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Mather + Platt

Installation, Operating and Maintenance


Instruction Manual
for
Vertical Pumps

These instructions must be read prior to installing, operating,


using and maintaining this equipment

MPPL/IM/VP/2006/0

Mather + Platt

Table of Content

EC declaration of incorporation (QA02-45) for, pumps without prime mover


EC declaration of conformity (QA02-46) for, pumps with CE prime mover.
1

Preface and Copyright Information

1-1

Preface
Copyright
Manufacturer
Rights of alteration

1-1
1-1
1-1
1-1

General safety information

2-1

Safety symbols used in the man

2-1

Guides lines used and CE certification


Declaration of Incorporation or conformity
Duty conditions
Safety & control devices
Safety instructions
Safety instruction for the operator
Electrical connection and electrical work
Operation with different pump fluid
Sound pressure
Prime mover selection
Warranty
Remarks

2-1
2-1
2-2
2-2
2-2
2-3
2-4
2-4
2-4
2-5
2-5
2-6

Product description

3-1

General product information


Proper use and fields of application
Conditions of use
Construction

3-1
3-1
3-1
3-2

Handling, transportation and storage

4-1

Handling
Delivery
Transport
Storage
Returning to supplier

4-1
4-1
4-2
4-2
4-2

Installation

5-1

5.1

Introduction

5-1

5.2

Requirements for the operating area

5-1

5.3
5.4
5.5
5.6
5.7
5.8

Cleaning
Foundations
Soleplate installation & pump assembly/installation
Alignment of pump and driving unit
Pipe work
Use of diesel engine as prime mover

5-1
5-2
5-3
5-6
5-8
5-9

1-1
1-2
1-3
1-4

2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2.10
2.11
2-12
2-13

3
3-1
3-2
3-3
3-4

4
4-1
4-2
4.3
4.4
4-5

MPPL/IM/VP/2006/0

Table of Content

Mather + Platt

Start up

6-1

Introduction
Pipe work flushing
Cleaning of bearing
Direction of rotation
Availability of liquid
Pre-starting checks

6-1
6-1
6-1
6-1
6-1
6-2

Normal starting checks


Running checks
Normal shut down
Emergency shut down

6-2
6-3
6-3
6-3

Maintenance

7-1

Routine maintenance & frequency of inspection


Overhaul maintenance
Spares
Lubrication

7-1
7-2
7-5
7-6

Troubleshooting

8-1

Lists, Tables & Type Plates

A-1

List of machine operators


Maintenance and inspection log
Type plates
Leveling Records
Alignment Protocol
Pre-Starting checks
Pump commissioning report
Issue & Feedback report

A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8

Machine data sheet

B-1

Performance

B-1
B-1
B-1
B-3
B-4

6
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10

7
7.1
7.2
7.3
7.4

A1
A2
A3
A4
A5
A6
A7
A8

B
B1
B2
B3
B4
B5

Pressure limits
Flange loads
Bearing lubrication & gland packing data
Recommended bolting & screw torques

MPPL/IM/VP/2006/0

Mather + Platt

EC declaration of incorporation

EC declaration of incorporation
According to annexure V of machinery directive 98 /37 /EC,
We hereby state that this product (Pump without prime mover)
Product designation
Type designation

:
:

Pump serial no
Prime mover designation
Type designation
Prime mover (CE) serial no

:
:
:
:

Vertical pump
Refer section B5 serial No 1 to 43 of the
manual & the name plate on the pump
Refer the name plate on the pump
Not applicable.
Not applicable.
Not applicable.

fulfills the following relevant legal requirements:


EC Machinery directive 98 / 37 / EC
Harmonized standards used, in particular:
EN 809:1998
ISO 12100-1:2001
ISO 12100-2:2002
EN 1050
Manufacturer
Address

:
:

Telephone
Fax
e-mail

:
:
:

Representative (within EEA)


Address

:
:

Telephone
Fax
e-mail

:
:
:

Mather and Platt Pumps Ltd.,


Mumbai Pune Road, Chinchwad, Pune411019, India.
+91 (0)20 27442100.
+91 (0)20 27442211.
headoffice@pun.matherplatt.co.in
WILO AG,
NortkirchenstraBe 100, 44263 Dortmund,
Germany
+49 231 4102-0
+49 231 4102-363
info@wilo.de

Pune, 01.07.2006

Mather & Platt Pumps Ltd


Pune
A. V. Joshi
Deputy General Manager - Quality Assurance

QA02-45 REV 0

Mather + Platt

EC declaration of conformity

EC declaration of conformity
According to annexure V of machinery directive 98 /37 /EC,
We hereby state that the Mather & Platt product (Pump with prime mover), refer prime
mover manual name plate, instruction manual & CE declaration of conformity
Product designation
Type designation

:
:

Pump serial no
Prime mover designation
Type designation
Prime mover (CE) serial no

:
:
:
:

Vertical pump
Refer Section B5 Serial No 1 to 43 of the
manual & the name plate on the pump
Refer the name plate on the pump
Refer the name plate on the prime mover
Refer the name plate on the prime mover
Refer the name plate on the prime mover

fulfills the following relevant legal requirements:


EC Machinery directive 98 / 37 / EC
Harmonized standards used, in particular:
EN 809:1998
ISO 12100-1:2001
ISO 12100-2:2002
EN 1050
Manufacturer
Address

:
:

Telephone
Fax
e-mail

:
:
:

Representative (within EEA)


Address

:
:

Telephone
Fax
e-mail

:
:
:

Mather and Platt Pumps Ltd


Mumbai Pune Road, Chinchwad, Pune411019, India.
+91 (0)20 27442100
+91 (0)20 27442211
headoffice@pun.matherplatt.co.in
WILO AG,
NortkirchenstraBe 100, 44263 Dortmund,
Germany
+49 231 4102-0
+49 231 4102-363
info@wilo.de

Pune, 01.07.2006

Mather & Platt Pumps Ltd


Pune
A. V. Joshi
Deputy General Manager - Quality Assurance

QA02-46 REV 0

Mather + Platt

Preface and Copyright Information

Preface and Copyright Information

1.1

Preface

Dear Customer
Thank you for purchasing one of our company's products. This operating and maintenance manual must be read
carefully before installation & initial start-up to ensure safe and efficient use. This documentation contains all
the necessary information for the product, allowing you to use it properly. In addition, you will also find helpful
information, which will enable you to recognize potential dangers, reduce repair costs, down times and increase
the reliability and working life of the product
The operating company is responsible for ensuring that all persons working with or on this product are at least
18 years of age and have read and understood this manual. Only qualified and trained personnel should be
assigned to work on the product. All safety requirements and specific manufacturer's requirements must be
fulfilled before the product is put into operation.
This operating and maintenance manual supplements any existing national regulations on industrial safety and
accident prevention. This manual must be made accessible to personnel working at all times and also be made
available where the product is used.
In a case where there is any doubt as to the functioning or adjustment of any parts of the equipment, or in the
event of any trouble which cannot be remedied by reference to the information contained in this manual,
MATHER & PLATT PUMPS LTD. should be consulted immediately at their Pune address mentioned below. In
communicating with the Company, the Pump Serial Number should always be quoted.

1.2

Copyright

This operation and maintenance manual has been copyrighted by, the manufacturer. The operation and
maintenance handbook is intended for, the use by assembly, operating and maintenance personnel. It contains
technical information and diagrams which may not be reproduced or distributed, either completely or in part, or
used for any other purpose without the expressed consent of the manufacturer.

1.3

Manufacturer

Mather and Platt Pumps Ltd.,


Mumbai-pune Road,
Chinchwad,
Pune-411019,
India.
Tel.: +91 (0) 20 27442100
Fax: +91 (0) 20 27442111
Internet: www.matherplatt.com
e-Mail: headoffice@pun.matherplatt.co.in

1.4

Rights of alteration

The manufacturer reserves the right to make technical alterations to systems or components and contents of
manual.

This operating and maintenance manual refers to the product indicated on


the title page.

MPPL/IM/VP/2006/0

1-1

Mather + Platt
2

General Safety Information

General Safety Information

This operation and maintenance manual contains basic information, which must be strictly observed during
operation and maintenance. Not only the safety instructions listed in this chapter must be followed but also
those contained in other chapters, which refer to specific parts and procedures. The operator is responsible for
ensuring that personnel follow these instructions and guidelines.

2.1

Safety symbols used in the Instruction manual


This symbol indicates danger from general causes where noncompliance with safety instructions would affect personnel safety.
This symbol indicates danger from electrical causes where noncompliance with electrical safety instructions will involve a high risk to
personnel safety or loss of life.
This note symbol refers to safety requirements or notes that are of
critical importance to the user where non-compliance could damage the
pump or installation or cause it to malfunction.

2.2

Guidelines used and CE certification

Our products conform to the following EU guidelines:


-

Machinery directive 98 / 37 / EC.

In addition, several harmonized standards have been applied, e.g. EN 809, ISO 2100-1, ISO 12100-2 & EN
1050 (Risk assessment).
Please consult the EU Declaration of Conformity for the precise information and the guidelines in effect The EU
Declaration of Conformity is issued in accordance with EU Directive 98/37/EC, Appendix II A.
The CE symbol is found on the pump nameplate and motor & electrical panel nameplate when in M&Ps scope of
supply.

2.3

Declaration of Incorporation or conformity.

Since Mather & Platt does not manufacture prime mover, following conditions will apply. It is recommended that
customers should opt for CE marked prime mover.
When customer takes only bare pump, or pump with accessories without prime mover, Declaration of
Incorporation will be applicable. For unitized pumps with CE prime mover, Declaration of Conformity will
be applicable. Where customer opts for pumps with prime mover without CE, or supplies his prime mover for
unitization, which is not CE, Declaration of incorporation will be applicable.

MPPL/IM/VP/2006/0

2-1

Mather + Platt

General Safety Information


2.4

Duty conditions

This product has been supplied as per specifications in your purchase order/ approved data sheet & drawings. A
copy of these specifications / approved data sheet should be kept with these instructions.

The product must not be operated beyond the parameters specified for
the application. In case of any doubts, contact Mather & Platt for advice,
quoting Pump serial number.
If the duty conditions of pump are going to be different than the specifications in purchase order / approve data
sheet (e.g. liquid pumped, temperature or duty) it is requested the user seeks the written agreement of Mather
& Platt pumps Ltd., before start up.

2.5

Safety & control devices

Direct controls are applicable when pump is supplied along with motor/panels. When motor/panel are in end
users scope, it is advised to go for CE approved motors/panels.

These devices whether on pump/motor/electrical panels must never be


dismantled or disabled. They must be checked by, an authorized
technician for proper functioning before start-up. Refer to motor &
Electrical panel instruction manuals for electrical safety & control
devices information.

2.6

Safety instructions
-

Installation & service should be done by, qualified personnel only.

The installation / removal of the product must not be performed by one person alone.

Failure to comply with safety precautions could result in personnel injury or damage to
the equipment or installation. Failure to comply with safety precautions could also
invalidate any claim for warranty.

The operator is required to know mechanical/electrical specifications of the machine and


how to cut off the supply.

The operator must inform his/her superior immediately should any defects
irregularities occur. This applies to both the electrical and mechanical devices.

If fastening devices are separated from the pump after use, they should be
marked as fastening devices. Otherwise they should be carefully stored.

