Installation & Operation Manual - Sundyne · 02.09.19E, August 2007 Visit our website at SUNDYNE...

02.09.19E, August 2007 Visit our website at www.sundyne.com

SUNDYNE LMV/BMP-341 Pumps

Installation & Operation Manual

August 2007

COPYRIGHT All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of Sundyne Corporation. © 2007 Sundyne Corporation

WARRANTY Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship. If any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be defective. Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to equipment caused by abnormal conditions, vibration, failure to properly prime or to operate equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable for consequential or incidental damages.

Instruction and Operation Manual

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USING THIS MANUAL: This manual is part of the final data package for your Sundyne LMV pump. This manual provides useful information for the Sundyne pump, including how to: install it, maintain it, service it, troubleshoot problems and order parts. In addition to this manual, the final data package includes: drawings, Sundyne specification sheet with test performance curves, test data, inspection data, material certificates if required, driver, coupling and auxiliary equipment information. All dimensions are provided in English units followed by SI units in parenthesis. This manual contains the following sections: i. Introduction to the Sundyne Pump ii. Safety Precautions iii. Critical Startup Checklist 1. Installation Describes how to install the pump and how to store it until you install it. 2. Lubricating Oil System Provides the following information: how to prepare the gearbox for start-up; how the lubricating oil

system works; and specifications for gearbox lubricants. 3. Start-up Provides the procedure for starting the pump. 4. Servicing Provides procedures for servicing the pump. 5. Operation and Control of Sundyne Pumps

Factors that are critical to proper pump operation. 6. Process End Disassembly and Maintenance of the Seals Provides an understanding of the process end of the pump. Describes how to remove the gearbox

and seal housing from the pump case, and detailed disassembly of the process end including mechanical seals.

7. Gearbox Disassembly Provides procedures for disassembling the gearbox of the pump, and suggestions for inspection of

disassembled hardware. 8. Inspection of Disassembled Hardware 9. High Speed Shaft End Play

Provides a detailed description of how to set end play on the high speed shaft before re-assembly. 10. Gearbox and Process End Reassembly

Provides a detailed re-assembly procedure for the gearbox and pump. 11. Spare Parts

Contact and reference information.


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12. Gearbox and Pump Situation Improvement

Provides a table for looking up gearbox and pump problems; identifying possible causes; and finding the appropriate corrective action.

13. Pump Mechanical Seals Situation Improvement

Provides a table for looking up seal problems; identifying possible causes; and finding the appropriate corrective action.

Appendix A Drawings, including pump and gearbox cross section drawing, exploded process end assembly drawing and seal arrangement cross section drawings, complete with component item numbers. Appendix B Coupling Manufacturer’s Bulletin for Alignment


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i. Introduction to the Sundyne Pump The Sundyne LMV pump has a single impeller stage, with an integral speed-increasing gearbox. It’s purpose is to increase the pressure of a continuous flow fluid by applying centrifugal action. Sundyne LMV Pumps are most commonly used in HPI, CPI, and Boiler Feed applications. They are also used in refineries, petrochemical plants, and power generation plants. Within these facilities, Sundyne Pumps are used in high head, low to medium flow processes. Sundyne LMV Pumps offer industrial quality in a compact unit that is simple to maintain. It provides high-energy performance and competitive efficiencies. For detailed specifications of Sundyne LMV Pumps, see the specification sheet and bill of material or consult Sundyne Corp. For the primary components, reference the Pump and Gearbox section. For more information about additional custom equipment for the basic Sundyne LMV Pump product, see the brochure that accompanies this manual. ii. Safety Precautions

Text Symbols

The following symbols may be found in the text of this manual.

They have the following meanings:

WARNING: Text accompanied by this symbol indicates that failure to follow directions could result in bodily harm or death.

ELECTRICAL HAZARD: Text accompanied by this symbol indicates that failure to follow directions could result in electrical damage to equipment or electrical shock.

RECOMMENDED: Text accompanied by this symbol indicates recommended usage.

REMINDER: Text accompanied by this symbol indicates a reminder to perform an action.

EQUIPMENT USE ALERT: Text accompanied by this symbol indicates that failure to follow directions could result in damage to equipment.

Equipment and Safety Precautions

Sundyne Corporation manufactures centrifugal pumps to exacting International Quality Management System Standards (ISO 9001) as certified and audited by Lloyd’s Register Quality Assurance Limited. Genuine parts and accessories are specifically designed and tested for use with these products to ensure continued product quality and performance. Sundyne cannot test all parts and accessories sourced from other vendors; incorrect design and/or fabrication of such parts and accessories may adversely affect the performance and safety features of these products. Failure to properly select, install or use authorized Sundyne pump parts and accessories is considered misuse and damage or failure caused by misuse is not covered by Sundyne’s warranty. Additionally, modification of Sundyne products or removal of original components may impair the safety of these products and their effective operation.


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CAUTION Sundyne pumps may handle hazardous, flammable, and/or toxic fluids. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in accordance with applicable environmental regulations.

Note: Safety procedures must be applied prior to any installation, maintenance, or repair of a Sundyne pump. Failure to follow safety precautions may lead to injury!

Wearing Personal Protective Equipment To ensure safety, protective equipment must be worn at all times when installing, performing maintenance, or repairing equipment. The following safety recommendations must be adhered to for optimum safety:

• Safety glasses, with the minimum requirement of side shields, must be worn at all times.

• Steel-toed shoes must be worn when lifting equipment greater than 15 pounds (7 kg) or if pallet jacks or forklifts are operated.

• Hearing protection is strongly recommended at all times when noise levels exceed 85 dB during an eight (8.0) hour period.

Note: Chemical resistant gloves must be used if chemicals are utilized (refer to Using Chemicals for additional information).

Note: A dust mask respirator must be worn if chemicals have warning labels regarding fumes, dust, or mists.

When using more than one piece of protective equipment, consider their compatibility. For example, safety glasses will not interfere with hearing protection equipment. Be sure to clean all pieces of personal protective equipment immediately after each use.

Using Forklifts Any persons operating a forklift must have an active recognized operator license. Note: Before initializing forklift operation, verify that the lift is in a safe operating position.

Ensuring Electrical Safety All electrical sources must be powered-off before installation, service, or repair of equipment occurs. Note: Sundyne recommends that a Lock-out/Tag-out program be followed prior to altering the

equipment. Locks or tags must be provided to warn employees that equipment is temporarily unavailable.

Once all work has been completed, the person installing the lock or tag must remove it according to company procedure.

Testing Equipment Prior to performing a test on newly installed, maintained, or repaired equipment; all personnel in the immediate area must be warned. Note: Follow company procedures prior to equipment testing at all times.


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Using Chemicals Any chemicals to be used must be accompanied by a relevant material safety data sheet (MSDS), in accordance with government legislation. If applicable, use chemical proof gloves. Note: An eye wash station (or equivalent) should be available in the event of injury. If any

hazardous or flammable chemicals pass through the equipment, a complete decontamination of the equipment is required.

Protection from Falling Fall protection and associated preventative measures are required when working on equipment located six feet or higher from the ground. Note: Follow company fall prevention procedures prior to working on equipment.

Preventative Machine Guards Preventative guards must remain in place on all equipment. Note: Only remove the guards while performing maintenance or repair.

Replace the guards immediately after working on the equipment and prior to start up.

EXPLOSION/FIRE HAZARD

Note: Never use an acetylene torch, open flame, or heat to attempt to remove parts that have seized together in Sundyne equipment. Any residual process gas or liquid that is flammable can result in an explosion or fire with potential for serious injury or death.

iii. Critical Startup Checklist Know Your Machine Before servicing and starting up the Sundyne LMV-341 pump, carefully review the specification sheet, the outline drawings, performance curves, and this instruction manual. It is important you become familiar with the pump configuration before starting and operating the pump. Driver Instructions Carefully follow the installation and starting instructions provided by the manufacturer of the driver. This is included in the final data package. Auxiliaries 1. Check the utility connections. 2. Verify that the auxiliary piping conforms to Sundyne’s drawings. 3. Verify the connections of the switches, the instruments, and their settings. 4. Calibrate all measurement equipment (Flow meters, Current or Ampere meters, Pressure meters,

etc.). Environmental Control System Install a system to control the environment of the seal, if required, and verify that port 1 is properly vented. If required install overhead drain piping.


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Pressurized Fluid Loop: Pressurize double seal buffer loop or external seal flush, if required, prior to admitting fluid into pump casing. Check Driver Rotation Rotation must be in the same direction as the arrow stamped or cast on the pump casing. Gearbox Servicing: Fill gearbox within 1/4 inch (6.4 mm) from top of oil level sight glass with lube oil which conforms to the specification in Table 9.1. Where applicable, operate auxiliary lube pump to fill heat exchanger and filter. Add oil as necessary through fill fitting until oil level stabilizes in sight glass. The gearbox alone requires approximately six U.S. quarts (5.7 liters). Starting Pump Start pump with suction valve completely open while throttling discharge valve, to bring pump to design operating point. Heat Exchanger If a heat exchanger for the gearbox is installed, adjust the cooling flow to keep the temperature of the oil to the bearings at 120°-140°F (49°-60°C). Check Check total head, flow rate, and power consumption against pump specification sheet. Power consumption should not exceed 364 hp (271 kW) max. continuous. Check that specific gravity, viscosity and NPSH are in accordance with specification sheet. These conditions will significantly alter performance of the pump. Process Conditions Do process conditions; suction pressure, suction temperature, discharge pressure, agree with specification sheet information? Check with your Sundyne representative if you must test or run a different fluid/specific gravity than shown on the specification sheet. Auxiliary Lube Pump If you have an auxiliary lubrication pump, unlock the electrical circuit and start it in the “hand” position. Check for oil leaks and recheck the oil level. Piping Connections Are the following bolted/threaded connections tight: a. Pump flange bolts? b. Seal environment piping and port connections? c. Cooling water connections to heat exchanger? (if applicable) d. Gearbox oil drain plug? e. Pump case drain plug?


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1. Installation This section contains the following: Introduction: Provides a brief description of the pump and how it is used. Inspection: Important items to inspect as soon as you receive your pump. Short-term Storage: Procedure for units installed within 6 months. Long-term Storage: Procedure for units installed after 6 months. Suction and Discharge Piping: Procedures to set up the suction and discharge piping. Seal Environment Control System: Procedures to set up the seal environment controls,

even if you use the standard system supplied by the factory. Gas buffer system procedures are included.

