Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
AC2675
REVISION D
DESCRIPTION......................................................3 MAINTENANCE..................................................19
OPERATIONAL LIMITS .......................................3 GENERAL MAINTENANCE.............................19
MAXIMUM WORKING PRESSURE.....................3 MAINTENANCE OF PUMP DUE TO FLOOD
SEAL OPERATING LIMITS .................................3 DAMAGE ........................................................19
PACKING .........................................................3 BEARING LUBRICATION – GREASE................20
PUMP IDENTIFICATION.......................................3 PACKING SEAL ..............................................21
SAFETY INSTRUCTIONS.....................................4 CLEANING WITHOUT DISMANTLING
ADDITIONAL SAFETY REQUIREMENTS:........4 PUMP .............................................................21
ADDITIONAL SAFETY REQUIREMENTS............5 MAINTENANCE TIME TABLE............................ 22
ELECTRICAL SAFETY: ....................................5 TROUBLE SHOOTING ...................................... 23
THERMAL SAFETY: .........................................5 CHANGING ROTATION ..................................... 26
MECHANICAL SAFETY:....................................5 SERVICE INSTRUCTIONS ................................. 27
INSTALLATION....................................................6 DISASSEMBLY AND REASSEMBLY
PUMP LOCATION ............................................6 PROCEDURES................................................ 27
RECEIVING PUMP ..........................................6 DISMANTLING (PUMP WITH PACKING)........ 27
TEMPORARY STORAGE.................................7 ASSEMBLY (PUMP WITH PACKING) ........... 30
LOCATION .......................................................7 APPENDIX “A” ENGINEERING DATA..............
FOUNDATION...............................................7 33APPENDIX “B” .................................................. 34
BASE PLATE SETTING (BEFORE PIPING) 8 EXPLODED VIEW – 8200 SERIES FIRE
GROUTING PROCEDURE...............................8 PUMP............................................................... 34
SEE ANSI/OSHA COUPLER GUARD REPLACEMENT PARTS LIST .......................... 35
REMOVAL/INSTALLATION ...............................8 INSTRUCTIONS FOR ORDERING PARTS ...... 36
ALIGNMENT PROCEDURE .............................8 APPENDIX “C” FIELD TEST REPORT ............... 37
ANSI/OSHA COUPLER GUARD USEFUL FORMULAS...................................... 38
REMOVAL/INSTALLATION ..............................9
DOWELING.................................................14
NOTE
SUCTION AND DISCHARGE PIPING............14 The information contained in this book is intended
STUFFING BOX LUBRICATION.....................16 to assist operating personnel by providing
PACKING .......................................................16 information on the characteristics of the
OPERATION.............................................18 purchased equipment.
2
DESCRIPTION PUMP IDENTIFICATION
The 8200 Series Centrifugal Fire Pumps are There are two identification plates on each pump.
framed mounted pumps which feature – high The pump rating plate gives identification and
efficiency, rugged construction, compact design, rating information. Figure 1 shows an example of a
foot mounted volute and regreasable bearings. typical Rating Plate.
These features, along with the horizontal split
case, make installation, operation and service Permanent records for this pump are referenced
easy to perform. by the Serial Number and it must, therefore, be
used with all correspondence to order all spare
parts and replacement parts. The fourth digit
OPERATIONAL LIMITS indicates the specific pump on orders for more
Unless special provisions have been made for than one pump. For example, if an order called for
your pump by AC Fire Pump Systems, the six pumps, all pumps would have the same first
operational limits for 8200 Series Centrifugal Fire three sets of digits and the last digit will change to
Pumps are as follows: identify each of the six. (e.g. 03-123456-01-01, 03-
123456-01-02, etc.)
MAXIMUM WORKING PRESSURE The frame plate, shown below in Figure 2, gives
Listed on pump nameplate. information concerning the bearings and their
lubrication. The inboard and outboard bearing
numbers refer to the bearing manufacturer’s
SEAL OPERATING LIMITS numbers.
PACKING
PH Limitations 7-9; Temperature Range 0 to
+200°F
For use on open or closed systems which require
a large amount of makeup water, as well as
systems which are subjected to widely varying
chemical conditions and solids buildup.
3
ADDITIONAL SAFETY REQUIREMENTS
ELECTRICAL SAFETY: MECHANICAL SAFETY:
CAUTION
WARNING
5
INSTALLATION
PUMP LOCATION NYLON SLING,
CHAIN OR WIRE
Locate the pump so there is sufficient room for ROPE
inspection, maintenance and service. If the use of
a hoist or tackle is needed, allow ample head
room.
7
e. Check to make sure the piping can be
BASE PLATE SETTING (BEFORE PIPING)
aligned to the pump flanges without
NOTE: This procedure assumes that a concrete placing pipe strain on either flange.
foundation has been prepared with anchor or hold
down bolts extending up ready to receive unit. It f. Grout in base plate completely (See
must be understood that pump and motor have “Grouting Procedure”) and allow grout to
been mounted and rough aligned at the factory. If dry thoroughly before attaching piping to
motor is to be field mounted, consult factory for pump. (24 hours is sufficient time with
recommendations. AC Fire Pump Systems approved grouting procedure.)
cannot assume responsibility for final alignment.
GROUTING PROCEDURE
Grout compensates for uneven foundation,
NOTE:
ALLOW 1" FOR
TO KEEP SHIMS IN distributes weight of unit, and prevents shifting.
SHIMS. PLACE ON
PLACE ALLOW GROUT
TO FLOW AROUND
Use an approved, non-shrinking grout, after
BOTH SIDES OF
ANCHOR BOLTS.
HOLD DOWN LUGS. GROUT ONLY TO
TOP OF BASE RAIL.
setting and leveling unit (See Figure 6).
a. Build strong form around the foundation to
PUMP BASE contain grout.
RAIL
b. Soak top of concrete foundation
thoroughly, then remove surface water.