It is of vital importance that the system is shut down immediately by the operator if any
problems arise which may endanger the safety of personnel and/or plant. Problems of
this kind include:
-

or

expressly

Failure of the safety and/or control devices.


Damage to critical parts.
Damage to electric installations, cables and insulation.

Main controls for the pumps should be located for easy view of the operator from the
control position.

The removable and/or mobile equipment for lifting loads should be used in a manner that
ensures the stability of -the equipment during operation.

Measures should be taken to bar persons from standing beneath a suspended load.
Furthermore, it is also prohibited to move suspended loads over exposed workplaces
where people are present.

MPPL/IM/VP/2006/0

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Mather + Platt

General Safety Information

The fastening devices should be adapted to the conditions at hand (weather, hooking
system, load, etc.) If these are separated from the pump after use, they should be
expressly marked as fastening devices. Otherwise they should be carefully stored.

Only fastening devices, which are legally designated as such and officially approved, may
be used.

When using mobile working equipment for lifting non-guided loads, measures should be
taken to prevent them from tipping, sliding, slipping etc.

If mobile working equipment is used for lifting loads, a second person should be present
to coordinate the procedure if needed (for example, if the operator's field of vision is
blocked).

While unloading the pump from the truck lift the pump by passing wire rope beneath the
box containing the pump or pump assembly.

The load to be lifted must be transported in such a way that there is no danger of injury in
the event of a power failure. Additionally, when working outdoors, such procedures must
be interrupted immediately if weather conditions worsen.

When working in enclosed spaces care should be taken to provide sufficient fresh air.
Provide sufficient ventilation.

When welding or working with electronic devices, ensure that there is no danger of
explosion.

When working with pumps using hot liquid appropriate care should be taken. It is advised
to use PPE irrespective of warning signs on pump/insulation provided depending upon the
temperature of liquid handled.

Environmental safety: Disposal of any unwanted/scrap material should be disposed in


appropriate way so as not to cause any harm to the environment. No hazardous material
is used in M & P pumps.

These instructions must be strictly observed. Non- compliance can lead


to serious personal injury and/or damage to the machine.

2.7

Safety instructions for the operator


-

Local regulations for the prevention of accidents must be observed. Dangers resulting
from electrical energy are to be prevented. National/local energy supply company
regulations must be followed.

Guards for moving parts (e.g. coupling) must not be removed from the machine while in
operation.

For safety reasons, safety and control devices must not be removed
without
authorization. Personnel must have the requisite specialist
knowledge.
Use Standard Personnel protective equipments against sharp corners for protection
of hands, for eyes when using grinders, Special PPE against electrical shocks,
against sound (Cl 2.8) etc.

MPPL/IM/VP/2006/0

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Mather + Platt

General Safety Information


2.8

Electrical connection and electrical work

Refer to the instruction manual for motor and panels at the time of installation and connection. Motors or
electrical control panels are operated with alternating or industrial high-voltage current. It is recommended to
use CE marked motor and / or electrical panel if they are not in M&Ps scope of supply. The local regulations
must be adhered to. The "Electrical connection" data sheet in the respective motor and panel instruction
manual must be followed when connecting the product. The technical specifications on the nameplate and in the
machine data sheet must be strictly observed.
Ensure that there is a provision for isolation of all energy sources and locking. If the machine has been switched
off by, a protective device, it must not be switched on again until the error has been corrected.
The electrical system (machine including protective devices and operating position) must always be grounded.
Refer pump GA drawing & respective manuals of motor/electrical control panel for connecting earthing suitable
as per motor rating and relevant regulations and standards including proper earthing lug size and fasteners.. If
there is a possibility that people can come into contact with the machine and the pumped liquid (e.g. at
construction sites), the grounded connection must be additionally equipped with a fault current protection
device.

Electrical work (connection, maintenance and repair work) may only, be


carried out by a qualified electrician. Any unused wires must be disconnected! The cable ends must never be immersed in the pumped
liquid!
Refer instruction manual of respective equipments like motor, panels
etc for safety instruction to be followed when connecting these
equipments to the pump and power supply and for the operation.

2.9

Operation with different pumped fluids

The pump supplied is intended for specific fluid. Refer pump data sheet and order confirmation. For any change
in pumped fluid refer M&P before hand.

2.10

Sound pressure

Depending on the size and capacity (kW), the products produce a sound pressure of approximately 75dB (A) to
110dB (A).
The actual sound pressure, however, depends on several factors. These include, for example, the installation
type, fastening of accessories and pipeline, operating site condition, background noise, etc.
Once the product has been installed, we recommend that the operator makes additional measurements under
all operating conditions.

In accordance with the laws in effect, guidelines, standards and regulations, ear protection must be worn if the sound pressure is greater
than 85dB (A). The operator is responsible for ensuring that this is
observed!
For actual values on sound level & vibration at the time of pump testing
on test bed refer to the Pump performance test certificate submitted
along with other certificates.

MPPL/IM/VP/2006/0

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Mather + Platt
2.11

General Safety Information

Prime mover selection

When prime mover is in M&Ps scope of supply, Electrical motors/diesel engines/steam turbines etc. are
selected mutually with the customer/end user depending upon his requirements & absorbed power by the pump
at duty point. Prime mover will be with CE marking.
When pump is supplied along with prime mover and/or with control panel when in M&Ps scope, manufacturers
instruction manual for respective equipment will be provided to the customer/end user along with the pump
instruction manual.

2.12

Warranty

This chapter contains the general information on the warranty. Contractual agreements have the highest
priority and are not superseded by the information in this chapter!
The manufacturer is obliged to correct any defects found in the products it sells, provided that the following
requirements have been fulfilled:

General information
-

The materials used caused the defects or the way the product was manufactured or designed.

The defects were reported in writing immediately to the manufacturer within the agreed warranty
period.

The product was used only as prescribed.

All safety and control devices were connected and inspected by authorized personnel.

Warranty period
If no other provisions have been made, the warranty period applies to the first 12 months from the date of
delivery / installation or 18 months from the date of dispatch from the works whichever is earlier. For details
refer the warranty certificate provided. Other agreements must be made in writing in the order confirmation.

Spare parts, add-ons and conversions


Only original spare parts as supplied by the manufacturer may be used for repairs, replacements, add-ons and
conversions. Only these parts guarantee a long working life and the highest level of safety. These parts have
been specially designed for our products. Self-made add-ons and conversions or the use of non-original spare
parts can seriously damage the product and/or injure personnel.

Maintenance
The prescribed maintenance and inspection work should be carried out regularly. This work may only, be
carried out by, qualified, trained and authorized personnel. The maintenance and inspection log supplied
must be properly updated. This enables you to monitor the status of inspections and maintenance work. Quick
repairs not listed in this operation and maintenance manual and all types of repair work may only be performed
by the manufacturer and its authorized service centers.

List of machine operators


The machine operator list must be filled out completely by signing this list, all persons working on or with the
product confirms that they have received, read and understood this operating & maintenance manual.

Damage to the product


Damage as well as malfunctions that endanger safety must be eliminated immediately by, authorized
personnel. The product should only be operated if it is in proper working order. During the agreed warranty
period, the product may only be repaired by, the manufacturer or an authorized service workshop. The
manufacturer reserves the right to recall the damaged product to the factory for inspection.
MPPL/IM/VP/2006/0

2-5

Mather + Platt

General Safety Information


Exclusion from liability

No liability will be assumed for product damage if one or more of the following points apply:
-

Incorrect design on our part due to faulty and/or incorrect information provided by the customer.

Operation of product different/beyond the parameters specified in purchase order/approved data


sheet.

Non-compliance with the safety instructions, the regulations and the requirements
operating and maintenance manual.

Improper installation & pipe work.

Faulty construction site and/or construction work.

Chemical, electrochemical and electrical influences.

Improper assembly/dismantling.

Improper maintenance.

Unqualified repairs.

Wear.

and this

This means the manufacturers liability excludes all liability for personal, material or financial injury.

2.13

REMARKS

To avoid ambiguity in the use of the word `replace' the words `replace' and
renew' are used in this manual in the following context:
Replace - To put back, in its existing state, a part or component that has
previously been removed.
Renew

- To substitute a new part of component for a worn or damaged one.

MPPL/IM/VP/2006/0

2-6

Mather + Platt

Product description

Product description

3.1

General product information

The machine is manufactured with great care and is subject to constant quality controls. Trouble-free operation
is guaranteed if it is installed and maintained correctly.

3.2

Proper use and fields of application

Vertical pumps are used in cooling tower condensate circulation, condensate extraction for thermal and nuclear
power plants, irrigation & water supply, fire fighting, general industrial water supply and low NPSH
requirements etc.

Precise information about this can be found on the order confirmation


and on the pump data sheet.

3.3

Conditions of use
All vertical pump models are for use in non-hazardous area.
For precise details about the model of the pump and design operating
conditions, see Pump nameplate, motor nameplate & panel name plate
when in supply scope and the pump data sheet. Do not operate the
pump away from specified operating range. Operating beyond duty
point may not pose a risk to the operator but will reduce the efficiency
of the pump or damage the pump itself. Operation more than 5 minutes
at close valve condition is not recommended. For hot liquids this is not
recommended at all.
A dry run must be avoided at all cost. Ensure that always site NPSH-A is
more than NPSH-R. Minimum submergence should be sufficient for
vortices free operation.

MPPL/IM/VP/2006/0

3-1

Mather + Platt

Product description
3.4

Construction

3.4.1

General description

The pump is a vertical end suction pump. The unit is divided into three basic elements:
a.
b.
c.

The pumping stages including bowl assembly.


Intermediate piping works and extension shafting.
Delivery bend & motor stool assembly.

The pumping stages are freely suspended from the delivery bend by intermediate pipe-work, depending upon
the site conditions. In surface discharge installation, the delivery bend & motor stool are placed above floor
level. The thrust bearing situated in the motor stool assembly supports the static-weight of the rotating
assembly and also absorbs any axial thrust that is developed within the unit during operation.
In sub-surface installation, delivery branch is located below operating floor. When expansion joint is installed
between pump delivery branch and discharge line, a thrust block is provided opposite to delivery branch to take
hydraulic thrust caused by delivery bend.
When the pump is in operation fluid is directed by a suction bell-mouth into the impeller inlet. Rotation of the
impeller vanes imparts energy to the fluid. This kinetic energy is converted into pressure energy as the liquid
flows through diffuser vanes.

3.4.2

Detailed description

3.4.2.1 Suction bell mouth


The suction bell mouth forms the inlet to the pump assembly and it is secured to the pump casing by studs and
nuts. The bell mouth is designed specifically to stabilize and direct the flow of the incoming fluid into the eye of
the impeller.

3.4.2.2 Diffuser casing


The pump casing and diffuser are combined into a single unit and are in the form of a semispherical casting,
which also incorporates delivery guide vanes. The guide vanes structure is centrally
disposed within the
casting and is bored to accommodate a bearing bush for the pump shaft. A spigoted flange is provided on
the casting for the purpose of connecting it to rising main pipe. O-ring is provided between two flanges.
When the head is not obtained by single stage, multistage pump is used. Number of Diffuser Casings &
impellers are assembled in series to obtain desired head.

3.4.2.3 Rising main pipe


Rising main pipes have flanged connections. Spigot joints are provided in flanges to ensure concentricity. The
top rising column is connected to delivery bend.