Baseplate Mounting and Grouting: Use this information for grouting the baseplate. Driver and Coupling: Procedures to align the driver and pump. Do this after grouting, and

before connecting the piping for suction and discharge. Once the suction and discharge piping is connected, confirm the final alignment.

Inspection 1. When you receive the Sundyne LMV Pump, check for any damage. If you find any, inform the

carrier and Sundyne Corp. promptly. 2. Use Outline drawings in the last section of final data package, and reference the Pump and

Gearbox bill of material to ensure that all auxiliary items are properly included. 3. Check the gear shaft carefully. Seal drag may cause it not to turn freely at first; this is normal. If

the gear shaft binds, it may be damaged, or may need adjusting.

Short-term Storage - 1 day to 6 months 1. If the pump is to be stored near strong chemicals or salt water, protect it immediately. To do this,

follow steps 5 through 10 from the long-term storage procedures below. 2. Protect the unit from moisture and dust. 3. Make sure that the factory’s shipping covers for the housing flanges and the seal ports are

securely in place. 4. Carefully follow the storage instructions provided by the manufacturer of the motor or turbine

driver.


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Long-term Storage - 6 months or more If you store the Sundyne LMV Pump for a long period of time, the following methods are very important. If you require further instructions, please contact Sundyne Corporation at (303)-425-0800 USA and ask for the Field Service Department. 1. Be sure the storage area is indoors and has: Humidity below 65%; and temperature range from

45° to 85°F (7°C to 29°C). 2. Do not allow contact of airborne chemicals with the internal components of the unit. 3. If the unit is being stored near strong chemicals or salt water, protect it immediately. 4. Protect the unit from moisture and dust. 5. Make sure that the factory’s shipping covers for housing flanges and seal ports are securely in

place. 6. Prevent corrosion to the components of the gearbox and the fluid-end. 7. Use desiccant bags to absorb moisture 8. Purge the internal components with an inert gas. 9. Flood component internals with oil. 10. After long-term storage, have an authorized Sundyne service engineer inspect all components

and supervise any necessary repair to be sure that they work properly. Any components not made by Sundyne (except mechanical seals) must be inspected or replaced as determined by the manufacturer’s authorized personnel, at the purchaser’s expense. Any Field Service work must be clearly stated at the time of purchase to validate an Extended Warranty.

Because storage location and unknown factors at the site or storage are beyond our control,

Sundyne does not accept any liability for damage to the equipment during storage, nor do we guarantee the quality of the equipment during and after the storage period. An Extended Warranty will be null and void if the proper equipment preparation is not maintained.

Installing the Suction and Discharge Piping - Guidelines Note: The installation should provide a straight length of pipe on the inlet and outlet of the pump. Minimum straight lengths are recommended as 10 diameters on the inlet and 5 diameters on the outlet. Step 1 Clean the suction line. Step 2 Install a strainer to protect the impeller from damage by mill scale, welding slag, or other

foreign particles. Step 3 Make sure that the piping is aligned with the pump flanges. Step 4 Support all piping independently of the pump. Step 5 When you move the piping into place, never use excessive force at the flanged suction

and discharge connections. This could strain the unit. For suggested parameters reference the Pump, Gearbox, Process and Instrumentation sections of this manual.


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Step 6 Use suction pipe that has a diameter at least as large as the diameter of the suction inlet

of the pump. Step 7 Make sure that the suction and discharge piping do not have unnecessary elbows,

bends, and fittings. These increase the losses caused by friction. Also, be sure that all piping and fittings are large enough to minimize losses caused by friction.

Step 8 Before you connect the piping to the pump, tighten the pump base plate hold down-bolts

on the pump. Step 9 Do not use elbow parts near the suction flange. Step 10 Use block valves and pressure bleeds on both suction and discharge pipes to isolate the

pump during shutdown, minimize process leakage, and reduce the likelihood of back-flow through the pump, which can cause reverse rotation. A check valve should also be located downstream from the pump discharge.

Seal Environment Control System For the seals used with the Sundyne LMV pump, always maintain the environment shown on the specification sheet for your unit. For some arrangements and applications, you may need a buffer system to control the seal environment. For many applications, you can obtain a standard system from the factory. Make sure that the system is installed properly and that the ports are open or plugged, as applicable. Always be sure to leave port 1 free to drain leakage from the gearbox oil seal and vent the process seal. This port can be attached to a flare line, but should not have back pressure in excess of 5 psi (34.5 kPa). You must vent the case drain port 1 to atmospheric pressure and allow it to gravity drain properly. Otherwise oil could contaminate the outboard seal or allow process seal leakage into the gearbox. A liquid buffer system is used with double and tandem liquid seals. The buffer liquid is introduced into port 7, allowed to flow through the seal cavity, and out of port 2. Buffer flow should be 0.5 to 3.0 GPM (1.9 to 11.6 Liters/min) with an inlet temperature of 60° to 120°F (16° to 49°C) and inlet pressure as indicated on the specification sheet. If a closed or open loop buffer system is used, the buffer may require cooling prior to returning to port 7. Otherwise, heat generated by seal friction will build up in the buffer, resulting in shorter seal life. Baseplate Mounting & Grouting A rigid concrete mounting base is recommended for all installations. The concrete foundation should have minimum deflections and freedom from resonant frequencies in the operating range of the equipment being supported. The stand shall be secured in position by 1” diameter bolts. The bolts shall be installed in the foundation per the Installation Drawing, with sufficient length to protrude 1/4 inch (6.4mm) above the nut. The customer shall provide a 4” x 4” x 1/4” steel plate (101.6 mm x 101.6 mm x 6.4 mm) under each leveling screw. The base plate should be leveled prior to grouting. Grout shall set for a minimum of forty eight (48) hours before tightening the foundation bolts, or set for the minimum time suggested by the manufacturer of the grout.


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Driver and Coupling

Lock-out starting switch on the driver prior to working on coupling. You should review and know your company’s Lock-out / Tag-out procedure prior to working on energized equipment. A. UNITS WITH VERTICAL OR HORIZONTAL STANDS - ALIGNMENT—

(1) If other than Sundyne supplied couplings are used, they must be flexible disc or gear type couplings capable of tolerating parallel and angular misalignment of .005 inch (.13 mm) maximum, as well as axial end play float of .060 inch (1.52 mm) maximum. Always refer to the coupling manufacturer’s recommendations for installation and maintenance.

The motor and pump coupling hubs are installed at the factory. For alignment specifications, see

Appendix B (Coupling Manufacturers Bulletin). Align the driver and pump after grouting and before you connect the suction and discharge piping. After you install the piping, inspect the alignment again.

2. Lubricating Oil System Remote skid mounted systems

The oil used in Sundyne gearboxes must meet the specifications presented in Gearbox Lubricant Recommendations (see following page). In general, an ISO viscosity grade 32 oil will meet these specifications. Before using any oil, you should verify its properties by consulting its manufacturer. Failure to use the proper gearbox lubricant will void the warranty. No other additives are recommended.

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Field Engineering Bulletin

Sundyne & Sunflo & HMP Gearbox Lubricant Recommendations

EFFECTIVE : MAY 2006 Rev: E

For years the preferred gearbox lubricant for Sundyne pumps and compressors has been automotive automatic transmission fluid (ATF). However, over time the additives in automatic transmission fluid have changed to coincide with the technical improvements in automobile transmissions. The additives in the new formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne gearboxes and could compromise mechanical integrity and reliability of the equipment. ISO Viscosity Grade 32 or 46 general purpose or synthetic oils are the recommended lubricants for Sundyne gearboxes as shown in Table 1 below. ISO VG 46 lubricants are now recommended for high horsepower gearbox models 33X and 34X with spherical roller bearings and high ambient temperature installations. Gearbox lube oil should be changed twice yearly or more frequently in severe environments which may be detrimental to the lubricant. Oxidized oil is frequently characterized by a darkening and/or thickening of the oil. Operating of gearboxes with oxidized lubricant should be avoided. Synthetic oils possess different characteristics than conventional mineral oils which make them desirable for various extreme conditions such as high and low temperature operation. Synthetic oils offer very low pour points, high temperature oxidation stability and a higher viscosity index. The operation of Sundyne equipment in high or low ambient conditions may require special consideration of gearbox lubricant and/or supplemental protective equipment such as heat exchangers or gearbox heaters. The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that contains an inert additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne gearboxes. Use of lubricants containing inert additives will void the product warranty. Table 1: Use ISO Viscosity Grade 32 Lubricant ** Use ISO Viscosity Grade 46 Lubricant

Models: LMV/BMP-311 LMC/BMC-311F

LMC-BMC-311 LMV/BMP-313 LMC/BMC-313 LMV-322 All Sunflo Gearboxes HMP-3000 HMP-5000

Models: LMV/BMP-331 LMV/BMP-341 LMC/BMC-331F LMC/BMC-341F LMC/BMC-331P LMC/BMC-341P LMV/BMP-333 LMV/BMP-343 LMC/BMC-333 LMC/BMC-343 LMC/BMC-337 LMV-346 BMP-338 LMC/BMC-347 BMP-348

** Use ISO VG 46 lubricant for high ambient temperatures above 40 °C (100 °F).


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Recommended ISO VG 32 gearbox lube oil specifications: Gravity, API 28 - 37 Pour Point, °C (°F) -7 (20) max. Flash Point, °C (°F) 204 (400) min. Viscosity, cSt at 40°C cSt at 100°C SUS at 100°F SUS at 210°F

28.8 to 35.2 5.2 min. 150 to 180 44 min.

Viscosity Index 95 min. ISO Viscosity Grade 32 Color, ASTM D 1500 1.5 Neutralization Number, Maximum 0.20 Rust Protection, ASTM D 665, A & B Pass Demulsibility, ASTM D 1401 Time to 0 ml emulsion at 54°C (130°F) after 30 min. at 82°C (180°F) after 60 min.

Pass Pass

Foam Limits, ASTM D 892 Sequence 1 Sequence 2 Sequence 3

25/0 max. 50/0 max. 25/0 max.

Note: No other additives are recommended.

