have the necessary specialist knowledge.
Maintenance work may only be carried out by authorized persons.
The laws and regulations valid at the place of use must be observed when operating the
pump. In the interest of occupational safety, operators, supervisors and machine operators
are responsible for observing the regulations.
Perform functional inspections before starting work.
Tools and other objects may only be kept in their correct places; otherwise they can
jeopardize safe operation.
Operating media (e.g. oils, lubricants and cleaning agents) for maintenance, servicing and
repair work and oil changes must be collected in suitable containers and disposed of
correctly, (in accordance with statutory guidelines applicable in the country).
Wear protective gloves when carrying out cleaning work, particularly when using solvents or
petroleum ether. Avoid naked flamers and smoking during cleaning.
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SAFETY INSTRUCTIONS
1.3. SAFETY INSTRUCTIONS
1. The pumps may only be operated and maintained by persons who are qualified and
competent to operate such machines.
WARNING
The electrical machines and units are equipment with an industrial heavy-current
connection.
These items of equipment have dangerous conductive with rotating parts during
operation.
Serious material or health damage may be caused by removal of safety facilities,
incorrect use and wrong operation.
The persons responsible for the pump must therefore guarantee that:
1. Only qualified persons are assigned to work on the pump.
2. This manual is available to operating persons and that they follow it.
3. Non-qualified persons do not operate the pump and are not allowed in its
proximity.
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SAFETY INSTRUCTIONS
WARNING
The electrical connection must be made by a qualified electrician in accordance
with the local regulations.
The mains voltage must be the same as the voltage stated on the rating plate.
The electrical circuit diagrams must be observed with regard to electrical
connection of the pump.
If the motor was switched off by the triggering of a safety element, it should
not be switched back on again. The fault must be located and remedied.
Switching back on without fault correction presents a risk of explosion.
2. The operator must be instructed about his pumps power supply and how to switch it off.
3. The operational reliability of the safety equipment must be checked daily.
4. The operator must report to his superior as quickly as possible for any fault or irregularity which
occurs. This applies to both the mechanical and electrical units.
5. It is absolutely essential that the operator shuts down the pump immediately if faults occur which
jeopardize safety.
These include:
1. Failure of the safety facilities
2. Damage to important pump components
3. Damage to electrical units and lines as well as insulation
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SAFETY INSTRUCTIONS
6. The operator is forbidden to modify electrical connections. Only trained specialists may perform
this work.
Dry running is not permissible.

Briefly switching on for maximum 10 seconds is possible
without any danger.
Do not switch on if theres a fault.
7. Work on the pump may only be carried out if the current is switched off and when the moving
parts are no longer turning. Unauthorized switching-on must be prevented by suitable measures.
WARNING
Never put hands and objects into the pump while turning.
8. The pump may only be switched on when it is installed and flooded.
WARNING
Wear protective gloves when carrying out cleaning work,
particularly when using solvents or petroleum ether.
Naked flames and smoking are forbidden.
Operating media (e.g. gear oils, transformer oils, lubricants

and cleaning agents) for maintenance work and servicing and
oil changes must be collected in suitable containers and
disposed off correctly.
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MANUFACTURERS REGULATIONS
1.4. MANUFACTURERS REGULATIONS
1.4.1 General
These instructions must always be kept at hand where the pump is in use. It is essential that these
instructions be read before work is started by all persons involved in working with or on the pump
(make entry in the machine operator list).
Person(s) who will only occasionally work on the pump (e.g. for assembly and maintenance) must
also read and understand the operating and maintenance manual.
It is essential to follow the instructions in the operating and maintenance manual of the pump. This
applies strictly to the general and special safety instructions at the start of this manual and in the
appropriate chapters.
If in doubt, consult the person responsible for safety and accident prevention in your division.
1.4.2 Correct behavior

Use the pump only for the intended liquids and data sheet parameters.
Any other use is regarded as a special application which must be clarified with the manufacturer.
The manufacturer is not liable for use of the pump for purposes other than those for which it was
designed.
The pump is operated from the control unit intended for this purpose.
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MANUFACTURERS REGULATIONS
Faults which can impair safety must be remedied immediately.
Unauthorized modification / application of the
pump
render the manufacturers liability VOID for any

resulting damage.
1.4.3 Behavior during operation

All accident prevention regulations must be observed.
A further precondition for safe operation is that the additional instructions in this operating and
maintenance manual are observed.
1.4.4 Original parts and safety

Original parts and accessories are designed specially for the pump by WPIL Limited.
We expressly point out that original parts and accessories not supplied by WPIL Limited are not
tested and released by the company. The installation and/or use of such products can impair the
active and/or passive performance / safety of the pump.
WPIL Limited shall not be liable for any damage arising from
the use of non-original parts and accessories.
1.4.5 Maintenance and inspection list
Keeping the maintenance and inspection list (Chapter 7 of the operating and maintenance manual)
will help you to monitor the stipulated inspection and maintenance work.
1.4.6 Damage
Damage must be immediately remedied by specialists only.
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RECEIVING & CHECKING

2.1 UNLOADING & INSPECTION
All pump parts are precision machined parts. Unload with adequate care. Check the following:
Contents against packing list.
All components for damages.
Shafting for straightness and damage in case of broken crate or careless handling.
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RECEIVING & CHECKING

2.2 SHORTAGES AND DAMAGES
Any shortages or damages should be immediately noted on the receipted documents of freight
agent/carrier to facilitate prompt and satisfactory resolution.
REPORT ALL TRANSIT DAMAGE / SHORTAGE

IMMEDIATELY ON FREIGHT AGENT / CARRIER
RECEIPT.
Late reports of shortage/transit damage will
cause controversy and delay prompt &
satisfactory resolution.
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STORAGE & SHIFTING

3.1 ENVIRONMENTAL BRIEFING
All pump parts are precision machined. All parts supplied should be stored indoors in a dry (45%
RH) and non-corrosive environment.
The effective life of preservatives applied at the factory is 60 days including transportation period,
unless specifically agreed other-wise.
HIGH-HUMIDITY / COASTAL & CORROSIVE

ENVIRONMENTS
A.) Inspect pump and parts periodically to ensure that
preservatives are intact.
B.) All machined surfaces and exposed shafting must be
coated with rust preventive agents suitable for the local
environment.
C.) Turn pump rotor manually each week a few turns.
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STORAGE & SHIFTING

3.2 RECOMMENDED STORAGE PROCEDURE
DO NOT DISCARD ORIGINAL PACKING BOXES. REPACK AND STORE & MOVE IN ORIGINAL PACKING
BOXES.
Storage area must be level and not at risk of flooding.
All openings need to be sealed against ingress of dirt, particulate matter and water.
All small parts need to be stored in covered boxes with preservative paper.
Rubber parts like o-rings, gaskets and bearings need to be stored in closed containers.
Keep heavy components off the ground by using supports.
Shafting need to be removed from boxes, coated with preservative and then re-boxed
with preservative paper.
INSPECT ALL PARTS PERIODICALLY TO ENSURE

PRESERVATIVES ARE INTACT AND NO SIGN OF
CORROSION IS VISIBLE.
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STORAGE & SHIFTING

3.3 RECOMMENDED MOVEMENT / SHIFTING PROCEDURE
Pump assembly, thrust bearing assembly, all shaftings & small parts must be moved in boxed
condition only.
DO NOT MOVE LOOSE PARTS. STICK TO

ORIGINAL FACTORY PACKAGING METHODS
FOR MOVEMENT.
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PREPARATION FOR INSTALLATION