3.4.2.4 Rotating element


The rotating element consists of the pump shaft, impellers, intermediate extension shafting and solid muff
couplings.
Impellers are keyed to the pump shaft and axially located by pump bearing Sleeve. The complete impeller and
sleeve assembly is end tightened against step on the shaft by an impeller nose cap which is locked in position
by a locking screw. Intermediate shafts are coupled by solid muff coupling.

3.4.2.5 Impellers
Impellers may be of axial flow or mixed flow (open or close). Refer specifications / datasheet / General
arrangement drawing / cross sectional drawing for details. The impeller varies in size according to capacity of
the individual pump. Close type impellers are hydraulically balanced to reduce axial thrust.

MPPL/IM/VP/2006/0

3-2

Mather + Platt

Product description

3.4.2.6 Neck rings / throat liner


The impellers necks are accurately machined to provide a close running fit in the neck rings that surround
them. The close clearance between the neck rings and impeller necks minimize the leakage of fluid from the
high-pressure areas to the low-pressure areas of the pump.
To enable this close clearance to be restored periodically as wear takes place, the neck rings are renewable.
Semi-open impeller has 0.8 to 1.0 mm gap between throat liner and impeller vanes.

3.4.2.7 Delivery bend / Delivery tee


Delivery bend, which forms discharge branch of the pump unit is a fabricated component and situated above
operating floor level. The bottom flange of the delivery bend supports rising main pipe and pump bowl
assembly. It accommodates the stuffing box and split gland assembly for sealing the top shaft.
In sub-surface discharge configuration, delivery tee is located below operating floor. If space permits, delivery
tee accommodates the stuffing box and split gland assembly for sealing the top shaft. Alternatively stuffing box
is provided in bottom flange of motor stool. Thrust block, if provided, is located opposite to delivery branch.
Tapping is provided in outlet flange of delivery pipe to accommodate pressure gauge.

Refer general arrangement drawing for the position of delivery branch,


stuffing box and thrust block.
3.4.2.8 Motor stool
It is a fabricated structure. In surface discharge installation, bottom flange of motor stool rests on the top of
delivery bend. In sub-surface discharge configuration, motor stool rests on sole plate.
The top flange of motor stool supports the drive motor. Pump thrust bearing assembly, non-reverse ratchet
assembly (when provided) and coupling between pump and motor are mounted in the motor stool. Openings
are provided to access the parts housed in motor stool.
When hollow shaft motor is provided with combined thrust bearing for pump and motor, motor stool and
coupling to connect pump - motor shafts are not provided.

Refer cross sectional drawing for the configuration of motor stool.


3.4.2.9 Thrust bearing assembly
It consists of thrust bearing to take up axial and radial thrust. Small verticals pumps have grease lubricated
bearings while medium to large verticals have oil lubricated bearings. Pump may have white metal lined bearing
as customer requirement. Refer Fig. 7, which is a general indicative figure of the assembly.

Refer to general arrangement drawing/cross sectional drawing /


thrust-bearing assembly drawing supplied along with the pump for
exact configuration and details.
3.4.2.10 Non reverse ratchet (Optional)
Non Reverse Ratchet is mechanical device to prevent the reverse rotation of pump motor during flow reversal
condition. It consists of a fixed ratchet and rotating pins as shown in typical cross sectional drawing.
The ratchet plate teeth allow pins to slide up during normal direction of rotation. However during reversal the
pins engage with the teeth and prevent reverse rotation.

MPPL/IM/VP/2006/0

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Mather + Platt

Transport & storage

Lifting, Transport and storage

4.1

Handling

In order to prevent damage or serious injury when lifting & transporting the product, the following points must
be observed:
-

Lifting transport work may only be carried out by, qualified personnel. The safety instructions must
be followed at all times.

Only suitable lifting gear and load carrying equipment with valid test certificates and adequate lifting
capacity for the loads involved (such as belts/wire ropes/slings) should be used for lifting &
transporting the product. If chains are used, they should be secured against slipping along with
protective cover to prevent damage to the product, paint and/or injury to personnel.

See also "General Safety Information", section 2.

Fig. 1
Lifting diagram
While handling care should be taken so that pump flanges, shaft
extensions, suction bell mouth etc. are not damaged
Safe working load of wire ropes reduces with increase in included angle
of wire ropes.
Reduction of lifting Capacity with increase in
included angle between legs
Included
angle
Lifting
Capacity

MPPL/IM/VP/2006/0

0
100%

30

60

90

120

95%

75%

70%

50%

4-1

Mather + Platt

Transport & storage


4.2

Delivery

On arrival, the delivered items must be inspected for damage and a check made that all parts are present. If
any parts are damaged or missing, the transport company or the manufacturer must be informed on the day of
delivery. Any claim made at a later date will be deemed invalid. Damage to parts must be noted on the delivery
or freight documentation.

4.3

Transport

Only the appropriate and approved fastening devices, transportation means and lifting equipment may be used.
These must have sufficient load bearing capacity to ensure that the product can be transported safely. The
product is delivered by the manufacturer / shipping agency in suitable packaging. This normally precludes the
possibility of damage occurring during transport and storage. The packaging should be stored in a safe place if
the location used is changed frequently.

4.4

Storage

Short-term storage
The equipments as shipped have adequate protection for short-term storage in a covered, dry and ventilated
location at the job site prior to installation.

Long-term storage
If the equipment will be subject to extended storage condition prior to installation, then the manufacturer must
be informed about storage duration, so that special protection can be recommended.
The following should be taken into consideration for storage
-

Place the product on firm foundation and secure it against falling. HSC pumps, End suction pumps
and multistage pumps should be stored horizontally and Vertical pump assemblies vertically.

Never put down or pick up the product when it is not secured. Bending
the product should be avoided at all costs. It can cause major damage
to the product and/or serious injury to persons.
-

Any suction or delivery pressure connections on products should be closed tightly before storage to
prevent impurities.

The machine must be protected from direct sunlight, heat, dust, and frost.

The rotors or propellers must be turned at regular intervals. This prevents the bearing from locking
and the film of lubricant on the mechanical shaft seal is renewed.

If product is to be stored for a longer period, contact M&P for


preservation measures to be taken.

4.5

Returning to the supplier

Products, which are delivered to the plant, must be clean and correctly packaged.
In this context, clean means that impurities have been removed and decontaminated if it has been used with
materials, which are hazardous to health.
The packaging must protect the product against damage.
If you should have any questions please contact M&P.

Products, which are not suitably packaged on delivery, are no longer


covered by guarantee!

MPPL/IM/VP/2006/0

4-2

Mather + Platt
5

Installation

Installation

In order to prevent damage to the machine or serious injury during installation the following points must be
observed:

5.1

Installation work assembly and installation of the machine may only be carried out by, qualified
persons. Any errors in fitting or refitting will not pose risks to persons but pump will malfunction or
performance of pump will be affected or internals will be affected. The safety instructions must be
followed at all times.

Before any installation work is carried out, the machine should be inspected for damage that may
have occurred during handling, transport & storage.

See also General Safety information, Section 2.

Introduction

This section provides instructions on the recommended methods of installing vertically suspended mixed flow
pumps. Careful attention must be paid to the customer and contractors installation drawings during the
installation procedures to ensure that the pumping set is accurately positioned on the correct datum levels.
The installation of the pump set may be divided into five stages, namely preparing the foundations, installing
the pump, installing the drive unit, alignment, connecting the pipe work and coupling the drive.

5.2

Requirements for the operating area


Pumping machinery should have adequate access and working room for
maintenance operations. Adequate overhead space for lifting devices
and working clearance must be provided.

5.3

Cleaning

Clean any anticorrosive protection from the mounting surfaces using a rag moistened with white spirit.

Do not use any chlorinated solvents such as carbon tetrachloride and


trichloroethylene. Bearings, shafts etc should be cleaned and coated
with lubricant till such time they are actually taken for installation.

MPPL/IM/VP/2006/0

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Mather + Platt

Installation
5.4

Foundations

Installation of the pump cannot be done in continuous sequence because two time periods are required to
permit to grout to set. The first period occurs after soleplate has been leveled and foundation bolts half
grouted. The second time lag occurs after full grouting of soleplate, which is after final alignment of pump and
driving unit after piping.
A suitable foundation for the pump must be prepared with pockets to accommodate the foundation bolts. The
strength of the foundations must be adequate for the static & dynamic loads imposed and depend upon the
local soil conditions.
The top surface over which the soleplate rests must be left rough to assist in keying of the final grout and
sufficient allowance must be made for the thickness of the steel packing and leveling shims beneath the
soleplate, the requirement being approximately 25 mm.
Foundation work is usually completed before the pump arrives on site but it is mentioned here because it is
logical to begin the installation procedure sequentially.

Indicative drawing for foundation.


For details & dimensions refer general assembly drawing.
Fig. 2

MPPL/IM/VP/2006/0

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Mather + Platt
5.5

Installation

Soleplate & pump installation

5.5.1 Soleplate installation


The sole plate has machined surfaces on both top and bottom; therefore no distortion of mounting plate can be
caused due to weight of the unit when supported on a leveled surface of sole plate. To avoid the distortion of
sole plate if mounted directly on the uneven surface of foundation, initially the top surface of foundation over
which the sole plate rests must be left rough to assist in keying the final grout, after the sole has been leveled
by positioning steel packer plates at suitable intervals on the foundation surface as described in 5.5.2. Ensure
that the surface beneath each packing plate is solid by crushing any protrusion or alternatively each packer
plate may be placed on a thin screen of cement.

5.5.2 Leveling of sole plate


5.5.2.1

Provide suitable packer plate (25 mm to 30 mm thick) or taper wedges on the foundation one each
of either side of foundation bolt and in-between around 250 mm center to center. It is advisable to
provide thin layer of cement below the packer plate.

5.5.2.2

Lift the soleplate and lower it on the foundation. Insert the foundation bolts through the holes in the
soleplate and screw a nut on to each bolt until the bolt protrudes through the nut by a length, which
is sufficient to accommodate a lock nut.

5.5.2.3

Level the soleplate as follows.

a.

Use I beam straight edge and an engineers master level (with accuracy of 0.02 mm / meter) for
leveling the soleplate. I-beam should rest on the machined surfaces of the soleplate.

These machined surfaces where level is being checked must be clean


and free from paint, burrs etc.
b.

Adjust the level of the soleplate by inserting shims between the soleplate and the packer plate until
the soleplate is leveled. and supported on all the packing blocks at the height as shown in the
general arrangement drawing. For checking the levels & straightness, I-beam type straight edge
should be used extensively in conjunctions with engineers master level. Level should be achieved
within 0.05 mm per 250 mm. Also ensure that elevation of bedplate is adjusted suitably as shown in
General Arrangement Drawing.

5.5.2.4

When the soleplate is leveled, grout the foundation bolts only. Care should be taken so as not to
disturb the verticality of foundation bolts. For grouting use rich mix of 1: 1:2 of cement, sand and
gravel below 12 mm. Alternatively quick setting grout mix can be used.

5.5.2.5

When the grout has set, gently but firmly tighten the foundation bolts. Care must be taken not to
distort the soleplate or loosen the foundation bolts in the grout by excessive tightening.

5.5.2.6

Carefully re-check the level of the soleplate and make adjustments that are necessary by fine
shimming. Ensure that the sole plate is leveled, as per the site datum level, various centerlines etc.

