Varley+pump+selection+handbook

  • 2,606 views
Uploaded on

pumps

pumps

More in: Technology , Business
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
No Downloads

Views

Total Views
2,606
On Slideshare
0
From Embeds
0
Number of Embeds
0

Actions

Shares
Downloads
153
Comments
1
Likes
3

Embeds 0

No embeds

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
    No notes for slide

Transcript

  • 1. API 676 Pumps Standard Varley Pump Diesel Engine Pumps Pump selection handbook for double helical gear pumpsht_pump_manual NEW.indd 1 7/11/07 15:45:23
  • 2. ht_pump_manual NEW.indd 2 7/11/07 15:45:23
  • 3. Pump selection handbook for double helical gear pumpsht_pump_manual NEW.indd 3 7/11/07 15:45:27
  • 4. Index of range of Varley gear pumps Section Title Page Number 1. Introduction 6 2. Features, benefits, operating range 7 3. Nomenclature and pump sizing 8 . Ordering information 9 5. Pump performance indication guide 10-13 6. Pump performance curves 1-26 7. Dimension drawings 27-5 8. Section drawing and parts list 6-51 9. Alternative assembly (mechanical seal and plain cover) 52  www.varleypumps.comht_pump_manual NEW.indd 4 7/11/07 15:45:48
  • 5. Section Title Page Number 10. Table of approximate viscosity comparisons 53 11. Definition of hydraulic terms 54 12. System design typical fuel oil pumping 55 13. Installation, operating and maintenance instructions 56-59 1. Service and maintenance 60-63 15. Quotation form 6-65 16. Notepad 66 Sales office ☎ +44 (0) 1582 731144 5ht_pump_manual NEW.indd 5 7/11/07 15:46:04
  • 6. 1. Introduction When you use Varley Pumps you benefit from over 50 years of experience and development. The Varley Double Helical Gear Pump Handbook has the performance indicator guide on pages 10-11. A more been revised to bring the data into line with customer accurate guide to performance and power curves can be requirements. found on pages 12-2 taking viscosity into account. It is a reference book designed to help you select and You can now specify your pump precisely using the specify a pump precisely. nomenclature system given on page 8. Should you prefer, our engineers or agents will be only too pleased to make If you need to pump a liquid with lubricating properties a suitable selection for you on receipt of full details of your at flow rates between 0.5 igpm and 200 igpm against requirements. pressures varying from 5 p.s.i to 500 p.s.i then Varley pumps can provide you with robust reliable solutions. Varley Pumps are approved by: NCB power generation Larger pumps can be supplied for special applications. authorities, British Rail, British Steel, British Gas, Lloyds, The Post Office, The Admiralty, Bureau Veritas, Norske With knowledge of the output required and the differential Veritas and American Bureau of Shipping to name but a few. pressure (approximately the same as discharge pressure if inlet pressure low), a provisional choice can be made from 6 www.varleypumps.comht_pump_manual NEW.indd 6 7/11/07 15:46:22
  • 7. 2. Features, benefits, operating range Varley Pumps can give you: Features Benefits Compact design Easy fitting Double helical motors Smooth non-pulsating flow Balanced rotor Thrust eliminated Journal roller bearings Long life High suction lift capability Self-priming High interchangeability Economic maintenance Flexible coupling Easy maintenance Standard metric motors Faster deliveries All motorised units bracket mounted Saves space/eliminates need for base plate Pumps custom tested as standard No adjustment required on site Capacity range: 0.5 igpm (0.1 M3/H) – 200 igpm (55M3/H) Standard Materials Viscosity range: Up to 15000 secs Redwood No. 1 1. Front cover, body, rear cover Pressures: Up to 500 p.s.i (35 kg/cm2) Close grained cast iron to B.S.152 (grade 1) Suction lift: Up to 20+ Hg (5mm) 2. Shafts Temperatures: Up to 350°F (176°C) (main and idler) Steel to B.S.970 (EN36B) 3. Double helical rotors Steel to B.S.970 (EN9) 4. VJournal roller bearings To B.S.292 5. Bearing housings Cast iron to B.S.152 (grade 1) 6. Seal Packed gland or mechanical seal Other options available, please contact us at varley@haywardtyler.com or on +(0)1582 7311 Integral by-pass relief valve fitted as standard (can be Other Products supplied without if not required) (separate publications available) Standard paint finish Hammer Green (Styrenated Alkyd) VARLEY Tanker Pumps VARLEY Atex Pumps VARLEY API 676 Positive Displacement Pumps VARLEY Engine Pumps (3D CAD models available) Sales office ☎ +44 (0) 1582 731144 7ht_pump_manual NEW.indd 7 7/11/07 15:46:23
  • 8. 3. Nomenclature and pump sizing The nomenclature used to describe a Varley pump is designed to specify the unit in full as follows: Example explained below 5M1TR/01 5 M 1 T 4 R/ 01 Pump Size Mounting Motor Motor Speed Relief Valve Relief Valve Horsepower Enclosure (by-pass) & Seal type Pump size Speed at 50Hz Corresponds to nominal output in igpm at 120 rpm:  pole – 120rpm 1, 2, 5, 7, 10, 20, 30, 35, 50, 75, 100, 150, 200 6 pole – 960 rpm 8 pole – 720 rpm Mounting Lower speed available using gearbox. M Horizontal motorised unit V Vertical motorised unit Integral Relief Valve (by-pass) B Base plate mounted motorised unit R omitted from reference when not required F Foot mounted bare shaft extension pump SS Short shaft Relief Valve (by-pass) and Seal type Temperature range: Motor Horsepower 0° to 20°F sizes 1 to 100. Dependant on application ½, ¾, 1, 1 ½ etc. 0° to 120°F sizes 150 and 200. Enclosure T totally enclosed fan cooled FLP flame and explosion proof Relief Return to Intake Return to Tank Without By-pass Valve Seal Type Mechanical Seal Gland Mechanical Seal Gland Mechanical Seal Gland Packing Packing packing Anti- Clockwise 0 01 05 02 06 03 Suffix Clockwise 5 51 55 52 56 53 suffix Temperature range: 21° to 360°F sizes 1 – 100. 121° to 360°F sizes 150 and 200. Anti- Clockwise 22 19 23 20 2 21 Suffix Clockwise 72 69 73 70 7 71 suffix 8 www.varleypumps.comht_pump_manual NEW.indd 8 7/11/07 15:46:23