4.1 REQUIRED TOOLS,MATERIALS AND EQUIPMENTS
The materials and equipment necessary for installation of the pump will vary with the size of the
pump and type of the installation. The list of lifting equipments and hand tools at Table below is
offered as a guide only.
The installation rig should be rated to hold at
least 1.5 times the weight of the complete
pumping unit i.e. the assembled pump and
driver.
S.No.
TOOLS & MATERIALS
QUANTITY
REMARKS
Washing Oil, Kerosene
For washing of parts
Emery Cloth Paper
For cleaning of parts
Molycote (anti-galling grease)
For assembly
Sealing tape/Thread compound for pipe
For auxiliary piping
Line Marker
2 Sets
For alignment of foundation
Chisel
3 Sets
For foundation preparation
Lifting Nylon Slings of suitable capacity
2 nos.
For installation & rigging
2 nos.
For assembly
and 3 m long
8
1 / 5 / 10 lb Hammer
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9
File Set
2 sets
For assembly
10
Screw Driver
2 each
For assembly
11
Adjustable Wrench
1 no.
For assembly
12
Pipe Wrench
2 nos.
For auxiliary piping / Line Shaft.
13
Allen Key(2 mm to 10 mm size)
14
15
1 set
For assembly
Wire Brush
2 nos.
For assembly
Single ended / double ended wrench(10mm
2 each
For assembly
to 36mm)
16
Plumb Bob with string
1 no.
For installation
17
Nylon hand hammer
2 nos.
For installation
18
Eye bolt of various sizes
19
D-shackle of various sizes (5 /7.5 M)
1 set
For rigging
20
Socket wrench
1 set
For assembly
21
Position marker punch
1 set
For assembly
22
Gap gauge (feeler gauge)
2 sets
For erection
23
Scraper
2 sets
For assembly
24
Marking String
For assembly
25
Ring spanner
2 nos. each
For assembly
For rigging
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26
S.S. shims of various sizes (0.1 mm to 2 mm)
27
Mobile hoist/ travelling crane
1 no.
For assembly
For assembly depending on size &
weight of the pump
28
Bearing pullers
1 no.
For Bearing removal
Measuring tools required during installation:
Sno.
Tools & Materials
Quantity
Precision Class Spirit Level Gauge (Accuracy 0.02 1 no
Remarks
For level checking
mm/ M)
2
Steel Tape (5, 10M)
1 each
For measurement of foundation
Dial Gauge with Magnet Holder & Clamps
1 set
For alignment checking
(Minimum division 0.01mm)

4
Gap Gauge (feeler gauge)
2 sets
For assembly
Edge 1.5 M long
1 No.
For Leveling
Straight Steel Scale (1 M)
1 each
For assembly
Straight Edge (Ibeam type) 1.5 m long,
1 no.
For level checking
Accuracy-0.05mm/M
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4.2
INSTALLATION DRAWINGS
Collect and arrange the following drawings:
Foundation drawing (refer pump General Arrangement drawing),

Installation dimensional drawing (refer pump General Arrangement drawing & pump crosssectional drawing),
Functional unit layout, (as per design by you), and

Piping diagram (as per design by you).
Finalize the method of installation based on these documents before starting work.
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4.3 PREPARING THE PUMP FOUNDATION
The foundation must be built to support the weight of the entire pump unit when the pump is full of
water. It should be rigid enough to withstand and prevent vibrations. The loading details of the
pump are given in General Arrangement Drawing.
WPIL recommends that a concrete foundation be used wherever possible.
Steel I-beams or timbers may also be used, but they should be strong enough to prevent spring
action and braced (tied together) to prevent lateral movement.
In case of concrete foundation, the top surface of the foundation should be left rough to allow
proper binding of final grout mixture. Also the top surface level should be lower in height by at least
20 to 35 mm to permit leveling of base plate.
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4.4
LAYOUT & INSPECTION OF PUMP PARTS FOR INSTALLATION
All pump accessories should be checked for correctness and cleanliness.
All small components and fasteners should be separated assembly-wise as per crosssectional drawing & checked for correctness and cleanliness.
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4.5 HOISTING INSTRUCTIONS
Nylon slings (of rated load capacity) for lifting the pump assembly should pass at positions on the
pump branches as shown in Fig. 4.5.a
Horizontal/Vertical Pump Lifting Arrangements

Fig:- 4.5a
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To lift the prime-mover (electric motor), pass sling as shown in Fig 4.5.b
Fig: 4.5b
Never lift the entire pump assembly by the

eye-bolts or from the bearing housing or
from the shaft extension.
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4.6 LAYOUT OF PIPE WORK, VALVES and ACCESSORIES
It is important to ensure that pipe work, valves etc. connected to the pump are adequately
supported. Ensure that the pump does not carry the weight of the pipe work when filled with water
or tend to be dragged in any direction.
No strain is put on the pump casing flanges

by the pipe work else would disturb the
pump alignment leading to vibrations.
Never connect a pump to the piping; always

connect pipe to the pump
4.6.1 SUCTION PIPING

To avoid the formation of air pocket, the installation of suction pipe work must be arranged under
the following conditions:
Always as few bends as possible

Suction pipe work must be perfectly air tight
There must be a gradual rise in the suction pipe work towards the pump
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In case of an elbow is required at the pump suction flange, it should have a long radius.
Location of the elbow from the pump flange should be more than 2D of straight pipe.
In case of an expander is required at the pump suction flange, it should be eccentric type to
avoid the air pockets.
In case of strainer is provided, for clear water the total area of these holes should exceed
three times the area of the bore of the pump suction branch.
Typical good and bad suction arrangements are shown in Fig 4.6.1.a & b and typical layouts are
shown in Fig. 4.6.1.c & d
Good suction layouts, showing pipes rising all the way to the pump.
Bad suction layouts, which will cause air pockets and failure to pump.
Fig. 4.6.1.a
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Fig. 4.6.1.b
Showing how the fault in the illustration on the left may be avoided.
Showing how an air pocket may be formed when the suction pipe is bigger than the pump branch.
avoided.
Typical Layout Flooded Suction (Fig. 4.6.1.c)

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Typical Layout Suction Lift (Fig. 4.6.1.d)

4.6.2 DELIVERY PIPING
Pipe work, valve, fitting etc. are located in the delivery pipe line should be adequately
supported to avoid any strains on the pump flange.
If an expansion joint is used it is recommended that this should be located at a distance not
less than 2D from pump flange.
The intermediate spool piece between pump and expansion joint needs to be anchored.
Improper anchoring may subject to large reaction forces which could be detrimental to the
installation.
A check valve is recommended in the case of back flow/high pressure surge is anticipated.
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INSTALLATION PROCEDURES
5.1 LEVELING & GROUT TYPE
The purpose of grouting is to prevent lateral shifting of the base plate, not to fix irregularities in the
foundation. Base plates are normally fabricated M.S. channel width plates at top and bottom
accurately machined to have parallel plane surfaces. The base plate looks similar to as shown in Fig.
5.1.a
Base Frame with Channel (Fig. 5.1.a)

5.1.1 LEVELING OF BASE PLATE
1. Mark the base plate/base frame and foundation bolts position as per GA Drawing.
2. Grout foundation bolts, as per GA drawing, using quick setting cements.
3.WPIL recommends that 20-30 mm of epoxy grout is maintained under the base frame.
4.In case epoxy grout is not available, level using leveling wedges. Fill the gap between sole plate
and foundation with quick setting concrete. Refer fig. 5.1.1.a & b
5.Level base plate/base plate with the help of straight edge and spirit level in two directions at 90
degrees by either leveling wedges or leveling nuts on anchor bolts.
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6. Allow curing time for grout as per manufacturers recommendations. Setting time is usually 48
hrs and the grouting becomes hard in 72 hrs.
7. In case of vertical installation, the pump should be mounted following the practices outline for
base plate mounted pumps similar to horizontal pumps.
8. If the pump is driven via a universal joint drive shaft, there may be a requirement to offset the
pump shaft w.r.t. the driver. Optimal offset will typically be in the range 0 to 4 depending on shaft
design. Consult the separate user instructions before installation.
9. Any support for the universal joint drive shaft, Plummer blocks must not exhibit resonant
frequencies in the range of 0.8 to 1.2 of nominal pump speed.
10. In case of vertical pump, the alignment of the unit is achieved by adding or removing shims
between the motor stool and the pump casing. The motor has a spigot fit in to the motor stool and
it is therefore not possible to achieve any horizontal movement at this interface.
Before leveling, the sole plate should be high

enough in grout thickness.
Preferred levelness is dead-level. Maximum
acceptable tolerance is 0.15 mm/meter.
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Fig. 5.1.1.a
FOUNDATION BOLT FIXING DETAILS WITH BASE PLATE

