Godwin Dri-Prime CD Series Manuale utente

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges

Dri-Prime®Pumps

Manual No. : 95-0019-0000 Issue : 12 Date : - Nov 2011

Pump Serial No.

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

2 95-0019-0000 Iss 11

INDEX

1INTRODUCTION................................................................................................................................ 3

1.1 Manual Purpose .........................................................................................................................................................3

1.2 Information for the User, Operator or Maintenance Personnel. .................................................................................3

2WARRANTY....................................................................................................................................... 4

3HOW TO USE THIS MANUAL .......................................................................................................... 4

4SAFETY ............................................................................................................................................. 5

4.1 Lifting..........................................................................................................................................................................5

4.2 General.......................................................................................................................................................................6

5PUMP SERIAL NUMBER .................................................................................................................. 7

5.1 Spares........................................................................................................................................................................7

6INSTALLATION ................................................................................................................................. 7

6.1 Versions......................................................................................................................................................................7

6.1.1 Motor Adaptor..............................................................................................................................................7

6.1.2 Bearing Bracket...........................................................................................................................................7

6.2 Alignment....................................................................................................................................................................8

6.2.1 Alignment Procedure...................................................................................................................................8

6.3 General Installation Notes..........................................................................................................................................9

7OPERATION .................................................................................................................................... 10

7.1 General.....................................................................................................................................................................10

7.2 Flooded Suction........................................................................................................................................................10

7.3 Compressor/Vaccum pump disconnection...............................................................................................................10

7.4 Draining....................................................................................................................................................................11

8MAINTENANCE............................................................................................................................... 12

8.1 Bearings ...................................................................................................................................................................12

8.1.1 Re-greasing procedure..............................................................................................................................12

8.2 Seal coolant level .....................................................................................................................................................13

8.3 Seal removal.............................................................................................................................................................14

8.3.1 Front cover & pump body removal ............................................................................................................15

8.3.2 Removing the impeller...............................................................................................................................16

8.3.3 Removing the rear wear plate ...................................................................................................................18

8.4 Seal configuration.....................................................................................................................................................18

8.4.1 Removing the seal.....................................................................................................................................19

8.4.2 Inspection ..................................................................................................................................................19

8.5 Seal fitting.................................................................................................................................................................20

8.5.1 Preparation................................................................................................................................................20

8.5.2 Fitting the seal ...........................................................................................................................................20

8.5.3 Fitting the wear plate .................................................................................................................................23

8.5.4 Fitting the impeller.....................................................................................................................................24

8.5.5 Front cover & pump body fitting.................................................................................................................25

8.5.6 Preparing for service .................................................................................................................................25

8.6 Bearing Bracket & Motor Adaptor Dismantling.........................................................................................................26

8.6.1 Preparation for dismantling........................................................................................................................26

8.6.2 Dismantling................................................................................................................................................26

8.7 Bearing Bracket & Motor Adaptor Assembly............................................................................................................28

8.7.1 Preparation for assembly...........................................................................................................................28

8.7.2 Assembly...................................................................................................................................................28

8.8 Air Compressor.........................................................................................................................................................32

8.8.1 Filter Replacement ....................................................................................................................................32

8.9 Vacuum Pump..........................................................................................................................................................32

8.10 Non Return Valve.....................................................................................................................................................32

8.11 Drive Belts................................................................................................................................................................32

8.11.1 Timing/HTD Belt Replacement (air compressor)......................................................................................32

8.11.2 Belt Replacement (vacuum pump) ...........................................................................................................32

8.11.3 Link belt tensioning and replacement.......................................................................................................33

9TOOLS ............................................................................................................................................. 35

9.1 Tool Kits....................................................................................................................................................................35

9.2 Special Tools............................................................................................................................................................36

10 FAULT FINDING.............................................................................................................................. 36

11 TECHNICAL DATA.......................................................................................................................... 37

11.1 Designations, Sizes & Capacities.............................................................................................................................37

11.1.1 CD range ..................................................................................................................................................37

11.1.2 HL Range..................................................................................................................................................38

11.1.3 NC Range.................................................................................................................................................38

11.2 CD Range data.........................................................................................................................................................39

11.3 HL Range data .........................................................................................................................................................40

11.4 NC Range Data........................................................................................................................................................41

11.5 Spanner Torques......................................................................................................................................................42

11.6 Thread Locking Compounds ....................................................................................................................................42

11.7 Belt Tensioning.........................................................................................................................................................43

11.7.1 Force and deflection method....................................................................................................................43

11.7.2 Belt frequency method..............................................................................................................................43

11.7.3 Belt tension figures –HTD/Timing belts ....................................................................................................43

11.7.4 Belt tension figures Link............................................................................................................................43

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

95-0019-0000 Iss 11 3

1 INTRODUCTION

1.1 Manual Purpose

This manual contains useful and important information to allow the pump to be properly installed, operated and maintained.