GROUT
c. Base plate should be completely filled with
APPROX. 1" GAP
grout.
a. Use blocks and shims under base for f. Approximately 14 days after the grout has
support at anchor bolts and midway been poured or when the grout has
between bolts, to position base thoroughly dried, apply an oil base paint to
approximately 1" above the concrete the exposed edges of the grout to prevent
foundation, with studs extending through air and moisture from coming in contact
holes in the base plate. with the grout.
8
and vertical planes. Final alignment should be d. Spread the inner guard and pull it over the
made by moving and shimming the motor on the coupler.
base plate, until the coupling hubs are within the
recommended tolerances measured in total run- Installation
out. All measurements should be taken with the
a. Check coupler alignment before
pump and motor foot bolts tightened. The shaft of
proceeding. Correct if necessary.
sleeve bearing motors should be in the center of
its mechanical float. b. Spread the inner guard and place it over
the coupler.
NOTE: Proper alignment is essential for correct
pump operation. This should be performed after c. With the inner guard straddling the
base plate has been properly set and grout has support bracket, install a capscrew
dried thoroughly according to instructions. Final through the hole (or slot) in the support
alignment should be made by shimming driver bracket and guard located closest to the
only. Alignment should be made at operating pump. Do not tighten the capscrew.
temperatures.
d. Spread the outer guard and place it over
WARNING: Unexpected Start-up Hazard the inner guard.
Disconnect and lock out power before
servicing. Failure to follow these instructions could e. Install the outer guard capscrews by
result in serious personal injury or death and following the step stated below which
property damage. pertains to your particular pump:
i. For pumps with a motor saddle support
ANSI/OSHA COUPLER GUARD bracket: Ensure the outer guard is
REMOVAL/INSTALLATION straddling the support arm, and install
but do not tighten the two remaining
WARNING: Unexpected Start-up Hazard capscrews.
Disconnect and lock out power before
servicing. Failure to follow these instructions could ii. For pumps without a motor saddle
result in serious personal injury or death and support bracket: Insert the spacer
property damage. washer between the holes located
closest to the motor in the outer guard,
NOTE: Do not spread the inner and outer guards and install, but do not tighten, the two
more than necessary for guard removal or remaining capscrews.
installation. Over spreading the guards may alter
f. Position the outer guard so it is centered
their fit and appearance.
around the shaft, and so there is less than
a 1/4" of the motor shaft exposed. On
Removal guards that utilize a slotted support
a. Remove the two capscrews that hold the bracket, the inner guard will have to be
outer (motor side) coupler guard to the positioned so there is only a 1/4" of the
support bracket(s). pump shaft exposed.
b. Spread the outer guard and pull it off the g. Holding the guard in this position, tighten
inner guard. the three capscrews.
c. Remove the capscrew that holds the inner
guard to the support bracket.
9
ANSI/OSHA Coupling Guard Exploded View
For Typical 8200 Series Fire Pump Installation INNER GUARD
OUTER GUARD
SUPPORT
BRACKET
NUT
BRACKET SUPPORT BRACKET
LOCKWASHER ATTACHED INSIDE HERE
CAPSCREW SUPPORT
IN LINE WITH BOLT
FLAT WASHER
SPACER WASHER
10
Grid Couplings
Method 2 – For Orange Hytrel Insert, 3500
RPM Operation, or All Other Coupler NOTE: The following procedure is intended
Types Except as Noted Below for mounting and alignment of Rexnord
Industries, LLC. and Clarke Fire Protection
(See Figure 7B)
Products, Inc., Tapered Grid Couplings.
a. Make sure each hub is secured to its
respective shaft and that all connecting Adequate lubrication is essential for
and/or spacing elements are removed at satisfactory operation. Grease supplied by
this time. the coupling manufacturer is highly
recommended. Other greases to be used
b. The gap between the coupling hubs is set should be approved by the coupling
by the manufacturer before the units are manufacturer.
shipped. However, this dimension should
be checked. (Refer to the coupling Alignment is shown using a spacer bar and
manufacturer’s specifications supplied straight edge. Rexnord Industries, LLC. and
with the unit.) Clarke Fire Protection Products, Inc. state
c. Scribe index lines on coupling halves as this practice has been proven for many
industrial applications. Superior alignment
shown in Figure 7B.
can be achieved through the use of dial
d. Mount dial indicator on one hub as shown indicators as shown above.
for parallel alignment. Set dial to zero.
1. Clean all metal parts using non-flammable
e. Turn both coupling halves so that index solvent.
lines remain matched. Observe dial
reading to see whether driver needs 2. Lightly coat seals with coupling vendor
adjustment (See paragraph i below). supplied grease and place on shafts
before mounting shaft hubs.
f. Mount dial indicator on one hub as shown
for angular alignment. Set dial to zero. 3. Install keys and mount hubs with flange
faces flush with shaft ends or as otherwise
g. Turn both coupling halves so that index specified.
lines remain matched. Observe dial
reading to see whether driver needs 4. Reposition hubs on shafts as required to
adjustment (See paragraph i below). achieve the required hub gap shown in
Figure 7H or otherwise specified. The
h. Assemble coupling. Tighten all bolts and length of engagement on each shaft
set screw(s). It may be necessary to should be roughly equal to the shaft
repeat steps c through f for a final check. diameter.
i. For single element couplings, a 5. Tighten setscrews.
satisfactory parallel misalignment is
.004"T.I.R., while a satisfactory angular 6. Bring the pump and motor halves of the
misalignment is .004"T.I.R. per inch of coupler into approximate height alignment,
radius R (See Figure 7B). by placing equal amounts of shims under
all the motor feet.
DIAL
7. Tighten the motor bolts.
PARALLEL INDICATOR
8. Use a spacer bar equal in thickness to the
ALIGNMENT gap specified in Figure 7C. Insert bar, as
shown below, to same depth at 90°
INDEX LINE
intervals and measure clearance between
bar and hub face with feeler gauges. The
RESILIENT difference in minimum and maximum
SEPARATOR
measurements must not exceed the
angular installation limits shown in Figure
7H.