  • 9. . Ordering information Ordering You are advised to give the following additional information so that we can ensure that the correct unit is supplied: 1. Flow rate 2. Working pressure 3. Fluid details including viscosity at operating temperature and the condition . Rotation (anti-clockwise looking at shaft end standard) 5. Top or bottom drive (top drive standard) 6. Suction conditions 7. Operating temperature Standard pumps will be supplied unless otherwise requested Mechanical seal The mechanical seal type fitted as standard to the Varley gear pump, is of a single unbalanced design. Standard construction is of Stainless-Carbon-Viton. Hard face, dual rotation and PTFE seals can be accommodated within the standard range. Our engineers are on hand to advise you of any requirements. Gland packing PTFE impregnated synthetic fibre yarn packing. Max shaft service speed 26 m/s and up to 350 psi. Viscosity Varley pumps are suitable for viscosities up to 15,000 secs. Redwood No. 1 and even higher for certain specialised conditions (in such cases we should be consulted to ensure correct application). The performance curves contained within this brochure cover the following viscosities: - 75, 310 and 700 seconds Redwood No. 1. They are intended as a guide to indicate the b.h.p. requirement for each size of pump within the Varley range. Interpolation is possible but we recommend that you check with the sales office for viscosities very different to those shown. Example A transfer oil pump to handle fuel oil at 75 secs, Redwood No. 1 viscosity from underground storage tank to an elevated service tank. Rate of flow 6 igpm at 50 p.s.i. The b.h.p absorbed on duty is determined by curve “C” (lower) on the graph i.e. 0.5 H.P. Thus a nomenclature of 5M1/2 TR is derived if your requirement is a horizontal motorised unit, to which should be added the appropriate assembly type number e.g. 5M1/2 TR/01. Should any other type of mounting be required, the type reference would be modified accordingly. E.g. 5V11/2 TR/01. 5B11/2 TR’/01, 5SR/01, 5FR/01 When ordering please provide precise details of pump duty. Alternatively please complete the form at the back of the handbook. Note Varley Pumps Ltd reserve the right to make additions to or deletions from the Varley pump range, and make dimensional alterations without notice. The availability of any item shown in this handbook should therefore be checked at the enquiry stage. Sales office ☎ +44 (0) 1582 731144 9ht_pump_manual NEW.indd 9 7/11/07 15:46:23
  • 10. 10 5. Varley pump performance indication guide Units Pressure psi Power Hpht_pump_manual NEW.indd 10 English units with motors running at 50Hz pumping oil with viscosity of 300 seconds Redwood no.1 Flow igpm Speed 120 rpm Pump Model Discharge 1 2 5 7 10 20 30 35 50 75 100 150 200 Pressure Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow 25 0.50 1.6 0.50 3 0.75 6 1.00 7 1.00 10 1.5 19 1.5 28 3 33  9  70 7.5 97 12.5 150 50 0.50 1.6 0.75 3 0.75 6 1.00 7 1.5 10 2 19 2 28  32 5 9 7.5 69 10 96 15 18 75 0.50 1.6 0.75 3 1.00 6 1.5 7 1.5 10 2.5 19 2.5 27  32 7.5 7 7.5 68 10 9 18 17 100 0.50 1.6 0.75 3 1.00 6 1.5 7 1.5 10 2.5 19  27 5 31 7.5 6 10 68 13 93 20 15 125 0.50 1.6 0.75 3 1.5 6 2 7 2 9 3 19  26 7.5 30 7.5 5 150 0.50 1.6 1.0 3 1.5 6 2 7 2 9  18 5 26 7.5 30 10 5 www.varleypumps.com 200 0.75 1.5 1.0 3 1.5 6 2 7 2.5 9 300 0.75 1.5 1.5 3 2 6 00 1.00 1.5 1.5 3 500 1.00 1.5 Above Table for guidance only Please check Performance with our Works before making final selection7/11/07 15:46:24
  • 11. Varley pump performance indication guide Units Pressure psi Power Hpht_pump_manual NEW.indd 11 English units with motors running at 50Hz pumping oil with viscosity of 300 seconds Redwood no.1 Flow igpm Speed 960 rpm Pump Model Discharge 1 2 5 7 10 20 30 35 50 75 100 150 200 Pressure Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow 25 0.33 1 0.50 2 0.50  0.75 5 0.75 6 1 13 1 19 2 21 3 31 3 7  65 7.5 103 15 192 Sales office 50 0.33 1 0.50 2 0.50  0.75 5 0.75 6 1.5 13 1.5 19 2 20 3 31  6 5 6 7.5 100 18 180 75 0.33 1 0.50 2 0.75  1 5 1 6 1.5 13 1.5 18 2.5 20  30  5 6 62 10 97 25 173 100 0.50 1 0.50 2 0.75  1 5 1 6 2 13 2 17 3 20  29 5 5 7.5 61 12.5 97 25 170 125 0.50 1 0.75 2 0.75  1.5 5 1.5 6 2 13 2 16  19 5 28 150 0.50 1 0.75 2 0.75  1.5 5 1.5 6 3 12 3 1  18 5 28 ☎ +44 (0) 1582 731144 200 0.50 1 0.75 2 1  1.5 5 2 6 300 0.50 1 1 2 1.5 3 00 0.75 0.9 1 2 500 0.75 0.9 Above Table for guidance only 11 Please check Performance with our Works before making final selection7/11/07 15:46:24