5.5.3 Installation/assembly of pump


Depending upon column length of the pump it may not be possible to dispatch the pump in fully assembled
condition and pump needs to be assembled at site in sequential manner. For installation and assembly purpose
suitable beams are required to be placed across the opening over the sole plate.
Following sequence should be followed while erection of pump:
5.5.3.1

Lower the pump assembly, comprising of suction bell mouth with suction strainer, casing & diffuser
and rising main pipe (bottom) in the sump with the help of sling and EOT crane. Support the
assembly on Beams placed across the opening over the soleplate, (If necessary supporting channels
must be held together with help of tie rods).

5.5.3.2

Couple first intermediate shafts with pump shaft by solid muff coupling.

Where SS components are fitted, contact surfaces should be dusted


with molybdenum disulphide paste to prevent galling.
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Mather + Platt

Installation
5.5.3.3

Lift bottom shaft protection tube, if provided, and lower on to the pump assembly. Lift first
intermediate rising main pipe and lower on to the top flange of bottom rising main pipe. Ensure that
the O rings have been placed between the flanges. Insert screws & nuts to tighten them.

5.5.3.4

Take first intermediate bearing bracket and lower it on to first intermediate shaft till it is located in
groove of top flange of bottom rising main pipe. Ensure that 'O' ring are fitted on both sides of
bearing bracket.

5.5.3.5

Slowly raise the whole assembly slightly, comprising of the bottom rising main pipe and pump
assembly, remove channels and lower the assembly further into the sump till supporting flanges or
lugs of bottom pipe are rested on channels across the sole plate opening.

5.5.3.6

Assemble 2nd intermediate shaft to 1st intermediate shaft through muff coupling.

5.5.3.7

Take 2nd rising main pipe & lower its slowly with the help of slings and crane on the bottom rising
main pipe. Ensure that intermediate bearing bracket is located correctly.
Insert bolts and nuts and tighten them properly and evenly.

Rubber O ring should be inserted on both sides of intermediate bearing


bracket.
5.5.3.8

Assembly of remaining shaft tubes, if provided, rising main pipes and intermediate shaft is done in
same way as explained in seq. earlier.

5.5.3.9

Lift delivery bend and lower on to the top flange of rising main pipe. Tighten the fasteners. Care
must be taken to have a O ring between two flanges.
Raise entire assembly, remove temporary support beams and lower down till bottom flange of
delivery bend rests on sole plate & fix it with soleplate.
Lift delivery bend and lower on to the top flange of rising main pipe. Tighten the fasteners. Care
must be taken to have a O ring between two flanges.
Raise entire assembly, remove temporary support beams and lower down till bottom flange of
delivery bend rests on sole plate & fix it with soleplate.

5.5.3.10

Stuffing box assembly: The packing supplied with pumps by Mather & Platt Ltd. is packed in
separate box and should be fitted at site as under:

a.

The stuffing box and gland sleeve should be thoroughly cleaned and full entry of gland into stuffing
box must be checked.

b.

Insert three rings of gland packing into stuffing box.

c.

Check if each ring of packing length passes round the shaft and meets end to end, theends being cut
square.
Insert logging ring in the stuffing box.
Insert remaining three rings of gland packing into stuffing box.
The packing ring should be inserted into the stuffing box. Each ring should be pushed into position
individually using the gland.

d.

The joint of each ring must be positioned at 180 deg from joint of its neighbor.

e.

Fit gland square with stuffing box and gland nuts should be screwed up to little more than finger
tightness.
While re-packing, if packing is available in complete coil from or rope form, then the quantity
required for immediate use only should be taken. Each ring of requisite length should be cut so that
it passes once round the shaft and meets end to end, the ends being cut square.
Packing should be handled with care and it should not be allowed to pick-up dust or abrasive foreign
matter by coming into contact with floors or dirty benches. It is bad practice to hammer packing to
facilitate the insertion.

MPPL/IM/VP/2006/0

5-4

Mather + Platt
5.5.3.11

Installation

Thrust bearing assembly:


(Please refer the typical cross section of thrust bearing assembly)

Thrust Bearing:
Thrust bearing assembly provided on this pump comprises of bearing housing, cover, thrust block,
locknut, Oil lubricated spherical roller thrust bearing or Grease lubricated deep groove ball bearing
as Guide bearing, angular contact ball bearing as Thrust bearing. The outer race of bearing is fitted
in the housing where as the inner race is fitted on the thrust block.
For grease lubricated bearing the top surface of thrust block is provided with 6 or 8 equi-spaced
holes into which the locking screw can be engaged. The rotating element is set at desired position by
engaging the locking screw in the nearest hole, after rotating the lock nut through requisite number
of turns.
This thrust bearing assembly requires very little maintenance other than occasional feeding up of
lubricating Oil/Grease. The thrust bearing assembly should be completely dismantled, cleaned and
reassembled after 8000 hours approximately (Grease lubricated bearings) and 2000 hrs
approximately or as required by site conditions (Oil lubricated bearings).
For oil-lubricated bearings when level of oil goes down below required level, the fresh lubricating oil
should be filled up to the required quantity.
For Grease lubricated bearings the fresh lubricating grease should be filled up to the required
quantity with help of grease gun after every 2000 hrs. running of pump. Before greasing, the grease
drain plug should be opened so that while filling the fresh grease, the deteriorated grease drains out.
During assembly of thrust bearing (oil lubricated) follow the following procedure:
Fit oil retaining bush to bearing housing.
Fit inner race of thrust bearing on thrust block & outer race in bearing housing.
Fit bearing housing to motor stool.
Fit thrust block on top shaft so that inside diameter of thrust bearing fits on thrust block.
Fit bearing cover to bearing housing.

During tightening of the lock nut, measure the total float of the rotating
element and maintain it at half position from bottom for closed type
impeller or to get 0.8 to 1.0 mm front clearance for semi-open impeller.
Lock the lock nut on thrust block with the help of locking screw.
5.5.3.12

Fit mounting plate and then ratchet plate at their respective position.

5.5.3.13

Fit pump half coupling on top shaft. An adjusting ring is provided below pump half coupling. This
ring can be machined to maintain the gap of 5 mm 2 mm between pump half and motor half
coupling.

5.5.3.14

Place the motor on top flange of motor stool and complete the alignment as given in 5.6.

5.6

Alignment of pump and driving units:

The following procedures outline recommended practice given in BS-3170 in 1972 (Appendix A) for checking
shaft alignment. This method is independent of the truth of the coupling or shaft and is therefore not affected
by canted coupling faces or eccentricity of the outside diameter of the coupling. Before commencing the
alignment, rotate each shaft independently to check that the bearings run freely and that the shaft is true to
0.1mm or better. Check that no damage can be caused when the shaft of the driven unit is turned. Coupling
should be loosely coupled and the halves must be free to move relative to each other, otherwise gauge
Indicators can be incorrect. Where, tightly fitting pins or spring prevent loose coupling, the springs or pins
should be removed, a line scribed across both half couplings and readings taken only when the two marks are
aligned.

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Mather + Platt

Installation

Before proceeding for alignment please ensure


a. Bearings are properly lubricated.
b.

Pumps with stainless steel internals shaft should be rotated only


after taking pump liquid inside the casing. Any dry rotation may
cause severe damages to pump internals.

5.6.1 Radial alignment


Clamp a dial gauge on one of the couplings or to the shaft as shown in figure 4. with the plunger resting on the
rim of the other half coupling. Set the dial zero. Rotate the coupling and note the reading at each quarter
revolution. Any variation in the readings indicates the deviation from alignment and the position of one of the
units must be adjusted until the readings at each quarter revolution are identical or within the tolerances given
below.

If fitment of dial gauge is not feasible use small straight edge across the two coupling
half flanges.

5.6.2 Angular alignment


Angular alignment for vertical pumps is totally dependent on the accuracy of leveling of sole plate and motor
stool, since any adjustment at later stage is practically not feasible. How ever one can check the angular
alignment as follows
After isolating the driven unit from its power supply, clamp two dial indicators are dramatically opposite points
on one half coupling or to the shaft behind it with the plunger resting on the back of the other half coupling as
shown in figure3. Rotate the coupling unit the gauges are in line vertically and set the dial to read zero. Rotate
the coupling by 180 and record the readings on each gauge. The readings should be identical, though not
necessarily zero. Either positive or negative readings are acceptable provided they are equally positive or
negative. Adjust the position of one of the units if necessary. Rotate the couplings unit the gauges are in the
line horizontally and adjust the dial to zero. Repeat the operation outlined above by rotating the coupling by
180.
In case where fitment of dial gauge is not feasible check gap between two coupling half with the help of filler
gauge.

5.6.3 Alignment tolerances


a
b
c

Pump speed
< 1000 rpm
> 1000 rpm to 1800 rpm
1800 rpm to 3000 rpm

Angular alignment
0.15 mm TIR
0.1 mm TIR
0.1 mm TIR

Radial alignment
0.15 mm TIR
0.15 mm TIR
0.1 mm TIR

TIR- Total indicated reading


The above tolerances are general guidelines since it may very with
different types of coupling and its manufacturers standards. However it
is recommended that for higher speeds greater degree of accuracy must
be observed.
All the alignments (angular as well as radial) have to be carried out by
using 3 dial indicators, simultaneously.

MPPL/IM/VP/2006/0

5-6

Mather + Platt

Installation

Couplings

Fig. 2

Fig. 3

MPPL/IM/VP/2006/0

5-7

Mather + Platt

Installation
5.7

Pipe work

No stress must be imposed on the pump casing by the pipe work; either by the weight of the pipes or by the
tightening of badly fitting pipes. Experience has showed that such stress can seriously affect the alignment of
the pump unit. All pipe worked attached to the pump must be fully supported and the mating faces of the pipe
flanges must be parallel and all bolt holes coinciding with each other. It is important therefore that alignment of
the pump and motor should be re-checked after the pipes are finally fitted. Resetting or supporting the pipes
must correct any deviations in the alignment.

Fig. 4

5.7.1 Suction condition


Intake design
Pump intake by way of sump should supply evenly distributed vortices free flow with adequate submergence of
pump.
Use of strainer
If strainer is used it should have opening area which is three times the area of the upstream pipe. Differential
pressure gauge / switch should be fitted across strainer to monitor any chocking and resultant pressure drop. It
is advisable to connect this to operation logic of pump.
Sump Design
The design of sump has great influence on trouble free & smooth operation of pump. The special attention must
be paid to sump design When two or more no. of pumps are operated in combinations of working +
standby conditions. It is recommended that when space & site constraints do not allow the suction sump design
as per recommendation of HIS the suction sump design should be verified by a model study.
Whenever model study has been carried out previously for optimizing
regarding corrective structures should be fully implemented.

MPPL/IM/VP/2006/0

5-8

sump

design, its

recommendation

Mather + Platt

Installation

5.7.2 Delivery conditions


A suitable sluice valve should be fitted in the delivery pipe as near to
the pump as possible, along with non-return valve. Pump casings have
sometimes been cracked by pressure surges imposed on them through
the absence a non-return valve. It is often an advantage to provide
these valves with by-pass connections, although these are not always
required.

5.7.3 Stuffing box packing


Pumps are dispatched from our Works with the stuffing boxes unpacked; otherwise, packing will be aged. The
packing is packed with greaseproof paper and dispatched with the pump. The softest possible packing i.e.
plaited cotton impregnated with oil and colloidal graphite is recommended for most duties. Required number of
lengths of packing should be cut off so that each length will pass once round the shaft sleeve line and meet to
end. The ends of packing must be cut square. After cleaning the stuffing box and shaft sleeves the packing
should be inserted into the stuffing box. Each ring should be pushed into position individually using the glands
joint of each ring must be positioned 180 from joints of its neighbor. if a logging ring is included in them
arrangement should be inserted into the stuffing box at the appropriate time during the packing sequence so
that it is aligned with the cooling water connection. The gland should now be fitted square with the pump
casing and the nut should be screwed up to little more than finger tightness.