ANGULAR DIAL
ALIGNMENT INDICATOR
11
FIGURE 7E – SEATING THE GRID
FIGURE 7C – USING SPACER BAR
14. Pack the spaces between and around the
9. Align so that a straight edge rests within grid with as much as coupling vendor
the limits shown in Figure 7D on both supplied grease as possible and wipe off
hubs as shown below and also at 90° the excess until flush with the top of the
intervals without rotating the coupling. grid.
Check with feelers. The clearance must
15. Position seals on hubs to line-up with
not exceed the PARALLEL OFFSET
grooves in cover. Position gaskets on
installation limits specified in Figure 7H.
flange of lower cover half and assemble
covers so that the match marks are on the
same side.
12
17. Ensure the lube plugs are installed in the
cover.
WARNING: Coupling Failure
Fastener Tightening
Installation Limits Torque Values
End Float
Parallel Physical Cover Fastener Flange Maximum
Offset Angular Hub Gap Limit (Min) Tightening Torque Type Allowable
Size (P) (x-y) +/- 10% 2xF Values 31 & 35 RPM Lube Wt.
In. Series In. Series
Fasteners Fasteners
Max Inch Max Inch Inch Inch (lb*in) (lb*in) lb
1040T 0.006 0.003 0.125 0.211 100 120 3600 0.12
1050T 0.008 0.004 0.125 0.212 200 250 3600 0.15
1060T 0.008 0.005 0.125 0.258 200 440 3600 0.19
1070T 0.008 0.005 0.125 0.259 200 440 1800 0.25
1080T 0.008 0.006 0.125 0.288 200 825 1800 0.38
13
time and alignment is within the tolerance. Where flanged joints are used, assure that
See Doweling Section. inside diameters match properly.
Remove burrs and sharp edges when making
CAUTION: Extreme Temperature and/or
up joints.
Flying Debris Hazard
Eye protection and gloves required. Failure to Do not “spring” piping when making any
follow these instructions could result in property connections.
damage and/or moderate personal injury. Provide for pipe expansion when hot fluids are
to be pumped.
NOTE: Pump may have been doweled to
base at factory. Suction Piping
DOWELING When installing the suction piping, observe
the following precautions. Figure 8 shows
Dowel the pump and driving unit as follows: some correct and incorrect suction piping
a. Drill holes through diagonally opposite feet arrangements.
and into the base. Holes must be of a The sizing and installation of the suction
diameter 1/64 inch less than the diameter piping is extremely important. It must be
of the dowel pins. Clean out the chips. selected and installed so that pressure losses
b. Ream the holes in feet and base to the are minimized and sufficient liquid will flow
proper diameter for the pins (light push fit). into the pump when started and operated.
Clean out the chips. Many NPSH (Net Positive Suction Head)
problems can be attributed directly to
c. Insert pins to be approximately flush with improper suction piping systems.
feet.
Friction losses caused by undersized suction
SUCTION AND DISCHARGE PIPING piping can increase the fluid’s velocity into the
pump. As recommended by the Hydraulic
General Institute Standard ANSI/HI 1.1-1.5-1994,
suction pipe velocity should not exceed the
When installing the pump piping, be sure to
velocity in the pump suction nozzle. In some
observe the following precautions:
situations pipe velocity may need to be
Piping should always be run to the pump. further reduced to satisfy pump NPSH
Do not move pump to pipe. This could make requirements and to control suction line
final alignment impossible. losses. Pipe friction can be reduced by using
pipes that are one to two sizes larger than the
Both the suction and discharge piping should
pump suction nozzle in order to maintain pipe
be supported independently near the pump
velocities less than 5 feet/second.
and properly aligned, so that no strain is
transmitted to the pump when the flange bolts
are tightened. Use pipe hangers or other
supports at necessary intervals to provide
support. When expansion joints are used in
the piping system, they must be installed
beyond the piping supports closest to the
pump. Tie bolts should be used with
expansion joints to prevent pipe strain. Do not
install expansion joints next to the pump or in
any way that would cause a strain on the
pump resulting from system pressure
changes. It is usually advisable to increase
the size of both suction and discharge pipes
at the pump connections to decrease the loss
of head from friction.
Install piping as straight as possible, avoiding
unnecessary bends. Where necessary, use
45-degree or long sweep 90-degree fitting to
decrease friction losses.
Make sure that all piping joints are air-tight.
14
SUCTION PIPE INSTALLED WITH A
Suction piping should be short in length, as
CHECK VALVE
GRADUAL RISE TO PUMP
GATE VALVE
direct as possible, and never smaller in
INCREASER diameter than the pump suction opening. A
LEVEL
minimum of ten (10) pipe diameters between
any elbow or tee and the pump should be
CORRECT
allowed. If a long suction pipe is required, it
CENTER LINE
OF PIPE should be one or two sizes larger than the
AIR POCKET
suction opening, depending on its length.
CAUTION:
An elbow should not be used directly
INCORRECT before the suction of a double suction pump if its
plane is parallel to the pump shaft. This can cause
an excessive axial load or NPSH problems in the
pump due to an uneven flow distribution. If there is
AIR POCKET no other choice, the elbow should have
straightening vanes to help evenly distribute the
flow. Failure to follow these instructions could
INCORRECT result in injury or property damage.
16
1. Liquid is clean, free from sediment and More pressure is required, however, for
chemical precipitation and is compatible abrasive slurries than for clear liquids.
with seal materials. Examination of the leakage will indicate
whether to increase or decrease external
2. Temperature is above 32°F and below pressure. If slurry is present in the leakage,
160°F. increase the pressure until only clear liquid
3. Suction pressure is below 75 psig. drips from the box. If the drippage is corrosive
or harmful to personnel, it should be collected
4. Lubrication (pumped liquid) has lubricating and piped away.
qualities.