Fig. 5.1.1.b
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5.2 INSTALLING THE PUMP ASSEMBLY
The horizontal & vertical pumps are supplied in assembled condition from the works (as shown in
Fig. 5.2.a & 5.2.b). The accessories like couplings, coupling guard, motor stool & pump stool (in
vertical pump) etc. are supplied separately, are to be assembled with the pump and motor shaft
respectively at site and to be installed on the base frame/base plate. The following steps shall be
followed in installing the pump assembly.
Sling and hoist the pump with its half coupling and gently lower in position on the leveled
base plate.
Check that no gap exists between pump feet and the respective machined pads on the base
plate.
Locate the pump fixing bolts and tighten down.
Similarly locate the prime mover with its coupling half in position on the leveled base plate.
Rotate each shaft independently by ensuring that the bearings run freely and that shafts are
true within 0.1mm. Coupling pins should not be fixed during this check.
Fig. 5.2.a
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Vertical Pump Assembly (Fig: 5.2b)
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5.3 COUPLINGS
5.3.1 FLEXIBLE COUPLING
For horizontal pumps, the couplings used are Flexible pin bush type similar to as shown in Fig.
5.3.1a & b. Both couplings are identical except 5.3.1b with the exception of bore and the pins can
be inserted from either side.
Ref.
Description
Coupling Pin
Coupling Bush
Distance Sleeve
272
Locking Washer
276
Flexible Coupling (Pin Half)
277
Flexible Coupling (Bush Half)
A Type Flexible Coupling

Fig. 5.3.1.a
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Ref. Description
2
Coupling Pin
Coupling Bush
54
Coupling Key
272
Retaining Washer
275
Locking Nut
276
Flexible Coupling (Pin Half)
277
Flexible Coupling (Bush Half)
B Type Flexible Coupling

Fig. 5.3.1.b
5.3.2 COUPLING ALIGNMENT

The pump unit has been manufactured to allow field alignment. The unit must be properly aligned
at the time of installation. The importance of correct alignment can not be over emphasized.
Alignment should be checked and corrected as required after:
1. Mounting
2. Piping is connected
3. Pump or driver is moved for any reason.
Angular and parallel mis-alignment are corrected by shifting the motor and adding or removing
shims from under the motor feet.
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5.3.2.1 RADIAL ALIGNMENT
The radial alignment (intersection of axis) refer fig. 5.3.2.1a, for the rotating unit are carried out
with the help of dial gauge.
Clamp the dial indicator to one of couplings or to the shaft behind it, with the plunger resting
on the rim of the other half coupling.
Set the pointer to zero.
Rotate the coupling and note the readings at each quarter revolution (90).
Any variation in readings indicates a deviation in alignment. The position of one of the units
must be adjusted until the readings at each quarter revolution are within the specified
tolerances given below.
For detecting this type

of error
To check intersection of axes (Shaft in line at coupling end)
Fig. 5.3.2.1.a
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5.3.3.2 ANGULAR ALIGNMENT
The angular alignment (parallelism of axis) refer fig. 5.3.2.2a, for the rotating unit are carried out
with the help of dial gauge.
1.Clamp two dial gauge indicators at diametrically opposite points on one half of the coupling, on
to the shaft behind it, with plungers resting on the back of the coupling.
2.Inscribe a line across both of couplings for reference, readings are to be taken only when the two
marks coincide.
3.Rotate the couplings until the gauges are in line vertically and set the gauges to zero.
4.Rotate the coupling through half revolution.
5.If the alignment of the pump and its driving unit is correct the reading of both gauges should be
the same, though not necessarily zero.
6.Equally positive or negative readings are acceptable.
7.Adjust the position of any one of the units to correct the readings.
8.Rotate the couplings until the gauges are in line horizontally and reset the dial so that the
pointers are at zero.
9.Repeat the operations from point 4 to 7.
Coupling up to 300mm
Coupling > 300mm
0.05mm (0.002)
0.07mm (0.003)
RADIAL & ANGULAR ALIGNMENT NOT TO EXCEED

0.5mm (0.004) ON DIAL GAUGE
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For detecting this type

of error
To check the parallelism of axes (Angular alignment)

Fig. 5.3.2.2a
5.3.2.3 ALTERNATIVE METHOD FOR ALIGNMENT
Angular and parallel misalignment can alternatively quickly be checked by using the straight edge
and feeler gauge as described below.
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Fig. 5.3.2.3a
Check for angular alignment by inserting the taper or feeler gauges between the coupling faces at
90 intervals. The unit is in angular alignment when these four measurements are the same, or
within recommended tolerances.
Check for parallel alignment by placing a straight edge across both coupling rings on all four sides.
The unit is in parallel alignment when the straight edge rests evenly across both coupling rings in all
four directions.
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5.4
INSTALLING THE ACCESSORIES
5.4.1 PRIMING CONNECTION

Priming connection has been provided in the upper half of the casing to fill the casing with water
from some outside source until suction pipe and casing are completely filled with the water. Priming
may also be accomplished by the use of vacuum pump. Sometimes put valves are also used for
priming purpose depending upon the size of the pump.
5.4.2 AIR VENT CONNECTION
The air vent connection is provided at the top of the casing near the priming plug to provide the air
release valve for the removal of air during priming. It is necessary to exhaust air from suction pipe
and pump casing, as any air that remains in trapped will interfere with operation or hinder pump
from lifting water and will loose the priming.
5.4.3 PRESSURE GAUGE CONNECTION
Connect a compound gauge to suction of pump and pressure gauge to discharge flange of the
pump. It is advisable to furnish shut-off valves between flange gauged connections and gauges. The
gauges are necessary for an adequate check on pump performance.
5.4.4 STUFFING BOX PACKING
Packing and repacking of stuffing box should be done with great skill and care. Normally the pump
is dispatched from works along with packing. However, the time between the date the pump is
dispatched from works and date it is commissioned is more than three months, replace the packing.
For various pump models, refer the packing sizes as per the following Table 5.4.4. For installation
purpose, refer the pump assembly drawing (Fig. 7.3.3). Mechanical seal is optional and factory
assembled.
THE PACKING RING JOINTS SHOULD BE
STAGGERED AND EACH RING SHOULD
BE PUSHED IN TO POSITION
SEPARATELY.
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PUMP SIZE & TYPE
SHAFT SLEEVE
STUFFING BOX DATA
DIA. AT PACKING
HORIZONTAL
VERTICAL
SIZE OF PACKING
No. OF RINGS PER

BOX
SQ. (mm X mm)

8 LN 18
8 LNV 18
101.6
15.88
8 LN 21
8 LNV 21
114.3
15.88
8 LN 29
8 LNV 29
114.3
15.88
10 LN 18
10 LNV 18
88.9
15.88
10 LN 22
10 LNV 22
114.3
15.88
10 LN 26
10 LNV 26
114
15.88
12 LN 14
12 LNV 14
88.9
15.88
12 LN 17
12 LNV 17
101.6
15.88
12 LN 21
12 LNV 21
114.3
15.88
12 LNH 21
12 LNHV 21
114.3
15.88
14 LN 19
14 LNV 19
95
19.05
16 LN 23
16 LNV 23
114
15.88
16 LN 35
16 LNV 35
165.1
19.05
20 LN 26
20 LNV 26
152.4
19.05
20 LN 28
20 LNV 28
152.4
19.05
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24 LN 34
24 LNV 34
140
19.05
24 LN 42
24 LNV 42
190.5
19.05
30 WLN 30
30 WLNV 30
130
20
30 LN 41
30 LNV 41
203.2
19.05
Table 5.4.4
5.4.5 MECHANICAL SEAL
The typical mechanical seal assembly is shown in fig. 5.4.5.a The correct functioning of the seal
must be checked regularly. No adjustment is possible locally. When leakage reaches an
unacceptable level, the seal will need replacement.
PART
DESCRIPTION
119
SEAL RING
220
MATING RING
301
O-RING
321
O-RING
412
SPRING
431
GRUB SCREW
449
SPRING HOLDER
554
DRIVE COLLAR
Fig. 5.4.5.a
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PUMP START-UP & OPERATION