  • 12. 12 Varley pump performance indication guide Units Pressure psi Power Hpht_pump_manual NEW.indd 12 US units with motors running at 60Hz pumping oil with viscosity of 300 seconds Redwood no.1 Flow Usgal/min Speed 1160 rpm Pump Model 1 2 5 7 10 20 30 35 50 75 100 150 200 Discharge Pressure Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow 25 0.40 1.5 0.60 2.9 0.60 5.8 0.90 7.3 0.90 8.7 1.2 19 1.2 28 2.4 31 3.6 45 3.6 68 4.8 94 9 150 18 279 50 0.40 1.5 0.60 2.9 0.60 5.8 0.90 7.3 0.90 8.7 1.8 19 1.8 28 2.4 29 3.6 45 4.8 67 6 93 9 145 21 262 75 0.40 1.5 0.60 2.9 0.90 5.8 1.2 7.3 1.2 8.7 1.8 19 1.8 26 3 29 4.8 44 4.8 65 7.2 90 12 141 30 251 100 0.60 1.5 0.60 2.9 0.90 5.8 1.2 7.3 1.2 8.7 2.4 19 2.4 25 3.6 29 4.8 42 6 65 9 89 15 141 30 247 125 0.60 1.5 0.90 2.9 0.90 5.8 1.8 7.3 1.8 8.7 2.4 19 2.4 23 4.8 28 6 41 150 0.60 1.5 0.90 2.9 0.90 5.8 1.8 7.3 1.8 8.7 3.6 17 3.6 20 4.8 26 6 41 www.varleypumps.com 200 0.60 1.5 0.90 2.9 1.2 5.8 1.8 7.3 2.4 8.7 300 0.60 1.5 1.2 2.9 1.8 4.4 400 0.90 1.3 1.2 2.9 500 0.90 1.3 Above Table for guidance only Please check Performance with our Works before making final selection6/11/07 12:28:19
  • 13. Varley pump performance indication guide Units Pressure psiht_pump_manual NEW.indd 13 US units with motors running at 60Hz pumping oil with viscosity of 300 seconds Redwood no.1 Power Hp Flow Usgal/min Speed 1720 rpm Pump Model 1 2 5 7 10 20 30 35 50 75 100 150 200 Discharge Pressure Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow Pwr Flow 25 0.60 2.3 0.60 4.4 0.90 8.7 1.2 10 1.2 15 1.8 28 1.8 41 3.6 48 4.8 71 4.8 102 9 141 15 218 Sales office 50 0.60 2.3 0.90 4.4 0.90 8.7 1.2 10 1.8 15 2.4 28 2.4 41 4.8 46 6 71 9 100 12 139 18 215 75 0.60 2.3 0.90 4.4 1.2 8.7 1.8 10 1.8 15 3 28 3 39 4.8 46 9 68 9 99 12 137 21 214 100 0.60 2.3 0.90 4.4 1.2 8.7 1.8 10 1.8 15 3 28 4.8 39 6 45 9 67 12 99 15 135 24 211 125 0.60 2.3 0.90 4.4 1.8 8.7 2.4 10 2.4 13 3.6 28 4.8 38 9 44 9 65 150 0.60 2.3 1.2 4.4 1.8 8.7 2.4 10 2.4 13 4.8 26 6 38 9 44 12 65 ☎ +44 (0) 1582 731144 200 0.90 2.2 1.2 4.4 1.8 8.7 2.4 10 3 13 300 0.90 2.2 1.8 4.4 2.4 8.7 400 1.2 2.2 1.8 4.4 500 1.2 2.2 Above Table for guidance only 13 Please check Performance with our Works before making final selection6/11/07 12:28:20
  • 14. 6. Pump performance curves 14 www.varleypumps.comht_pump_manual NEW.indd 14 6/11/07 12:28:22
  • 15. Pump Performance Curves Sales office ☎ +44 (0) 1582 731144 15ht_pump_manual NEW.indd 15 6/11/07 12:28:24
  • 16. Pump performance curves 16 www.varleypumps.comht_pump_manual NEW.indd 16 6/11/07 12:28:26
  • 17. Pump Performance Curves Sales office ☎ +44 (0) 1582 731144 17ht_pump_manual NEW.indd 17 6/11/07 12:28:28
  • 18. Pump performance curves 18 www.varleypumps.comht_pump_manual NEW.indd 18 6/11/07 12:28:30
  • 19. Pump Performance Curves Sales office ☎ +44 (0) 1582 731144 19ht_pump_manual NEW.indd 19 6/11/07 12:28:32
  • 20. Pump performance curves 20 www.varleypumps.comht_pump_manual NEW.indd 20 6/11/07 12:28:34
  • 21. Pump Performance Curves Sales office ☎ +44 (0) 1582 731144 21ht_pump_manual NEW.indd 21 6/11/07 12:28:36
  • 22. Pump performance curves 22 www.varleypumps.comht_pump_manual NEW.indd 22 6/11/07 12:28:38
  • 23. Pump Performance Curves Sales office ☎ +44 (0) 1582 731144 23ht_pump_manual NEW.indd 23 6/11/07 12:28:39
  • 24. Pump performance curves 24 www.varleypumps.comht_pump_manual NEW.indd 24 6/11/07 12:28:41
  • 25. Pump Performance Curves Sales office ☎ +44 (0) 1582 731144 25ht_pump_manual NEW.indd 25 6/11/07 12:28:43
  • 26. Pump performance curves 26 www.varleypumps.comht_pump_manual NEW.indd 26 6/11/07 12:28:45
  • 27. 7. Dimension Drawings drawings Spigot Mounted Pump Sizes 1-2S Sales office ☎ +44 (0) 1582 731144 27ht_pump_manual NEW.indd 27 6/11/07 12:28:47
  • 28. Dimension drawings spigot mounted pump sizes 5-7S 28 www.varleypumps.comht_pump_manual NEW.indd 28 6/11/07 12:28:49
  • 29. Dimension Drawings Spigot Mounted Pump Sizes 10-20S Sales office ☎ +44 (0) 1582 731144 29ht_pump_manual NEW.indd 29 6/11/07 12:28:51
  • 30. Dimension drawings spigot mounted pump size 30S 30 www.varleypumps.comht_pump_manual NEW.indd 30 6/11/07 12:28:52
  • 31. Dimension Drawings Spigot Mounted Pump Size 35-100S Sales office ☎ +44 (0) 1582 731144 31ht_pump_manual NEW.indd 31 6/11/07 12:28:54
  • 32. Dimension drawings spigot mounted bare shaft pump sizes 150S & 200S 32 www.varleypumps.comht_pump_manual NEW.indd 32 7/11/07 13:04:14
  • 33. Dimension Drawings Foot Mounted Bare Shaft Sizes 1-2F Sales office ☎ +44 (0) 1582 731144 33ht_pump_manual NEW.indd 33 7/11/07 13:04:16
  • 34. Dimension drawings foot mounted bare shaft sizes 5-7F 34 www.varleypumps.comht_pump_manual NEW.indd 34 7/11/07 13:04:18
  • 35. Dimension Drawings Foot Mounted Bare Shaft Sizes 10-20F Sales office ☎ +44 (0) 1582 731144 35ht_pump_manual NEW.indd 35 7/11/07 13:04:20
  • 36. Dimension drawings foot mounted pump size 30F 36 www.varleypumps.comht_pump_manual NEW.indd 36 7/11/07 13:04:22
  • 37. Dimension Drawings Foot Mounted Bare Shaft Sizes 35-100F Sales office ☎ +44 (0) 1582 731144 37ht_pump_manual NEW.indd 37 7/11/07 13:04:24
  • 38. Dimension drawings foot mounted pump sizes 150F & 200F 38 www.varleypumps.comht_pump_manual NEW.indd 38 7/11/07 13:04:26
  • 39. Dimension Drawings Horizontal Motorised Pump Sizes 1-2M Sales office ☎ +44 (0) 1582 731144 39ht_pump_manual NEW.indd 39 7/11/07 13:04:28
  • 40. Dimension drawings horizontal motorised pump sizes 5-7M 40 www.varleypumps.comht_pump_manual NEW.indd 40 7/11/07 13:04:30
  • 41. Dimension Drawings Horizontal Motorised Pump Sizes 10-30M Sales office ☎ +44 (0) 1582 731144 41ht_pump_manual NEW.indd 41 7/11/07 13:04:32
