`
`Reciprocating
`Plunger Pumps
`Installation, Care and
`Operation Manual
`
`200T-5
`
`300Q-5
`
`165T-5
`
`60T-3
`
`Covering the
`following pumps:
`30T-2
`60T-3
`80T-3 Atex Certified
`100T-4
`130T-4
`165T-5
`200T-5 Atex Certified
`250T-5
`300Q-5 Atex Certified
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`130T-4
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`250T-5
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`80T-3
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`30T-2
`
`100T-4
`
`P.O. Box 4638
`
`Houston, Texas 77210-4638
`
`Sales / Technical Information
`
`USA Tollfree: 1-800-324-4706
`Phone: 1 (918) 447-4600
`Fax: 1 (918) 447-4677
`Internet: http://www.nov.com
`
`REVISED: August 27, 2010
`REVISED: February 18, 2009
`REVISED: July 17, 2008
`ISSUE: September 15, 2003
`
`Page 1 of 83
`
`
`
`
`
`Reciprocating
`Plunger Pumps
`Installation, Care and
`Operation Manual
`
`200T-5
`
`300Q-5
`
`165T-5
`
`60T-3
`
`Covering the
`following pumps:
`30T-2
`60T-3
`80T-3 Atex Certified
`100T-4
`130T-4
`165T-5
`200T-5 Atex Certified
`250T-5
`300Q-5 Atex Certified
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`130T-4
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`250T-5
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`80T-3
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`
`
`30T-2
`
`100T-4
`
`P.O. Box 4638
`
`Houston, Texas 77210-4638
`
`Sales / Technical Information
`
`USA Tollfree: 1-800-324-4706
`Phone: 1 (918) 447-4600
`Fax: 1 (918) 447-4677
`Internet: http://www.nov.com
`
`REVISED: August 27, 2010
`REVISED: February 18, 2009
`REVISED: July 17, 2008
`ISSUE: September 15, 2003
`
`Page 2 of 83
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`SUPPLEMENT FOR
`ALL PUMP MANUALS
`
`
`! WARNING !
`
`
`
`PRESSURE
`
`RELIEF
`
`VALVES
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`! NOTICE !
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`
` Our technical publications relative to
`reciprocating pumps state that pressure
`relief valves must be installed in the
`discharge systems from these units.
`This supplement is issued to emphasize
`the importance of relieving the discharge
`system of all pressure which exceeds the
`rated working pressure applied by the
`manufacturer to the specific pistons and
`liners (or plungers and packing) in any
`particular unit.
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`Page 3 of 83
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`! WARNING !
`
`For the protection of persons and property the discharge system from each Reciprocating Pump must be
`equipped with a device which relieves the system of all pressures which exceed the pressure rating applied
`by the manufacturer to each particular piston or plunger diameter. Allowances will be made for pressure
`surges which are inherent with the reciprocating action of piston and plunger pumps. The percentage of
`pressure allowance appears later in this publication and in the “Standards of the Hydraulic Institute” (13th
`edition).
`
`The relieving device must provide for instantaneous pressure relief, it may be a valve designed for automatic
`or manual resetting; however, if preferred, rupture discs or burst discs may be installed.
`
`FAILURE to comply with the procedures outlined in the Warning may result in damage to the pump and
`related equipment and more importantly may cause serious bodily injury or death!
`
`
`THE PRESSURE RELIEF VALVE:
`
`
`1. This valve must be a full opening type.
`
`2.
`
`It must have a working pressure rating, equal
`to or greater than, the maximum working
`pressure of the pump.
`
`
`3. The through capacity of the valve, when fully
`opened, must be sufficient to relieve the full
`capacity of the pump without excessive
`overpressure.
`
`
`
`RUPTURE DISC OR BURST DISC:
`
`
`1. These discs must have a diameter which is
`not less than the pipe size of the pressure
`relief flange.
`
`
`2. These discs must have a rupture or burst
`pressure rating consistent with the
`specifications tabulated later in this
`publication.