It also contains important instructions for preventing possible accidents and serious damage whilst carrying out those

activities.

Carefully read these instructions before commencing any of these activities.

The purpose of this Installation, Operating and Maintenance Manual is to provide the installer, owner or user of the

equipment with sufficient information to carry out those tasks for the CD, HL & NC ranges of Dri-Prime® Pumps.

Pump model designations covered by this manual are: -

CD75 HL80 NC80

CD80D HL100 NC100

CD80M HL110M NC150

CD100M HL125MS

CD103M HL150M

CD140M HL150MHD

CD150M HL200M

CD160M (Mk 1 & 2) HL130M

CD180M HL160M

CD200M HL225M

CD225 HL250M

CD250M HL260M

CD300M

CD400M

CD500M

The information contained in this manual was correct at the time of publication. It is subject to amendment at any time.

Should any doubt exist about the veracity of the information, contact Godwin Pumps Ltd for clarification before proceeding.

The pump may be supplied as a bare shaft pump end or packaged with a driver into a pump set. This manual covers the

pump end only. For packaged pump sets, information on equipment other than the pump end is contained in separate

documentation.

1.2 Information for the User, Operator or Maintenance Personnel.

Installation and maintenance is designed to be carried out using simple hand and service tools. A range of special tools

designed to ease dismantling and reassembly is available from Godwin Pumps Ltd. When the user has insufficient tools,

experience or ability, this work should not be attempted. Under no circumstances should makeshift tools or equipment be

used, as this may adversely affect safe working practices and pump operation.

Because of the number of different units covered by this manual, the user must ensure that they are reading the correct

instructions and viewing the correct diagrams for the unit they are working on.

Ensure that suitably qualified personnel carry out the installation. The variety of conditions and environments in which this

equipment can be used means that the operator and those responsible must satisfy themselves as to the safety and

acceptability of each application and operating condition of this equipment. Standard pumps are designed for use with

predominately clean or dirty water. For all other applications, including sea water, consult Godwin Pumps Ltd. Under no

circumstances will Godwin Pumps Ltd be responsible or liable for indirect or consequential damages arising from the use or

application of this equipment.

Parts that have not been approved by Godwin Pumps Ltd cannot be relied upon for correct material, dimensions or finish.

Godwin Pumps Ltd cannot therefore be held responsible for any damage arising from the use of such parts. This and failure

to observe any instruction or procedure in this manual will invalidate the warranty.

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

4 95-0019-0000 Iss 11

2 WARRANTY

Unless special arrangements have been agreed and signed by both parties Godwin Pumps Ltd. will apply the following

policy over defects found after delivery.

We will make good, by repair or the supply of a replacement, defects which, under proper use, appear in the goods within a

period of twelve calendar months after the goods have been delivered (1) and arise solely from faulty design (other than a

design made, furnished or specified by you for which we have disclaimed responsibility in writing), materials or

workmanship: provided always that defective parts have been returned to us if we shall have so required. We shall refund

the cost of carriage on such returned parts and the repaired or new parts will be delivered by us free of charge.

Our liability under this clause shall be in lieu of any warranty or condition implied by law as to the quality or fitness for any

particular purpose of the goods, and save as provided in this clause we shall not be under any liability, whether in contract,

tort or otherwise, in respect of defects in goods delivered or for any injury (2), damage or loss resulting from such defects as

from any work done in connection therewith.

(1) For export orders, within a period of twelve calendar months after the goods have been delivered or, if delivery is

delayed by reason of customer instructions or lack of instructions, within a period of 18 months after the goods have

been notified as ready for despatch (whichever period expires the earlier).

(2) For UK orders, other than personal injury caused by our negligence as defined in Section 1 of the Unfair Contract

Terms Act, 1977.

3 HOW TO USE THIS MANUAL

Read this section before installing, operating or carrying out any maintenance on the unit.