  • 42. Dimension drawings horizontal motorised pump sizes 10-30M larger bracket size 42 www.varleypumps.comht_pump_manual NEW.indd 42 7/11/07 13:04:34
  • 43. Dimension Drawings Horizontal Motorised Pump Sizes 35-50M Sales office ☎ +44 (0) 1582 731144 43ht_pump_manual NEW.indd 43 7/11/07 13:04:36
  • 44. Dimension drawings horizontal motorised pump sizes 75-200M 44 www.varleypumps.comht_pump_manual NEW.indd 44 7/11/07 13:04:38
  • 45. 8. Section Drawing and Parts List 1-2S Sales office ☎ +44 (0) 1582 731144 45ht_pump_manual NEW.indd 45 7/11/07 13:04:40
  • 46. 8. Section drawing and parts list 5-7S 46 www.varleypumps.comht_pump_manual NEW.indd 46 6/11/07 12:31:58
  • 47. Section Drawing and Parts List 10-20S Sales office ☎ +44 (0) 1582 731144 47ht_pump_manual NEW.indd 47 6/11/07 12:32:00
  • 48. Section drawing and parts list 30S 48 www.varleypumps.comht_pump_manual NEW.indd 48 6/11/07 12:32:02
  • 49. Section Drawing and Parts List 35-100S Sales office ☎ +44 (0) 1582 731144 49ht_pump_manual NEW.indd 49 6/11/07 12:32:04
  • 50. Section drawing and parts list 150S 50 www.varleypumps.comht_pump_manual NEW.indd 50 6/11/07 12:32:06
  • 51. Section Drawing and Parts List 200S Sales office ☎ +44 (0) 1582 731144 51ht_pump_manual NEW.indd 51 6/11/07 12:32:08
  • 52. 9. Alternative assembly (mechanical seal and plain cover) 52 www.varleypumps.comht_pump_manual NEW.indd 52 6/11/07 12:32:09
  • 53. 10. Table of Approximate approximate viscosity comparisons Viscosity Comparisons The following table lists several commonly used viscosity measurements for quick, easy conversion from one to another. Although the values are only approximate, they are sufficiently accurate for most pump calculations. The tables are especially useful because all values may be compared directly with each other. Sales office ☎ +44 (0) 1582 731144 53ht_pump_manual NEW.indd 53 6/11/07 12:32:11
  • 54. 11. Definition of hydraulic terms Head: Static discharge head: The hydraulic pressure is expressed in pounds per square Is the hydraulic pressure exerted at the pump discharge inch (psi) gauge using atmospheric pressures as the by the liquid at rest, commonly measured as the difference datum. It can be determined by use of pressure gauges or in the elevation between the pump discharge port and the can be computed by using pipe friction tables and static delivery point. head measurements. Total discharge head: Friction head: Is the total hydraulic pressure at the discharge port with the This is the hydraulic pressure exerted to overcome frictional pump in operation (the sum of the static discharge head resistance of a piping system to the liquid flowing through it. and the friction head of the discharge piping). Static suction lift: Total pumping head The hydraulic pressure below atmospheric at the intake (or dynamic head): port with liquid at rest. It is usually expressed in or Is the sum of the total discharge head and the total suction converted to inches of mercury (Hg) vacuum. lift; or the difference between the total discharge head and the total suction feet. Total suction lift: Is the total hydraulic pressure below atmospheric at the Head expressed in feet: intake port with the pump in operation (the sum of the static Although the foregoing definitions refer to the “head” suction lift and the friction head of the suction piping). as expressed in psi, it is also proper to specify the total pumping head in feet of liquid or water. Conversions can be made between these expressions of psi to feet but since Flooded suction: there will normally be an appreciable difference between Is a very indefinite term which has been carelessly used the feet of head or a particular liquid and the feet of head for so many years that its meaning is no longer clear. More of water, it is extremely important to specify which term is often than not, it merely indicates that suction conditions being used. have not been accurately determined. One point to remember is that a static suction head may become a suction condition when the pump goes into operation, due Pressure (psi) = head(ft) x Specific Gravity to friction in the suction pipe work. 2.31 Total suction head: Is the hydraulic pressure above atmospheric at the intake port with the pump in operation (the difference between the static suction head and the friction head of the suction piping). 54 www.varleypumps.comht_pump_manual NEW.indd 54 6/11/07 12:32:11
  • 55. 12. System Design 12. System Fuel Oiltypical fuel oil pumping Typical design Pumping System arrangements (for light fuel oils) The main criteria is to maintain a constant pressure and correct flow to the burners 2. Dead leg system A dead leg system may extend to many hundreds of feet. 1. Daily service tank systems Constant pressure is maintained by incorporating a relief Constant pressure to within a few inches water gauge, may valve in the by-pass. be maintained at the burners. Note: By-pass line should return to tank – not to intake. If Note: An overflow, size to handle full flow from the pump, returned to intake any entrapped air will re-circulate and should be incorporated to limit problems in the event of a cause burner ignition problems. float switch failure. 3. Main ring system 4. Underground tank system For feeding burners placed around the perimeter of a Suction lifts should be kept to a minimum. factory. Pipe sizing must be such as to ensure that losses do not adversely affect burner performance. Note: The return line should not be fed into the intake but back to tank. Failure to do so can result in entrapped air Note: Pump is normally sized to give a circulation flow re-circulating. around the ring equal to 2 ½ times the total burner requirements. Sales office ☎ +44 (0) 1582 731144 55ht_pump_manual NEW.indd 55 6/11/07 12:32:14