5.8

Use of diesel engine as prime mover


The location of installation of installation should have facility for
disposal of exhaust gases and supply of continuous air. Pump house
should have acoustic design.

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6

Start-up

6.1

Introduction

Start-up

This chapter covers the commissioning and operation of pump only. For commissioning of motor, engine,
turbine & electrical panels respective instruction manuals should be referred.
This procedure also should be adapted after each major overhaul.
See also General Safety information, Section 2.

6.2

Pipe work flushing

Before
the pumps are brought into service, either on
initial commissioning or on re-commissioning after
overhaul, the pipe work associated with the pumps must be flushed through. This will clear deposits or scales
which may have accumulated in the pipes, and which could damage the internal components of the pumps.

6.3

Cleaning of bearings

Where possible, especially if the unit has been in store for a long period before commissioning, the bearings
should be cleaned and flushed out with clean white spirit or good quality paraffin. Waste should not be used for
this purpose, as particles of foreign matter may be left behind which would cause damage when the bearing is
in service. Bearings should be then filled with recommended grade and quality of fresh lubricant to the level.
Refer list of lubricants at the end of this manual.
Ball and roller bearings are given an initial charge of grease before leaving Mather & Platt Works and do not
require any attention beyond the normal greasing routine before the first servicing period. Only greases
selected from the table at the end of the manual or their equivalent should be used. Bearings should never be
over greased.

6.4

Direction of rotation

Disconnect the drive coupling and run the motor to check its direction of rotation. A directional arrow is
provided on the pump unit.

6.5

Availability of liquid

Efficient operation of the pump depends upon fine running clearance that is lubricated by the pumped fluid.
Sufficient fluid must be available to ensure that the pump is flooded at all times to prevent seizure of the
internal components. Wherever external flushing/lubrication is provided it should be available before starting
the pump.
If on starting, a pump fails to generate at least its rated delivery head, as indicated on the pump nameplate, it
must be stopped immediately, the cause ascertained and rectified, before re-starting.
Ensure that minimum submergence is available as recommended.
Open all ancillary inlet and outlet isolating valves such as, bearing cooling systems, gland sealing, or cooling
systems, air vents, leak-off connections etc.
The efficient operation of a centrifugal pump depends upon fine running clearances, which are lubricated by the
pumped liquid. Any attempt to run the pump dry or partially full may result in seizure of the rotating internal
components. These pumps must therefore be properly
primed before starting, with venting of all the air,
gases, vapor etc.

Any attempt to run the pump dry or partially full may result in seizure of
the rotating internal components.

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Start-up
6.6

Pre-starting checks

6.6.1

Ensure that sufficient fluid is available at the pump suction for satisfactory operation of the pump.
Efficient operation of the pump depends upon the running clearance, which are lubricated by
pumped liquid. Any attempt to run the pumps dry or partially full will result in seizure of internal
rotating components.

6.6.2

Normally centrifugal pumps are started with delivery valve closed. How ever for mixed flow as well
as axial flow pumps where power consumption at closed valve is higher it is recommended to start
the pump with delivery valve in suitably open / throttle condition. It is also advisable to provide non
return valve in the delivery line.

6.6.3

Ensure that bearings have been filled with proper grade of lubricant.

6.6.4

Check that there is no blockage in the strainer at the end of pump.

6.6.5

Check for free rotation of the unit when coupled.

6.6.6

Check that delivery pressure gauges are connected. Test and make available any alarm, signals,
interlock systems and any of the protective devices incorporated in the auxiliary and main pumping
control system.

6.6.7

Ensure that all electrical checks on motor, relay setting in panel etc have been carried out in
accordance with the instructions of motor manufacturer.

6.6.8

Ensure that stuffing box sealing water seal connection is provided as shown in GA Drawing.

Refer checklist A.6 for recording the data.

6.7

Normal Starting checks

6.7.1

When all the foregoing pre-start checks are satisfactory, depress the appropriate `START' button on
the control panel and run the pump at its rated speed.

6.7.2

Check that the pump is rotating in the correct direction. This is indicated by a direction arrow on the
motor stool / delivery bend.

6.7.3

Check the ammeter reading to ensure that the motor is not being

6.7.4

Check that the pumping unit is generating not less than its rated delivery pressure indicated in the
data sheet/name plate.

overloaded.

If the pumping unit fails to generate at least its rated delivery pressure
it must be stopped immediately, the cause ascertained, the fault
rectified before restarting.
6.7.5

Ensure that the stuffing box is not overheating and that there is slight leakage from the gland. There
may be at first a tendency for the stuffing boxes to run warm because of the high viscosity lubricant
in the packing. During the first few minutes of running with new packing, a small quantity of very
viscous fluid will be extruded, but the flow should cease when the packing has settled down.

6.7.6

Check that the bearing is not overheating. The ideal running temperature of bearings is 40 C to 60
C for ball bearings and 40 C to 55 C for bush bearings. This ideal figure may be extended
provided the temperature is steady and not rising, but on no occasion should the temperature
exceed 82 C for all bearings and 75 C for bush bearings. Overheating of ball and roller bearings is
frequently caused by over packing them with grease. An Increase in the running temperature after
adding grease is normal, but the temperature should return to its previous level, as the grease is
distributed.

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Start-up

If the bearings are overheating its cause should be investigated


immediately.
6.7.7

If the foregoing checks are satisfactory, open the delivery valve slowly and bring the pump gradually
up-to its rated parameters based on pressure gauge and ammeter readings. Unless the pump is
fitted with a special leak-off device, it should not be run for a long period against a closed delivery
valve.

6.7.8

Check that the driving unit is not being overloaded during valve

opening.

Overloading may occur if the pump is discharging into an empty system


when the delivery head will be temporarily lower than that for which
the pump is designed. Careful regulation of the discharge valve until the
system is fully charged will prevent this.
6.7.9

Check vibration of pump set and ensure that vibration level is within limits specified in Hydraulic
Institute Standard of America. Check that noise level is within stipulated limits.

6.7.10

Check the pump and motor for overheating, excessive vibration and noise. Report any faults. During
first commissioning, the pumps may be run for 8 hours trial operation and all the parameters like
delivery pressure, current, bearing temperature, etc. Be recorded periodically.

6.8

Running Checks:

Once the pump is started and duty conditions are set, operator intervention is not required except running
checks and unless pump is to be stopped.
Make the following checks at regular intervals. It is recommended that they be made at every change of shift.
6.8.1

Check the suction and discharge pressure gauge for


normal operating pressure, if there is
significant drop in the suction or discharge pressure the pump may have lost its supply. In the event
of this fault occurring, the pump must be stopped immediately and the cause of liquid loss
eliminated.

6.8.2

Check the stuffing box assembly for overheating.

6.9

Normal Shutdown

6.9.1

Depress the appropriate STOP button on the control panel.

6.9.2

When the pump has come to rest, close the pump delivery valve.

6.9.3

Isolate any ancillary supplies.

6.10

Emergency Shutdown

In the event of any malfunction of the equipment, trip the pump set. When the pump has come to rest, close
discharge valves, isolate the driving unit power supply & rectify the fault.

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Start-up

Fig. 5 Vertical Pump-Axial Flow


MPPL/IM/VP/2006/0

6-4

Mather + Platt

Start-up

Fig.6 Vertical Pump-Mix Flow


MPPL/IM/VP/2006/0

6-5

Mather + Platt

Start-up
Ref

Description

Qty

4130

Grease shield

3280

Key (thrust block)

3012

Lock nut

3020

Locking washer

2883

Thrust block

2882

Thrust bearing housing

2601

Angular contact ball bearing

2600

Deep groove ball bearing

2007

Ratchet holder plate

2004

Ratchet pin

2001

Ratchet bush

2000

Ratchet plate

4890

Sole Plate

4830

Flexible coupling (PH)

4680

Motor stool

4660

Flexible coupling (MH)

4600

Erection packers

4580

Coupling guard

4221

3250

Anti rotation pin (Gland


sleeve)
Key (Flexible coupling)

3032

Sleeve nut

2410

Gland packing

--

2318

Leak off bush

2311

Gland

2106

Gland sleeve

1822

Adjusting ring

1804

Top shaft

1152

Rising main pipe (Top)

1040

Delivery bend

(pairs)

Fig. 7A Typical Cross section of vertical pump (Part 1)

MPPL/IM/VP/2006/0

6-6

Mather + Platt

Start-up

4910

Suction bell mouth

4900

Suction strainer

4250-1

O ring

4250

O ring (Casing & diffuser)

3260

Key (Solid muff coupling)

3210

Key (Impeller)

2834

Intermediate brg. sleeve

2832

Impeller sleeve

2830

Bearing bush (Pump)

2801

Bearing bush
(Intermediate)

2800

2060

Intermediate bearing
bracket
Split collar

2050

Solid muff coupling

1805

Intermediate shaft

1802

Pump shaft

1704

Impeller distance piece

1651

Impeller nose cap

1504

Impeller

1181

Neck ring

1151

1150

Rising main pipe


(Intermediate)
Rising main pipe (Bottom)

1030

Casing & diffuser

Fig. 7b Typical Cross section of vertical pump (Part 2)

MPPL/IM/VP/2006/0

6-7

Mather + Platt
7

Maintenance

Maintenance

See also General Safety information, Section 2.

7.1

Routine maintenance & frequency of inspection

Vertical pump requires very little routine maintenance beyond periodic replenishing of grease/oil in the bearing
assemblies. However, serious troubles can be often avoided by regular observation and analysis of various
working parameters. Some of the routine maintenance checks for this purpose are as under:

7.1.1

To keep daily logbook records of working parameters like suction and discharge pressure, flow rate,
current drawn, bearing temperature, etc. These parameters should be recorded twice a shift. Any
sudden change should be a signal for investigation. Refer Section A.2 for Maintenance & Inspection
log.

7.1.2

Bearings will normally run at a temperature of 30C -35C above ambient temp. The ideal running
temperature of bearings is 40 C to 60 C for ball bearings / roller bearings. This ideal figure may
be extended provided the temperature is steady and not rising, but on no occasion should the
temperature exceed 82 C for all bearings. Overheating of ball and roller bearings is frequently
caused by over packing them with grease. An Increase in the running temperature after adding
grease is normal, but the temperature should return to its previous level, as the grease is
distributed.

7.1.3

Vibration & sound level readings should be taken once in a fortnight and values compared with that
of previous records.

7.1.4

Check that there is sufficient leakage from the gland packing to ensure proper cooling and
lubrication.

7.1.5

Pump bearings should be replenished with correct grade of grease/oil after every 1000 Hrs. Grease
should be changed completely after every 3000 hours or as required by site condition.
Recommended type and grade of grease is indicated in section 7.4

7.1.6

Fault Finding - Many of the common faults which occur on centrifugal pumps and which can be
diagnosed by observations are given in the chart under section 8.

In case fault can not be diagnosed, please fill up the Issue/Feed back
report no SR01-02 and send to service department at Mather & Platt
headquarters at Pune / nearby regional office or the representative
within EEA.