6.1 PRE-START PROCEDURES
Before the pump is brought in to the service, suction and delivery pipe work should be flushed and
the sump clear of all debris like foreign material, silt and other deposits. This is done to prevent
damage to the pump internals.
IF PUMP IS STORED FOR MORE THAN
ENSURE THE INLET PIPE AND PUMP
THREE MONTHS, THE BEARING SHOULD
CASING ARE COMPLETELY FULL OF
BE DISMANTLED, CLEANED & RE-
LIQUID BEFORE STARTING
GREASED.
CONTINUOUS DUTY OPERATION.
ENSURE THAT THE PUMP IS GIVEN THE
WHENEVER COUPLING GUARD IS
SAME ROTATION AS THE PUMP
REMOVED OR DISTURBED, ENSURE
DIRECTION ARROW CAST ON THE
THAT THE PROTECTIVE GUARD IS
PUMP CASING/ NAME PLATE.
SECURELY REFITTED PRIOR TO

STARTUP.
Consult the applicable manufacturers instructions for detailed information for the prime mover
(motor, engine or steam turbine) coupling, drive-shaft, electric driver, gear-head or mechanical seal
applicable to the pump. Prior to start-up, check/do the following:
1. Open the vent connection on top of the pump upper casing to allow the trapped air to escape.
Let liquid run out until casing is free from air bubbles.
2. In the case of vertical installation, open vent connection at the front of the upper half casing and
disconnect the seal flush line at the mechanical seal/ stuffing box to allow the trapped air to escape.
Let liquid run out until free from air bubbles.
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3. That the pump operates with suction lift and is fitted with foot valve. Fill suction pipe and casing
with liquid at a pressure of 1 to 2 bar from external source.
4. In case pump operates with suction lift without foot valve, the pump casing vents on suction
volute must be connected to an external vacuum pump priming system.
5. In case of mechanical seal pump, all piping to the seal should be connected and properly
lubricated.
6. Check that all cooling, heating and flushing lines are operating and are regulated for required
flow.
7. Check that allowable runout shaft with seal is 0.050 mm.
8. Check wiring of the driver.
9. Check rotation of driver with the coupling halves disconnected i.e. under no-load condition.
10. Check that all connections to driver and starting device are as per the wiring diagram.
11. Check that voltage, phase, and frequency of the supply line are as per the motor name plate.
12. Rotate the shaft manually to ensure that the impellers rotate freely.
13. Check driver bearings for proper lubrication and oil level in housing.
14. Check that auxiliary seal components are properly vented.
15. Check discharge piping and pressure gages for proper operation.
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6.2 IMPORTANT START-UP INSTRUCTIONS
Following these helpful guidelines will assure longer life for your pump.
1.Check the tightness of pump set holding down bolts. (Refer torque as per the table 7.3.3.1)
2.Pump/base plate should not be used as pipe anchor.
3.Suction and discharge piping should be anchored as close as possible to the pump flanges to
reduce vibration and prevent strain on the pump casing.
4.Expansion joints, if used, they must be properly tied and located on the side of the pipe anchor
away from the pump.
5.Ensure adequate liquid is available in the sump and that sump levels are within the recommended
values to meet NPSHR (Net positive suction head).
6.If the pump loses its prime or breaks suction, immediately shut it down and investigate the cause.
DO NOT RUN PUMP DRY!

The impellers and bearing have small clearances and may bind / seize and
cause serious trouble.
7.Ensure that suction valve is fully open.

8.Ensure that delivery valve is closed. The pump may be started with a fully open delivery valve
provided the system operating pressure is standing on the discharge side of the pump NRV (if
fitted).
9.Issue permission to startup after obtaining clearance from the concerned official to whom the
essential system condition is known.
10.Start the pump through panel or local station.
11.Allow pump to reach its full speed and check the pressure gauge reading.
12.At this point the pump should generate a pressure higher or equal to its rated pressure.
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13.If the generated pressure is lower the rated pressure stop the pump immediately and
investigate.
14.Rectify the fault and re-prime the pump before restart.
15.If the pressure is within the satisfactory limits, slowly open the delivery valve to permit charging
the line.
16.Care to be taken to avoid prolonged operation at near closed valve condition. It should not be
more than five minutes.
17.Ascertain the pump total head from the pump test sheet or pump name plate.
18. If the pump capacity is much higher than the supplied pump, it is better to throttle the pump
than to let it break suction. Only pumps may be throttled, however, the throttling should be limited
to 50 percent of design flow.
NOTE: Throttling may affect the driver load.
19.When the pump is stopped, the flow of liquid backing down through the pump will cause the
pump to rotate backward.
NEVER START THE PUMP AGAIN WHILE THIS
BACKWARD ROTATION IS HAPPENING!
If you do, you will place a severe strain on the
shafting and it may break. Always allow the pump to
stop completely before restarting it.
20.The bearing should be watched for signs of over heating. The bearing temperature may be
allowed to rise 50C above ambient but not to exceed 80C for both oil & grease lubricated
bearings.
Normally recommended intervals between oil/grease changes are 4000 hours or at least every six
months. The quality of grease should be of lithium soap base.
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NEVER MIX GREASES CONTAINING DIFFERENT
BASES, THICKENERS OR ADDITIVES.
21. Do not operate the pump for long period at low capacity on account of overheating from
churning.
22. If necessary, bypass arrangements may be adopted to save the pump operations at low
capacity.
23. The gland should be checked to make sure that they are not cracked and rubbing on shaft
sleeves causing overheating and overloading of motor.
24. When the pump is in operation, there should be some leakage at the stuffing box packing (Fig.
6.3.a). For cooling and lubrication, allow approximately 60 drops of liquid to escape each minute.
Fig. 6.3.a
25. In case of mechanical seal fitted with the pump, the seal leaks slightly at start-up, allow a
reasonable amount of time for the seal to adjust itself. Liquids with good lubricating qualities
normally take longer to wear in the seal than liquid with lesser qualities. When a seal starts out with
a slight leak and gets progressively less with running, it indicates leakage across the seal faces and
continued running will usually eliminate this. Where leakage occurs immediately and remains
constant, unaffected by running, it usually indicates a secondary seal damage (shaft packing), or
the seal faces are warped out of flat. See Section 6.3 (Troubleshooting), for possible causes and
remedies.
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EXTERNAL FLUSH OR QUENCH SHOULD BE
NEVER RUN A MECHANICAL
STARTED BEFORE THE PUMP IS RUN AND
SEAL DRY EVEN FOR A
ALLOWED TO FLOW FOR A PERIOD OF FIVE
SHORT TIME.
MINUTES AFTER THE PUMP HAS STOPPED.
26. After the pump set has run out for an hour, all readings should be suitably logged in site
records.
27. The pump set should be allowed to run for another hour or so to observe any undue change in
parameters or until such time as the pump stabilizes.
TOLERANCE : VIBRATION LEVELS