A common error is to open the external piping
5. Liquid is non-toxic and non-volatile. valve wide and then control the drippage by
tightening the packing gland. A combination
When the liquid being pumped contains of both adjustments is essential to arrive at
solids or is otherwise not compatible with the optimum condition. The life of packing
packing materials, an outside supply of seal and sleeve depends on careful control more
liquid should be furnished. In general, than any other factor.
external-injection liquid (from an outside
source) is required when any of the above
FLOWMETER
conditions cannot be met.
The standard stuffing box consists of rings of
packing (see assembly section for number of
rings), a seal cage, a bushing and a gland. A PRESSURE
shaft sleeve which extends through the box GAUGE PRESSURE
REDUCING
and under the gland is provided to protect the VALVE
shaft.
A tapped hole is supplied in the stuffing box
directly over the seal cage to introduce a
STUFFING BOX
clean, clear sealing medium. The stuffing box
must, at all times, be supplied with sealing FIGURE 9 – CONTROLLED PRESSURE
liquid at a high enough pressure to keep the SYSTEM
box free from foreign matter, which would
quickly destroy the packing and score the
shaft sleeve.
Only a sufficient volume of sealing liquid to
create a definite direction of flow from the
stuffing box inward to the pump casing is
required, but the pressure is important. Apply
seal water at a rate of approximately .25
GPM at a pressure approximately 15 to 20
psig above the suction pressure.
(Approximately one (1) drop per second.)
One recommended method to minimize error
in regulating flushing water is a “Controlled
Pressure System” (Figure 9). It is important to
set the pressure reducing valve adjusted to a
value slightly exceeding the maximum
stuffing box operating pressure (assuming it
is reasonably constant). A flow indicating
device will detect a failing of the bottom
packing rings allowing leakage in the pump.
External sealing liquid should be adjusted to
the point where the packing runs only slightly
warm, with a very slow drip from the stuffing
box. Excess pressure from an external
source can be very destructive to packing.
17
OPERATION
WARNING: Rotating Components
WARNING: Unexpected Startup Hazard Hazard
Disconnect and lockout power before Do not operate pump without all guards in place.
servicing. Failure to follow these instructions could Failure to follow these instructions could result in
result in serious personal injury or death, or serious personal injury or death and property
property damage. damage.
g. Assure that pump bearings are properly b. Open fully all valves in the suction line.
lubricated. c. Prime the pump.
h. Assure that coupling is properly lubricated, NOTE: If the pump does not prime properly,
if required. or loses prime during start-up, it should be
i. Assure that pump is full of liquid (See shutdown and the condition corrected before
Priming) and all valves are properly set the procedure is repeated.
and operational, with the discharge valve d. When the pump is operating at full speed,
closed, and the suction valve open. open the discharge valve slowly. This
j. Check rotation. Be sure that the drive should be done promptly after start-up to
operates in the direction indicated by the prevent damage to pump by operating at
arrow on the pump casing as serious zero flow.
damage can result if the pump is operated
with incorrect rotation. Check rotation OPERATING CHECKS
each time the motor leads have been a. Check the pump and piping to assure that
disconnected. there are no leaks.
18
b. Check and record pressure gauge b. Keep fluid moving in the pump and
readings for future reference. insulate or heat the pump to prevent
freezing.
c. Check and record voltage, amperage per
phase, and kw if an indicating wattmeter is CAUTION: Bearing/Seal Damage Hazard
available. Do not let heated pump temperature rise
above 150°F. Failure to follow these instructions
d. Check bearings for lubrication and
could result in property damage and/or moderate
temperature. Normal temperature is 180°
personal injury.
maximum.
e. Make all pump output adjustments with
FIELD TESTING
the discharge line.
A typical performance curve for a specific pump
CAUTION: Cavitation Damage Hazard can be obtained from AC Fire Pump Systems.
Do not throttle the suction line to adjust the This can be used in conjunction with a field test,
pump output. Failure to follow these instructions if one is required. All AC Fire Pump Systems
could result in property damage and/or moderate tests and curves are based on the Hydraulic
personal injury. Institute Standards. Any field test must be
conducted according to these Standards.
FREEZING PROTECTION Unless otherwise specifically agreed, all capacity,
Pumps that are shut down during freezing head, and efficiencies are based on shop tests
conditions should be protected by one of the when handling clear, cold, fresh water at a
following methods. temperature not over 85°F.
a. Drain the pump; remove all liquids from Appendix “C” (Pages 36-37) contains a field test
the casing. report sheet and some useful equations which can
be used when conducting a field test.
MAINTENANCE
GENERAL MAINTENANCE MAINTENANCE OF PUMP DUE TO FLOOD
Operating conditions vary so widely that to DAMAGE
recommend one schedule of preventative WARNING: Unexpected Startup Hazard
maintenance for all centrifugal pumps is not Disconnect and lockout power before
possible. Yet some sort of regular inspection must servicing. Failure to follow these instructions could
be planned and followed. We suggest a result in serious personal injury or death, or
permanent record be kept of the periodic property damage.
inspections and maintenance performed on your
pump. This recognition of maintenance procedure
WARNING: Electrical Shock Hazard
will keep your pump in good working condition,
Electrical connections to be made by a
and prevent costly breakdown.
qualified electrician in accordance will all
One of the best rules to follow in the proper applicable codes, ordinances, and good practices.
maintenance of your centrifugal pump is to keep a Failure to follow these instructions could result in
record of actual operating hours. Then, after a serious personal injury or death, or property
predetermined period of operation has elapsed, damage.
the pump should be given a thorough inspection.