`
`
`
`LOCATION OF THE RELIEF VALVE:
`
`1. The relief valve must be placed in the
`discharge line as close as possible to the
`pump fluid end or it may be mounted on the
`pump discharge manifold.
`
`
`2. The relief valve must be on the pump side of
`any discharge strainer.
`
`
`
`
`
`3. The relief valve must be between the pump
`fluid end and any valve in the discharge
`system.
`
`
`4. There must be no restricting device(s)
`between the relief valve and the pump fluid
`end.
`
`
`
`THE RELIEF VALVE DISCHARGE LINE:
`
`
`1. The relief valve discharge line should not
`terminate in the pump suction line.
`
`
`2. The line should terminate in the supply tank,
`if possible.
`
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`3. The line must be securely anchored.
`
`4. The line must be the same pipe size as, or
`may be larger than, the discharge connection
`on the relief valve.
`
`
`5.
`
`If the line is of great length, this must be
`taken into consideration in sizing the relief
`valve.
`
`
`6. There must be no restrictions or valves in the
`relief valve discharge line.
`
`
`
`NOTE: Follow the foregoing instructions if
`rupture discs or burst discs are installed.
`
`SUGGESTED SET PRESSURES FOR THE PUMP RELIEF VALVES:
`OPERATING PUMP PRESSURE:
`PUMP TYPE:
`Piston Pressure Rating – Plus 25%
`Double Acting – Duplex
`Piston Pressure Rating – Plus 10%
`Double Acting – Triplex
`Piston Pressure Rating – Plus 10%
`Double Acting – Quintuplex
`Piston Pressure Rating – Plus 10%
`Single Acting – Triplex
`Plunger Pressure Rating – Plus 25%
`Single Acting – Simplex
`Plunger Pressure Rating – Plus 20%
`Single Acting – Duplex
`Plunger Pressure Rating – Plus 10%
`Single Acting – Triplex
`Plunger Pressure Rating – Plus 10%
`Single Acting – Quintuplex
`Plunger Pressure Rating – Plus 10%
`Single Acting – Septuplex
`Note: The above set pressures are to be observed when installing rupture discs or burst discs.
`
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`Page 4 of 83
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`
`
`Installation, Care and Operation
`Manual
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`
`Foreword…
`
`
`
`This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO equipment.
`Because of the many factors which contribute to the function or malfunction of this machinery, and not having complete
`knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore
`confine the scope of this presentation and when situations encountered are not fully encompassed by complete,
`understandable instructions, these situations must be referred to the manufacturer.
`
`
`When other than routine servicing is necessary, it can be most efficiently performed if the unit is removed to an area
`of adequate space where an over-head crane, hydraulic lift, bearing pullers, impact tools, etc., are accessible.
`
`
`The dimension and tolerances specified in this publication are those desirable for the most efficient operations of the
`equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible
`or economically feasible to reestablish such strict alignment and correct all dimensional deviations.
`
`
`Improvements in design, engineering, materials, production methods, etc., may necessitate changes in these
`products and result in inconsistencies between the content of this publication and the physical equipment. We reserve
`the right to make these changes without incurring any liability or obligation beyond that which is stipulated in the
`purchase contract.
`
`
`The pictures, photographs, charts, diagrams, drawings, verbal contents and specifications are not to be construed
`as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. National Oilwell Varco makes no warranty,
`either expressed or implied beyond that which is stipulated in the purchase contract.
`
`
`NATIONAL OILWELL VARCO pumps are manufactured by National Oilwell Varco at the McAlester, Oklahoma
`plant. The serial number, assigned each pump is stamped on the power end. Please refer to this serial number when
`ordering parts for the pump.
`
`
`The right and left sides of the pump are determined by viewing the pump from the back of the power end, looking
`toward the fluid end. This position is also used to identify the plungers and their related parts as being number one, two
`and three, beginning at the left side of the pump.
`
`
`
`! CAUTION ! CAUTION ! CAUTION !