95 Microns peak to peak when run at 1450 rpm. Measurement shall
be on pump bearing housing. Refer Hydraulic Institute Standards
(ANSI/HI-1994) for different speeds.
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Trouble shooting chart
6.3.1
NO LIQUID DELIVERED
6.3.2
INSUFFICIENT PRESSURE
6.3.3
INSUFFICIENT CAPACITY
6.3.4
PUMP LOSES PRIME AFTER STARTING
6.3.5
PUMP OVERHEATS AND SEIZES
6.3.6
SHORT BEARING LIFE
6.3.7
VIBRATION AND NOISE
6.3.8
STUFFING BOX LEAKS EXCESSIVELY
6.3.9
SHORT SEAL LIFE
6.3.10 MECHANICAL SEAL LEAKS

6.3.11 USING TOO MUCH POWER
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PUMP START-UP & OPERATION (Trouble shooting chart)

6.3.1 NO LIQUID DELIVERED
TROUBLE
INDICATOR
NO LIQUID
DELIVERED
POSSIBLE CAUSES
RECOMMENDED REMEDIES
Lack of priming
Pump or suction pipe not completely filled with

liquid. Fill pump and suction pipe completely with
liquid.
Check for leaks in suction pipe joints and fittings.
Vent casing to remove accumulated air. Check and
replace packing and shaft sleeve for wear if
required.
Loss of Prime or Air

leaks
Suction valve closed
Open valve.
Open pump and inspect for obstruction.
Impeller plugged
Suction lift too high
Check the liquid level in the sump, static lift may

be too high. Maintain the required level/suction
pressure to meet the NPSHR of the pump. Measure
with mercury column or vacuum gauge while pump
is in operation. If static lift is too high, liquid to be
pumped must be raised or pump lowered.
Foot valve/strainer
clogged
Inspect and clean the foot valve and/or strainer.

Area through foot valve should preferably 2 times,
if strainer is used, area should be 3-4 times the
area of suction pipe.
Speed too slow
Check motor voltage or frequency may be low.

Check the pumps speed is consistent with
manufacturers recommendations.
Wrong rotation
Rotation must be as indicated by arrow on pump

nameplate. Check engagement of motor coupling.
Parallel operation of
pumps unsuitable for
operations
Check the system head curve with the pump curve

and see the suitability of the pump.
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6.3.2 INSUFFICIENT PRESSURE
TROUBLE
INDICATOR
INSUFFICIENT
PRESSURE
POSSIBLE CAUSES
Speed too slow
Check motor voltage or frequency may be

low. Check the pumps speed is
consistent with manufacturers
recommendations.
Air leaks
piping
in
suction
Check the piping joints for air leakage.

Check for gaskets in place and tighten
the bolts to prevent air leakage.
Mechanical defects
Defective impeller, wearing rings or

packing. Inspect impeller, wearing rings
and packing. Replace if vane sections
eroded or damaged. Replace wearing
rings, packing if worn out.
Wrong rotation
Rotation must be as indicated by arrow

on pump nameplate. Check engagement
of motor coupling.
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6.3.3 INSUFFICIENT CAPACITY
TROUBLE
INDICATOR
INSUFFICIENT
CAPACITY
POSSIBLE CAUSES
Speed too slow
Check motor voltage or frequency may be low. Check the

pumps speed is consistent with manufacturers
recommendations.
Lack of priming
Pump or suction pipe not completely filled with liquid. Fill

pump and suction pipe completely with liquid.
Suction lift too high
Check the liquid level in the sump, static lift may be too
high. Maintain the required level/suction pressure to
meet the NPSHR of the pump.
Air leaks in suction

piping
Check the piping joints for air leakage. Check for gaskets
in place and tighten the bolts to prevent air leakage.
Air leaks in to pump

through stuffing
boxes
Inspect and replace the incorrect/worn out packing.
Foot valve/strainer
partially clogged
Inspect and clean the foot valve and/or strainer. Area

through foot valve should preferably 2 times, if strainer
is used, area should be 3-4 times the area of suction
pipe.
Excessive amount of
air/gas in liquid
Inlet of suction pipe insufficiently submerged. The inlet

pipe to be sufficiently submerged at least 2-3 feet in
liquid.
Suction valve throttle
Check and open valve.
Impeller passage
partially plugged
Total head of system
higher than designed
head of pump
Wrong rotation
Dismantle the pump, inspect passage, clean if required.
pump unsuitable
Check the system head curve with the pump curve and
see the suitability of the pump.
Take suitable measure to reduce the friction losses or

static lift or replace the pump.
Rotation must be as indicated by arrow on pump
nameplate. Check engagement of motor coupling.
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6.3.4 PUMP LOSES PRIME AFTER STARTING
TROUBLE
INDICATOR
PUMP LOSES
PRIME AFTER
STARTING
POSSIBLE CAUSES
Pump or suction pipe

not completely filled
with liquid
Check and fill liquid completely.
Suction lift too high or

water level too low
Check NPSHA > NPSHR, proper

submergence, loses at strainers and
fittings.
Excessive amount of
air or gas in liquid
Check and purge from pipes.
Air or vapor pocket in

suction line
Check suction line design for pockets.
Air leaks in to suction

line
Check air tight pipe then joints and

gaskets.
Air leaks in to pump

through mechanical
seal, sleeve joints,
casing joint or pipe
lugs
Inlet of suction pipe
insufficiently
submerged
Check air tight assembly then joints and

gaskets.
Check cut out system design.
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6.3.5 PUMP OVERHEATS AND SEIZES
TROUBLE
INDICATOR
PUMP
OVERHEATS AND
SEIZES
POSSIBLE CAUSES
Operation at very low

capacity
Lack of prime- Fill pump and suction pipe

completely with liquid. Suction lift too
high- If static lift is too high than liquid to
be pumped must be raised or pump to be
lowered.
pump unsuitable for
operation
Misalignment
Check the system head curve with the

pump curve and see the suitability of the
pump.
Check for misalignment both angular and
radial and correct to tolerance limit.
Rotor out of balance
Check and balance the rotor

with in the specified grade.
Check the bearing lubrication and replace
the bearing.
Bearing worn out
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6.3.6 SHORT BEARING LIFE
TROUBLE
INDICATOR
SHORT
BEARING LIFE
POSSIBLE CAUSES
Operation at high
capacity
Misalignment due to
pipe strain
Measure value and check maximum

permitted.
Check the flange connections and eliminate
strains using method permitted.
Shaft bent
Check shaft run-outs within acceptable

values (0.05 mm).
Check for signs of this and correct it.
Rotating part rubbing

on stationary part
internally
Bearings worn
Shaft running off
centre because of
worn bearings or
misalignment
Impeller out of
balance resulting in
vibration
Excessive trust
caused by mechanical
failure inside the
pump
Excessive grease in
ball bearings
Lack of lubrication for
bearings
Improper installation
of bearings
Damage bearings due
to contaminations
Wrong direction of
rotation
Replace bearings
Check misalignment and correct if necessary.
Check bearings for excessive wear.
Check and balance the impeller to the
required grade (ISO 6.3 Grade).
Check wear condition of impeller, its
clearances and liquid passages.
Check method of re-greasing.
Check hours run since last change of
lubricant.
Check method of assembly or state of
cleanliness during assembly and type of
bearing used.
Check contamination source and replace
damaged bearings.
Reverse two phases on motor terminal box.
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6.3.7 VIBRATION AND NOISE
TROUBLE
INDICATOR
VIBRATION
AND NOISE
POSSIBLE CAUSES
Inadequate grouting
Check base plate grouting, re grout if required. Also piping

supports for anchoring.
Misalignment
Check for misalignment both angular and radial. Correct to

tolerance limits.
Isolate driver from pump unit, if vibration continues. Inspect
driver and determine the cause utilizing vibration frequency
analyzer and/or pump assembly. Consult motor/pump
manufacturer.
Motor imbalance
Driver
Foreign Material in unit
Mechanical Defects
Inspect volute, impeller and suction piping for foreign