The length of this operating period will vary with The servicing of centrifugal pumps after a flooded
different applications, and can only be determined condition is a comparatively simple matter under
from experience. New equipment, however, normal conditions.
should be examined after a relatively short period
of operation. The next inspection period can be Bearings are a primary concern on pumping units.
lengthened somewhat. This system can be First, dismantle the bearings; clean and inspect
followed until a maximum period of operation is them for any rusted or badly worn surfaces. If
reached which should be considered the operating bearings are free from rust and wear, reassemble
schedule between inspections. and relubricate them with one of the
recommended pump lubricants. Depending on the
19
length of time the pump has remained in the flooded NOTICE:
area, it is unlikely that bearing replacement is necessary; Make sure the grease container, the greasing
however, in the event that rust or worn surfaces appear, it device, and the fittings are clean. Failure to do
may be necessary to replace the bearings. so can result in impurities entering the bearing
housing when you regrease the bearings.
Next, inspect the stuffing box, and clean out any foreign
matter that might clog the box. Mechanical seals should
be cleaned and thoroughly flushed. 1. With fully enclosed coupling guards, regrease
pump while pump is running.
Couplings should be dismantled and thoroughly cleaned. a. With old style open ended guards, stop pump,
re-grease, and hand turn shaft before re-
Any pump that is properly sealed at all joints and starting.
connected to both the suction and discharge should
2. Wipe dirt from the grease fittings before greasing.
exclude outside liquid. Therefore, it should not be
3. Fill both of the grease cavities through the fittings
necessary to go beyond the bearings, stuffing box,
with the recommended grease. Stop when grease
and coupling when servicing the pump.
leaks out at shaft.
4. If needed, stop pump and wipe off excess grease.
5. Restart pump.
BEARING MAINTENANCE
The bearing temperature usually rises after
BEARING LUBRICATION SCHEDULE you regrease due to excess supply of grease.
Temperatures return to normal in about two to four
First lubrication,
First
operating hours as the pump runs and purges the
assembled Lubrication interval, excess grease from the bearings. Maximum normal
Type of lubrication,
pumps and pump, polyurea-based bearing housing temperature for polyurea-based
bearing replacement
replacement grease, operating hours
bearing frames
bearings grease is 225°F (107°C) and for lithium-based grease
180°F (82°C).
Grease- Not applicable, Hand pack • 3600 hours, 2 pole
lubricated lubricated before bearings before • 7200 hours, 4 pole
bearings shipment pressing on • 50% for severe LUBRICATING GREASE REQUIREMENTS
the shaft. After conditions: dirty, wet
bearing frame and/or above 100°F NOTICE:
assembly, (38°C) ambient • Never mix grease of different consistencies
follow relube • 50% for bearing frame (NLGI 1 or 3 with NLGI 2) or with different
instructions to temperature above
thickeners. For example, never mix lithium-
lube bearings. 180°F (82°C)
• 75% for lithium-based based grease with a polyurea-based grease.
grease This can result in decreased performance.
• Remove the bearings and old grease if you
need to change the grease type or consistency.
Failure to do so can result in equipment damage
REGREASE THE GREASE-LUBRICATED BEARINGS or decreased performance.
It is important to lubricate pumps and motors that
require regreasing with the proper grease. See the motor
service instructions and nameplate for motor regreasing
information. Pumps are to be regreased using the grease
types listed below or approved equal. Always keep
pump and motor properly lubricated.
20
SPECIFICATIONS – GREASE TYPES
21
MAINTENANCE TIME TABLE
EVERY MONTH Check bearing temperature with a thermometer, not by hand. If bearings are
running hot (over 180°F), it may be the result of too much lubricant. If changing the
lubricant does not correct the condition, disassembly and inspect the bearings. Lip
seals bearing on the shaft may also cause the housing to run hot. Lubricate lip
seals to correct.
EVERY 3 Check grease lubricated bearings for saponification. This condition is usually
MONTHS caused by the infiltration of water or other fluid past the bearing shaft seals and
can be noticed immediately upon inspection, since it gives the grease a whitish
color. Wash out the bearings with a clean industrial solvent and replace the grease
with the proper type as recommended.
EVERY 6 Check the packing and replace if necessary. Use the grade recommended. Be
MONTHS sure the seal cages are centered in the stuffing box at the entrance of the stuffing
box piping connection.
Take vibration readings on the bearing housings. Compare the readings with the
last set of readings to check for possible pump component failure (e.g. bearings)
Check shaft or shaft sleeve for scoring. Scoring accelerates packing wear.
Check alignment of pump and motor. Shim up units if necessary. If misalignment
reoccurs frequently, inspect the entire piping system. Unbolt piping at suction and
discharge flanges to see if it springs away, thereby indicating strain on the casing.
Inspect all piping supports for soundness and effective support of load. Correct as
necessary.
EVERY YEAR Remove the upper half of the casing. Inspect the pump thoroughly for wear, and
order replacement parts if necessary.
Check wear ring clearances. Replace when clearances become three (3) times
their normal clearance or when a significant decrease in discharge pressure for the
same flow rate is observed. See Engineering Data Section for standard
clearances.
Remove any deposit or scaling. Clean out stuffing box piping.
Measure total dynamic suction and discharge head as a test of pump performance
and pipe condition. Record the figures and compare them with the figures of the
last test. This is important, especially where the fluid being pumped tends to form a
deposit on internal surfaces. Inspect foot valves and check valves, especially the
check valve which safeguards against water hammer when the pump stops. A
faulty foot or check valve will reflect also in poor performance of the pump while in
operation.
NOTE: The above time table is based on the assumption that after start-up, the unit had been constantly
monitored and such a schedule was found to be consistent with operation, as shown by stable readings.
Extreme or unusual applications or conditions should be taken into consideration when establishing the
maintenance intervals.
2
TROUBLE SHOOTING
Between regular maintenance inspections, be alert for signs of motor or pump trouble. Common
symptoms are listed below. Correct any trouble immediately and AVOID COSTLY REPAIR AND
SHUTDOWN.
CAUSES CURES
No Liquid Delivered
1. Lack of prime. Fill pump and suction pipe completely with liquid.
2. Loss of prime. Check for leaks in suction pipe joints and fittings; vent casing to remove
accumulated air. Check mechanical seal or packing.