Recommended ISO VG 46 gearbox lube oil specifications: Gravity, API 28 - 37 Pour Point, °C (°F) -7 (20) max. Flash Point, °C (°F) 204 (400) min. Viscosity, cSt at 40°C cSt at 100°C SUS at 100°F SUS at 210°F

41.4 to 50.6 6.5 min. 217 to 260 48.8 min.

Viscosity Index 95 min. ISO Viscosity Grade 46 Color, ASTM D 1500 2.0 Neutralization Number, Maximum 0.25 Rust Protection, ASTM D 665, A & B Pass Demulsibility, ASTM D 1401 Time to 0 ml emulsion at 54°C (130°F) after 30 min. at 82°C (180°F) after 60 min.

Pass Pass

Foam Limits, ASTM D 892 Sequence 1 Sequence 2 Sequence 3

25/0 max. 50/0 max. 25/0 max.

Note: No other additives are recommended.


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Startup Refer also to the Critical Startup Checklist in this manual. If a Sundyne supplied control panel is to be used with the Sundyne LMV Pump, use the control

panel recommended start-up procedure in addition to the steps below. Before starting the LMV Pump, complete the following procedure in the order in which the steps are provided here:

Run-In of the Pump: If the pump(s) is to be run-in under conditions which are considerably

different from those that the unit is designed for (such as type of liquid suction pressure, flow rate, etc..) Sundyne should be consulted to insure that the run-in conditions are compatible with the pump.

Step 1 Make sure that the driver has been serviced as the manufacturer recommends. Step 2 For the auxiliaries: Check the connections of the utilities; verify that the auxiliary piping

meets the requirements shown in Reference C, Process and Instrumentation.

Step 3 Install flushing screens in all field-assembled piping connections. Clean these screens prior to commissioning. Check frequently for cleanliness and clean as needed.

Step 4 Vent seal cavity through seal vent (port 5 or port 6). Step 5 If buffer fluid or external seal flush auxiliary piping is required, this system should be

commissioned prior to admitting process fluid into the pump. If the buffer fluid is not operating, process fluid will leak out of the pump into the gearbox or atmosphere and damage to the mechanical seals will occur. Additionally, if the seal flush is not operating, contaminants may cause seal face damage. Refer to the section in this instruction manual for the Seals and Process End Disassembly.

Step 6 Prime the lubricating system, as follows:

All LMV-341 units require an auxiliary lubrication pump for start-up. • Fill the oil reservoir with lubricating oil in accordance with Gearbox Lubricant

Recommendations, Field Engineering Bulletin 40.2.04 • Add oil as necessary through the fill opening (see tagging information on the

LMV-341 gearbox) until the oil level stabilizes at the top of the bull’s eye in the sight glass

• Start the auxiliary lubricating pump, and run it until the oil reaches the correct pressure and temperature. Add oil as necessary until the oil level stabilizes 3/4 of the way from the bottom of the gearbox oil level sight glass.

Step 7 Turn on the cooling water to the lubrication system heat exchanger.

Step 8 For double seal configurations, the buffer system must be pressurized to the pressure

specified on the Sundyne specification sheet and/or on drawings prior to pressurizing the unit.

Step 9 Open suction valve. Open discharge valve to setting required to provide design flow. Step 10 Start Pump - adjust discharge valve to bring the pump to the design operating point. Step 11 Adjust cooling water supply to heat exchanger so that oil temperature to the bearings

stabilizes at 120ºF (49ºC) with ISO-32 oil or 120-140ºF (49-60ºC) with ISO-46 oil.


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3. Servicing General Requirements To increase the operating life of your pump and keep it in good operating condition, you should

inspect and service it regularly. Measure all of the operating parameters documented in the specific maintenance procedures and log your measurements. Make sure that all major equipment, such as lubricating pumps, heat exchangers, and instrumentation, perform according to the manufacturer’s recommendations. Whenever you find a deviation from specifications, identify its source immediately, and take any corrective steps that are required to bring the unit into manufacturer’s specifications.

Regular Maintenance Gearbox Oil: Check the level of the oil in the gearbox immediately before and after initial start-up,

and regularly while the pump is running. Be sure to keep the level of the oil at the top of the “bulls eye” in the sight glass.

You can add oil while the pump is running (see tagging information on the LMV-341 gearbox for

where to add oil during operation). The location is different from the “Initial Fill” location. Each fill location must be used for its tagged purpose.

Failure to add oil through the correct port on the LMV-341 gearbox will cause blow back of the lubricant, possibly causing injury to the operator.

DO NOT OVER FILL THE GEARBOX. This can cause damage to the internal components.

Oil Pressure: The correct oil pressure from the main pump of the gearbox depends on the configuration of the bearings and the characteristics of the lubricating oil used. In the normal operation, the oil pressure supplied to the gearbox should be between 25-60 psig (172-414 kPa). Recommended limits are 20 psig (138 kPa) decreasing alarm and 15 psig (103 kPa) decreasing shutdown.

Changing the Gearbox Oil and Filter: Change the oil in the reservoir and the oil filter elements

every 6 months. SFHC recommended synthetics may go for a longer period of time before an oil change is required.

Seal Leakage: Check the seal ports regularly. Excessive leakage is dependent on process liquid,

but considered as approximately one pint per week. If persistent excessive leakage is present, consider the use of a double or tandem seal configuration with a buffer fluid.

Anti-Friction Bearings: Roller bearings on the low speed shaft should be replaced at any of the

following times: after ten years, or if there appears to be unusual wear, or the bearings are assessed as damaged.

Driver: Inspect the driver to make sure that it performs according to the manufacturer’s

specifications. Coupling: Inspect the coupling according to the manufacturer’s specifications. Never operate the

pump without first checking the coupling guard.

A pump with a missing or incorrectly installed coupling guard could cause serious or fatal injury.


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4. Operation and Control of Sundyne Pumps: I. OPERATION While the application of the pump in any particular system is not within the scope of this instruction

manual, the importance of proper operation cannot be ignored. Several factors must always be considered. The experienced operator will be aware of the effects.

A.) SUCTION CONDITIONS: The most common reasons for improper centrifugal pump

operation are those relating to proper flow of liquid into the impeller. To avoid turbulence at the eye of the impeller, the suction pipe should be straight for a minimum of ten pipe diameters beyond the suction flange. Another rule of thumb is that suction piping should be at least one pipe size larger than the pump suction flange.

It is essential that liquid reaching the impeller eye have enough vapor pressure to prevent it

flashing to a gas in the impeller. The result of the liquid flashing is cavitation, a phenomenon which can cause damage to the impeller and inducer. Cavitation is noticeable as a “pumping gravel” noise in centrifugal pumps. In high speed single stage pumps this sound may not be discernible. The way to prevent cavitation is to maintain suction pressure at a high enough level and suction temperatures low enough to maintain Net Positive Suction Head available (NPSHa) greater than Net Positive Suction Head required (NPSHr) by the pumps (See Sundyne Specification Sheet).

B.) MINIMUM FLOW CONDITIONS: Centrifugal pumps can also experience vibrations from

internal flow separations and re-circulation at low flow conditions. The operator should be aware of the minimum flow recommendations of the manufacturer. While a pump can operate with some noise due to recirculation without harm to the pump, excessive noise and vibration are signs that the pump may be subject to damage if operation continues. Noise and vibration may be accentuated by resonance in the discharge line, especially when a control valve is located well down stream from the pump.

C.) ENTRAINED GASES: Entrained gases in the fluid will reduce the head and capacity of the

centrifugal pump. Normally it is considered that two to three percent entrainment is limiting. The pump has been found to operate very well under adverse conditions of gas entrainment. However, the operator should expect a reduction in performance.

D.) SYSTEM HEAD CURVE: The flow at which a centrifugal pump operates depends upon the

point of intersection of the system (head) curve with the pump characteristic (head versus flow) curve. In order for control to be steady, the system curve must intersect the pump characteristic curve at a significant angle, Examples of satisfactory and unsatisfactory angles of intersection are shown on the following diagram.


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NOTE: The curve for pump A has a significant angle of intersection with system curves D and E. The system curve D could represent a system with the control valve wide open while system E could represent the same system but with the throttle valve partially closed to reduce flow from flow 1 to flow 2. Pump curve B, on the other hand, will provide only flow 2, even with the control valve wide open (curve D). When the control valve is partially closed to create system curve E, the curve E and the lower pump curve B are nearly parallel. The lack of significant angle of intersection means that the pump flow is likely to drift aimlessly and not respond to control valve position.


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II. CONTROL

Proper operation of the Sundyne LMV pump (as with any other centrifugal pump) requires that the pump be operated in a range where (1) the system head curve and pump performance curve intersect at a significant angle (2) the pump does not operate below the minimum flow recommended and (3) the pump does not operate “in the break” or beyond the maximum capacity recommended. Rule of thumb would establish the maximum capacity as 10% beyond the design flow. Refer to the Sundyne Pump Control Bulletin for additional information.

III. PUMP CONTROL DURING START-UP

1. SINGLE UNITS A. Start pump with the suction valve open while throttling the discharge valve to bring the pump to the design operating point. B. If the pump must start against a high system back pressure and the process fluid is near to boiling, a bypass line back to the supply tank (preferably flow controlled) may be required to maintain minimum stable pump flow until the pump can establish flow through the system.

2. SERIES INSTALLATION In series operation, it is necessary to have a bypass from the discharge of the first stage back to the supply vessel. A block valve should be placed between the bypass line and the stage unit. Typical start-up procedure is as follows:

A. Open the suction and bypass block valves the first stage and close the suction blockvalve of the second stage B. Start the first stage unit and maintain design flow. C. Open the suction valve to the second stage unit and close the bypass. D. Start the first stage unit and control with discharge valve until design flow and head is maintained.

3. PARALLEL OPERATION Check valves must be placed in the discharge piping of each pump to prevent back-flow when one unit is started prior to others. It is advantageous to install separate bypass loops around eachpump for additional operational flexibility.

A. Start first unit as described above for single units. B. Start second unit on bypass and maintain minimum flow. Open discharge valve on second unit and maintain the design flow of both units. It is preferable that the units not operate at their peak head capability.


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5. Process End Disassembly and Maintenance of the Seals

This section provides the procedure for disassembling the Sundyne LMV Pump and its seal housings for maintenance of the seals. Refer to the Sundyne Pump Specification Sheet to determine the specific configuration and optional equipment included in your unit. Item Numbers in Parentheses throughout the text correspond to item numbers in the illustrations and parts lists.