  • 56. 13. Installation, operating and maintenance instructions Installation, operating and maintenance instructions Most pump problems occur at start up! These notes have been prepared to help you prevent problems as well as deal with them. All Varley pumps are covered by a one year warranty against defects in manufacture. The commencement date of the warranty is the date of despatch of the unit from our factory unless otherwise agreed. The warranty also covers damage sustained in transit, provided both carrier and ourselves receive written notification of any damage within 48 hrs from date of despatch. Notes for the guidance of installers 1. The pump should be installed first and the pipe work built away from the pump. This should avoid strain being imposed upon the pump by poorly aligned pipe work. Such strain may result in rapid seal breakage, bearing failures or broken pipe ports. On pumps, which have threaded ports, care should be taken to see that the pipe does not bottom into the port, or the threads will be damaged and the port broken. Support the pipe to prevent strain due to its weight being imposed upon the pump. 2. Determining the suction port: Provided that the build of the pump has not been altered after despatch from our factory, the correct direction of rotation is indicated by an arrow on the pump front cover. This same arrow has marked upon it the suction port position (namely the tail of the arrow) and discharge port (the head of the arrow). In any case, a positive check may be obtained by observing the domed protrusion on the side of the non-drive end cover of the pump – the suction port is always on the same side of the pump as that protrusion (see diagram 4). 3. Ensure that on suction pipe work there is no possibility of any leakage, which could result in air being drawn into the pump. 4. Filter: A full flow filter on micron mesh should be fitted on the suction side of the pump. If this is not provided, check to see whether or not one is to be fitted. In cases where the fluid to be pumped is guaranteed to be free from foreign matter, no filter need be fitted but it is desirable to insert a piece of fine gauze between flanges in the pipe work so that weld slag, thread cuttings, sand, etc. will be trapped by the gauze and prevented from entering the unit. This gauze should be removed once the pipe-work system is totally clean. Start up Before start up it is wise to check the following points: 1. Check that the pump shaft turns freely. If the pump is jammed solid, it is likely that already some foreign matter has been introduced into the pump and the gears are jammed. This must be rectified immediately. 2. If the pump will turn but is rather stiff it is likely that the pump is gland packed and the packing has dried out somewhat on the shaft. In this case, slacken off the two setscrews a couple of turns and continue to turn by hand until the pump frees. 56 www.varleypumps.comht_pump_manual NEW.indd 56 6/11/07 12:32:15
  • 57. Installation, operating and maintenance instructions N.B. the pump should not spin freely, but should have a very slight resistance to movement with a gland packed unit. If it is still stiff after adjusting setscrews, lightly tap the pump with a soft hammer in case the material parts have been forced together during installation. 3. Although Varley pumps are self- priming, it is much easier and safer, on an initial start, to hand prime the pump with a thin lubricating oil. This guarantees that all parts are well ‘wetted’ and will result in rapid pick up of fluid being pumped. (This procedure is unnecessary where the pump is beneath the level of the liquid in the tank). 4. A gland packed pump may leak along the shaft on initial start up, but it is wise to allow a short time of running in this condition for it to bed in before any effort is made to adjust the gland, Adjustment should then be carried out until there is just an occasional drip of liquid from the gland area, adjustment should be done carefully over a period of hours taking each nut down evenly a little at a time. On some units, and especially on hot oil units, a slight leak may develop across the pump end cover joints. Should this occur, all the nuts on the end covers of the pump should be checked for tightness. 5. All units have had their relief valves set with respect to discharge pressure, but should this set pressure prove to be unsuitable on site, it can be varied by screwing the relief valve setting screw on the non drive end cover of the pump in or out, depending on whether the pressure needs to be increased or decreased. If the correct pressure cannot be set an alternative spring available from our spares department, may be required. Fault finding and correction: 1. Failure to prime a. Check that all valves are in open position b. Check for leaks in suction line and seal c. Check that the by-pass valve is not blocked in the open position – clean if necessary d. Check that the filter is not blocked – change or clean if necessary. 2. Reduction in flow rate a. Check that the by-pass valve is closed – clean and reset as required b. Check that there are no leaks in the pump or in the system c. Check the any regulating valves in both the suction and discharge lines are correctly set d. Check for increased pressure in discharge line. Sales office ☎ +44 (0) 1582 731144 57ht_pump_manual NEW.indd 57 6/11/07 12:32:16