3. Suction lift too high (a If there is no obstruction at inlet and suction valves are open, check for
negative suction gauge pipe friction losses. However, static lift may be too great. Measure with
reading). mercury column or vacuum gauge while pump operates. If static lift is
too high, liquid to be pumped must be raised or pump lowered.
4. System static head too Check with factory to see if a larger impeller can be used; otherwise,
high. cut pipe losses or increase speed – or both, as needed. But be careful
not to overload driver by more than the service factor.
5. Speed too low. Check whether motor is directly across-the-line and receiving full
voltage. Frequency may be too low. Motor may have an open phase.
6. Wrong direction of Check motor rotation with directional arrow on pump casing. If rotation
rotation. is correct with arrow, check the relationship of the impeller with casing.
(This will require removing casing upper half.)
See Figure 10 on page 25.
7. No rotation. Check power, coupling, line shaft and shaft keys.
8. Impeller loose on shaft. Check key, locknut and set screws.
9. Impeller completely Dismantle pump and clean impeller.
plugged.
10. System head or required Check pipe friction losses. Large piping may correct condition. Check
discharge head too high. that valves are wide open.
Not Enough Liquid Delivered
11. Air leaks in suction piping. If liquid pumped is water or other non-explosive and explosive gas or
dust is not present, test flanges for leakage with flame or match. For
such liquids as gasoline, suction line can be tested by shutting off or
plugging inlet and putting line under pressure. A gauge will indicate a
leak with a drop of pressure.
12. Air leaks in stuffing box. Replace packing and sleeves if appropriate or increase seal lubricant
pressure to above atmosphere.
13. Speed too low. See item 5.
14. Discharge head too high. See item 10.
15. Suction lift too large. See item 3.
2
TROUBLE SHOOTING (CONT.)
CAUSES CURES
16. Impeller partially plugged. See item 9.
17. Cavitation; insufficient a. Increase positive suction head on pump by lowering pump or
NPSHA (Net Positive increasing suction pipe and fittings size.
Suction Head Available).
b. Sub-cool suction piping at inlet to lower entering liquid temperature.
c. Pressurize suction vessel.
18. Defective impeller. Inspect impeller, bearings and shaft. Replace if damaged or vane
sections badly eroded.
19. Foot valve too small or Area through ports of valve should be at least as large as area of
partially obstructed. suction pipe (preferably 1.5 times). If strainer is used, net clear area
should be 3 to 4 times area of suction pipe.
20. Suction inlet not immersed If inlet cannot be lowered or if eddies through which air is sucked
deep enough. persist when it is lowered, chain a board to suction pipe. It will be drawn
into eddies, smothering the vortex.
21. Wrong direction of Symptoms are an overloaded driver and about one third rated capacity
rotation. from pump. Compare rotation of motor with directional arrow on pump
casing. If rotation is correct with arrow, impeller may have to be turned
180°. (See CHANGING ROTATION.)
22. System head too high. See item 4.
23. Defective mechanical seal. Repair or replace seal.
Not Enough Pressure
24. Speed too low. See item 5.
25. Air leaks in suction piping See item 11.
or stuffing box.
26. Mechanical defects. See item 18.
27. Vortex at suction inlet. See item 20.
28. Obstruction in liquid Check to see if suction and discharge valves are fully open. Dismantle
passages. pump and inspect passages and casing. Remove obstruction.
29. Air or gases in liquid. May be possible to over rate pump to a point where it will provide
adequate pressure despite condition. Better provide gas separation
chamber on suction line near pump and periodically exhaust
accumulated gas. See item 17.
2
TROUBLE SHOOTING (CONT.)
CAUSES CURES
Pump Operates For Short Time, Then Stops
30. Insufficient NPSHA. See item 17.
31. System head too high. See items 4 and 10.
Pump Takes Too Much Power
32. Head lower than rating; Machine impeller’s O.D. to size advised by factory or reduce speed.
thereby pumping too much
liquid.
33. Cavitation See item 17.
34. Mechanical defects. See items 18, 19, 21, and 23.
35. Suction inlet not See item 20.
immersed.
36. Liquid heavier (in either Use larger driver. Consult factory for recommended size. Test liquid for
viscosity or specific viscosity and specific gravity.
gravity) than allowed for.
37. Wrong direction of See item 6.
rotation.
38. Stuffing box glands too Release gland pressure. Tighten reasonably. If sealing liquid does not
tight. flow while pump operates, replace packing.
39. Casing distorted by Check alignment. Examine pump for rubbing between impeller and
excessive strains from casing. Replace damaged parts. Repipe pump.
suction or discharge
piping.
40. Shaft bent due to damage Check deflection of rotor by turning on bearing journals. Total indicator
– through shipment, run-out should not exceed .002" on shaft and .004" on impeller wearing
operation, or overhaul. surface.
41. Mechanical failure of Check wear rings and impeller for damage. Any irregularity in these
critical pump parts. parts will cause a drag on shaft.
42. Misalignment. Realign pump and driver.
43. Speed may be too high. Check voltage on motor. Check speed versus pump nameplate rating.
44. Electrical defects. The voltage and frequency of the electrical current may be lower than
that for this motor was built, or there may be defects in motor. The
motor may not be ventilated properly due to a poor location.
45. Mechanical defects in If trouble cannot be located, consult factory.
turbine, engine or other
type of drive exclusive of
motor.
2
CHANGING ROTATION
WARNING: Rotating Components 3. Set the rotating element back in the
Hazard casing and reassemble the pump.
Do not operate pump without all guards in place. Failure NOTE: The impeller and casing are in the
to follow these instructions could result in serious same relationship to each other as they were
personal injury or death and property damage. originally. The shaft and motor are also in the
8200 Series centrifugal pumps can be operated same relationship to each other as they were
clockwise or counterclockwise when viewed from originally. The suction and discharge are
the coupling end of the pump. If you wish to offset, so the piping will need to be changed
reverse the suction and discharge nozzles; i.e., to accommodate the new flange locations.
change rotation, this can be accomplished with the 4. Reassemble the pump and realign the
same pump as follows: coupling as called for in the alignment
instructions.