Follow your organization’s Lock-out/Tag-out instructions before working on the pump. Failure to follow adequate Lock-out/Tag-out procedures could cause serious injury.

Tandem Seal Configurations:

Disconnect the seal buffer system before draining the pump. Tandem seal buffer fluids are typically supplied at atmospheric pressure.

Double Seal Configurations:

The pump must be drained before the seal buffer system is depressurized, otherwise reverse pressure may cause the inboard seal to fail.

Only Sundyne factory parts should be used for replacements, especially those affecting assembly

stackup such as shaft sleeves and mating rings. Failure to do so can lead to premature failure. The following replacement parts will be required as a result of pump disassembly and seal housing

removal:

Table 6.1 PART DESCRIPTION ITEM NUMBER QUANTITY O-Ring Packing 936A 1 O-Ring Packing 936B 1 O-Ring Packing 936C 1 O-Ring Packing 936D 1 O-Ring Packing 936E 1 O-Ring Packing 936G 1 O-Ring Packing 936H 2 O-Ring Packing 936J 2 O-Ring Packing 936Z 1 O-Ring Packing 936V 1 Lower Seal 60A 1 Upper Seal 60B 1 Thermal Barrier Gasket 87A 1

NOTE: An O-Ring repair kit is available, containing the O-Rings required to replace the gearbox and pump mechanical seals.


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Reference Shutdown Procedure: Step 1 Disconnect the piping between the heat

exchanger and the gearbox. If your unit has a remote oil filter; disconnect the piping from the remote filter to the gearbox. Remove bolts (909D) securing the coupling guard. Remove the coupling guard. Disengage both ends of the coupling spacer and remove the center section. Attach hoist to the gearbox using eyebolts in the tapped holes on the upper housing. Remove nuts (914A) from the pump housing studs. Remove the gearbox and seal housing from the pump housing by lifting them with a crane. Place gearbox on a suitable support with the impeller facing upward. (Sundyne support stand shown in the figure to the left.)

NOTE: The diffuser can be removed from the pump case at this time. To remove the diffuser insert three 5/6”-18 eye bolts into the top of the diffuser (13). Loosely thread a length of rope through these eye bolts and tie ends together. Grasp the rope between the 5/16”-18 eye bolts and lift the diffuser (13) clear of the pump case. Removing the diffuser from the pump case requires that the o-rings (936B), and (936C), be replaced upon reassembly.


20

Step 2 Prevent impeller (2) from rotating and

bend locking tab washer clear of impeller vanes. Unscrew inducer (9), which has left-hand threads, to remove.


21

Step 3 Remove impeller (2). It may be necessary to pry under the impeller and cover (15) to loosen it from the shaft. Pry on opposite sides of the impeller so that the impeller is removed evenly. Unscrew impeller bolt (3), which has left-hand threads, to remove.

The impeller is dynamically balanced and should be replaced or rebalanced if it shows any sign of damage.

Step 4 Remove diffuser cover (15) from seal

housing (30).

Use a flat blade screw driver inserted into pry slot of cover (15) to help lift cover from seal housing (30).


22

Step 5 Remove the seal rotating face (51a). Step 6 Remove hex head cap screws (905E),

washers (916A) and remove lower mechanical seal (60A) from the seal housing.


23

Step 7 Remove spacer sleeve (66). Step 8 Remove o-ring (936J). Step 9 Tandem or double seal arrangements

only: Remove upper seal rotating face (51B).

Use two small screwdrivers to lift up the rotating face.


24

Step 10 Remove the hex head cap screws (905A),

lock washers (154AT), and flat washers (916AG) from seal housing (30).


25

Step 11 Install two 3/4” eye bolts, approximately

180° from each other, through the seal housing (30) flange face.

Step 12 Lift seal housing (30) from gearbox.

Use hoist and equal length chain hooks attached to the two 3/4” eye bolts to lift seal housing off the gear box.


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Step 13 Turn seal housing (30) over so you can

see the upper seal (60B), and remove the Thermal Barrier Gasket (87A).

It may help to have people on hand to assist in rotating the seal housing.

Step 14 If the upper seal (60B) needs to be

removed, remove hex head cap screws (905A), and lock washers (916B).


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Step 15 Remove the upper mechanical seal (60B).

Carefully inspect the seals for abrasive particles and excessive seal face wear while in the retainer. Replace or rebuild any faulty mechanical seal. Seals may be rebuilt by replacing the carbon seal nose, o-ring, and springs, providing the retainer is not damaged or heavily worn. A seal repair kit may be available; contact your customer representative or the factory. Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than .0002 inch (.0051 mm).

Step 16 Remove spacer sleeve (50B) from high

speed shaft. Note: o-ring (936J) will be lifted off the high speed shaft along with the spacer sleeve (50B).

Clean and inspect all items for unusual wear or damage. Replace all worn parts and o-rings during reassembly.

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7. Gearbox Disassembly Note: In order to disassemble gearbox it is necessary to complete steps 1 through 16 of the

Process End Disassembly.

Step 1 If you have not drained the oil from the gearbox you should do so now. Remove hex head cap screws (905E) and lock washers (916A) from the gearbox seal (60C) flange.

Step 2 Remove gearbox seal (60C).

It is helpful to use a small flat blade screw driver to lift the seal flange up from the aluminum gearbox face, being careful not to hit the I.D. of the seal face against the high speed shaft (A130 ASSY).


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Step 3 Carefully inspect the seal for abrasive particles or excessive seal face wear and any binding of the carbon seal nose. Replace or rebuild any faulty mechanical seal. Seals may be rebuilt by replacing the carbon seal nose, o-ring, and spring providing the retainer is not damaged or heavily worn. Replace the seal flange o-ring (936P). A seal repair kit may be available; contact your customer representative or the factory.

Step 4 Remove o-ring (936K).

Step 5 Remove rotating face (51D).

Use two small flat blade screw drivers to help lift rotating face out of pocket in the gearbox taking care not to damage the gearbox seal o-ring chamfer at the I.D. of the rotating face (51D). Inspect the rotating face for any cracks, chips, or grooves. If any cracks or chips are present replace the rotating face. Replace or lap the seal rotating face if the wear track is rough or worn to a depth greater than .0002 inch (.0051 mm).


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Step 6 Rotate gearbox in holding device so that the input shaft (A120 ASSY) is now pointing up. Make certain that the gearbox is steady and held in place by clamps. Remove nuts (914F) and (914E), remove flat washers (916J) and (916H). Next remove the 2 alignment bolts (909C) and 7 holding bolts (909B), and flat washers (916H) and (916J) making sure that the alignment bolts are removed first.

Step 7 Remove the four round hex head socket screws (included with item 115) located on the top of the input seal (115).

Failure to remove these screws and input seal drive lock collar will result in damage to either the input seal (115) and/or the input shaft (A120 ASSY).


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Step 8 Gently pry input seal drive lock collar (included with item 115) located on the top of the input seal (115) to remove.

Step 9 Remove Inlet Housing Install two 5/8” eye bolts into the top of the upper gearbox housing (101B). Use a hoist to lift the upper gearbox housing (101B) away from the other gearbox housings.

At the start of lifting of the upper gearbox housing, gently tap the input shaft if necessary to free it from the upper housing.


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Step 9 Continued

It is a good idea to look into the upper gearbox housing (101B) and verify that the idler shaft assembly (A140 ASSY) is free of upper gearbox housing. If it is not free, loosen the shaft by hand before lifting the upper gearbox further.

Step 10 After the mechanic rests the upper gearbox housing (101B) on a bench or table remove the input seal (115) from the upper gearbox housing (101B). Inspect seal. If it was leaking or is damaged replace input seal (115) with a new item.

Step 11 Remove Input Shaft Assembly To accomplish this the mechanic must first lift up the idler shaft assembly (A140 ASSY) and tilt it away from the input shaft assembly (A120 ASSY).


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Step 11 Continued The mechanic should install a lifting eye to the input shaft assembly (A120 ASSY) and lift straight up and away from the bearing plate (102). Note: The top of the input shaft includes 3/8-16 UNC threads to install a lifting eye.

Step 12 Lube Pump Removal If it is necessary to remove the lube pump follow steps 12-14. Otherwise skip ahead to step 15. It is necessary to remove the sump tube assembly before removing the lube pump. Loosen the tube-fitting nut and remove sump tube TU03AW03 or TU03AW04.

Step 12 Continued Remove the tube fitting and nipple from the bearing plate.


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Step 13 Remove the 2 socket head cap screws (905BU), 10-24 x 2.5” long screws, from the lube pump assembly (A160 ASSY). There are two screws that hold the lube pump in place and two screws that hold the lube pump together. If by chance when removing (905BU) you loosen the shorter screws, replace immediately and move to the next screw on the lube pump assembly (A160 ASSY).

Step 14 Install two 1/4”-20 screws into the top of the lube pump assembly (A160 ASSY). These screws are used to pull the lube pump assembly (A160 ASSY) out of the bearing plate (102).


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Step 14 Continued Remove the lube pump assembly (A160 ASSY) from the bearing plate (102). Step 15 Remove the pressure relief valve (175) from the top of the bearing plate (102). (Pictured in the lower right corner of the photograph). Inspect the pressure relief valve (175) for any foreign matter. If any particles or sludge is found replace with a new pressure relief valve (175). Remove 1/2” NPT pipe plug (924M) from the top of the Bearing plate (102). Remove o-rings (936T) and (936Y), from the lower bearing plate (102) and replace with new items (936T) and (936Y) during reassembly.

Step 16 Remove the bearing plate (102) from the lower gearbox housing (101A). Make certain you use the 5/8” eyebolts to lift evenly and slowly.

It is a good idea to use a hoist with equal length chains and hooks to facilitate an even lift of the bearing plate (102). If the bearing plate (102) is not lifted evenly it will catch the upper high speed journal bearing (151B) on the high speed shaft (A130 ASSY) and possibly damage the shaft or the bearing.

Step 17 Move the bearing plate to a workbench or table. Remove and inspect the upper high speed journal bearing (151B) and the upper thrust washer (155B) from the bearing plate (102). First remove the 3 hex head cap screws (905N) and lock washers (154E). Next pull the high speed journal bearing (151B) from the bearing plate (102). Save shim (158). Inspect the bearing for rub marks or uneven wear marks. If the bearing has scratches or dings or any unusual wear replace the upper high speed journal bearing with a new item (151B). If the upper high speed journal bearing checks good, tag the bearing as upper high speed journal bearing (151B). This will help insure it does not become mixed up with the lower high speed journal bearing (151A). Inspect the thrust washer (155B). If there are any burns or rubs replace the thrust washer (155B).


