PUMP
OPERATING MANUAL
IN
ORDER TO FACILITATE PRE-AND POST-INSTALLATION PROCESSES,WE
STRONGLY
RECOMMEND OUR CLIENTS TO FOLLOW THE BELOW GIVEN
INSTALLATION
AND OPERATING INSTRUCTIONS AND READ USEFUL TIPS
PROVIDED
UNDER TWO HEADINGS:
A- IMPORTANT ISSUES ASOUT
PUMPING SYSTEM TO BE CONSIDERED
PRIOR
TO AND FOLLOWING THE START UP
1-
DETERMINE TOTAL CAPACITY OF YOUR SYSTEM.WHILE DETERMINING TAKE POSSIBLE FUTURE CAPACITY INCREASES INTO
ACCOUNT SO THAT YOU WOULDNT HAVE TO RENEW BOTH THE SYSTEM AND PUMP IN FUTURE.
2-IF
HIGH VISCOSITY FLUID PUMPING IS THE CASE FOR YR PLANT ,THEN
WHEN
SELECTING PIPES FOR PUMPING LINE PREFER THOSE WITH LARGE
PIPE
SECTION.THIS WAY YOU’LL NOT ONLY AVOID HIGH PRESSURE FROM DEVELOPING AT SUPPLY
LINE,POWER WASTAGE,OVERLOADING THE PUMP BUT YOU’LL ALSO MAKE USE OF IT WHEN
CAPACITY IS INCREASED,SELECTING PIPES WITH SMALLER PIPE SECTION OF THE PIPES
WILL NOT ONLY LEAD TO UNNECESSARY OVERLOADING OF THE PUMP,NEEDLESS POWER
WASTAGE BUT WILL ALSO SET GROUNDS FOR YR PLANT TO FACE UNDERCAPACITY PRODUCTION.THUS
NEVER SELECT PIPES WITH PIPE SECTION SMALLER THAN THE DIAMETERS OF PUMP’S
SUPPLY INLET AND DISCHARGE OUTLET.
3-MAKE
SURE THAT NO SHARP ELBOWS ARE USED IN YOUR PIPING IF POSSIBLE ALWAYS AVOID
INSTALLING VERTICAL ELBOWS AND PREFER
SMOOTH HORIZANTAL ELBOWS.
4-ESPECIALLY
WHEN VISCOUS LIQUIDS ARE CONCERNED PLAIN,DIRECT
AND
SHORTEST POSSIBLE LINING SHOULD BE PREFFERED.IN OTHER WORDS ELBOWS SPOULD BE
AVIODED AS MUCH AS POSSIBLE WHEN FORMING THE SUCTION LINE.
5-PREFER
BALL VALVES
6-SINCE
FILTERS LAID IN THE SUCTION LINE WILL CAUSE GREAT RESISTANCE ESPECIALLY IN THE
CASE OF VISCOUS AND SEMI VISCOUS FLUIDS MAKE SURE THAT FILTERS ARE SIZED AS
LARGE AS NECESSARY.
7-PREPARE
PACKINGS TO BE USED AT JOINTS WITH DILIGENCE.ESPECIALLY MAKE SURE THAT PACKINGS
DONT DIMINISH PIPE CROSSING DIAMETER.
8-WHEN
CONNECTING PIPING WITH PUMP,PIPES SHOULD BE CONNECTED IN SMOOTH SYMMETRY WITH
PUMP,AXIAL DEVIATION SHOULD BE AVOIDED AT ALL COSTS.
9-HIGH
VACUUMING AT VERY LOW CYCLE IS ESSENTIAL FOR PUMPING
HIGH
VISCOSITY FLUIDS.THUS LOCATE YOUR PUMP TERMINAL SO THAT
YOU CAN
ACHIEVE SHORTEST SUCTION LINE.
10-CONNECT
PIPE JOINTS SO THAT WOULD BE SEALED AGAINST AIR INTAKE.
11-DONT
INSTALL PUMP BEFORE PIPING IS COMLETE.IF MUST THEN MAKE SURE THAT YOU SECURELY
SEAL PUMP INLET AND OUTLET TO AVOID ANY FOREIGH SUBSTANCES FROM GETTING INTI
PUMP,BECAUSE THEY MAY DAMAGE PUMP.
12-WHEN
PIPING IS COMPLETE THOROUGHLY CLEAN YOUR PIPING FROM ALL RESIDUES AND PARTS
THAT MAY BREAK FREE
13-YOU
WILL DECIDE ON THE DRIVE POWER OF THE PUMP,WHEN DECIDING ALWAYS CONSIDER THE
SAFETY FACTOR BY BEARING IN MIND VARIOUS FLUIDS TO BE USED.