`
`
`
`
`EXERCISE SAFETY IN ALL PERFORMANCES: DO NOT IGNORE ANY WARNINGS; USE ONLY APPROVED
`METHODS, MATERIALS AND TOOLS. DO NOT PERMIT ANY FUNCTION OF QUESTIONABLE SAFETY;
`ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY IS YOUR BUSINESS AND
`YOU ARE INVOLVED.
`
`
`! WARNING ! WARNING ! WARNING !
`
`
`
`
`BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED FROM ITS
`POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY FORM OF ENERGY
`FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR MECHANICAL ENERGY INTO OR
`FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE COMPRESSOR/AIR SYSTEM, ETC.
`
`
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`Page 5 of 83
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`
`Installation, Care and Operation
`Manual
`
`! WARNING ! WARNING ! WARNING !
`
`
`
`
`
`FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN
`PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH.
`
`
`! ATTENTION - NOTICE - IMPORTANT !
`
`THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP,
`COMPONENTS OR ATTACHMENTS.
`
`
`
`
`! ATTENTION !
`
`PUMP NOMENCLATURE:
`ALL PUMP SIZES WITHIN THIS MANUAL WILL BE DESCRIBED WITH THE NEW OR CURRENT
`NOMENCLATURE. THE OLD 'J' MODEL PUMP NOMENCLATURES DESCRIBED ON THE FRONT COVER, BUT
`NOT INCLUDED IN THIS MANUAL EXCEPT AS NEEDED, ARE TO BE UNDERSTOOD AS BEING INCLUDED WITH
`THE NEW NOMENCLATURES.
`
`
`
`
`
`
`! WARNING ! WARNING ! WARNING !
`
`BEFORE SERVICING PUMPS:
`
`1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE.
`
`2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.
`
`3. RELIEVE OR “BLEED OFF" ALL PRESSURE FROM THE PUMP FLUID CYLINDER(S).
`
`
`
`
`FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING
`CAN RESULT IN SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE.
`
`
`
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`www.nov.com
`
`3
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`Page 6 of 83
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`
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`Installation, Care and Operation
`Manual
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` Plunger Pump Nomenclature Example….
`
`
`
` 60 T- 3 L 14 S F
`
`
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`
`
`
`
`RATED INPUT
`HORSEPOWER
`
`T = TRIPLEX
`Q = QUINTUPLEX
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`*F = FLANGED, T = THREADED
`
`*S = SPHERICAL SEAT VALVES
`*A = CAGE VALVES
`*B = NEW CAGE VALVES
`*C = TAPERED SEAT VALVES
`
`**CYLINDER MATERIAL
`NUMBER
`
`*L = LOW PRESSURE
`*M = MEDIUM. H = HIGH
`
`*STROKE LENGTH (IN.)
`
`*NOMENCLATURE MAY BE SHORTENED IN PARTS LISTS OR OTHER
`INSTANCES TO LEAVE OFF THE MATERIAL, VALVE TYPE, ETC. THIS
`FULL NOMENCLATURE DESCRIPTION IS GIVEN FOR INFORMATIONAL
`PURPOSES.
`
`**CYLINDER MATERIAL NUMBER EXAMPLES INCLUDE:
`14 = 9D NICKEL ALUMINUM BRONZE
`12 = FORGED STEEL
`06 = 316 S.S.