After a long period of service, wear will occur in parts of the pump,
necessitating
the
renewal of a few components.
Parts, those are
most likely to be affected are impeller/ wearing ring, bearing, neck
rings, bearing sleeves and bearing bushes. Logbook records will
indicate wear as gradual deterioration of performance is noticed. Once
this is known, pumps should be taken for overhaul. It is recommended
that yearly stripping & checking of wear & tear and clearances should
be done and overhauling where required.

MPPL/IM/VP/2006/0

7-1

Mather + Platt

Maintenance
7.2

Overhaul maintenance

7.2.1

General information

It is inevitable after long service that certain components will become worn. Frequently it is more economical
to renew the worn components completely, but where site machining and engineering facilities are available
most components can be restored if wear is not too far advanced.
It is impossible to be mandatory regarding the periods at which major overhauls should be undertaken as this
will be dependent upon the fluid being pumped, the site operating conditions, and the length of operational
availability required.
The determination of when major overhaul should be carried out will depend upon the performance of the
pump, i.e. its rate of deterioration by reference to instrumentation, during the current operational period. If
the hydraulic or mechanical performance has deteriorated to such an extent that no further deterioration can be
tolerated during the next operational period, wearable components should be renewed.
If related pair of components show a marked degree of wear in relation to the rest of the unit, then it may be
sufficient to renew only the heavily worn components. If the wear is uniform throughout the pump, then all
wearable components may require renewal.
Measurements should be taken and recorded of all wearable components at the first, and every subsequent
overhaul period. Reference to these records will enable an accurate assessment of the rate of wear to be made,
and a reasonably accurate forecast regarding when a particular component may require renewal can be made.
Information regarding original design dimensions and clearances is furnished in data sheet. Any other
information if needed can be obtained on application from Service
Department, Mather & Platt Pumps Ltd.,
Chinchwad, Pune 19 India. Such request must quote nameplate number and type of the pump in question.
The parts most likely to be affected are:
1.
2.
3.
4.
5.

Impeller / wearing rings.


Neck Rings.
Bearing bush.
Bearing sleeves.
Bearings.

Before commencing dismantling operations, ensure that the following tools and tackles are available
1.

A crane / chain pulley block suitable for handling the weight of pumping unit.

2.

A selection of ring and open-ended spanners in British, American, and Metric sizes.

3.

Eye-bolts in British and Metric sizes.

4.

Cotton rope, wire rope and slings.

5.

Hardwood and metal packing blocks.

6.

Miscellaneous tools including a set of Allen keys, drills, pin

7.

Extractor / puller for bearing and coupling.

MPPL/IM/VP/2006/0

7-2

drivers, files etc.

Mather + Platt
7.2.2

Maintenance

Removing the top motor

a.

Isolate the pump motor electrically.

b.

Isolate the pump system hydraulically.

c.

Clear the area of any equipment that might impede the free lifting of the pump.

d.

Disconnect and remove the driving coupling.

e.

Disconnect the electrical supply cables from the motor terminal block.

f.

Attach slings and lifting apparatus to the motor lifting attachments.

Refer to motor instruction manual and follow the instructions for lifting
the motor.
g.

7.2.3

Remove the screws / bolts, or nuts, from the motor flange and lift the motor off the combined
delivery bend & motor stool. Support the motor on timber packing blocks with the coupling hub clear
off the ground.

Dismantling the intermediate assembly

The intermediate assembly consists of delivery bend, motor stool, rising main pipes, intermediate shafts, muff
coupling etc.
Dismantling of intermediate assembly is done in reverse sequence as explained in (Installation of pump).

Unnecessary removal of the bearings should be avoided because


removal of the bearing can damage it and cause deterioration of the
interference fit. Except where removal is necessary to give access to the
other parts, bearing should be removed only if they need close
inspection. Symptoms, which will indicate the state of bearing, are the
condition of the lubricant, the bearing running temperature, noise level
and vibration during operation.

7.2.4

Dismantling the pumping stages

Pumping stages assembly consists of suction bell mouth, diffuser casing, impeller pump shaft, rising main pipe, etc.
Dismantling is done in following sequence:
a.

Remove the fasteners securing to diffuser casing & rising main pipe and lift the rising main pipe off
the pump shaft.

b.

Dismantle the suction bell mouth from diffuser casing.

c.

Remove the locking screw and unscrew the impeller nose cap.

d.

Remove the impeller. It may be necessary to apply heat to the impeller for removal. Apply heat
uniformly from the shrouds inwards towards the hub. Before removing the impeller put a reference
mark on the shaft for ease of re-assembly at correct center position.

e.

Remove the retainer ring, bearing bush from pump bearing bracket.

MPPL/IM/VP/2006/0

7-3

Mather + Platt

Maintenance
7.2.5

Examination Of Internal Components

With the bell mouth, diffuser casing, impeller and shaft dismantled, the internal components and clearances can
be checked.

7.2.6

Neck rings / throat liner

Examine the neck rings / Throat liners, for wear or grooving. Light scoring will not be detrimental to the
hydraulic performance of the pump, but deep or profuse grooving, coupled with extensive wear will impair the
efficiency of the machine.
Use an internal micrometer to measure the bore of casing ring, taking measurements at intervals around the
circumference to check for uneven wear. A comparison between this dimension and that of the impeller neck
will indicate the amount of diametrical clearance between the casing neck ring and the impeller neck. If this
clearance is 150% or more than the original design clearance, or if the deterioration in hydraulic performances
has been such that no further deterioration can be tolerated during the next operation period,
The impeller-wearing ring to casing neck ring clearance must be restored to the original design value by fitting
small- in-bore neck rings, bored out to suit the diameter of the impeller.

7.2.7

Shaft Sleeves

The shaft sleeve should be examined to see if it is grooved, scored or generally worn. The outside diameter of
the each sleeve should be measured and a comparison made with the bore of the bush bearing through which
the sleeve passes. The amount of clearance between the two can thus be checked to determine whether or not
it is within acceptable limits.

7.2.8
a.

Impeller and wearing ring


Inspect the impeller as follows:
i.
ii.
iii.
iv.

Examine the impeller for damage.


For corrosive /erosion pitting.
Cavitations pitting.
Bent or cracked vanes, inlet and outlet vane end wear.

Any of the above may be repaired, or cause the impeller to be scrapped. Further information should be sought
from M + P, Service Dept. Chinchwad, Pune before any decision on repair work is taken.
b.

Around the eye, wearing rings protects the impeller. Examine around the eye at neck portion for
grooving in alignment with spindle axis; slight grooving is acceptable but deep or profuse grooving
must be remedied by machining the impeller by taking a polish cut on wearing ring. Spare wear
rings are supplied with excess outside diameter to facilitate machining after fitting. The wear rings
are shrink fitted on impeller neck and are screwed.

c.

To check wear, around the impeller neck, use precision instruments such as out side micrometer to
accurately measure the outside diameter. Measurements should be taken at intervals around the
circumference to check the uneven wear. Differences between the neck OD and the neck ring ID
measured will give us the clearance between the two. Clearance thus obtained should not be more
than 150% of maximum designed clearance.

7.2.9

Shaft & Keys

Shaft should be checked for the trueness, or any other mechanical damage and corrosion. If the shaft is not
true within 0.1 mm TIR, it should be replaced / repaired. Examine the shaft keys and key ways. Remove
damaged or worn out keys.

MPPL/IM/VP/2006/0

7-4

Mather + Platt

Maintenance

7.2.10 Bearings
Examine the thrust and guide bearings for wear or damage.

7.2.11 Reassembly of pumping stages


a.

Before commencing to re-assemble the pump, thoroughly clean and de-burr all flanges and mating
surfaces, making sure that all traces of jointing material are removed.

b.

Fit all casing, neck rings and bearing bush in their respective positions. Slide impeller over pump
shaft and lock it against bearing bush carrier by impeller nose cap.

c.

Lift the assembly and assemble suction bell mouth.

d.

Lift rising main pipe (bottom) and pass it over pump shaft and connect with casing. Ensure that `O
ring is fitted between them.

e.

Assembly of remaining part is done exactly as described in Installation of pump.

While assembling stainless steel component, molybdenum-disulphide


paste should be applied to prevent galling / seizure and also to
facilitate easy removal in future.

7.3

Spares

We recommended the following spares for various periods normally desired by pump users:
a.
b.
c.

For two years operation: Gland packing and bearings.


For three years operation: Gland packing, bearings, neck rings, Gland sleeve, intermediate bearing
sleeves.
For five years operation: One rotating element.

MPPL/IM/VP/2006/0

7-5

Mather + Platt

Maintenance
7.4

Lubrication

RECOMMENDATIONS FOR CENTRIFUGAL PUMPS ARE GIVEN BELOW:

International Manufacturers
Where pumps are fitted with stainless shafts, we recommend that a colloidal graphite lubricant, e.g. Oil Dag
(Achesons) be added by an amount corresponding to 1 % to 2% by volume of lubricating oil as shown in the
schedule.
MANUFACTURER

OIL

GREASE

GREASE

Ring oil Bush type


Bearings

Ball & Roller Bearings

For use with Mechanical


Grease pumps

Alexander Duckham Co.


Ltd.

Duckhams H2

Duckhams LB 15

Duckhams, LB 10

Esso Petroleum Co. Ltd.

Thresso 47

T.S.D. 807, (U.K.)

Firmax 1

Esoo multi Purpose


Grease H. (0verseas)
Germ Lubricants Ltd

Normal shafts,

Germac Neo Astra

Germ Gun Grease

Crem Dyno bear MH


Mobile Companies
throughout the world

Mobil' DTE oil Medium

Mobil Grease No.3

Mobil Grease No 2

National Benzole Co. Ltd

TCC-2

MPG - 1

MO- 1

Power Petroleum Co. Ltd

BP Energol TH 80HB /

BP Energrease LS3

BP Energrease

BP Energol TH 100 HB

PR 3 OR LS 3

Regent Oil Co. Ltd.

Caltex Regal OIL B (R&O)

Caltex Multifac 2

Caltex Multifac 2

Shell Companies
throughout the world

Shell Tube, Oil 29 / or


Vltrea 31

Shell Nerita Grease 3 / or


Shell Alvania Grease 3

Shell Unedo Grease 1

Sternol Ltd

Deotoyl M

Stemoline LHT

Sternoline T

Valvoline Oil Co

Valvoline No 1 or No.2
Turbine Oil

Volvine No. G.LI. Ball &


Roller Bearing grease

Valvoline F.V 18

Wakefield-Dick Industrial
Oils Ltd

Perfecto Light

Spheerol A.P. 3

Spheerol A.P. 2 OR
impervia T

Perfecto Special X
Hyspin 70

MPPL/IM/VP/2006/0

7-6

Mather + Platt

Maintenance

Indian Manufacturers
MANUFACTURER

Ring oil/Bush type


Bearings

Grease

Indian Oil Corporation

Servo System-46

Servogem-2/3

Hindustan Petroleum

Enclo-46

Lithon-2/3

Bharat Petroleum

Hydral-46

Multipurpose Grease-3

Grease Lubricated Bearing

For oil Lubrication:


1.

ISO Grade 46 oil.

2.

All above oils are compatible with each other when fresh.

3.

It is unsafe to mix oil of two or more grades for use in Bearings.

4.

Number 46 is Viscosity at 40 degree centigrade in centistokes.

For Grease Lubrication:


1.

Only lithium base Grease to be used.

2.

Numbers mentioned stands for consistency.