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Step 18 Remove idler shaft (A140 ASSY). To do this the mechanic must lift the high speed shaft (A130 ASSY) slightly while pulling the idler shaft (A140 ASSY) up and away from the high speed shaft (A130 ASSY).

Step 19 Remove the high speed shaft (A130 ASSY).


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Step 20 Remove Lower Idler Bearing Remove the 2 socket head cap screws (905AB) from lower idler journal bearing (151D). Remove the lower idler journal bearing (151D). Use bearing puller tool TK01AW02 available from Sundyne. Thread two 1/4”-20 screws through the tool into the top of the lower idler journal bearing (151D). Thread the bearing puller into the lower idler journal-bearing cavity and pull (jack) the lower idler journal bearing (151D) out of its location. Inspect the lower idler journal bearing (151D) for any unusual wear, rubs, scratches, or burns. If any abnormalities are found replace the lower idler journal bearing (151D) with a new item.

Step 21 Remove Upper Idler Bearing Remove socket head cap screws (905AA) from the upper idler journal bearing (151C) located in the upper gearbox housing (101B). Remove the upper idler journal bearing (151D) following the same procedure as step 20 above. Use bearing puller tool TK01AW02 available from Sundyne. Thread two 1/4”-20 screws through the tool into the top of the upper idler journal bearing (151D). Thread the bearing puller into the upper idler journal-bearing cavity and pull (jack) the upper idler journal bearing (151D) out of its location. Inspect the upper idler journal bearing (151D) for any unusual wear, rubs, scratches, or burns. If any abnormalities are found replace the lower upper journal bearing (151D) with a new item.

Step 22 Remove Lower High Speed Bearing Remove socket head cap screws (905M) and lock washers (154D) from lower high speed journal bearing (151A). Remove thrust washer (155A) by lifting up and off the lower high speed journal bearing (151A). Inspect the thrust washer (155A) for any abnormal wear, burns, scratches or rubs. If any of these conditions are found, replace the thrust washer (155A) with a new item.


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Step 23 Remove the lower high speed journal bearing (151A) by pulling it straight up and out of the lower housing. Inspect the lower high speed journal bearing (151A) for any rubs, unusual wear marks or scratches. If anything appears abnormal replace the bearing (151A) with a new item. If the bearing checks out good then tag bearing as lower high speed journal bearing (151A), so it does not become mixed up with the upper high speed journal bearing (151B). Step 24 Remove the oil filter (185). Step 25 Remove o-rings (936T), (936T), and (936Y), from the lower gearbox housing (101A) and replace with new items (936T), (936T), and (936Y) during reassembly.

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8. Inspection of Disassembled Hardware

Step 1 Clean and wash all gearbox housings (101B), (102), and (101A) with solvent and blow

dry with clean high pressure air. Step 2 Make certain to flush out all lube passages and blow dry with clean high pressure air.

Check all lube passages with a flashlight to verify cleanliness. Step 3 Inspect all bearing locations for critical size requirements (see Table 8.1). If any

dimensions are found to be out of tolerance replace that housing. Step 4 Inspect all bearings for damage. If any damage is found replace the bearings with new

items. Step 5 Inspect all shaft bearing surfaces for scratches, burns, dents, or dings. If bearing

surfaces on shafts are burned and/or scored the shaft should be replaced. Scratches, nicks, or dings on shafting should be lightly stoned and polished to remove high spots.

Step 6 Check shaft runnouts for trueness. Replace shaft if it is bent. Step 7 Inspect all shafts with gears. If gears are missing teeth, or are burned, replace gear or

integral gear shaft as required. If gears show abnormal wear patterns, or have nicks and dings on the gear teeth, lightly stone or hone and polish nicks and dings from gear teeth. If abnormal wear pattern is evident this could indicate a bent shaft.

Step 8 Inspect the bearing thrust faces on the idler shaft (A140 ASSY). If thrust faces are burned

or scored, replace the shaft. Check the thrust surface on the lower spur gear for abnormalities, replace as necessary.

Step 9 Inspect the thrust face on the idler spur gear, which is pressed onto the idler shaft (A140

ASSY). If the thrust face on this gear is burned or scored replace this gear. If there are nicks or dings in the thrust face lightly stone or hone and polish these areas back to the original surface.

Step 10 Inspect the internal lube pump (A160 ASSY) o-ring seal groove. If there are any nicks or

dings in this area polish or hone them back to the original surface. If this cannot be accomplished replace the lube pump (A160 ASSY). If your gearbox had a catastrophic lube failure due to the lube pump (A160 ASSY) you should replace the lube pump as a complete assembly.

Step 11 Inspect the gearbox seal (60C). If the carbon seal nose is nicked, scratched, or dinged,

disassemble the seal and try to lap the seal nose back into tolerance. The flatness specification is two light bands or .00002” (.00051 mm) flatness minimum. If this cannot be achieved replace the carbon seal nose. Check the constant force spring inside the seal retainer. If it is cracked, bent or deformed other than the cone shape, it should be replaced. Contact your customer service representative for part numbers on this seal.


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Step 12 Inspect all the sleeves and spacers that were disassembled from the high speed shaft, process end. If there are any nicks or dings in the sleeves or spacers lap the locating surfaces back into tolerance. The specification for these sleeves and spacers is two light bands flatness or .00002” (.00051 mm) and parallel conditions between the faces of the sleeves or spacers of .0003” (.0076 mm) maximum. If these specifications cannot be maintained then replace the sleeves or spacers with new hardware.

Step 13 Inspect the process seals (60A and 60B). If the carbon seal nose is nicked, scratched or

dinged, disassemble the seals and lap the seal nose back into tolerance. Specification for flatness on these seal noses are two light bands or .00002” (.00051 mm) flatness. Install a seal repair kit for the specified seals in your unit. See your Sundyne Pump Specification Sheet or Recommended Spare Parts List for the part numbers.

Step 14 Inspect all rotating faces in your unit (process and gearbox). If rotating faces are nicked,

cracked, or have wear rings from seal contact replace them with new hardware. Check the flatness of the rotating faces to factory specifications. Flatness is specified at two light bands or .00002” (.00051 mm) flatness. The gearbox seal rotating face (51D) is to have a matte finish. specified as 10-15 Ra micro finish, while still maintaining the flatness of .00002” (.00051 mm) or two light bands.

Step 15 Inspect the high speed shaft shoulder where the gearbox seal rotating face locates.

Check for nicks or dings, and raised surfaces on this shoulder. If any abnormalities are found, the shoulder will need to be relapped to factory specification of two light bands flatness or .00002” (.00051 mm). If this specification cannot be met replace the high speed shaft (A130 ASSY).

Step 16 Inspect the high speed shaft (A130 ASSY) thrust surfaces. If these show abnormal wear,

burns, gouges, deep circular scratches or wear patterns, replace the high speed shaft (A130 ASSY) with a new assembly.

Step 17 Lubricate all other parts thoroughly with light turbine oil.

Table 8.1 Item No. Description Characteristics Critical Size

±.0005” (.013 mm) 101A HO06AW03, Upper, G’box

Housing Upper, Input Bearing Bore Ø 4.7256” (110.010 mm)

Upper, Idler Bearing Bore Ø 3.6255” (92.088 mm) 102 PL01AY04 Bearing Plate Lower Input Bearing Bore Ø 4.3311” (110.010 mm)

Upper High Speed Shaft Bearing Bore

Ø 3.1880” (80.975 mm)

101B HO05AW03 Lower, G’box Housing

Lower, High Speed Shaft Bearing Bore

Ø 3.1880” (80.975 mm)

Lower, Idler Bearing Bore Ø 3.6255” (92.088 mm)


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9.0 Bearing and Shaft Clearances Idler Shaft Upper Bearing (400 HP Gearbox Only) Maximum clearance for replacement: 0.0085 inches (.22 mm)

Lower Idler Bearing & Shaft Clearances Maximum clearance for replacement: 0.0063 inches (.16 mm)

Input Shaft Upper Bearing


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Input Shaft Lower Bearing

Journal Bearing and High-Speed Shaft Clearances Maximum clearance for replacement: 0.0055 inches (.14 mm)

Tilting Pad Thrust Bearing and High-Speed Shaft Clearances Maximum clearance for replacement: 0.0055 inches (.14 mm)

Tilting Pad Radial and High-Speed Shaft Clearances Maximum clearance for replacement: 0.0055 inches (.14 mm)

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10. High Speed Shaft End Play If a new high speed shaft assembly (A130 ASSY), lower gearbox housing (101A), upper or lower high speed journal bearing (151A or 151B), or thrust washers (155A or 155B) are installed, the high speed shaft end play must be measured and reset. NOTE: For accurate checking of shaft end play, all parts must be dry and free of oil. Step 1 Install the lower high speed journal bearing (151A) into the lower gearbox housing

(101A). Install the hex head cap screws (905M) and the lock washers (154D). Tighten screws (905M) to the specified torque per table 9.1.

Step 2 Install the upper high speed journal bearing (151B) into the bearing plate (102). Install the

hex head cap screws (905N) and lock washers (154E) and tighten to the specified torque per table 9.1.

Step 3 Place both thrust washers (155A and 155B) into lower high speed journal bearing. Install

the high speed shaft assembly (A130 ASSY) into the lower gearbox housing (101A) through the lower high speed shaft journal bearing (151A).

Step 4 With the aid of two large diameter alignment bolts (909C), install the bearing plate (102)

without the o-rings (936T), (936T) and (936Y). Clamp the bearing plate (102) and the lower gearbox housing (101A) together with two “C” clamps or bolts.

Step 5 With the shaft in a vertical position, move the shaft up and down while measuring the

total end play with a dial indicator or depth micrometer. Shaft end play must be .015 +/-.002 inch (.38+/- .05 mm). If end play is not within this limit, calculate the shim thickness required to place the shaft within the proper end play. Select the required thickness shim using (158) series shim spacer sizes.