`(Inquire about other material numbers)
`
`
`
`
`
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`4
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`Page 7 of 83
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`Installation, Care and Operation
`Manual
`
`PAGE
`
`
`Table of Contents…
`
`ATEX WARNING STATEMENTS
`
`I. PUMPS and PUMP UNITS
`
`A. 80T Pump
`
`1. Nameplate ................................................................................................................................................ 10
`
`2. Declaration of Incorporation ..................................................................................................................... 11
`
`B.200T Pump
`
`1. Nameplate ................................................................................................................................................ 12
`
`2. Declaration of Incorporation ..................................................................................................................... 13
`
`C. 300Q Pump
`
`1. Nameplate ................................................................................................................................................ 14
`
`2. Declaration of Incorporation ..................................................................................................................... 15
`
`INSTALLATION
`
`I. GENERAL
`A. Lifting ........................................................................................................................................................ 16-17
`
`
`B. Pump Mounting ............................................................................................................................................. 18
`
`C. Alignment ...................................................................................................................................................... 18
`
`D. Suction Line .................................................................................................................................................. 18
`
`E. Discharge Line .............................................................................................................................................. 19
`
`F. Power End ..................................................................................................................................................... 19
` G. Fluid End ....................................................................................................................................................... 20
`
`H. Plunger Packing ............................................................................................................................................ 20
`
`I. Plunger Packing Lubrication ........................................................................................................................... 20
`
`J. Suction Pulsation Dampener
`1. Low Pressure - Plastic Body................................................................................................................ 20-21
`2. High Pressure - Aluminum Body .............................................................................................................. 21
`
`
`LUBRICATION
`
`I. GENERAL
`A. Oil .................................................................................................................................................................. 22
`
`
`OPERATION
`
`I. GENERAL
`
`A. Operation Check List .................................................................................................................................... 23
`
`MAINTENANCE
`
`I. GENERAL
`
`A. Daily Maintenance ........................................................................................................................................ 24
`
`B. Monthly Maintenance .................................................................................................................................... 24
`
`C. Storage ......................................................................................................................................................... 25
`
`D. Start-Up After Storage .................................................................................................................................. 25
`
`II. TROUBLE SHOOTING GUIDE ...................................................................................................................... 26-28
`
`
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`5
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`Page 8 of 83
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`Installation, Care and Operation
`Manual
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`PAGE
`
`
`Table of Contents (Continued)...
`
`OVERHAUL AND REPAIR
`
`I. GENERAL
`
`A. Tools Required ............................................................................................................................................... 29
`
`B. Check Points and Adjustments
`
`1. 30T, 60T, & 80T ........................................................................................................................................ 29
`
`2. 100T, 130T, 165T, 200T, 250T & 300Q .............................................................................................. 29-30
`
`DISASSEMBLY
`
`I. POWER END
`
`A. Intermediate Rods and Oil Wiper Retainers .................................................................................................. 31
`
`B. Crankshaft Assembly ..................................................................................................................................... 31
`
`30T, 60T, & 80T ........................................................................................................................................... 32
`
`J-100 & J-150 .............................................................................................................................................. 32
`
`100T, 130T, 165T, 200T, 250T & 300Q ...................................................................................................... 33
`
`C. Crankshaft Bearings (All Pumps) .................................................................................................................. 33
`
`II. FLUID END
`
`A. Fluid Cylinder Removal
`30T, 60T, & 80T ........................................................................................................................................... 34
`100T, 130T, J-150, 165T, 200T, 250T & 300Q ........................................................................................... 34
`B. Stuffing Boxes and Plunger Removal
`30T, 60T, & 80T ........................................................................................................................................... 34
`100T, 130T, J-150, 165T, 200T, 250T & 300Q ........................................................................................... 35
`C. Fluid End Valve Removal .............................................................................................................................. 35
`
`
`
`
`
`
`
`ASSEMBLY
`
`I. POWER END
`A. Crankshaft Main Bearings
`
`
`30T, 60T, & 80T ........................................................................................................................................... 36
`
`100T, 130T, J-150, 165T, 200T, 250T & 300Q ........................................................................................... 37
`
`B. Crankshaft and Center Support Bearings
`
`200T, 250T & 300Q ..................................................................................................................................... 38
`
`100T, 130T, 165T, 200T, 250T & 300Q ...................................................................................................... 38
`
`C. Connecting Rod and Crosshead Assembly ................................................................................................... 39
`
`D. Connecting Rod to Crankshaft Assembly
`
`J-30 and J-60 (with Old Style straight cut connecting rods) ........................................................................ 39
`
`J-100, & J-150 (with Old Style straight cut connecting rods) ....................................................................... 39
`
`30T, 60T, 80T, 130T, 165T, 200T, 250T & 300Q (with New Style connecting rods) ............................ 40-41
`
`E. Intermediate Rods and Oil Seal Retainers
`
`30T, 60T, 80T, 100T and 130T .................................................................................................................... 41
`
`100T, 130T, 165T, 200T, 250T & 300Q ...................................................................................................... 41
`
`All Pumps ..................................................................................................................................................... 42
`
`
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`6
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`Page 9 of 83
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`Installation, Care and Operation
`Manual
`
`
`Table of Contents
`
`ASSEMBLY (Continued)...