material and remove. Also repair any accompanying
damage.
Shaft running off center because of worn bearings or
misalignment. Inspect impeller bearings and shaft for
damage and repair or replace as required.
Rotor out of balance
Balance the impeller to the specified grade.
Clogged impeller or
foreign material in
pump
Foundation not rigid
Back flush. Pull, check for damage and replace.
Vortex problems in
sump
Resonance
Excessive grease or oil
in antifriction bearing
housing
Motor noise
Cavitation due to low
submergence or
operation beyond
maximum capacity
rating
Foreign material in
pump
Entrained air
Check the proper tightness of the foundation bolts and check

for no gap between the base plate and finished floor level.
Re grouting is recommended.
Increase pump submergence. Apply sump modification such
as; relocate pump in sump, lower the inlet velocity in sump.
System frequency at or near pump speedLoosen anchor
bolts. Change pipe loading.
Fill the quantity of grease as recommended.
Check for bearing failure. Install RTDS in bearing housing.
Monitor bearing oil level.
Insufficient NPSH available. Evaluate system head conditions
and reduce pump capacity, if possible. Change pumps
impeller to lower NPSH design to meet the system NPSH
available.
Back flush or pull and inspect.
Air separation can also cause hydraulic noise. Bleed off
entrained air.
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6.3.8 STUFFING BOX LEAKS EXCESSIVELY
TROUBLE
INDICATOR
STUFFING BOX
LEAKS
EXCESSIVELY
POSSIBLE CAUSES
Packing is worn out or

not properly lubricated
Packing is improperly
inserted
Inspect packing, lubrication line and

lantern ring location to ensure flow.
Inspect packing for correct size and avoid
overlaps.
Packing is not right

kind for liquid handle
Packing selection should be checked

against manufacturer recommendation.
Shaft scored
If shaft/sleeve scored excessively,

repacking alone may not stop excessive
leakage. Hence replace shaft/sleeve.
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6.3.9 SHORT SEAL LIFE
TROUBLE
POSSIBLE CAUSES
INDICATOR
SHORT SEAL LIFE Abrasive particles in
fluid
Prevent abrasives from accumulating at
seal faces. Flush line maybe required. Use
abrasive separator or filter.
Seal running too hot
Increase cooling of seal faces (for

example, by increasing flush line flow).
Check for obstructed flow in cooling lines.
Equipment mechanical
misaligned
Align properly. Check for rubbing of seal

on shaft.
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6.3.10 MECHANICAL SEAL LEAKS
TROUBLE
INDICATOR
MECHANICAL SEAL
LEAKS STEADILY
(OPTIONAL)
SEAL LEAKS
INTERMITTENTLY
POSSIBLE CAUSES
Faces not flat

Blistered carbon graphite
seal faces
Check for incorrect installation dimensions.

Check for gland plate distortion due to overtorquing of gland bolts. Improve cooling flush
line, if overheated. Check gland gasket for
proper compression. Clean out any foreign
particles between seal faces and re-lap faces.
Check for cracks and chips at seal faces during
installation. Replace primary and mating rings,
if damaged.
Replace secondary seals.
Secondary seals nicked or

scratched during
installation
Worn out or damaged Orings
Compression set of
secondary seal (hard and
brittle)
Chemical attack (soft and
sticky)
Spring failures
Erosion damage of
hardware and/ or
corrosion of drive
mechanism
Faces not flat
Blistered carbon graphite
seal faces
Secondary seals nicked or

scratched during
installation
Worn out or damaged Orings
Compression set of
secondary seal (hard and
brittle)
Chemical attack (soft and
sticky)
Spring failures
Erosion/Corrosion
damage of hardware
Check for proper seal selection with seal

manufacturer.
Check for proper lead-in on chamfers, burrs,
etc.
Review with seal manufacturer for alternate
materials selection.
Replace parts.
Check for incorrect installation dimensions.
Check for gland plate distortion due to overtorquing of gland bolts. Improve cooling flush
line, if overheated. Check gland gasket for
proper compression. Clean out any foreign
particles between seal faces and re-lap faces.
Check for cracks and chips at seal faces during
installation. Replace primary and mating rings,
if damaged.
Replace secondary seals.
Check for proper seal selection with seal
manufacturer.
Check for proper lead-in on chamfers, burrs,
etc.
Replace parts.
Check for square-ness of stuffing box to shaft.
Align shaft, impeller and bearing to prevent
shaft vibration and/or distortion of gland plate
and/or mating ring.
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6.3.11 USING TOO MUCH POWER
TROUBLE
INDICATOR
USING TOO MUCH
POWER
POSSIBLE CAUSES
Speed too high
Check voltage and frequency on motor.
Improper impeller trim
Pull pump and inspect. Modify existing

impeller to provide actual system
requirements.
Take suitable measure to reduce the
friction losses or static lift or replace the
pump.
Check alignment of pump and driver, also
foundations.
Total head of system

lower or higher than
pump design head
Pump out of alignment
or shaft bent
Pumping sand, silt, or
foreign material i.e.
heavier liquid than
allowed for
Test liquid for viscosity and specific

gravity.
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MAINTENANCE OF THE PUMP

7.1 PREVENTIVE MAINTENANCE TABLE
It is recommended that a maintenance plan and schedule is adopted, in line with the user
instructions. It should include the followings :
S#
Stage
Pump start-up
Preventive maintenance checks/actions
Static lift/water level in the sump is adequate and that sump

water level are within the recommended value.
If the pump sets have been stored for more than three
months, the bearing housing should be cleaned and old
grease should be washed out. Re-grease the bearing housing
DE and NDE side as per recommendation specified in manual.
Refer lubrication chart (7.3.6).
Ensure that the pump is properly primed by opening the vent

on pump top casing and shut the vent after ensuring that the
entrained air is removed.
Ensure that pump shaft is free in rotation.
Startup the prime mover on no load condition to check the

direction of rotation.
Ensure that suction valve is fully open.
Ensure that delivery valve is closed. The pump may be started

with a fully opened delivery valve in case NRV is fitted.
Start the pump through panel or local station.
Allow pump to reach its full speed and check the pressure
gauge reading. At this point the pump should generate a
pressure higher than its rated pressure. If the pressure is
lower than rated pressure, stop the pump and investigate.
Rectify the fault and re-prime the pump before re-start.
If pressure is within satisfactory limits than slowly open the

delivery valve, to permit charging the line.
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Care to be taken to avoid prolonged operation at near close

valve condition.
The pump set should be allowed to run for one hour or so to

observe any undue change in performance parameter.
The delivery sluice valve should be closed prior to going in to

STOP mode.
Do not go in to start mode when pump rotor is subjected to

reverse flow or reverse rotation.
2.
3.
Pump operation
Temporary shut-
Change grease in bearing housing every 1000 hours running.
Grease motor bearings as per motor manufacturers

instruction.
Adjustment of gland packing / change of gland packing in

case of leakage.
Pack grease at every 500 hours of operation.
Check temperature of motor bearings, motor winding and

pump bearing. Bearings will normally run between
temperatures of 30 to 60C.
Any abrupt change in bearing temperature is much more

indicative of trouble than a constant high temperature. If so
than it is to be investigated and rectified.
Check input current, voltage, frequency, sump water level,

suction and discharge pressure gauge readings and enter all
the observations in log book with date and time at-least once
in a day.
Tighten all loose bolts and check for excessive vibration.
Check for some excessive leakage through stuffing box while

the pump is in operation. If the leakage can not be reduced
by gland adjustment than replace the packing as per 7.3.1
The discharge valve should be closed before shutdown of the

pump to prevent back flow.
If NRV is installed in the delivery line then discharge valve can