1. Remove the impeller from the shaft, and
relocate the two impellers per Figure 10 for the 5. The rotation of the motor must be
desired rotation. (Follow the disassembly changed by switching the motor leads.
procedures given in this manual.)
NOTE: Unless the motor rotation is reversed
2. With the rotating element out of the the impeller will run backward.
casing, remove the casing from the base
and turn 180°. (Factory bases are drilled
for both rotations.)
SUCTION
CW ROTATION
“A”
“A”
CLOCKWISE ROTATION
VIEWED FROM THE COUPLING END
“A”
“A”
IMPELLER VANE
SUCTION ORIENTATION “A-A”
SUCTION DISCHARGE
COUNTERCLOCKWISE ROTATION
VIEWED FROM THE COUPLING END
When working on the pump, use accepted 3. Remove seal lines (1-952-0).
mechanical practices to avoid unnecessary
damage to parts. Check clearances and conditions 4. Remove gland bolts (1-904-9), washers (1-
of parts when pump is dismantled and replace if 909-9), and gland (1-014-9) from each
necessary. Steps should usually be taken to stuffing box.
restore impeller and casing ring clearance when it 5. Remove all casing main joint cap screws
exceeds three times the original clearance. (2-904-1) and dowels (2-916-0). Use slot
in casing main joint and separate the
DISMANTLING (PUMP WITH PACKING) casing halves with a pry bar. Lift upper
WARNING: Unexpected Startup Hazard half casing (2-001-7) by castlugs.
Disconnect and lockout power before NOTE: Casings have jacking screws.
servicing. Failure to follow these instructions could
result in serious personal injury or death, or 6. Remove packing (1-924-9) and seal cage
property damage. (1-013-9) from each stuffing box.
7. Remove cap screws (3-904-9) which hold
WARNING: Electrical Shock Hazard bearing housings (3-025-3) to the casing
Electrical connections to be made by a and lift rotating element out of lower
qualified electrician in accordance with all casing (2-001-8). Rotating element may
applicable codes, ordinances, and good practices. now be moved to suitable working
Failure to follow these instructions could result in location.
serious personal injury or death, or property
damage. 8. Pull coupling half and key (3-911-2) off
shaft (3-007-0).
WARNING:
NOTE: A spare rotating element can be
Prior to working on pump the power source
installed at this point.
should be disconnected with lockout provisions so
power cannot be re-energized to the motor. Close 9. Remove cap screws (5-904-9) from
isolating suction and discharge valves. Failure to bearing covers (5-018-0).
follow these instructions could result in property
damage, severe personal injury, or death. 10. Remove bearing housings (3-025-3),
locknut (3-516-4), and lockwasher (3-517-
4). Mount bearing puller and remove
CAUTION: Extreme Temperature Hazard
bearings (3-026-2). Remove retaining
Allow pump temperatures to reach
collar and split ring on outboard side and
acceptable levels before proceeding. Open drain
snap ring on inboard side.
valve, do not proceed until liquid stops coming out
of drain valve. If liquid does not stop flowing from CAUTION:
drain valve, isolation valves are not sealing and DO NOT REUSE THE BALL BEARINGS.
should be repaired before proceeding. After liquid Failure to follow these instructions could result in
stops flowing from drain valve, leave valve open injury or property damage.
and continue. Remove the drain plug located on
the bottom of the pump housing. Do not reinstall
NOTE: Locknut and lockwasher are not used
plug or close drain valve until reassembly is
on inboard end bearing.
completed. Failure to follow these instructions
could result in property damage and/or moderate 11. Remove bearing covers (5-018-0) and
personal injury. push oil seals (3-177-9) out of bearing
covers. Pull deflectors (3-136-9) off shaft.
1. Drain pump by opening vent plug (2-910- Slide stuff box bushings (6-008-0) off of
9) and removing drain plugs (2-910-9) on shaft.
2
12. Remove casing rings (3-003-9) from CAUTION:
impeller (4-002-0). DO NOT EXCEED 275°F. Failure to follow
these instructions could result in injury or property
13. Remove set screw (3-902-9) from shaft
damage.
nuts. Remove shaft nuts (3-015-9),
O-rings (3-914-9), sleeves (3-009-9),
interstage bushing (3-231-0), and To further assist in removing the sleeves, hold the
impellers (4-002-0). shaft vertically and drop it on a block of wood. The
impeller weight should force both the impellers
NOTE: Apply heat uniformly to the shaft and sleeves from the shaft.
sleeve to loosen the sealant between the
shaft and sleeve.
2
2ND STAGE 1ST STAGE
IMPELLER IMPELLER
31
24. Assemble rotating element in lower half 31. Assemble seal water flush and bleed lines
casing. Correctly locate casing ring pins, (1-952-0).
stuff box bushing pins, and interstage
diaphragm pins in casing main joint slots. a) Clockwise – Figure 11
Sliding the inboard bearing housing b) Counter-clockwise – Figure 12
towards the coupling slightly will ease
assembly. 32. Check coupling alignment and realign if
necessary.
25. Bolt outboard bearing housing in place. Be
sure that both housings are seated
properly in lower half casing.
26. Bolt inboard bearing housing in place.
Rotating element should now turn freely.
CAUTION:
Double check rotation of pump before
installing the upper half casing. Failure to follow
these instructions could result in injury or property
damage.