3.

Grease of two different grades should not be used.

MPPL/IM/VP/2006/0

7-7

Mather + Platt
8

Trouble shooting

Trouble shooting Chart

Sl
No

Symptoms

Possible cause of trouble and remedies


(Each number is defined in the list
below)

--

Pump does not deliver water.

1,2,3,4,6,11,14,16,17,22,23

--

Insufficient capacity delivered.

2,3,4,5,6,7,8,9,10.11.14.17,20,22,23.29,30,31

--

Insufficient pressure developed

5,14,16,17,20,22,29,30,31

--

Pump loses prime after starting.

2,3,5,6,7,8,11,12,13

--

Pump requires excessive power.

15,16,17,18,19,20,23,24.26,27,29,33,34,37

--

Stuffing box leaks excessively.

12,13,24,26,32,33,34,35,36,38.39,40

--

Pump vibrates or it is noisy.

2,3,4,9,10,11,21.23,24,25.26.27,28,30,35,41,42,43,
44, 45,46,47

--

Bearings have short life.

24,26,27,28,35,36,41,42,43,44,45,46,47

--

Pump overheats and seizes.

1,4,21,22,24.27,28,35,36,41

Suction troubles

Remedies

Pump not primed

Ensure that casing is fully filled and water comes out


from air-cock.

Pump or suction pipe not completely filled with


liquid

Check leaking foot valve in case of negative suction

Suction lift too high.

Reduce by lowering pump elevation or increase

Water level.
4

Insufficient margin between pressure and vapor


pressure.

Check that NPSH available is at least 1 meter more 1


meter more than NPSH required.

Excessive amount of air in liquid.

Check the reasons and eliminate. Gas gets


entrapped in liquid. Air may be entering through
suction joints.

Air pocket in suction line.

Ensure pipe fully filled and there is no


bend for negative suction.

Air leaks into suction line

Tighten pipe joints with solution.

Air leaks into pump through stuffing boxes.

Ensure stuffing box sealing.

Foot valve too small or leaking.

Replace I Attend.

10

Foot valve partially clogged.

Clean

11

Inlet of suction pipe insufficiently submerged.

Ensure adequate submergence such that foot valve


is not exposed.

12

Water seal pipe clogged.

Clean or change.

13

Logging ring is improperly located

Position logging ring centrally under sealing holes of

in stuffing box, preventing sealing

stuffing box.

fluid from entering to form seal.

MPPL/IM/VP/2006/0

8-1

Mather + Platt

Trouble shooting
System Troubles

Remedies

14

Speed too low.

Check motor RPM, supply frequency, Motor


nameplate speed should be as specified on pump
nameplate.

15

Speed too high.

Check motor RPM and supply frequency.

16

Direction of rotating wrong.

Check correct direction of rotation for motor before


coupling to motor.

17

Total head of system higher than design head of


pump.

Check the causes and refer to M&P. Measure with


pressure gauge.

18

Total head of system lower than pump design


head.

Check the causes and refer to M&P. Measure with


pressure gauge.

19

Specific gravity of liquid different from design.

Refer to M&P.

20

Viscosity of liquid different from design.

Refer to M&P

21

0peration at very low capacity.

Check the causes and refer to M&P, Operate pump at


rated duty.

22

Parallel operation of pumps unsuitable for such


operation.

Refer to M&P with characteristics curves of pump.

Mechanical troubles

Remedies

23

Foreign matter in impeller.

Open and clean.

24

Misalignment.

Check with Dial gauge should be within limits and


without undue pipe stresses.

25

Foundations not rigid.

Check, vibration on Bedplate, check hollowness.

26

Shaft bent.

Dismantle and check, Replace shaft.

27

Rotating part rubbing on stationary part.

Incorrect assembly, correct the assembly.

28

Bearing worn.

Check lubrication, shaft run out, alignment, replace


if required

29

Wearing rings worn.

Replace.

30

Impeller damaged.

Replace.

31

Casing gasket defective, permitting internal


leakage.

Replace.

Shaft or shaft sleeves worn

Replace.

32

or scored at packing.
33

Packing improperly installed.

Use correct grade and size of packing

34

Type of packing incorrect for operating condition.

Use correct grade and size of packing.

35

Shaft running' out of center because of worn


bearings or misalignment.

Rectify.

36

Rotor out of balance, causing vibration.

Balance the rotor.

MPPL/IM/VP/2006/0

8-2

Mather + Platt

Trouble shooting

37

Gland too tight, resulting in no flow of liquid to


lubricate packing

Adjust gland. Ensure sealing water flow

38

Cooling liquid not being provided to water-cooled


stuffing boxes.

Provide.

39

Excessive clearance at bottom of stuffing box


between shaft and casing, causing packing to be
forced into the pump.

Check pumps assembly.

40

Dirt or grit in sealing, liquid leading to scoring of


shaft or shaft sleeve.

Provide clean liquid for flushing.

41

Excessive thrust caused by mechanical failure


inside pump or by failure of hydraulic balancing
device, if any (in case of multistage pump etc.)

Check pump operation and assembly

42

Excessive grease or oil in antifriction bearing


housing or lack of cooling, causing excessive
bearing temperature.

Attend.

43

Lack of lubrication.

Provide proper lubrication.

44

Improper installation of antifriction bearings


(damage, incorrect assembly of stacked bearings,
use of unmatched bearings as a pair I etc.)

Rectify or replace bearing.

45

Dirt in bearings

Investigate the cause and clean bearing.

46

Rusting of bearings from water in housing

Arrest water ingress.

47

Excessive cooling of water- cooled bearing,


resulting in condensation of atmospheric
moisture in bearing housing.

Reduce cooling water flow.

For any occurrence of any abnormal symptoms stop the pump and
investigate the cause for corrective action without delay.
For trouble shooting of prime mover, electrical panels, mechanical seals
refer the respective manufacturers instruction manual.
For gland packing details refer to cross sectional drawing of the pump.

MPPL/IM/VP/2006/0

8-3

Mather + Platt

Lists, Tables, Type Plates & Checklists

A Lists, Tables, Type plates & Checklists


A.1

List of machine operators

All persons working on or with the product confirms with their signatures that they have received, read and
understood this operating and maintenance manual. In addition they obligate themselves to conscientiously
follow the instructions provided. Non-observation releases the manufacturer from any warranty obligations.

Name

Starting date

Table 1: List of machine operators.

MPPL/IM/VP/2006/0

A-1

Signature

Lists, Tables, Type Plates & Checklists


A.2
Sl.
No.

Mather + Platt

Maintenance and inspection log


Date

MPPL/IM/VP/2006/0

Equipment
No

Details

Signature
Name

A-2

Remarks

Mather + Platt

Lists, Tables, Type Plates & Checklists

A.3

Type Plates

3.3.1

Type Plate for vertical pump

MODEL NO
YEAR OF MANUFACTURE

MANUFACTURERS SR. NO

PUMP TAG NO

4
5

WEIGHT OF EQUIPMENT

KGS

DISCHARGE

M / HR

SPEED

POWER

10

12

MATHER AND PLATT PUMPS LTD


CHINCHWAD, PUNE-411019, INDIA

RPM

BOWL
HEAD
P (max)

BAR

KW

TEMP

11

1-Model No
2-Year of manufacture
3-Manufacturers serial number
4-Pump tag number
5-Total weight of pump in kg
6-Rated discharge
7-Bowl head Maximum
8-Rated speed
9-Maximum pressure
10-Rated power
11-operating temperature
12-CE symbol

MPPL/IM/VP/2006/0

A-3

Lists, Tables, Type Plates & Checklists


A.4

Leveling Records

Required accuracy of level is 0.05 mm / 250 mm


Level achieved:

Level Bottle used:


Straight Edge used:

Checked by:

Verified by:

MPPL/IM/VP/2006/0

A-4

Mather + Platt

Mather + Platt
A.5

Lists, Tables, Type Plates & Checklists

Alignment Protocol

PUMP & MOTOR/ ENGINE/ TURBINE ALIGNMENT READINGS.


PUMP SR. NO:

PUMP TYPE :

DRIVER SR. NO:

MAKE:

A)

TYPE:

Before connecting Suction & Delivery Piping:


RADIAL

AXIAL

Gap between coupling halves:


B)

After connecting Suction & Delivery Piping:


RADIAL

AXIAL

Gap between coupling halves:


Required:
Acceptable Limit:

Checked by:
Verified by:

MPPL/IM/VP/2006/0

A-5

Lists, Tables, Type Plates & Checklists


A.6

Mather + Platt

Pre-Starting Checks for Pump set


Checked
on

Sl
No

Activities

Alignment with and without piping

Flushing of pipe lines and ensure no


leakages

Availability of sufficient liquid in sump /


suction as per specifications.

Installation of all instruments


a. Suction and delivery pressure gauges
b. Pressure switches
c. Temperature gauges
d. Any other as supplied / specified.

Operation of suction, delivery and inline


valves

Proper supports for piping and other


allied equipments.

Availability of flushing / sealing liquid for


stuffing box.

Availability of sufficient cooling liquid for


bearings as specified

Free rotation of pump and drive shafts

10

Lubrication of bearings

11

Checking of insulation resistance of


motor

12

Proper cable termination

13

Motor protection relay settings

14

Check all interlocks as specified /


provided

15

No
a.
b.
c.

16

Coupling of pump and drive and free


rotation of shafts in coupled condition

17

Suction valve is fully opened

18

Pump is fully primed and all air is vented

19

Delivery valve is closed (if required)

20

Emergency shut down is possible.

load trial operation of drive


Direction of rotation is ok
Noise and vibration within limits
Bearing temperatures and winding
temperatures are within limits
d. Overall operation is satisfactory

MPPL/IM/VP/2006/0

A-6

Remarks

Mather + Platt
A.7

Lists, Tables, Type Plates & Checklists

Pump commissioning report

SR02-04

Date:
Pump Details
a. Pump Sr.No.
b. Type of pump
c. Head
d. Capacity
e. Rpm
f. Construction

Details of Motor
a. Motor make
b. Sr. no.
c. Motor frame size
d. KW / HP
e. RPM
f. Voltage

Details of System
a. Application
b. Liquid
c. pH Value
d. Suction

PIPING DETAILS
a. Suction pipe size
b. Delivery pipe size
c. Valves
d. Expansion joints

Flooded/Lift

Pump operating
parameters
a. Suction pressure
b. Discharge pressure
c. RPM
d. DE bearing temperature
e. NDE bearing temperature
f. Duration of trial run

Motor operating
parameters
a. Current
b. Voltage
c. RPM
d. DE bearing temperature
e. NDE bearing temperature
f. Winding temperature
(maximum)

Observations & Remarks:

Checked by:
Verified by:

MPPL/IM/VP/2006/0

A-7

Lists, Tables, Type Plates & Checklists


A.8

Mather + Platt

Issue / Feedback report

SR01-O2 Page 1

Date:
To
Mather and Platt Pumps Ltd
P.O. Box No. 7, Chinchwad
Mumbai-Pune Road
Pune-411019, India.
1 Client / Site

Nature of complaint

Date of receipt of pump at


site & date of commissioning
Was erection/commissioning
in M & Ps scope
Pump details
Pump type:
P.D. No:
Flow:

4
5

Head:
RPM:
Efficiency:

Prime mover details


Make:
Sr. No.:
Frame size / Type:
KW/HP rating:

Motor
/ Engine
RPM:
Volts:
Full load current:
Insulating class:

7
a
b
c
d
e

Site layout
Suction pipe details, valves
Discharge pipe details, valves
Expansion joints, strainer etc.
Suction sump details
Suction conditions

Static head (Elevation difference


between pump centreline &
discharge point)

(Enclose drawings / Sketch / photographs)


:
:
:
:
: Flooded
/ Suction lift
Details:
:

Installation details

Base frame

Loose

Base frame levelling readings

No of packers below base frame

Alignment readings

-With pipe connection

-Without pipe connection

Coupling type & gap between


couplings halves

MPPL/IM/VP/2006/0

A-8

/ Turbine

/Anchored with foundation bolts

Mather + Platt

Lists, Tables, Type Plates & Checklists


SR01-O2 Page 2

9
a
b

Operation details
Application of pump
Solo / parallel / series
operation

Liquid specification
(Chemical analysis report)

Specific gravity:
Temperature :
Solid contents :

pH value :
Viscosity :

Operation parameters

Suction Pr.
:
Discharge
:
Motor current :
Frequency
:
VibrationsOverall readings:
Bearing temp. :
Suction pr.
:
Motor current :

Delivery Pr.
Speed
Volts

Parameters at close valve /


minimum flow condition

:
:

Filtered readings:
Discharge Pr.
Volts

Minimum flow :
10

Routine or major overhauls


carried out if any (Give
details)

11

Any other details or


observation

12

Investigation engineers
report

13

Spare requirement

14

Course of action finalized

15

Service Charges

Any other observation:

Prepared by:

MPPL/IM/VP/2006/0

Checked by:

A-9

:
:
:

:
:

Mather + Platt
B

Machine data sheet

Pump Technical data

B.1 Performance
Mather & Platt pumps are furnished for a particular duty and service conditions advised on your order / data
sheet. Changes in hydraulic system will affect the pumps performance. See Safety, Sec 2, duty condition.clause 2.3.

B.2 Pressure limits


The operating pressure has been selected to meet your specific requirements. See Safety, Sec 2, duty
condition -clause 2.3.

B.3 Temperature limitation


Refer the order specification/Data sheet.

B.4 Flange loads


Loads, which can be exerted on the pump flanges by the connecting, pipe flanges.

EACH NOZZLE

EACH END
NOZZLE

EACH SIDE
NOZZLE

EACH TOP
NOZZLE

Nominal size of the Nozzle Plate (INCHES)


FX
FY
FZ
FR
FX
FY
FZ
FR
FX
FY
FZ
FR
FX
FY
FZ
FR

1
117
145
95
210
117
95
145
210
145
95
117
210
163
124
81
220

1
135
166
109
240
135
109
166
240
166
109
135
240
192
147
96
260

1
142
176
116
255
142
116
176
255
176
116
142
255
247
189
124
335

2
160
200
130
290
160
130
200
290
200
130
160
290
340
260
170
460

2
200
255
160
370
200
160
255
370
255
160
200
370
510
390
325
720

3
240
300
200
430
240
200
300
430
300
200
240
430
700
530
350
950

4
320
400
280
570
320
280
400
570
400
280
320
570
980
740
500
1330

5
440
560
360
800
440
360
560
800
560
360
440
800
1300
1000
750
1800

(Ref API 610)


6
560
700
460
1010
560
460
700
1010
700
460
560
1010
1700
1300
870
2310

7
700
900
580
1300
700
580
900
1300
900
580
700
1300
2100
1600
1070
2850

8
850
1100
700
1560
850
700
1100
1560
1100
700
850
1560
2600
1900
1300
3500

9"
1000
1300
850
1900
1000
850
1300
1900
1300
850
1000
1900
3100
2400
1500
4000

10
1200
1500
1000
2200
1200
1000
1500
2200
1500
1000
1200
2200
3700
2800
1800
5000

11
1350
1650
1100
2400
1350
1100
1650
2400
1650
1100
1350
2400
4050
3100
2050
5550

12
1500
1800
1200
2600
1500
1200
1800
2600
1800
1200
1500
2600
4500
3400
2200
6100

14
1600
2000
1300
2900
1600
1300
2000
2900
2000
1300
1600
2900
4700
3500
2300
6300

Forces lb
Moments lb ft
Each Top Side Nozzle
Each Nozzle

2.2 = Kg

7.22 = Kg m

VERTICAL PUMPS: CNE/VMF/MFD


MPPL/IM/VP/2006/0

B-1

15
1800
2200
1400
3100
1800
1400
2200
3100
2200
1400
1800
3100
5200
3900
2600
7000

16
1900
2300
1500
3300
1900
1500
2300
3300
2300
1500
1900
3300
5400
4000
2700
7200

Mather + Platt

Machine data sheet

Loads, which can be exerted on the pump flanges by the connecting, pipe flanges.

EACH TOP
NOZZLE

FX
FY
FZ
FR

EACH NOZZLE

EACH END
NOZZLE

FX
FY
FZ
FR

EACH SIDE
NOZZLE

Nominal size of the Nozzle Plate (INCHES)

FX
FY
FZ
FR
FX
FY
FZ
FR

18"
2100
2500
1650
3650
2100
1650
2500
3650
2500
1650
2100
3650
5700
4250
2900
7600

20"
2250
2750
1775
3970
2250
1775
1750
3970
2750
1775
2250
3970
5900
4500
3100
8000

22"
2425
2950
1850
4250
2425
1850
2950
4250
2950
1850
2425
4250
6050
4650
3175
8250

24"
2550
3100
2025
4500
2550
2025
3100
4500
3100
2025
2550
4500
6200
4750
3250
8450

26"
2675
3300
2125
4750
2675
2125
3300
4750
3300
2125
2675
4750
6400
4900
3400
8750

(Ref API 610)

28"
30"
32"
33"
36"
2775 2825 2875 2900 2950
3400 3500 3600 3625 3675
2200 2775 2300 2325 2400
4900 5000 5150 5250 5300
2775 2825 2875 2900 2950
2200 2275 2300 2375 2400
3400 3500 3600 3625 3675
4900 5000 5150 5200 5300
3400 3500 3600 3625 3675
2200 2275 2300 2325 2400
2775 2825 2875 2900 2950
4900 5000 5150 5200 5300
6600 6800 7000 7200 7400
5000 5125 5150 5175 5400
3550 3600 3650 3675 3800
9000 9200 9400 9600 9900

38"
3000
3740
2470
5400
3000
2480
3740
5400
3740
2480
3000
5400
7620
5570
3930
--

40"
3055
3810
2545
5515
3055
2560
3810
5515
3810
2560
3055
5515
7845
5745
4065
--

42"
3110
3875
2525
5630
3110
2645
3875
5630
3875
2645
3110
5630
8075
5925
4200
--

44"
3170
3945
2700
5755
3170
2735
3945
5755
3945
2735
3170
5755
8315
6115
4345
--

46"
3225
4015
2780
5875
3225
2825
4015
5875
4015
2825
3225
5875
8560
6305
4490
--

48"
3285
4090
2865
6000
3285
2915
4090
6000
4090
2915
3285
6000
8810
6505
4645
--

Forces lb
Moments lb ft
Each Top Side Nozzle
Each Nozzle

2.2 = Kg

7.22 = Kg m

VERTICAL PUMPS: CNE/VMF/MFD

MPPL/IM/VP/2006/0

B-2

50"
3340
4165
2950
6130
3340
3010
4165
6130
4165
3010
3340
6130
9070
6710
4800
--

52"
3400
4240
3040
6260
3400
3110
4240
6260
4240
3110
3400
6260
9340
6920
4965
--

Mather + Platt

Machine data sheet

B.5 Bearings, Lubrication, Gland packing


SL
NO

PUMP MODEL

MAX
RPM

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

CNE 8
CNE 14
CNE 18
CNE 19
CNE 22
CNE 24
CNE 33
8 VMF
10 VMF
12 VMF
12 VMF1
12 VMF2
12 VMF5
16 VMF
16 VMF1
16 VMF2
16 VMF3
16 VMF4
16 VMF5
20 VMF
20 VMF 1
20 VMF3
20 VMF5
24 VMF5
30 VMF
30 VMF2
30 VMF4
36 VMF
36 VMF1
36VMF2
36 VMF3
36 VMF4
36 VMF5
36 VMF6
36 VMF8
64 VMF
400 VMF
500VMF
600 VMF
1200VMF
1200VMF1
1400-50MFD
1400 VMF
1400 VMF1
1600 VMF

3000
1800
1800
1800
1800
1800
1500
1800
1500
1500
1500
1500
1500
1500
1500
1500
1500
1500
1500
1000
1000
750
1000
750
600
750
1000
1000
600
600
600
600
600
600
750
500
1500
1000
750
600
500
500
500
500
500

MPPL/IM/VP/2006/0

B-3

Refer pump data sheet for


bearing details, cooling water
quantity and pressure etc.

Refer cross sectional drawing


for gland packing details

Mather + Platt

Machine data sheet

B.6 Recommended bolting & screw torques


Failure of threaded fasteners due to over-tightening can occur by bolt shank fracture or by stripping of the nut
and / or bolts thread. a bolt or screw assembled with a nut of appropriate class is intended to provide an
assembly capable of being tightened to the bolt proof load without thread stripping occurring.
The torque value to be set for a particular size of screw is dependent upon:
1.
2.
3.
4.
5.

Material of screw
Parent metal
Whether the screw is untreated or plated
Whether the screw is dry or lubricated
The depth of the thread

Tightening Torques Untreated Screw (Black finish) Friction of coefficient 0.14


Property Class
5.6
8.8
10.9
12.9

Torque
Nm
Ft. lb
Nm
Ft. lb
Nm
Ft. lb
Nm
Ft. lb

M6

M8

M10

M12

4.6
3.3
10.5
7.7
15
11
18
13

11
8.1
26
19
36
26
43
31

22
16
51
37
72
53
87
64

39
28
89
65
125
92
150
110

Nominal diameter Coarse thread


M16 M20 M24
M27
M30
95
70
215
158
305
224
365
269

184
135
420
309
590
435
710
523

315
232
725
534
1020
752
1220
899

470
346
1070
789
1510
1113
1810
1334

636
468
1450
1069
2050
1511
2450
1805

M33

M36

M39

865
637
1970
1452
2770
2042
3330
2455

1111
819
2530
1865
3680
2625
4260
3156

1440
1062
3290
2426
4520
3407
5550
4093

Tightening Torques Electrically Zink plated Friction of coefficient 0.125


Property
Class

Torque

5.6

Nm
Ft. lb
Nm
Ft. lb
Nm
Ft. lb
Nm
Ft. lb

8.8
10.9
12.9

MPPL/IM/VP/2006/0

M6

M8

M10

M12

4.3
3.1
9.9
7.3
14
10.3
16.5
12.1

10.5
7.7
24
17.7
34
25
40
29

21
15
48
35
67
49
81
59

36
25
83
61
117
86.2
140
103

Nominal diameter Coarse thread


M16 M20 M24
M27
M30

B-4

88
64
200
147
285
210
340
260

171
126
390
297
550
405
650
485

295
217
675
497
960
708
1140
84o

435
320
995
733
1400
1032
1660
1239

560
435
1350
995
1900
1401
2280
1681

M33

M36

M39

800
590
1830
1349
2580
1902
3090
2276

1030
768
2360
1740
3310
2441
3880
2535

1340
988
3050
2249
4290
3163
5150
3798