be closed after shutdown the pump.
down
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7.2 RECOMMENDED SPARE PARTS AND ORDERING PROCEDURE
7.2.1 PROCEDURE FOR ODERING SPARE PARTS:
List the serial number and model of the pump (refer the name plate).
List the part number (from the Bill of Material in cross sectional drawing).
List the Quantity.
List the complete Part Description (from the Bill of Material in cross sectional drawing).
To ensure continued satisfactory operation, replacement
parts to the original design specifications should be obtained
from WPIL. Any change to the original design specifications
i.e. modifications or use of a non standard part will invalidate
the pump safety certification.
7.2.2 RECOMMENDED LIST OF SPARE PARTS SUBJECT TO MOST WEAR.
Impeller ring with grub screw/ casing ring.
Line bearing in case of vertical pump assembly.
Shaft sleeve with O ring.
Gland Packing.
Complete Mechanical Seal (optional).
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7.2.3 RECOMMENDED LIST OF SPARE PARTS TO BE STOCKED IF DOWN TIME IS
CRITICAL. (Refer Sectional Drawing Fig. 7.3.3 for part nos.)
NAME OF PART
Casing ring with anti rotation pin
Stuffing box packing rings (Sets)
Shaft sleeve with O ring
Seal cage/ Lantern ring (Sets)
Water thrower/ Deflector
Bearing lock nut with washer
Bearing cover gasket
Casing split flange gasket
Bearing (DE & NDE)
Mechanical seal (optional)
PART No.
03, 24
15
07, 18
16
17
13
09
-
QUANTITY
02
02
02
02
02
01
02
01
02
02
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7.3 MAJOR MAINTANENCE OF PUMP
7.3.1 PACKING BOX ASSEMBLY / MECHANICAL SEAL
Put a warning board on starting device
with words.
MACHINE UNDER REPAIR :
DO NOT START/CONNECT
The major cause of the packing box troubles are due to excessively or unevenly tightened packing /
correct fitment of mechanical seal especially during the first hour of operation.
WE WOULD CALL THE ATTENTON OF THE USER ON THE FOLLOWING RECOMMENDATIONS.
Over tightening would immediately damage the packing.
To replace a damaged / worn out packing, following steps should be taken:
Remove split packing gland, old packing ring & finally lantern and end packing.
If pump is fitted with mechanical seal, then remove gland plate and mechanical seal, (refer
fig. 5.4.5a).
Prepare bevel-cut packing ring, carefully made according to the dimension of recesses. This
packing ring should be same grade as original packing.
Insert the packing ring by staggering the bevel-cut and fit it in original position. Reinstall the
split packing gland and tighten it gradually.
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7.3.2 BEARINGS
GREASE LUBRICATED BEARINGS:
Only Bearing grade grease should be used .Never use pink greases. Use Lithium based
Grease suitable for use up to 100 degree Celsius.
Pack grease moderately to avoid overheating of Bearings.(preferably every 500 hrs).
All pumps with grease lubricated bearings are greased at the factory. As a secondary
precaution, check and re-grease the bearing before starting the unit so as to ensure proper
lubrication. This is recommended if the pump has been stored for three months or more.
One third to half of the volume in the housing should be filled with grease for normal
applications. This will give the most ideal operating conditions. Greasing has to be done by a
grease gun through the grease plug provided in the bearing housing.
Complete Overhauls
This depends on hours of operations of the pump/ the severity
of the condition of service.
Do not open the pump for inspection unless there is an
indication of trouble inside the pump or in the bearings.
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7.3.3 PUMP ASSEMBLY (U) REMOVAL
Refer to the sectional drawing before dismantling of the pump (Fig. 7.3.3).
Typical View of U Pump Assembly
Fig. 7.3.3
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Cross Sectional Assembly
Fig: 7.3.3
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7.3.3.1 COMPLETE ROTATING ASSEMBLY REMOVAL
Care must be exercised in dismantling operation to prevent damage to parts of the pump.
Following points must be kept in mind during dismantling of the pump.
The pump is separated from the drive after the
pump has been electrically isolated & pump
casing is drained down.
For convenience at re-assembly, layout all parts in the

order in which they are removed.
Protect all machined faces against metal to metal
contact and corrosion.
Following Table 7.3.3.1 should be used for applying the fasteners torque.
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Screw/bolt size
M8 (5/16 in.)
M10 (3/8 in.)
M12 (1/2 in.)
M16 (5/8 in.)
M20 (3/4 in.)
M24 (7/8 in.)
Torque Nm (lbf-ft)
Pump feet fasteners
63 (46)
170 (125)
340 (250)
590 (435)
All other fasteners

10 (7)
20 (15)
34 (25)
84 (62)
165 (120)
285 (210)
Table 7.3.3.1
Withdraw the coupling guard and remove the coupling nut, bolts, distance pieces, washers
applicable to flexible pin bush type coupling. For any other type of coupling, refer the
manufacturer brochure.
Remove the sealing pipe (item 20) connected to the pump top half casing (item 02).
Withdraw dowel pins fitted in bearing housing (item 10) and loosen studs and nuts.
Remove bearing housing studs and nuts.
Remove hexagonal screws for bearing end covers (item 11,12) and slide the end covers from
location to reset on the shaft.
Disconnect the glands (item 14) from casing by unscrewing nuts from glands studs.
With a suitable punch, drive out the two straight roll pins which are used at the horizontal
split to align the upper (item 02) and lower casing halves (item 01).
Remove the bolts which hold the upper and lower half of the casing together.
By use of jacking screws located on the casing ease off the top half through equal jacking up
and sling the top half casing (item 02) through the eye bolts provided at the top of the
casing. Lift and place on the wooden supports.
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Remove split flange gasket carefully and store.
Sling the rotor assembly and carefully lift out from the bottom half casing in a perfectly
horizontal plane as the coupling weight will tend to move the rotor towards the prime-mover
during hoisting operation.
Casing neck rings will be dislodged with the
rotor. Hence care to be taken during hoisting
to prevent falling off.
7.3.3.2 DISMANTALING OF ROTOR SHAFT

The rotor assembly is removed as described in 7.3.3.1.Under mentioned procedure should be
followed for dismantling:
Lift out the rotor assembly. Use care in slinging, handling and supporting of the rotor for
subsequent dismantling.
Remove the impeller wearing ring (item 06) by removing the locking grub screw (item 22).
Withdraw the pump half coupling from the shaft (item 04) by means of puller and withdraw
the coupling key.
Withdraw the DE bearing housing (item 10). Note that the bearing is in interference fit with
the bearing housing (item 10) hence withdraw should be square with the bore/shaft.
Withdraw the DE bearing (item 09) from bearing housing by suitable puller.
Remove DE & NDE bearing housing end covers (item 11,12) and slide bearing housing off
the bearings.
Remove water thrower (item 18) from the shaft.
Remove gland packing (item 15) and lantern ring/seal cage (item 16).
Withdraw the sleeve nut (item 08).
Remove both the sleeves (item 07) from the shaft.

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Remove impeller (item 05) and impeller key (item 24).
Withdraw the NDE bearing housing (item 10).
Release the bearing lock washer at the NDE and remove bearing nut (item 13).
Remove the NDE bearing (item 09) and distance piece.
Remove water thrower (item 18), gland packing (item 15) & lantern ring/seal cage (item
16).
The rotor is fully dismantled for inspection and repair.