`
`II. FLUID END
`
`A. Stuffing Boxes and Plungers ......................................................................................................................... 42
`
`30T, 60T, 80T ........................................................................................................................................ 42-43
`
`100T, 130T, 165T, 200T, 250T & 300Q ...................................................................................................... 43
`
`B. Fluid Cylinders (All Pumps) ........................................................................................................................... 44
`
`C. Fluid Valves – Spherical, Tapered Seat Bottom Guided and Cage Type .................................................... 44
`
`D. Piping Installation .......................................................................................................................................... 44
`
`E. Plunger Packing Installation
`1. 850-N Packing .......................................................................................................................................... 45
`2. 1045 Packing ............................................................................................................................................ 46
`3. 699 Packing .............................................................................................................................................. 47
`4. Spring Loaded Kevlar Reciprocating Packing ..................................................................................... 47-48
`
`PAGE
`
`
`PLUNGER PUMP VALVES
`
`I. OPERATIONAL MAINTENANCE
`
`A. Suction and discharge ............................................................................................................................................. 49
`
`B. Valve Covers ............................................................................................................................................................ 49
`
`C. Valve Cage and Cover Seals .................................................................................................................................. 49
`
`D. Valve Springs ........................................................................................................................................................... 49
`
`E. Valve Cages ............................................................................................................................................................. 50
`
`F. Valve and Seat ......................................................................................................................................................... 50
`
`II. CAGE TYPE VALVES
`
`A. Nomenclature ........................................................................................................................................................... 51
`
`B. Valve Servicing Tools (charts) ................................................................................................................................. 52
`
`C. Disassembly Procedure...................................................................................................................................... 53-54
`
`D. Valve Parts Inspection
`1. Cage (Bottom Guide, Disc, Ball or Spherical) .......................................................................................... 55
`2. Valve, Bottom Guided and Seat ............................................................................................................... 56
`3. Valve, Spherical and Seat ........................................................................................................................ 56
`4. Valve, Disc and Seat ................................................................................................................................ 57
`5. Valve, Ball and Seat ................................................................................................................................. 58
`6. Springs ...................................................................................................................................................... 58
`7. Seals, Valve and Cage ............................................................................................................................. 58
`E. Assembly Procedure ........................................................................................................................................... 59-61
`
`
`
`
`III. TAPERED SEAT VALVES
`
`A. Spherical Valves and Seats
`1. Valve Removal Procedure .................................................................................................................................. 62
`
`
`2. Installation Procedure .................................................................................................................................... 62-64
`
`B. Tapered Seat-Bottom Guided Valves
`
`1. Valve Removal Procedure .................................................................................................................................. 65
`
`2. Installation Procedure .................................................................................................................................... 65-67
`
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`7
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`Page 10 of 83
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`Installation, Care and Operation
`Manual
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`
`Table of Contents (Continued)...