Step 6 Remove the alignment bolts (909C) and the “C” clamps from the bearing plate (102) and

lower gearbox housing (101A). Now remove the bearing plate (102). Step 7 Remove the upper high speed journal bearing (151B) from the bearing plate (102). Step 8 Place the required shim thickness (158) over the upper high speed journal bearing

(151B) and reinstall per step 2. Step 9 Repeat steps 3 through 5, and verify high speed shaft (A130 ASSY) end play. When end

play is within factory specification, repeat step 6. Step 10 Remove the high speed shaft (A130 ASSY) and the thrust washers (155A and 155B). Step 11 Install thrust washer (155A) into lower high speed shaft journal bearing (151A) and install

thrust washer (155B) into the upper high speed journal bearing (151B) with the flat side (no grooves) of each thrust washer towards the high speed journal bearing.

Step 12 Lubricate the upper and lower thrust washers (155A and 155B) with light turbine oil and

install the high speed shaft (A130 ASSY) into and through the lower high speed journal bearing.


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Step 13 Begin gearbox reassembly. Refer to the Gearbox and Process End Reassembly Procedure.

Step 14 Lubricate all assembled parts with light turbine oil as your mechanic proceeds with the

assembly.

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Table 9.1. Torque Values Gearbox

Sundyne Standard Steel Screws & Bolts and NACE Compliant Steel Screws/Bolts (BG Material) Torque Values

Item # Location Size English Metric 905H Oil Filter Manifold 3/8 - 16 x 1/2 22 - 25 ft-lbs 30 - 34 N-m 905L Gearbox Seal 1/4 - 20 x 1/2 75 - 80 in-lbs 8.5 - 9.0 N-m 905M, N Journal Bearings #10 - 24 x 1 35 - 40 in-lbs 4.0 - 4.5 N-m 905T Chemical Barrier Gasket 1/4 - 20 x 5/8 75 - 80 in-lbs 8.5 - 9.0 N-m 909B Gearbox Halves 1/2 - 13 x4 60 - 65 ft-lbs 81 - 88 N-m 909C Gearbox Halves, Alignment 5/8 - 18 x 4 17/64 60 - 65 ft lbs 81 - 88 N-m 906B Sight Glass #8 - 32 x 1/2 10 - 12 in-lbs 1.0 - 1.4 N-m

Pumps & Compressors* Sundyne Standard Steel Screws and Bolts

Torque Values Item # Location Size English Metric

3 Impeller Bolt/Inducer: LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m LMV-313, 343, BMP-338, 348 (High

Flow) 3/4 - 10 85 - 90 ft-lbs 115-122 N-m

LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m 906D Diffuser Attaching Screws 1/4 - 20 95 - 102 in-lbs 11 - 11.5 N-m 905E Mechanical Seal No. Spacer 1/4 - 20 x 12 95 - 102 in-lbs 11 - 11.5 N-m 905F Throttle Bushing/Mechanical Seal 1/4 - 20 x 12 9 5- 102 in-lbs 11 - 11.5 N-m 905G Double Seal with Spacer 1/4 - 20 x 3/4 95 - 102 in-lbs 11 - 11.5 N-m 914A Case Nuts 3/4 - 10 250 - 275 ft-lbs 340 - 375 N-m 914A Case Nuts 7/8 - 9 300 - 330 ft-lbs 405 - 445 N-m 905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 35 - 40 ft-lbs 47 - 54 N-m 905P Separator 1/4 - 20 x 5/8 95 - 102 in-lbs 11 - 11.5 N-m

Pumps & Compressors NACE Compliant Steel Screws / Bolts (BG Material)

Torque Values Item # Location Size English Metric

3 Impeller Bolt/Inducer: LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m LMV-313, 343, BMP-338, 348 (High

Flow) 3/4 - 10 85- 90 ft-lbs 115 - 122 N-m

LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m 906D Diffuser Attaching Screws 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 905E Mechanical Seal No. Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 905F Throttle Bushing/Mechanical Seal 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 905G Double Seal with Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m 914A Case Nuts 3/4 - 10 160 - 200 ft-lbs 217 - 270 N-m 914A Case Nuts 7/8 - 9 225 - 245 ft-lbs 305 - 332 N-m 905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 27 - 30 ft-lbs 47 - 54 N-m 905P Separator 1/4 - 20 x 5/8 70 - 75 in-lbs 8.0 - 8.5 N-m * When using Teflon® o-rings, allow 15 minutes between torquing for the Teflon® to cold flow. Repeat torquing until there is no change in torque.


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10. Gearbox and Process End Reassembly Step 1 Wash all gearbox housings and be certain the lubrication galleys are clear. Step 2 Attach the sight glass (191) using socket head cap screws (906B), and tighten to

specified torque per table 9.1. Step 3 Put pipe plugs (924A, 924AJ, 924R, and 924RP) in lower gearbox housing (101A). (As

applicable.) Step 4 Freeze lower idler journal bearing (151D) in dry ice for 1/2 hour and install into lower

gearbox housing (101A) with socket head cap screws (905AB). Step 5 Install lower thrust washer (155A) into bearing (151A) with grooves facing away from

bearing. No shims will be used at this position. Install the lower high speed journal bearing (151A) into the lower gearbox housing (101A). The lower high speed bearing can be distinguished from the upper high speed bearing by a hole in its flange that engages a pin in the lower gearbox housing. Apply blue Locktite 243 (or equivalent) to the hex head cap screw (905M) threads and install the screws and lock washers (154D). Tighten screws (905M) to the specified torque per table 9.1.

If the unit has vibration probes in the lower position, the probe brackets will be attached to the high speed bearing. In this case two of the hex head cap screws (905M) will be replaced with #10-24 studs, washers and nuts for attachment of the bearing and probe bracket. Apply red Locktite 272 (or equivalent) to the stud threads before installing.

Step 6 Install the high speed shaft assembly (A130 ASSY) into the lower gearbox housing

(101A) through the lower high speed shaft journal bearing (151A). Step 7 Install lube oil pump (A160 ASSY) with o-ring (936Z) into bearing plate (102), using

socket head cap screws (905BU) and lock washers (154Z). Lubricate o-ring (936Z) with compatible lubricant before installing lube pump. Before tightening the cap screws, verify that the threaded port of the lube pump is visible through the hole in the wall of the bearing plate.

Step 8 Install sump tube nipple (944B) and connector (944C) into the bearing plate (102). Step 9 Install pipe plugs (924AT, RL, RR, RX, Q, and QA) as required and relief valve (175) into

bearing plate (102). Step 10 Install the upper high speed journal bearing (151B) into the bearing plate (102). Apply

blue Locktite 243 (or equivalent) to the hex head cap screw (905N) threads and install screws and lock washers (154E) and tighten to the specified torque per table 9.1. Install upper thrust washer (155B) into bearing (151B) with grooves facing away from bearing. Use Vaseline to hold upper thrust washer in place.

If the unit has vibration probes in the upper position, the probe brackets will be attached to the high speed bearing. In this case two of the hex head cap screws (905M) will be replaced with #10-24 studs, washers and nuts for attachment of the bearing and probe bracket. Apply red Locktite 272 (or equivalent) to the stud threads before installing.


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Step 11 Set high speed shaft (A130 ASSY) end play. NOTE: SHIM BEHIND THE UPPER HIGH SPEED JOURNAL BEARING ONLY TO ACHIEVE

.015 +/- .002 inches (.38 +/- .05 mm). See previous section on setting High Speed Shaft End Play.

Step 12 Install idler shaft (A140 ASSY). Pull high speed shaft (A130 ASSY) up approximately 1.0”

to 1.5” (25.4 to 38.1 mm) and slide idler shaft (A140 ASSY) into the lower idler journal bearing (151D), meshing the gear teeth on the lower idler shaft spur gear and the high speed shaft gear.

Step 13 Install o-rings (936Y , 936T, and 936T) into the lower gearbox housing (101A).

Step 14 Install the bearing plate (102) onto the lower gearbox housing (101A). Be careful not to knock the upper thrust washer (155B) out of its location. Be careful not to scratch, ding, or dent the upper high speed journal bearing (151B).

Step 15 Install o-rings (936Y and 936T), into the bearing plate (102). Step 16 Install lower input shaft roller bearing (125D) race into the top of the bearing plate (102)

so it locates against the lube pump (A160 ASSY). Step 17 Install the sump tube (173) into the sump tube fitting (944C).

Step 18

Pull up on the idler shaft (A140 ASSY) approximately 1.0” to 1.5”. Install the input shaft assembly (A120 ASSY) into the bearing plate (102) and mesh the input shaft assembly (A120 ASSY) gear with the idler shaft (A140 ASSY) gear. Make certain that the slot in the lower end of the input shaft fits over the lube pump (A160 ASSY) drive pin.

Step 19 Freeze upper idler journal bearing (151C) in dry ice for 1/2 hour. Install the upper idler

journal bearing (151C) into the upper gearbox housing (101B). Use socket head cap screws (905AA) to secure the upper idler journal bearing (151C) to the upper gearbox housing (101B).

Install flatfoot input seal anti-rotation device in upper gearbox housing.


48

Step 20 Install the upper gearbox housing (101B) onto the bearing plate (102). Make sure that the upper input bearing race and the input shaft are leveled before installing the upper housing.

Step 21 Install alignment bolts (909C) and washers (916J) through gearbox housings. Install nuts

(914F) and washers (916J) onto alignment bolts (909C) and tighten to specified torque per table 9.1.

Step 22 Install fasteners (909B) and washers (916H) through gearbox housings. Install nuts

(914E) and washers (916H) onto fasteners (909B) and tighten to specified torque per table 9.1.

Step 23 Install Input Seal

t Before installing the input seal, note the location of the flat-foot anti-rotation device in the upper gearbox housing.

Step 23 Continued Note the flat on the seal, which is to be aligned over the flat foot in upper gearbox housing.


49

Step 23 Continued Remove the four round hex head socket screws (included with item 115) and the locking plate located on the top of the input seal (115). Retain these parts for reassembly. Install input seal (115) over input shaft assembly (A120 ASSY) and press into the upper gearbox housing (101B), seating the input seal (115) firmly against the locating shoulder in the upper gearbox housing (101B). To ease assembly, Tool T-HO06AY-47 is available from Sundyne. Gently tap insertion tool if necessary to fully seat the seal.

Step 23 Continued Re-install the locking plate and four hex head socket screws into the top of the input seal (115).