All individual parts, all important joints and all
wearing surfaces should be carefully examined
and parts appreciably worn should be renewed.
7.3.3.3 METHOD OF REMOVING DOWEL BUSHING :

As shown in sectional drawing (fig. 7.3.3) accurate alignment between the casing and bearing
brackets is obtained with the use of straight hollow dowel bushings. The dowel bushings have
internal threads which are used for milling the dowels see fig. 7.3.3.3a which shows the dowel
bushing puller installed in position as shown, tighten the hexagon head bolt to remove dowels.
Fig. 7.3.3.3a
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7.3.3.4 RE-ASSEMBLY OF THE ROTOR ASSEMBLY:
To assemble the pump reverse the dismantling procedure as described in 7.3.3.2 & 7.3.3.1
respectively, except the following instructions.
All bearings, wearing rings, gland packing ,sleeves should be checked and changed unless
found in good. The gland packing details should be referred as per 5.4.4.
Impellers should be checked, before assembly, for dynamic balancing to grade 6.3 of ISO
1940.
Shaft to be checked for its trueness on V roller support on an inspection table. Pump shaft
run out should be checked within 0.05 mm.
At bearing, impeller and coupling locations, the maximum permissible run out is 0.05 to 0.07
mm total indicated reading.
The clearance between impeller and casing neck ring should be maintained to the
recommended values. Renewal is recommended when the worn value is twice the clearance.
The diameter clearance value normally lies between 0.4 to 0.6 depending on the model size
and may be obtained from the pump manufacturers for the given pump model.
When reassembling the impeller on the shaft, it is important to mount the impeller so that
the vane tips point away from the apparent flow direction. The rotor always rotates towards
increasing sections of the volute as shown in fig. 7.3.3.4
Install the rotor in the casing and check to see that the rotor rotates freely by hand, wearing
surfaces at the impeller should not touch. Align the pump carefully and install the packing
and seal cage.
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FIG. 7.3.3.4
7.3.4 RE-ASSEMBLY OF THE PUMP UNIT:
The rotating element is now fully assembled as described in rotor assembly 7.3.3.4. The further
steps for pump assembly shall be followed as under.
Clean the casing and remove any protrusions on split flange of casing.
Ensure threads, gaskets and o ring (item 19) mating faces are cleaned. Apply thread
sealant to non face sealing pipe thread fittings.
Fit casing gasket to the bottom half horizontal flange using a small amount of contact
adhesive to prevent movement when the top half is fitted. Do not apply adhesive to the top
surface of the gasket.
Hoist the rotor assembly (as described in 7.3.3.4) and gradually lower in to the bottom half
casing (item 01). Care to be taken to see that neck rings and bearing housing get positively
located at spigot area.
Unlock the rotor assembly from the sling after locating in bottom half casing.
Fit the NDE bearing housing. Note that bearing is interference with the bearing housing.
Hence fitment should always be square to the bore/shaft.
Fit the DE bearing housing. Note that bearing is interference with the bearing housing. Hence
fitment should always be square to the bore/shaft.
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Apply grease of the recommended type to the bearings.
Locate dowel pins in bearing housing and insert studs through bearing housing and tighten
nuts both on DE & NDE sides.
Fix hexagonal screws to bearing housing end covers and tighten in position.
Now rotate shaft and ensure free rotation.
Apply a light layer of grease on split flange bottom half and locate gasket in position,
ensuring that bolt holes are all clear from any obstruction.
Fix dowel pins to casing top half.
Hoist the top half casing (02) and slowly lower on to the bottom half. Ensure perfect match
of the bolt holes. The dowel pins to be tapped in position.
Torque up the fixing screws. Firmly secure casing with nuts and bolts as per sequence as
shown in fig. 7.3.4
Torque up the fixing screws.
Rotate the shaft and ensure the free rotation.
Connect water seal pipes and other accessories.
Fit the coupling and align the pump and motor unit.
If mechanical seals are fitted, a small amount of silicon rubber sealant along the horizontal
joint line on the stuffing box face and fit the seal cover complete with gasket or o ring.
Care must be taken to ensure the seal seat bore is concentric to the shaft sleeve and it can
be achieved using filler gages between the stationary seal seat bore and the shaft sleeve.
Torque up the seal cover screws and check shaft/sleeve does not rub on seal cover or
stationary seal seat bore.
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7.3.5 DISMENTALING AND RE-ASSEMBLY OF U PUMPS
RECOMMENDATION
For Grease/Oil Lubrication, Refer Table
7.3.6.1 & 7.3.6.2
In U pump models, the horizontal pump unit is installed vertically along with pump and motor stools
directly coupled with motor (fig. 7.3.5.a). In some cases intermediate shafts and bearings are used
between the pump and motor. Since the horizontal pump unit is installed vertically hence the
dismantling and re-assembly procedure will remain same except the following steps.
Isolate the electrical connections of the motor.
Remove the motor half coupling bolts and free the coupling.
Hoist the motor from the motor stool after removing the motor stool bolts on motor side.
Remove the motor stool from the pump after removing the motor stool bolts from pump
side.
Remove the upper half casing after disconnecting the sealing lines and other accessories.
While lowering the casing upper half over the lower half, take care to ensure that the
wearing rings are correctly located in the upper half bores.
The remaining steps shall be followed as per 7.3.3.1, 7.3.3.2, 7.3.3.3, 7.3.3.4
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Fig. 7.3.5.a
Fig. 7.3.5.a
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7.3.6 LUBRICATION CHART
7.3.6.1 Recommended Grease Lubricants
Manufacturer
ESSCO Petroleum Co. Ltd.
Mobile Companies Throughout the world
Shell Companies throughout the world
Caltex
Castrol
Indian Oil
Grease Ball & Roller Bearings

Beacon 2 or Beacon 3
Mobilux Grease No. 3 or Mobilplex 48
Shell Alvania Grease 3
Caltex Multifak 2
Castrol Spheerol AP 3
Servogem 3
Table 7.3.6
It is unsafe to mix greases of two or more grades for use in ball bearings.
7.3.6.2 Recommended Oil Lubricants
Table 7.3.6.1
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7.4 REFRENCE DRAWING, MATERIAL OF CONSTRUCTION & TECHNICAL DETAILS
Reference drawing, material of construction & other technical details refer the following drawing for
respective jobs
General arrangement drawing.
Cross-sectional drawing.
For any correspondence/ordering spares, please quote the following.
CUSTOMER :
PROJECT :
WPIL REF. :
PUMP MODEL :
PUMP SERIAL No. :
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Contact Details
Contact WPIL
For any complaints and suggestion regarding Pumps
Email us: service@wpil.co.in
Phone: +91-120-3015784
Fax: +91-120-3015740
Factory Address:
WPIL LIMITED
A-5, Sector XXII, Meerut Road,
Ghaziabad - 201002, (U.P.), India
Corporate Office Address:

WPIL Limited
84/1 A, Topsia Road (South)
Kolkata 700 046, India
P: +91.33.3021.6800
F: +91.33.3021.6835
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WPE ES IOM Manual

WPIL designs are being regularly

WPE ES IOM Manual

The booklet covers the instructions for the following models of

shall not be bound to any Guarantee other than the guarantee

The guarantee shall forthwith and legally defunct in case:

Furthermore, all deliveries are subject our

Check the consignment immediately on arrival for damage and

WPE ES IOM Manual

WPE ES IOM Manual

Every WPIL pump has a name plate giving following details:

While you correspond with us for your

Clockwise, pump viewed from driven end.

WPE ES IOM Manual

WPE ES IOM Manual

The sense of rotation of the pump is indicated the arrow. Check

WPE ES IOM Manual

As soon as the pump is under pressure, slowly open delivery stop

A mechanical seal may never show visible leakage.

If a pump is in operation pay attention to the following:

WPE ES IOM Manual

Remove spacer coupling or if there is no such coupling, loosen driver and

Name of the firm

Speed 1450 rpm

Speed 2900 rpm/3600 rpm

WPE ES IOM Manual

Qty of grease for relubr of each bearing

Speed up to 1500 rpm

Speed above 1500 rpm

WPE ES IOM Manual

WPE ES IOM Manual

Because of design and

Size of Oil seal used in Bearing cap

Non drive end

Regularly check the outlet pressure.

A mechanical seal generally requires no maintenances. However, it should

WPE ES IOM Manual

WPE ES IOM Manual

WPE ES IOM Manual

In general failures in a pump unit are attributable to the following causes:

Failures in the pump

Pump doesn't deliver any liquid

Pump or suction pipe not sufficiently filled or de-aerated.

WPE ES IOM Manual

WPE ES IOM Manual

For any correspondence / ordering spares , please quote the

Corporate office address :

WPE ES IOM Manual

WPIL PUMP BASKET

INSTALLATION, OPERATION AND

A-5, Sector XXII, Meerut Road,

Ghaziabad - 201002, (U.P.), India

Trinity Plaza, 3rd Floor,

84/1 A, Topsia Road (South)

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