`
`GEAR REDUCER
`
`I. LUBRICATION AND MAINTENANCE
`A. General .......................................................................................................................................................... 68
`1. Oil ........................................................................................................................................................ 68-69
`2. Maintenance .............................................................................................................................................. 69
`
`PAGE
`
`
`II. OVERHAUL AND REPAIR
`A. General .......................................................................................................................................................... 70
`1. Disassembly .............................................................................................................................................. 70
`2. Assembly ............................................................................................................................................. 71-73
`3. Installation ................................................................................................................................................. 73
`
`
` P-55U LUBRICATOR
`
`I. PUMP OPERATING INSTRUCTIONS
`A. Operating Instructions .................................................................................................................................... 74
`1. Box Suction Pumps ................................................................................................................................... 74
`2. Flow Rate Adjustment ............................................................................................................................... 74
`3. Sight Glass ................................................................................................................................................ 74
`4. Overfilling of Sight Glass ........................................................................................................................... 74
`5. Reservoir Oil Level .................................................................................................................................... 74
`6. Pump Displacement .................................................................................................................................. 74
`
`
`STORAGE OF PUMPS
`
`I. GENERAL
`A. General .......................................................................................................................................................... 75
`
`
`B. Recommended Protection and Initial Storage ............................................................................................... 75
`
`C. Six Month Servicing ....................................................................................................................................... 76
`
`D. Pre-Installation Check After Storage ............................................................................................................. 76
`
`OWNERS RECORD ............................................................................................................................. 77
`
`TYPICAL WATERFLOOD PUMP INSTALLATION SUCTION and
`DISCHARGE PIPING ARRANGEMENT ........................................................................... 78
`
`VISCOSITY EQUIVALENTS ........................................................................................................ 79
`
`
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`
`Revisions effective August 27, 2010 – replaced the word multiplex with reciprocating.
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`8
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`Page 11 of 83
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`Installation, Care and Operation
`Manual
`
`
`ATEX Warning Statements…
`
`I. PUMPS AND PUMP UNITS
`
`
`1. Where a pump or pump unit is to be installed in a potentially explosive atmosphere ensure that this has been specified
`at the time of purchase and that the equipment has been supplied accordingly and displays an ATEX nameplate or is
`supplied with a certificate of conformity. If there is any doubt as to the suitability of the equipment please contact
`National Oilwell Varco before commencing with installation and commissioning.
`
`2. Process liquids or fluids should be kept within specified temperature limits, otherwise the surface of pump or system
`components may become an ignition source due to temperature rises. Where the process liquid temperature is less
`than 90ºC the maximum surface temperature will not exceed 194ºF (90ºC) provided the pump is installed, operated
`and maintained in accordance with this manual.
`
`3. Electrical installation and maintenance work should only be carried out by suitably qualified and competent persons
`and must be in accordance with relevant electrical regulations.
`
`4. All electrical equipment, including control and safety devices, should be suitably rated for the environment in to which
`they are installed.
`
`5. Where there may be a risk of an accumulation of explosive gases or dust, non-sparking tools should be used for
`installation and maintenance.
`
`6. To minimize the risk of sparking or temperature rises due to mechanical or electrical overload the following control and
`safety devices should be fitted. A control system that will shut the pump down if the motor current or temperature
`exceed specified limits. An isolator switch that will disconnect all electrical supply to the motor and ancillary electrical
`equipment and be capable of being locked in the off position. All control and safety devices should be fitted, operated
`and maintained in accordance with the manufacturer’s instructions. All valves on the system should be open when
`the pump is started otherwise serious mechanical overload and failure may result.
`
`It is important that the pump rotates in the direction indicated on the nameplate. This must be checked on installation
`and commissioning and after any maintenance has been carried out. Failure to observe this may lead to dry running
`or mechanical or electrical overload.
`
`8. When fitting drives, couplings, belts, pulleys and guards to a pump or pump unit it is essential that these are correctly
`fitted, aligned and adjusted in accordance with the manufacturer’s instructions. Failure to do so may result in sparking
`due to unintended mechanical contact or temperature rises due to mechanical or electrical overload or slipping of
`drive belts. Regular inspection of these parts must be carried out to ensure they are in good condition and
`replacement of any suspect part must be carried out immediately.
`
`9. Seals should be suitably rated for the environment. The seal and any associated equipment, such as a flushing
`system, must be installed, operated and maintained in accordance with the manufacturer’s instructions.
`
`10. Where a packed gland seal is fitted this must be correctly fitted and adjusted. This type of seal relies on the process
`liquid to cool the shaft and packing rings so a constant drip of liquid from the gland section is required. Where this is
`undesirable an alternative seal type should be fitted.
`
`11. Failure to operate or maintain the pump and ancillary equipment in line with the manufacturer’s instructions may lead
`to premature and potentially dangerous failure of co