Step 24 Turn the complete gearbox assembly over so the high speed shaft (A130 ASSY) is

pointing vertically toward the ceiling and the lower gearbox housing (101A) is on top. If there are pins in the gearbox at the seal mating face, be sure that the slots on the seal face align with the pins.

Step 25 Install the rotating face (51D) over the high speed shaft (A130 ASSY) with the chamfer in

the rotating face (51D) toward the high speed shaft shoulder (A130 ASSY). Step 26 Install the roll pin (918D) into the lower gearbox housing (101A). Use a soft mallet to seat

the roll pin (918D) into place. Step 27 Assemble seal o-ring (936P) to seal (60c).


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Step 28 Install the gearbox seal (60C) onto the lower gearbox housing (101A). Use socket head cap screws (905E) and lock washers (916A), and tighten to specified torque per table 9.1.

Step 29 Install o-ring (936H) and upper process seal (60B) or throttle bushing (21B) into seal

housing (30). Step 30 Deleted Step 31 Install o-ring (936K), sleeve (50) or (50B), onto high speed shaft (A130 ASSY). Step 32 Install o-ring (936J). Step 33 Install thermal barrier gasket (87A) onto seal housing (30). Step 34 Install seal housing (30) onto lower gearbox housing (101A). Step 35 Install hex head cap screws (905A), lock washers (154AT) and flat washers (916AG)

through seal housing (30) and tighten screws to specified torque value, see Table 9.1. Step 36 Install rotating face (51C) over high speed shaft (A130 ASSY). Step 37 Install o-ring (936J) over high speed shaft (A130 ASSY). Step 38 Install sleeve (50A) over high speed shaft (A130 ASSY). Step 39 Install o-ring (936J) over high speed shaft (A130 ASSY). Step 40 Install o-ring (936H), lower process seal (60A) into seal housing (30). Step 41 Install o-ring’s (936D), (936E), onto cover (15). Step 42 Install cover (15) onto seal housing (30). Step 43 Install rotating face (51A) over high speed shaft (A130 ASSY). Step 44 Install impeller bolt (3) into high speed shaft (A130 ASSY).

Note: The LMV-341 impeller bolt is not the same as is used for other Sundyne pumps. Due to a higher torque value, different material was required.

Step 45 Install impeller (2) over impeller bolt (3). Step 46 Install tab washer (5) onto impeller (2). Step 47 Install inducer (9) onto impeller bolt (3). Step 48 Tighten inducer (9) to correct torque specification, see Table 9.1. Step 49 Install initial fill pipe (951D), (947L), and (924RF) into upper gearbox housing (101B). Step 50 Install vent pipe (951C), (947D), and (186) into upper gearbox housing (101B).


51

Step 51 Install pressure gauge (942F), (177), and (193C), into upper gearbox housing (101B). Step 52 Reinstall the assembly of the gearbox/process end into the pump housing (1). Step 53 Reconnect all lubrication lines and electrical connections.


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11. Spare Parts

1. General Assemblies, subassemblies and components of the Sundyne LMV-341 pumps are illustrated

on the exploded and cross sectional views in Appendix A. Refer to your Sundyne Pump Specification Sheet for those options applicable to your pump. The corresponding parts lists, keyed to each part by item number, identify detail parts by part name, quantity and location.

2. Recommended Spare Parts Refer to your final data package for recommended spare parts identified for your particular unit.

These are provided as guidelines only. 3. Repair Kits Seal and O-ring repair kits are not illustrated herein, but may be purchased directly from

Sundyne Corporation. Seal repair kits contain all normal wearing parts (springs, washers, o-rings, carbon faces, etc.) of the pump or gearbox mechanical seals.

O-ring repair kits contain all o-rings necessary for maintenance or overhaul of the pump. The

use of these kits reduces maintenance time, prevents assembly mistakes, simplifies stocking and inventory, and reduces delivery time.

4. Ordering Spare Parts When ordering spare parts, give the unit serial number and list each part by the part number as

shown on the Bill of Material which is included with each pump shipment (preferred method), or list each part by item number (as listed in this manual), part name and pump model. Specify quantities desired.

Order parts from your Fluid Handling representative or directly from Sundyne Corporation at

one of the following locations. Sundyne Corporation Phone Number: +1-303-940-2989 14845 West 64th Avenue Fax Number: +1-303-940-2826 Arvada, Colorado 80007, USA Sundyne Corporation Europe Phone Number: +011-33-80-38-33-00 (13-15 Boulevard Eiffel Fax Number: +011-33-80-38-33-66 Zone Industrielle De Dijon-Sud 21600) B.P. 30 21604 Longvic Cedex France

Sundyne Nikkiso PHONE: +81-3-3444-6475 27-10, Ebisu 2-Chome, Shibuya-Ku FAX: +81-3-3444-6806 Tokyo 150-0013, Japan

Or visit our Genuine Service and Parts site at www.sundyne.com.


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LMV/BMP-341

RECOMMENDED SPARE PARTS LIST

FLUID END ITEMS TYPICAL CLASS (2)

LOC NO. OPTION (1) PART NUMBER DESCRIPTION 1 2 3 3 NIN BO03AAxxxx BOLT, IMPELLER 0 1 1 5 IN WA02AA01xxx WASHER, TAB 1 1 2 10 IN ST06AA01xxx STUD, INDUCER 0 1 1

21B SS BU02AW02xx1 BUSHING, THROTTLE 1 1 2 50 SS SL01AW02xx SLEEVE 0 1 1

50A DS,TS SL01AW0xxx SLEEVE, LOWER 0 1 1 50B DS,TS SL01AW04xx SLEEVE, UPPER 0 1 1 51A SS,TS RJ09AW03xx RING, MATING, LOWER 1 1 2 51C DS,TS RJ09AW06xxxx RING, MATING, UPPER 1 1 2 60A SS,TS SE04AAxxx SEAL, LOWER 1 1 2 60B DS,TS SE04AAxxx SEAL, UPPER 1 1 2 *60A ALL RK01SE05x SEAL REPAIR KIT 1 1 1 *60B ALL RK01SE05x SEAL REPAIR KIT 1 1 1 85 ALL GK01AC01TA GASKET 1 1 2 86 ALL GK01AA06TA GASKET 1 1 2

87A ALL GK01AW01 GASKET, THERMAL 1 1 2 108 ALL 20-099 GASKET, FLEXITALLIC 1 1 2

936A ALL 14-0xxxx O-RING 1 2 2 936AF SP 14-005xx O-RING 1 2 2 936B ALL 14-004xx O-RING 1 2 2 936C ALL 14-046xx O-RING 1 2 2 936D ALL 14-047xx O-RING 1 2 2 936E ALL 14-048xx O-RING 1 2 2 936F ALL 14-052xx O-RING 1 2 2 936G ALL 14-054xx O-RING 1 2 2 936H ALL 14-055xx O-RING 2 4 4 936J DS,TS 14-010xx O-RING 2 4 4

936JA SS,TS 14-054xx O-RING 2 4 4 936K ALL 14-053xx O-RING 1 2 2 936U SP,ISP 14-005xx O-RING 1 2 2 936V SP,ISP 14-035xx O-RING 1 2 2 936Z SP,ISP 14-052xx O-RING 1 2 2

NOTES: (1) Options: SS = Single Seal, DS = Double Seal, TS = Tandem Seal,

IN = Inducer, NIN = No Inducer, SP = Separator (with Insert), ISP = Integral Separator (2) Class 1 = Minimum recommended spare parts necessary to perform a startup and inspection

of a new unit. Class 2 = Minimum recommended spare parts necessary to cover 1-2 years of normal service Class 3 = Minimum recommended spare parts necessary for critical service, or units that will be

installed in remote locations. (3) * Items are alternate items, and should be purchased according to user's preference

(seal kits are available for mechanical seals only). Revised 11/09/99


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LMV/BMP-341

RECOMMENDED SPARE PARTS LIST

GEARBOX ITEMS TYPICAL CLASS (2)

LOC NO. OPTION (1) PART NUMBER DESCRIPTION 1 2 3 106 CB GK01AW02TA GASKET, CHEM BARRIER 1 1 2 115 ALL 20-314 SEAL, ASSY, INPUT 1 1 1 185 ALL 22-363 FILTER, OIL, SUNDGARD 2 5 5

125C ALL 21-119 BEARING, UPPER, INPUT 0 1 1 125D ALL 21-120 BEARING, LOWER, INPUT 0 1 1 151A ALL BE09AW0xxxxx BRG, JOURNAL, OUTPUT, LOWER 0 0 1 151B ALL BE09AW0xxxxx BRG, JOURNAL, OUTPUT, UPPER 0 0 1 151C ALL BE09AW010 BRG, JOURNAL, UPPER IDLER 0 0 1 151D ALL BE09AY040 BRG, JOURNAL, LOWER IDLER 0 0 1 155A ALL WA05AW0x WASHER, THRUST, LOWER 0 0 1 155B ALL WA05AW0x WASHER, THRUST, UPPER 0 0 1 51D ALL RJ09Awxxxx RING, MATING 0 1 1 60C ALL SE04AW01B10 SEAL, ASSY, GEARBOX 0 1 1 936N ALL 14-332UC O-RING, MANIFOLD 2 4 4 936P ALL 14-233UC O-RING, OUTPUT SEAL 2 4 4 936T ALL 14-332UC O-RING, LUBE PORT 6 12 12 936Y ALL 14-322UC O-RING, PARTING FLANGE 4 8 8

936ZF ALL 14-303UC O-RING, LUBE PUMP 2 4 4 A130 ALL SH01AW07xxxxx SHAFT, ASSY, HIGH SPEED 0 1 1 A160 ALL PU04AW0xx PUMP, LUBE, REVERSIBLE 0 1 1

NOTES: (1) Options: CB = Chemical Barrier (2) Class 1 = Minimum recommended spare parts necessary to perform a startup and inspection

of a new unit. Class 2 = Minimum recommended spare parts necessary to cover 1-2 years of normal service Class 3 = Minimum recommended spare parts necessary for critical service, or units that will be

installed in remote locations. Revised 4/2/03


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12. Gearbox and Pump Situation Improvement Table Pump performance is affected strongly by system factors such as suction pressure, temperature, specific gravity, driver speed, flow rate and control characteristics. These factors, as well as possible internal problems, should be considered carefully when analyzing pump system performance. Pump performance characteristics are shown on the specification sheet and performance curve. The Gearbox and Pump Troubleshooting Table provides useful information to assist in the analysis of gearbox and pump performance problems. Repair procedures appear under “MAINTENANCE”.