14-WHEN
ACTIVATING THE PUMP FOR THE FIRST
TIME,MAKE SURE THAT A VACUUM GAUGE AND MANOMETER IS INSTALLED WITH THE
PIPING.INDICATORS OF THESE DEVICES WILL SHOW YOU THE CURRENT
SITUATION
WITH THE PIPING.
15-TO
ENSURE THAT YOUR SYSTEM IS ALWAYS IN SERVICE.
ORDER
SPARE PARTS WHICH YOU MAY CHOOSE BY CONSULTING OUR FIRM AND HAVE THEM READY FOR
EMERGENCY.
16-MAKE
SURE THAT YOU DO REGULAR MAINTENANCE OF THE PUMP IN BELOW SPECIFIED PERIODS SO
THAT IT WILL NEVER GIVE AN ERROR AND LET YOU DOWN:
YOU MAY
DETERMINE MAINTENANCE INTERVALS ACCORDING TO.
A-DAILY
OPERATION HOURS OF THE PUMP
B-TYPE
OF SERVICE DELIVERED
C-EFFECT
OF THE PUMPED FLUID ON THE PUMP MATERIAL
17-WHEN
DETERMINING LOCATION OF THE PUMP IN THE SYSTEM,
A-MAKE
SURE THAT SUCTION LINE IS IN SHORTEST POSSIBLE LENGTH,
WITH
MINUMUM ELBOWS OR NO ELBOWS USED
B-BEARING
IN MIND THAT THE PUMP MAY BE REVISED IN FUTURE MAKE SURE THAT IT IS LOCATED IN A SPACIOUS PLACE.
B-CHECKLIST
TO BE FOLLOWED BEFORE STARTUP
1-MAKE
SURE THAT THE PUMP SHAFT IS ROTATED WITH EASE
2- WHEN
INSTALLING PUMP MAKE SURE THAT CONNECTIONS ARE
EXPANDABLE.
3-MAKE
SURE THAT THE PUMP IS INSTALLED IN ACCORDANCE
WITH THE DIRECTION OF ROTATION
SO THAT IT WILL PROVIDE BY –PASS FUNCTION.
4-MAKE
SURE THAT FILTERS INSTALLED IN THE SUCTION LINE ARE CLEAN.
5-MAKE
SURE VALVES ON BOTH SUCTION AND PUMPING LINE ARE TURNED ON.
6-BEFORE
ACTIVATING PUMP CHECK WHETHER THEY ARE WELL-LUBRICATED OR NOT.
7-BEFORE
STARTUP MAKE SURE THAT SUCTION VALVE IS TURNED OFF AND PUMPING VALVE IS TURNED
ON.AFTER ACTIVATING PUMP GRADUALLY TURN SUCTION VALVE ON.
8-BEFORE
ACTIVATING PUMP CHECK WHETHER THEY ARE WELL-LUBRICATED OR NOT
9-BEFORE
STARTING UP,ACCORDING TO THE CAPACITY OF THE PUMP
ADD 0,5
TO 2,5 LITRES OF MOTOR OIL NO .50 TO THE PUMP.
10-IN
MECHANIC SEAL PUMPS,NEVER ROTATE PUMP TO A DIRECTION CONTRARY TO THE ROTATION
DIRECTION SHOWN ON THE PUMP,OTHERWISE YOU MAY DAMAGE THE SEAL.
CONDITIONS
OF USING THE PUMP TO ENSURE BEST AND SAFEST
PERFORMANCE ARE
LISTED BELOW:
1-
IF THERE IS AIR LEAKAGE IN THE SUCTION LINE DONT APPLY FORCE TO THE
PUMP AND SEAL THE LEAKAGE.
2-
IF NOT USED IN BYPASS FUNCTION
MAKE SURE THAT NO VALVES ON THE PUMPING LINE ARE TURNED OFF.
3-
MAKE SURE THAT THERE ARE
MINUMUM NUMBER OF FITTINGS USED IN YOUR SYSTEM.
4-
DONT OPERATE PUMP WHEN DRY
5-
IN CASE OF VISCOUS LIQUIDS,AVOID SUDDEN OVERLOADING OF PUMP.
6-
CLEAN FILTERS REGULARLY ACCORDING TO THE RATE OF CLEANLINESS OF LIQUIDS
USED.
7-
DONT INSTALL PUMP FAR AWAY FROM SOURCE OF FLUIDS,PREFER THE MOST DIRECT
LINE OF PIPING.
8-
AFTER OPERATING PUMP FOR A WHILE,CONTROL TIGHTNESS OF BOLTS.