When the pump is being installed operated or maintained there are a number of practices that may lead to personal injury or

product damage. Your attention is drawn to the following symbols and their meaning used throughout this manual.

used to identify mechanical hazards

used to identify electrical hazards

CAUTION

This caution symbol draws attention to special instructions or procedures which, if not correctly followed,

may result in damage to, or destruction of equipment.

WARNING

This warning symbol draws attention to special instructions or procedures which, if not strictly observed,

may result in personal injury.

WARNING

A WARNING SYMBOL WITH THIS TYPE OF TEXT DRAWS ATTENTION TO SPECIAL INSTRUCTIONS

OR PROCEDURES WHICH, IF NOT STRICTLY OBSERVED, MAY RESULT IN SEVERE PERSONAL

INJURY, OR LOSS OF LIFE.

NOTE: - A note is used to draw your attention to additional important information.

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

95-0019-0000 Iss 11 5

4 SAFETY

WARNING

ALL ITEMS IN THIS SECTION, IF NOT STRICTLY OBSERVED, COULD RESULT IN SEVERE

PERSONAL INJURY OR LOSS OF LIFE.

4.1 Lifting

Use only lifting equipment of suitable capacity for the size and weight of the equipment being lifted

The equipment must always be lifted using safe working practices and in accordance with any local and national guidelines

or statutes. Figure 1, Figure 2, Figure 3 and Figure 4 show possible means of lifting. They are intended for guidance only. If

in doubt, consult Godwin Pumps Ltd or a local lifting expert.

Figure 1 Lifting smaller motor adaptor units Figure 2 Lifting smaller bearing bracket units

Figure 3 Typical lifting methods for close coupled bare shaft units (CD300M shown)

Figure 4 Typical lifting method for CD400 pumps

Whilst lifting the unit keep personnel well away and never allow people underneath.

CD100_02

CD225_02

HL100-02

HL100-04

CD400 LIFT

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

6 95-0019-0000 Iss 11

4.2 General

Personnel working on the pump must always wear clean, correctly fitting clothing and safety footwear. Clothing impregnated

with oil or fuel can constitute a health hazard through prolonged contact with the skin and may also constitute a fire hazard.

Signs on the unit (e.g. directional arrows, maintenance and serial number plates & fluid connections, etc.) must be kept

clean and clear.

Check the type of liquid that the pump has been used for before carrying out any maintenance work. Residues could be

hazardous to your health. If in doubt, flush thoroughly with clean water before commencing work.

Rotating equipment presents a hazard in itself. Alert surrounding personnel before starting and post notifications whilst in

operation.

Moving parts are guarded to protect you. Guards removed for maintenance must be replaced before starting the pump.

Never insert anything into the pump body whilst the pump is running and the suction or delivery hoses are disconnected.

Use all flange bolt holes and ensure the correct bolt size and quality is utilised when connecting suction and delivery hoses.

Collapsible hoses must never be used on the suction side of the pump.

Keep the hose end suction area free from debris. Although the pump can handle solids up to the size indicated in the

Technical Data section of this manual, larger or irregular solids may cause blockage with damage to pump components.

Always allow adequate ventilation for the pump driver. Diesel engines require air for both combustion and cooling. Electric

motors require air for cooling purposes. This air must never be allowed to re-circulate.

Be aware of burn and fire risks from items such as exhaust pipes and silencers. Never place flammable items around the

unit.

Diesel engine exhaust and some of its constituents are known in the State of California to cause cancer, birth defects and

other reproductive harm.

Liquid pressure may still be present even after shutdown of the pump. Particular attention should be paid to delivery lines

that are long, or rise through any height, as these can contain large volumes of liquid. These lines must be isolated and

drained down before commencing work. Sudden release of this liquid can cause serious injury to an operator either directly

or indirectly through the rotational motion it can induce.

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

95-0019-0000 Iss 11 7

5 PUMP SERIAL NUMBER

Every pump unit has a nameplate similar to one of those shown below. This nameplate lists the serial number and type of

the pump. These numbers must be quoted in any enquiry for spares or service.

Figure 5 Typical pump serial number plates

5.1 Spares

Use only genuine parts from your local Godwin Pumps Ltd supplier or distributor. Failure to do so may invalidate warranty

and/or reduce the pump’s working life.

6 INSTALLATION

All pumps in the range are designed to be run in one direction only. This is anti-clockwise when viewed from the suction

flange end or clockwise when viewed from the driving shaft end.