32
APPENDIX “A” ENGINEERING DATA
Pump Size A 8x6x14F-S H8x6x14F-S 8x6x14F-L H8x6x14F-L 8x6x18 H8x6x18
8200 8200 8200 8200 8200 8200
Number of Stages 2 2 2 2 2 2
Approval Flow Rate (GPM) 500/750 500/750 500/750 500/750 500/750 500/750
/1000 /1000 /1000 /1000 /1000 /1000
CASING DATA
(All Dimensions in Inches)
Flange Rating ASA Suction 125 or 250 125 or 250 125 or 250 125 or 250 125 250
Standard Discharge 250 800 250 800 250 250
Casing Material Cast Iron Ductile Iron Cast Iron Ductile Iron Cast Iron Ductile Iron
ASTM A48 ASTM A536 ASTM A48 ASTM A536 ASTM A48 ASTM A536
Class 35 Gr. 65-45-12 Class 35 Gr. 65-45-12 Class 35 Gr. 65-45-12
Max. Working Pressure (PSIG) 500 800 500 800 375 500
Max. Suction Pressure (PSIG) 100 300 100 300 100 200
Max. Hydrostatic Pressure (PSIG) 750 1200 750 1200 563 750
Standard Hydrostatic Test 625 1000 625 1000 468 625
Pressure (PSIG)
Casing Wall Thickness .75 .75 .75 .75 .75 .75
33
APPENDIX “B”
EXPLODED VIEW – 8200 SERIES FIRE PUMP
CLOCKWISE ROTATION
34
APPENDIX “B”
REPLACEMENT PARTS LIST
Part Number Part Name Quantity
1-952-0 Bleed Line 1
1-952-0 Flush Line 1
0-910-9 Pipe Plug 14
1-013-9 Seal Cage 2
1-014-9 Gland 2
1-901-9 Gland Bolt 4
1-909-9 Washer, Gland Bolt 4
1-924-9 Packing Ring 10
2-001-7 Casing, Upper Half 1
2-001-8 Casing, Lower Half 1
2-123-5 Casing Joint Gasket (Suction) 1
2-123-5 Casing Joint Gasket (Discharge) 1
2-904-1 Cap Screw (Casing) Varies with size
1-439-0 Dowel 2
3-003-9 Casing Ring 2
3-007-0 Shaft 1
3-009-9 Shaft Sleeve 2
3-015-9 Shaft Sleeve Nut 2
5-018-0 Bearing Housing Cover 2
3-025-3 Bearing Housing 1
3-026-3 Bearing, Inboard 1
3-026-4 Bearing, Outboard 2
5-050-4 Split Ring 1
5-421-4 Retaining Collar 1
3-169-9 Deflector 2
3-177-9 Lip Seal 2
3-516-4 Locknut 1
3-514-4 Lockwasher 1
3-902-9 Set Screw 2
5-904-9 Bearing Cover Bolt 8
3-911-1 Key (Impeller) 1
3-911-2 Key (Coupling) 1
3-914-9 O-Ring (Shaft Sleeve) 2
6-914-9 O-Ring (Stuffbox Bushing) 4
6-008-0 Stuffbox Bushing 2
3-034-0 Interstage Bushing 1
3-231-0 Interstage Diaphragm 1
3-914-7 O-Ring (Interstage Bushing) 3
5-915-0 Snap Ring (Bearing) 1
3-915-0 Snap Ring (Interstage Bushing) 1
4-002-0 Impeller 2
35
APPENDIX “B”
INSTRUCTIONS FOR ORDERING PARTS
When ordering parts for 8200 Series Fire Pumps, be sure to furnish the following information to the
AC Fire Pump Systems stocking distributor in your area:
– Serial Number
– Pump Size & Type
– Pump Model Number
– Pump Frame Number
– Description of Part
– Catalog Code
– Quantity Required
– Definite Billing and Shipping Instructions
– Date Required
Refer to parts list on page 34 for a complete parts list and recommended spare parts.
Parts should be ordered as far in advance of their need as possible, since circumstances beyond
the control of AC Fire Pump Systems may reduce existing stock. All parts are not carried in stock.
Some are made for each order. If replacement parts required are to be made of different materials than
originally specified, give exact requirements and the reason for changing. Special care in furnishing the
above information with the original order for parts will facilitate shipment.
36
APPENDIX “C” FIELD TEST REPORT
37
APPENDIX “C” FIELD TEST REPORT
USEFUL FORMULAS
Pressure (psig.) x 2.31
1) Head (ft.) = S.G. = specific gravity; S.G. of water = 1.0 at 70°F
S.G.
2) TDH (ft.) = Total Dynamic Head (ft.) = (Disch. pressure gauge reading - Suct. pressure gauge reading) +
(Discharge velocity head - Suction velocity head) +
(Elevation correction to disch. gauge - Elevation correction to suct. gauge)
5) Affinity Laws for correcting GPM, TDH, and BHP for speed (RPM):
GPM1 RPM1 RPM1
= or GPM1 = GPM2 x
GPM2 RPM2 RPM2
( RPM ) ( RPM )
2 2
TDH1 RPM 1 RPM 1
= or TDH1 = TDH2 x
TDH2 2 2
( ) ( RPM )
3 3
BHP1 RPM1 RPM 1
= or BHP1 = BHP2 x
BHP2 RPM2
P
6) NPSHA DETERMINATION:
NPSHA = Net Positive Suction Head Available
NPSHA = (Atmospheric pressure - Vapor pressure of liquid + Total suction head)
Total Suction Head = (Suction pressure gauge reading + Suction velocity head + Elevation correction to
suction gauge)
NOTE: NPSHA must always be greater than NPSHR (NPSHA NPSHR) for the pump to operate without concern
of cavitation.
NPSHR refers to Net Positive Suction Head Required by pump. This is a published value obtained from
the Pump Manufacturer’s curve.
2 of 2
38
Xylem
1) The tissue in plants that brings water upward from the roots;
2) a leading global water technology company.
Xylem, Inc.
8200 N. Austin Avenue
Morton Grove, Illinois 60053
Phone: (847) 966-3700
Fax: (847) 965-8379
www.acfirepump.com
A-C Fire Pump is a trademark of Xylem Inc. or one of its subsidiaries.
© 2014 Xylem Inc. AC2675D October 2014