  • 58. Installation, operating and maintenance instructions 3. Noisy running a. Check both suction and discharge lines for blockages b. Strip the pump down and look for damaged parts or foreign matter. 4. Pump has seized and will not turn a. Dismantle and clean b. Replace damaged parts Varley Pumps has an integrated Service and Spares Section, that will undertake fieldwork and manages the repair section at our works. The spares section will be pleased to help you identify spare parts and supply replacements. For those who wish to carry out their own maintenance, please refer to the following notes on servicing the units: Dismantling Remove pump from bracket, or base plate and proceed as follows: 1. Withdraw the coupling half from the pump shaft (first slackening the grub screw). 2. Carefully remove the key from its keyway. 3. Examine the shaft extension and keyway for cleanliness and carefully remove any burrs. 4. Remove setscrews (or nuts) and washers securing the front cover to the pump body. Break the joint by lightly tapping the cover with a soft hammer and withdraw the cover. 5. Detach rear cover in the same fashion as for the front cover removal. 6. If fitted, withdraw the spacing collar from the main shaft at the front cover end. 7. Remove any circlips and withdraw the complete rotating assemblies with bearings from the body. 8. In the case of pump size 1 to size 20, the housings will part from the rotor end faces sufficiently to allow the insertions of extractors for drawings the bearing inner races off the shafts. In the case of pumps size 35 and above the bearing housings complete with bearing outer races and rollers will slide freely off the shafts leaving the inner races still in position. 9. Do not attempt to press shaft through the rotors on any of the pump sizes, rotors are permanently secured to the shafts and they must be considered as one unit. Keep all bearing inner and outer races as sets. 10. Remove the outer races of the bearing from their housings. 11. On a gland packing pump, fully unscrew the gland adjustment setscrews and remove the gland retainer. Remove all the old packing and then clean and smooth the bore using a fine emery cloth or a small soft wire brush. 12. By-Pass valve Remove dome nut and release locknut. Screw out the setting screw, making sure the number of turns are counted. Remove the setting screw housing, spring and valve. 13. Mechanical seal The mechanical seal-rotating element should be removed from the pump, before the shaft assembly is pressed out. In removing this seal, it is advisable to use a dummy - shaft key to prevent the seal ring being cut when it passes over the keyway (see diagram 5). The seal collet should be removed by opening up the slot and sliding it off the shaft. The static seal face is in the front cover; this should be removed by light finger pressure. 58 www.varleypumps.comht_pump_manual NEW.indd 58 7/11/07 15:48:12
  • 59. Installation, operating and maintenance instructions Inspection Examine all parts for wear and damage and clean up or replace with new parts as necessary. It is unwise to rebuild a pump with worn components, and we fully recommend the replacement of bearings, gaskets, packing and mechanical seal. It is important to note that a mechanical seal is very unlikely to re-sit in the same place once the two seal faces have been split. Reassembly 1. Carefully press the outer races of the roller bearings into the bearings housings. 2. On sizes 1 to 20: Carefully press the bearing housing and bearing assemblies on to the shaft, ensuring that they are square to the shaft. Note that in this case the load should be placed on both the inner race of the bearing and the bearing housing at the same time. On sizes 35-200: Place the bearing spacers on the shaft, and press on the inner races. The bearing housings will now slide over the inner races. NB do not mix up inner and outer races. 3. Where supplied refit the circlips into the grooves in shafts. Check to see that the rotor turns freely in its bearings. 4. Match the main shaft assembly and the idlershaft assembly together and place them in the body from the rear towards the front of the pump. 5. Very carefully insert the assembly into the body ensuring square entry and that both assemblies are entering the pump together. Ensure the pressing is done on the outer race to prevent damage to rotors and bearing housings. 6. The assembly is correct when the housings are flush to the body. Fit locating washer and spacing collar, when provided, replace front and rear cover gaskets and fit the covers. Line up with a suitable bush between the shaft and front cover bore. 7. After tightening down the covers check that the mainshaft turns freely: if it does not it is probable that the bearings housings have closed up on the rotors. It is possible to ease them off, by lightly tapping the body with a hide hammer. 8. By-pass valve Assembly of by-pass should be effected in reverse order to the dismantling. Note on repacking the gland: The gland should be repacked using only moulded rings supplied by Varley pumps. Make sure that the ring joins are staggered to prevent a leakage path for the liquid. Then refit the gland retainer, and screw in the setscrews until the shaft has just the slightest resistance to movement, (though it should still be quite free to turn). Sales office ☎ +44 (0) 1582 731144 59ht_pump_manual NEW.indd 59 7/11/07 15:48:12