Rotation on electric motor driven pumps should be checked carefully – preferably with the coupling disconnected. On

installations where coupling disconnection is not possible apply power only for a brief instance, preferably with a soft start, in

order to determine rotation. A fast start or prolonged running in the wrong direction could cause parts to come loose.

CAUTION.

Failure to provide the correct rotation will give rise to poor performance, vibration and possible severe

damage to the pump.

6.1 Versions

Larger pumps (CD300/400/500 or HL130/160/225/250/260) can be supplied with or without an SAE adaptor fitted. With the

adaptor fitted they are suitable for direct coupling, without they are suitable for open coupling. The bearing bracket must be

adequately supported when used as open coupled units. If any doubt exists over the suitability of the support consult

Godwin Pumps Ltd.

Smaller pumps in the range are supplied as either motor adaptor or bearing bracket versions: -

6.1.1 Motor Adaptor

Motor adaptor (MA) versions of the pump are designed for close coupling to a suitable driver, usually a diesel engine. They

are supplied with transport feet that must be removed before attachment to the driver. Alignment of the pump to driver will

be taken care of by the flanged adaptor.

6.1.2 Bearing Bracket

Bearing bracket (BB) versions of the pump are designed for open coupling with the bearing bracket supported from the

same base but standing independently of the driver.

Correct alignment is critical for the longevity of the pump bearings, coupling and driver bearings. Follow the coupling

manufacturers’ instructions exactly.

See Section 6.2 for recommendations on alignment.

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

8 95-0019-0000 Iss 11

Pump Driver

Parallel alignment.wmf

Pump Driver

ngular alignment.wmf

6.2 Alignment

The following notes provide general guidance on alignment and its elimination.

It is normal practice to carry out any adjustment to alignment by moving the driver – not the pump. In designing any

structure to support the pump set allow an additional 0.25mm (0.010”) extra height difference between pump and driver

support for shimming purposes.

There are two forms of misalignment – parallel and angular. Both must be less than the coupling manufacturers’ guidelines

in order for the coupling and bearings to give long and trouble free operation.

It is essential that the baseplate or support structure be fully tightened down before commencing any alignment procedures.

This will ensure that no misalignment is introduced by support structure deformation.

Alignment must always be carried out before any pipework is attached to the pump. Keep a note of the actual figures. Carry

out a check after the pipework has been attached and compare the figures. Any discrepancy must have been introduced by

the pipework attachment and must be corrected by refitting the pipework before putting the pump into service.

CAUTION.

Incorrect coupling alignment will lead to premature bearing and /or coupling failure.

6.2.1 Alignment Procedure

Roughly align the pump and driver by eye.

a) Parallel alignment

Mount a dial gauge on the driver shaft with the gauge running on the outer-machined

diameter of the pump coupling (see Figure 6). If the driver shaft is not accessible then the dial

gauge can be mounted on the driver coupling.

Turn the driver shaft, note the total indicator reading, and adjust the driver position

accordingly. Recheck.

Figure 6 Initial parallel alignment check

b) Angular alignment

Mount the dial gauge on the driver shaft or coupling (as for step a)) and adjust the dial

gauge to run on a mating face of the coupling as close to the outer diameter as

possible (see Figure 7).

Turn the driver shaft, note the total indicator reading, and adjust the driver in the

direction required. Recheck.

Figure 7 Angular alignment check

c) Confirming parallel alignment

Mount a dial gauge on the pump shaft with the gauge running on the outer-machined

diameter of the driver coupling (see Figure 8). If the pump shaft is not accessible then

the dial gauge can be mounted on the pump coupling provided the mounting face is

concentric with the shaft.

Turn the pump shaft and note the total indicator reading. Adjust the driver in the

direction required and recheck.

Figure 8 Secondary parallel alignment check

After alignment the pump and driver should be fully tightened down and the alignment rechecked to ensure that nothing has

moved in the tightening down procedure.

If a dial gauge is not available, then vernier callipers (or a taper gauge) and a straight edge can be used, providing the

coupling is of a type that permits it.

Measure the gap between coupling faces with the vernier callipers (or taper gauge) at four points equidistant around the

circumference of the coupling. Adjust until all are equal.

Use a straight edge across both machined outer diameters of the coupling at four points equidistant around the

circumference to confirm parallel alignment.