YOU CAN
ACTIVATE THE PUMP ONCE YOU HAVE DONE ALL OF THE ABOVE
STATED.IF
NO FLUID IS PUMPED A MINUTE AFTER ACTIVATION THEN DONT OPERATE PUMP ANY
LONGER.JUST INCREASE THE AMOUNT OF OIL
ALREADY
ADDED TO THE PUMP AND TRY IT AGAIN.THIS WAY NOT ONLY YOU’LL ENSURE THAT PUMP ISNOT DRIED OUT BUT BY
ENABLING PUMP
TO
VACUUM BETTER YOU WILL ACHIEVE SUCCESSFUL PRIMING AS WELL.
IF
SYSTEM STILL FAILS TO ACHIEVE PUMPING DESPITE ALL OF THESE
MEASURES
THEN CEASE PUMPING AND EXA MINE THE BELOW LISTED ASPETS TO FIND THE CONCERNED
PROBLEM;
1-CHECK
THE SUCTION LINE.MAKE SURE THAT THERE IS NO AIR LEAKAGE
2-MAKE
SURE THAT THE SUCTION PIPE IS FULLY IMMERSED IN FLUID
3-CHECK
TO SEE WHETHER SUCTION HEIGHT IS SET HIGHER THAN NECESSARY OR NOT
4-CONTROL
WHETHER SUCTION PIPE’S SECTION IS TOO SMALL FOR THE
TASK IN
HAND OR NOT
TROUBLESHOOTING
A- IF DESIRED FLOWRATE IS NOT
ATTAINED,THEN
1-CHECK DIRECTION OF ROTATION IT MAY BE REVERSE
2-SUCTION PIPE MAY NOT BE FULLY IMMERSED IN LIQUID,MAKE
SURE
THAT IT IS FULLY IMMERSED.
3-THERE MAY BE A VALVE TURNED OFF ON SUCTION AND /OR
PUMPING
LINE OF THE SYSTEM
4-SUCTION LINE MAY HAVE AIR LEAKAGE.AVOID ANY LEAKAGE.
5-FILTERS COULD BE UNCLEAN OR CLOGGED.CLEAN FILTERS.
6-IMPROPER CHOICE OF FILTER MAY BE THE CASE MAKE SURE
THAT YOU SELECT RIGHT TYPE OF FILTER ACCORDING TO THE LIQUID
PUMPED.
7-IF CLAMPS ARE UTILISED ON THE SUCTION LINE,MAKE SURE
THAT
CLAMPS ARE NOT CLOSED.
8-IN THE SYSTEM BYPASS FUNCTION MAY BE SET UNDER THE
REQUISITE RESISTANCE LEVEL OR A RESIDUE
MAY BE JAMMING
BYPASS CLAMP.CLEAN BYPASS AND MAKE SURE THAT BYPASS CLAMP IS WELL POSITIONED.
9-IN SOFT SEALANT PUMPS,SEALANT MIGHT BE
CORRODED,ACCORDINGLY REPLACE SEALANT.
10-SUCTION LINE HAVE EITHER TOO THIN OR TOO LONG OR TOO
MANY
FITTINGS
11-IF PUMP IS IN SERVICE OVER A LONG PERIOD THEN ITS
OPERATING
PARTS MAY BE WORN OFF ACCORDINGLY REPLACE SUCH PARTS.
12-PUMP CYCLE MAY BE SET TO A LEVEL LOWER THAN NECESSARY
WITH RESPECT TO THE PUMP AND LIQUID PUMPED.
13-AIR INTAKE MAY BE IN CONCERN PRIME THE SYSTEM.
14-SUCTION HEIGHT MAY BE SET HIGHER THAN NECESSARY.
B-IF PUMP IS OPERATING YET PUMPING RATE IS DROPPING AT A
LATER
STAGE,THEN,
1-SUCTION PIPE MAY NOT BE IMMERSED SUFFICIENTLY IN
LIQUID.
2-VAPORISATION MAY BE THE CASE IN SUCTION LINE.LOWER
SUCTION HEIGHT.
3-THERE MAY BE AIR INTAKE.PRIME THE SYSTEM.
C-IF PUMP IS REQUIRING TOO MUCH PWER,THEN
1-THIS INDICATES THAT FLUID IS TOO VISCOUS FOR THE PUMP.
2-PUMPING LINE MAY BE CLOGGED.
3-SOFT SEALANT MAY BE TIGHTENED TOO MUCH.LOOSEN THE
SEALANT.
4-PUMP SHAFT MAY BE BENT.REPLACE THE SHAFT.
5-REVIEW SETTINGS OF THE PUMP AND MOTOR