  • 60. 14. Service and maintenance Note on assembly of mechanical seal Again, the mechanical seal should be assembled in a dummy key in the coupling keyway. The stationary carbon ring should be carefully pressed into the recess in front cover, care being taken to see that the carbon is pressed in squarely. N.B Great care must be taken to see that the carbon is not chipped or cracked during this operation (the carbon is a brittle component). It is wise to lightly smear the rotating face with clean lubricating oil before assembly of the front cover. It should be possible to reassemble a pump satisfactorily, provided normal fitting skill is exercised. Points to bear in mind when designing the installation. 1. Location of pumps Wherever possible the pump should be located close to the supply tank. This avoids the necessity for long suction pipe runs, which can often be troublesome. This is because no pump can literally ‘suck’, it normally requires atmospheric pressure to ‘push’ liquid into the pump. 2. Sizing of the pipe work Resistance to flow is reduced as pipe work size is increased, and consequently requires less motive power. We, therefore, do not apply a limitation to the maximum discharge pipe work that can be employed. It should be noted, however, that at no time should this be less than the port size of the pump. NB Care must be taken when choosing the diameter of suction pipe work when the pump is operating under suction lift. Should the diameter be too large, the pump will spend much of its time, on start up, evacuating the large volume of air in the pipe, and we strongly recommend the pipe size be kept to the same size as that of the suction port. 3. Noise Noise may be airborne, structure-borne, pipe-borne, or fluid-borne. The siting of the unit will take care if airborne noise and steps should be taken to mount the unit on a noise/vibration absorbing base if structure-borne noise could be a serious problem. Most fluid and pipe borne noise results from numerous changes of direction causing turbulent flow of the fluid and vibration of the pipe work. The number of bends should, therefore be kept to a minimum. This form of noise is frequently the most troublesome as pipe work often runs through a building and the noise is distributed throughout. The pipe work should also be firmly clipped to the wall, with some anti vibration material between clip and pipe. When pipe work is not near a wall it must be firmly supported. 4. Suction lifts It has already been mentioned that pumps should be mounted as closely as possible to the tank. Where this is impossible the imposition of a suction lift on the pump is often necessary. In such cases, it is essential that the pipe work be free from all air leaks. Therefore joints should be kept to a minimum. Even though the pump unit is self- priming a foot valve should still be fitted to the suction line in the tank. Without this the pump is called upon to 60 www.varleypumps.comht_pump_manual NEW.indd 60 7/11/07 15:48:13
  • 61. 14. Service and Maintenance prime the total length of the line at each start up which means longer periods of dry running before the fluid reaches the pumps and rapid wear can occur. 5. Filter New pumps rely on the maintenance of fine working clearances for efficient operation, so if there is any possibility of foreign matter finding its way into the tank and thence to the pump, a full-flow suction filter or 60-80 micron mesh must be installed to ensure long life. The mesh size will depend on both fluid and application e.g. plain bearings will require 20 mesh or less. 6. Valving Isolating valves should always be provided on either side of the pump to avoid the messy task of clearing lines before removal of the pump for maintenance. (See diagram 1 for suggested layout). Where two units pump the same line (especially on an automatic standby system), non-return valves should be fitted in the discharge from each unit to prevent back-flow of the unit through the stationary pump. A satisfactory valving arrangement is shown in diagram 2. 7. Effect of fluid viscosity Very careful attention must be paid to the pipe work layout when viscous fluids are being pumped. Suction lifts should be avoided if possible and all pipe work runs kept as short as possible to avoid large pipe work losses. Particular care must be taken when heat is required to bring the viscosity to an acceptable level. At start-up the liquid is often cold, resulting in a severe overloading of the pump and possibly a motor failure. If there is the possibility of cold starts, you should let us know and we can take it into account when specifying the unit. 8. By-pass valve The by-pass valves fitted to pumps of our manufacture are intended entirely as pressure relief valves to protect the pump and system against over-pressure should blockage occur in the discharge pipe work, or should the imposed load rise too high. It should not, therefore, be used as a pressure regulating valve in normal circumstances (and it will not normally give adequate regulation if any attempt is made to use it in this way). Sales office ☎ +44 (0) 1582 731144 61ht_pump_manual NEW.indd 61 7/11/07 15:48:14