Gearbox and Pump Trouble Shooting Table Symptom Possible Cause Corrective Action

No flow, No pressure at start-up

Pump not completely filled with liquid

Bleed all vapor or air from Port 6.

Allow more cool down time if pumping low temperature fluid.

Check suction line for air leak if suction pressure is lower than atmospheric pressure.

NPSH actually lower than NPSH requirement listed on specification sheet.

Suction line blocked - check screen and valve.

Excessive pressure drop through suction piping. Flow restricted by vapor pockets in high points of

suction line Suction tank level or pressure level too low. Entrained air or vapor in pumped fluid. NPSH reduced by presence of more volatile

fluids in process fluid. Contact a Sundyne Corporation representative about use of an inducer.

Failure of drive component, such as interconnecting shaft or impeller key, or missing from assembly

Disassemble and inspect.

Reverse direction of rotation.

Direction of driver shaft rotation must be as shown by arrow on pump case. NOTE: Impeller and driver rotate in the same direction.


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Gearbox and Pump Trouble Shooting Table continued Symptom Possible Cause Corrective Action

Insufficient flow or total head.

Flow to high. Check total head and flow rate against performance curve.

Wrong direction of driver shaft rotation (It is not possible for the pump to develop greater than 50 percent design head in this condition).

Direction of driver shaft rotation must be as shown by arrow on pump casing. NOTE: Impeller and driver rotate in the same direction.

NPSH actually lower than NPSH requirement listed on specification sheet

Refers to solutions listed under “No Flow, No Pressure at Startup”.

Flow too low, causing over heating of fluid resulting in internal boiling or unstable pump operation.

Increase through-rate.

Bypass part of pump discharge to supply tank. Use seal cavity bypass and vent the high point of

the pump to continuously increase inlet flow rate. Diffuser discharge throat

partially plugged or impeller damaged by passage of solid particle.

Clean this area of all obstructions and restore surfaces to a smooth polished finish (use emery cloth or machine), free of all corrosion pitting. Edge of diffuser throat must be sharp.

Corrosion and/or erosion of diffuser throat (may also be accompanied by corrosion/erosion of diffuser and cover surface adjacent to impeller.

If edge of throat is no longer sharp and smooth or has opened in size, head-rise may be reduced. Opening of the inlet area of the throat will result in higher flow rate and horsepower consumption. Corrosion/erosion of diffuser and cover surface will result in a significant horsepower increase.

Excessive recirculation from discharge to inlet.

Check flow through external plumbing.

Pump o-ring (936C) damaged or missing. Integral centrifugal separator orifice worn. Process fluid specific

gravity or viscosity different from values shown specification sheet.

Check actual viscosity and specific gravity at operating temperature. Viscosity higher than five centipose will cause reduced head and flow and increased power consumption.

Driver speed too low Check speed against value listed on specification sheet.

Pressure gauges or flow meters in error.

Calibrate instrumentation.


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Driver Overloaded. Fluid specific gravity or viscosity higher than values listed on specification sheet.

Check actual viscosity and specific gravity against value listed on specification sheet.

Electrical failure in electric driver.

Check circuit breaker heater size and setting.

Check voltage and voltage balance between phases.

Current for each phase should be balanced within three percent.

Mechanical gearbox or pump failure in driver

Remove driver and check for freedom of rotation of pump and gearbox shaft assemblies.

Remove fluid end and search for any mechanical failure.

Remove gearbox oil level sight glass and inspect bottom of sump for wear particles. Bearings are probably not damaged if no wear particles are present.

Corrosion pitting on surface of diffuser cover or diffuser, adjacent to impeller blades. Head-rise is also reduced by this condition.

Disassemble pump and inspect. Rough or pitted surfaces can cause friction losses which will significantly increase horsepower consumption. Clean these areas of all obstruction and restore surfaces to a smooth polished finish, (use emery cloth or machine). Check diffuser throat area at the inlet; erosion or corrosion resulting in roughness or increased area will increase horsepower consumption. NOTE: A larger throat size than design will allow a higher flow and horsepower for a given head-rise.

Excessive discharge pressure pulsation’s.

Flow rate too low. Increase flow rate through pump. Add bypass to suction tank if necessary.

Insufficient NPSH available. Refer to solution for insufficient NPSH under “No Flow, No pressure at startup”, above.

Defective flow control valve. Check control valve. Flow rate too low for control by

back pressure control valve or parallel pump operation.

Increase pressure drop between pump and control valve. Increase flow rate.

Change of gearbox oil from normal color to milky pink or yellow.

Gearbox oil contaminated with water or process fluid.

Inspect gearbox heat exchanger for leakage.

Check for excessive pump seal leakage. Inspect shaft sleeve o-rings. Verify that seal housing port 1 and other seal

drains are open for unrestricted seal leakage flow.


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Shaft sleeve rubs on inside diameter of seal.

Gearbox journal bearing failure. Install replacement exchange gearbox or repair gearbox as outlined under “MAINTENANCE”.

Excessive gearbox light turbine oil fluid consumption.

Low speed shaft seal (115) leakage.

Check drain port for leakage. Replace shaft seal if required.

High speed shaft mechanical seal (60C) leakage.

Check upper gearbox housing drain port for leakage. Replace shaft seal if required.

Leakage through heat exchanger into cooling fluid.

Pressure test heat exchanger and replace if required.

Excessive oil foaming

High oil level Shut down the unit and check oil level.

Low gearbox temperature. Adjust coolant to heat exchanger, keeping oil temperature at 140° F., 60°C.

Incorrect lubricant. Fill with light turbine oil. High gearbox temperature.

Heat exchanger fouled or coolant shut off.

Check coolant flow and / or clean heat exchanger.

Oil level too high. Check oil level and adjust.


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13. Pump Mechanical Seals Trouble ShootingTable

The below Pump Mechanical Seals Table contains trouble shooting procedures for units equipped with singles seals. This table also applies to Double and Tandem seal units. The repair procedures for mechanical seals are listed in the “SEAL MAINTENANCE” section of this manual.

Pump Mechanical Seals Trouble Shooting Table continued Problem Possible Cause Corrective Action

Sudden increase in seal leakage.

Severe cavitation or loss of suction causing vibration and bouncing of seal face.

Correct pump suction condition causing cavitation. Bleed vapor from seal cavity and restart unit.

Install double seal if loss of suction cannot be prevented.

Seal icing on low temperature pumps or icing when handling fluids which vaporize at a temperature of less than 32°F, 0°C at atmospheric pressure.

Quench with compatible fluid which will not freeze at pump temperature through seal drain port 2 or 7 to prevent ice formation on atmospheric side of seal during startup and in running condition.

Use purge of dry nitrogen gas through ports 2 or 7.

Install Double or Tandem seal if ice is caused by water in process fluid or supply external seal flush of compatible fluid which does not contain water.

Solid particles in seal cavity or seal spring area (seal faces usually have rough scratched appearance).

Inspect for clogged integral centrifugal separator orifices. Clean orifices if necessary.

Supply external clean seal flush or double seal if particles cannot be removed by separator.

Seal stationary face spring action is rough and sticky.

If parts are corroded, replace with parts made from compatible materials.

If formation of solids causes sticky seal analyze fluid properties. Use external seal flush or double seal arrangement.

Worn or damaged seal. Disassemble seal and rebuild or replace per instructions in maintenance section.

Wear pattern on seal rotating faces not uniform.

Lightly lap surfaces of shaft sleeve and impeller hub which contact rotating seal face to remove high spots. Install new seal faces.

Wear pattern on stationary face smooth but not uniform.

Lap flat or replace seal


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Pump Mechanical Seals Trouble Shooting Table continued Problem Possible Cause Corrective Action

Sudden Increase in seal leakage (continued).

Edges of stationary face chipped and seal face worn (vapor flashing in seal cavity will cause excessive wear and/or cracking of rotating face.)

Install seal cavity bypass to suction tank. Prevent loss of pump suction. Supply cool seal flush. Install double seal.

Seal rotating face cracked or broken. May be caused by damage at assembly or thermal shock caused by seal running dry.

Prevent loss of pump suction or supply continuous external seal flush.

Install double seal. Chemical attack of seal faces,

seal parts or o-rings. Investigate fluid properties and determine suitable materials for replacement.

Excessive radial high speed shaft movement.

Check high speed shaft journal bearings and replace if necessary.

Bent high speed shaft or severe out of balance.

Check if damage exists on impeller and/or inducer which will indicate that a large particle went through the pump.

Deposits on the impeller/inducer causing unbalance.

Damage to mechanical seal secondary seal (Teflon ® lip seal, U-cup elastomer, or o-ring).

Check for erosion and/or corrosion attack.

Install seal flush or double seal arrangement. Loose stack-up of high speed

shaft attaching components. Check for correct impeller bolt/inducer torque.

Check for cold flow of Teflon® “o-rings”.


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APPENDIX A

LMV-341 Drawings:

1. Pump and Gearbox Cross Section, 2. Pump Wet End Exploded View 3. Single Seal Arrangement Cross Section 4. Double Seal Arrangement Cross Section 5. Tandem Seal Arrangement Cross Section


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63

LMV-341 PUMP WET END EXPLODED VIEW


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Appendix B

Coupling Manufacturer’s Bulletin for Alignment

See your Coupling Manufacturer’s Bulletin for Alignment included in your unit’s Sundyne Final Data Package.


SUNDYNE

© Sundyne Corporation 2007 All Rights Reserved

14845 W. 64th Avenue • Arvada, Colorado 80007 USA • +1-303-425-0800 • FAX: +1-303-425-0896 • www.sundyne.com Sundyne Europe • Dijon (Longvic) • France • +33 (0) 3.80.38.33.00 • FAX: +33 (0)3.80.38.33.66

Sundyne Nikkiso • 27-10, Ebisu 2-Chome, Shibuya-Ku • Tokyo 150-0013, Japan • +81-3-3444-6475 • FAX: +81-3-3444-6806

ANSIMAG • ANYSPEED • CASTER • GSP • HMD/KONTRO • MASO/SINE • SUNDYNE COMPRESSORS • SUNDYNE • SUNFLO

Installation & Operation Manual - Sundyne · 02.09.19E, August 2007 Visit our website at SUNDYNE...

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