Pump Driver

Parallel ali

nment 1 .wmf

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

95-0019-0000 Iss 11 9

Hose line recommendations

6.3 General Installation Notes

Godwin Pumps Ltd. may refute warranty liability if the installation does not meet the requirements of the pump. Should any

doubt exist as to the suitability of an installation, then Godwin Pumps Ltd. should be consulted.

Only suitably qualified personnel (both mechanical and electrical) should carry out the installation. All local and national

regulations in force must be observed.

The coupling used to connect the driver and pump must have the correct characteristics for the purpose. If in doubt –consult

Godwin Pumps Ltd.

The completed pump set must be mounted on a firm level surface.

On bare shaft pumps guarding of the belts, pulleys and couplings is the responsibility of the installer.

Pump sets are supplied with guarding to meet general applicable standards but site conditions may necessitate further

measures such as railings or screens. These are also the responsibility of the installer.

The Godwin Dri-Prime pump range is designed to operate on long lengths of suction pipe but it is always advisable to

position the pump as close to the source as possible.

The Godwin Dri-Prime product is designed to handle small amounts of air leakage, but to ensure optimum pump

performance, it is advisable to ensure that the suction pipe work is airtight and the end is sufficiently submerged to prevent

air being drawn into the pipe.

A general-purpose strainer should be fitted to the end of the suction pipe work and the total area of the openings should be

at least three times the normal area of the suction pipe work. Strainer apertures should be no greater than the maximum

recommended solids handling size for the pump.

The suction and delivery pipe work should be kept as short as possible with a minimum number of large radii bends to

minimise pipe friction losses. To maximise flow rates, it is encouraged to fit larger diameter pipe work than the pump

connection sizes.

Lay out piping runs before connecting to the pump to ensure that tight bends and other flow restrictions are not included.

Figure 9 shows some common pipeline installation problems and their recommended solutions.

Figure 9 Common pipeline installation problems and their solutions

It is important that the suction and delivery pipe work is supported immediately after the pump connections to prevent

straining and possible misalignment of the equipment.

Installation, Operation and Maintenance Manual

CD, HL & NC Ranges of Dri-Prime®Pumps

10 95-0019-0000 Iss 11

Remove priming tower

complete and replace

with blanking plate

Disconnect

vacuum pump

drive

7 OPERATION

7.1 General

Before attempting to start the unit ensure that you are familiar with the controls and any local or national safety regulations.

If the unit is engine driven refer to the engine manufacturer’s manual.

If the unit is driven by an electric motor refer to the relevant control requirements.

Once the unit is started, the air compressor or vacuum pump will start to prime the pump and the unit will require no further

attention.

7.2 Flooded Suction

Should the unit be required to operate under flooded suction conditions (i.e. liquid to be pumped is above pump suction

connection – see Figure 10), then the air compressor or vacuum pump pipeline to the pump must be disconnected and the

pump opening blocked. The compressor or vacuum pump drive must also be disconnected to save wear on the compressor

or vacuum pump.

CAUTION.

Failure to disconnect the pipeline will result in serious compressor or vacuum pump damage and

consequential pump failure.

Figure 10 Flooded suction conditions

The duty of the pump should be carefully checked against the drive characteristics. In some instances this arrangement can

overload the driver.

7.3 Compressor/Vaccum pump disconnection

WARNING.

This procedure requires access to operating and rotational parts of the pump. Accidental start up could

cause injury.

To disconnect: -

a) Ensure that the driver is isolated and the unit cannot be started whilst the pump is being worked on.

b) Compressor units: -Disconnect the air delivery pipe to the ejector.

Vacuum pump units: - Disconnect the air suction pipe from the priming tower.

Compressor units: -Remove the ejector housing complete and replace with a plain blanking plate (see

c) Figure 11).

Vacuum pump units: -Remove the priming tower complete and replace with a plain

blanking plate.

Blanking plates are available from Godwin Pumps Ltd or may be fabricated on site.

d) Ensure that the blanking plate has a leak free joint to the pump

e) Remove the isolation means from the driver and restart the pump.

Figure 11 Typical blanking plate fitted in place of ejector housing

Remove the blanking plate, replace the ejector housing or priming tower, reconnect the air hose and reinstall the

compressor/vacuum pump drive when the pump is next required to self-prime.

HL100_09

HL100-05

Remove ejector

package and

blank off

Disconnect

compressor

drive

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