  • 62. Service and maintenance A system should not be designed using a return-to-inlet by-pass valve if the discharge is to be kept closed for long periods, since the fluid will then circulate around the pump and cause overheating. In this case the alternative return to tank system should be utilised. To avoid aeration of oil, the return line back to tank should be installed as far away as possible from suction line, then entry of this line into the tank must go below the oil level at all times (see diagram 3). Notes for the guidance of designers Because the pumping unit is relatively simple and inexpensive, its siting is sometimes given little thought. It is in fact the ‘heart’ of an installation and therefore the sizing and location are worthy of careful attention. Motors Motors are normally trouble free as long as they are kept in clean dry conditions. Where greasing points are fitted they should be given one shot of grease every few months running – but not more than one shot. Filters Filters should be cleaned regularly. Pump storage It sometimes happens that a unit must be obtained well before the plant is to be put into operation. If it should become necessary to store a pump, or to leave it on site for a lengthy period before operation, the following precautions should be taken. 1. On gland-packed pumps, loosen off the gland retainer set screws. 2. Liberally coat the pump shaft coupling and motor shaft with a protective oil. 3. Ensure that the motor windings are kept dry either by storing in warm, dry, clean conditions or install heaters in the motor. 4. Fill the pump body with a corrosion-inhibiting oil and, where the pump is in storage, seal off pump ports. About once a month give the pump shaft a couple of turns to prevent any standing corrosion effects. 62 www.varleypumps.comht_pump_manual NEW.indd 62 7/11/07 15:48:15
  • 63. Service and Maintenance Recommended Spares We are frequently asked to provide a list of recommended spares for units of our manufacture. To assist the user to assess his requirements we break out our recommendations into two headings – namely, ‘normal’ usage spares (those normally required to be replaced during the overhaul of a unit which has been maintained and operated correctly) and ‘strategic’ breakdown spares (those spares which should be held against breakdown when the unit is of strategic importance to the operation of a system). We give below our normal recommendation for a spares holding: 1 – set gaskets 1 – set gland-packing or mechanical seals 1 – set bearings and housings Strategic breakdown spares All those for normal repair, plus all the following: One complete set of internals, namely: - Main shaft assey Idler shaft assey Bearing housings By-Pass valve Obviously, if there are many pumps of the same type operating in a system it would be wise to hold spare pumps, together with sets of normal usage spares. Sales office ☎ +44 (0) 1582 731144 63ht_pump_manual NEW.indd 63 7/11/07 15:48:15
  • 64. 15. Request for quotation PLEASE COPY THIS FORM AND FAX TO +44 (0) 1582 402563 Please complete the form below and we will send you a quotation by return. If we require any more information we will be in touch. First Name: ...................................................................................................... Last Name: ...................................................................................................... Job Title: .......................................................................................................... Company: ........................................................................................................ Address: .......................................................................................................... City: ................................................................................................................. Country: .......................................................................................................... Postcode / Zip: ................................................................................................ Telephone No: ................................................................................................. Fax:.................................................................................................................. Email:............................................................................................................... 64 www.varleypumps.comht_pump_manual NEW.indd 64 7/11/07 15:48:15
  • 65. Fluid Environment Mounting Name: Safe Standard Viscosity: Hazardous Horizontal Operating Temperature: Indoors Vertical Contamination: Outdoors Tank Top Suction Flooded Lift metres Discharge Pressure: Relief Valve Yes Internal External No Drive Motor Volt Frequency Phase Other Details: Notes: Sales office ☎ +44 (0) 1582 731144 65ht_pump_manual NEW.indd 65 7/11/07 15:48:15
  • 66. 16. Notepad 66 www.varleypumps.comht_pump_manual NEW.indd 66 7/11/07 15:48:15
  • 67. ht_pump_manual NEW.indd 67 7/11/07 15:48:15
  • 68. Revision 3 © Varley Pumps Ltd Varley Pumps Ltd is a division of the Hayward Tyler Groupht_pump_manual NEW.indd 68 7/11/07 15:48:15