Truflo DAP Series Instruction manual

Installation,

Operation, &

Maintenance

Manual

A New Vision For Quality Pumps

DAP/DSP Series

This manual provides instructions for the Installation, Operation, and Maintenance of the TRUFLO DAP ANSI

Centrifugal Process Pump. This manual covers the standard production and common options that are

available. For special options, supplemental instructions are supplied. This Manual must be read and fully

understood before installation and start-up.

The design, materials, and workmanship incorporated in the construction of TRUFLO pumps make them

capable of giving, trouble-free service. The life and satisfactory service of any mechanical unit, however,

are enhanced and extended by correct application, proper installation, periodic inspection, condition

monitoring, and careful maintenance.

This instruction manual was prepared to assist operators in understanding the correct methods of installing,

operating, and maintaining these pumps.

TRUFLO shall not be liable for physical injury, damage or delays caused by a failure to observe the

instructions for Installation, Operation, and Maintenance contained in this manual.

Warranty is valid only when genuine TRUFLO parts are used.

Use of the equipment on a service other than stated in the warranty card will nullify the warranty, unless

written approval is obtained in advance from TRUFLO.

Additional manuals can be obtained by contacting your local TRUFLO representative or by calling 1-800-

789-7864.

CONTENTS

1. SAFETY

1-1 Nomenclature .............................................................................................................................................................................. 5

1-2 General Precautions ................................................................................................................................................................... 5

2. GENERAL INFORMATION

2-1 Pump Description ...................................................................................................................................................................... 6

2-2 Attached Information ............................................................................................................................................................... 7

2-2.1 Pump Nameplate .................................................................................................................................................................. 7

2-2.2 Included Information ........................................................................................................................................................... 7

2-3 Transportation & Storage ........................................................................................................................................................ 7

2-3.1 Storage Requirements ......................................................................................................................................................... 7

2-3.2 Handling / Lifting .................................................................................................................................................................. 8

3. INSTALLATION

3-1 Site / Foundation ........................................................................................................................................................................ 9

3-2 Level Baseplate ........................................................................................................................................................................... 9

3-3 Grout Baseplate .......................................................................................................................................................................... 9

3-4 Alignment Procedures .............................................................................................................................................................. 9

3-4.1 Alignment Check ................................................................................................................................................................... 10

3-5 Piping ............................................................................................................................................................................................ 10

3-5.1 General Notes ........................................................................................................................................................................ 10

3-5.2 Suction Piping ........................................................................................................................................................................ 11

3-5.3 Discharge Piping ................................................................................................................................................................... 11

3-5.4 Final Piping Check ................................................................................................................................................................ 12

4. OPERATION

4-1 Preparation for Start-up ............................................................................................................................................................ 13

4-1.1 Motor Rotation Check ........................................................................................................................................................... 13

4-1.2 Impeller Clearance Check .................................................................................................................................................... 13

4-1.3 Couple Pump and Driver ..................................................................................................................................................... 14

4-1.4 Lubricating Bearings .............................................................................................................................................................. 14

4-1.5 Shaft Sealing ............................................................................................................................................................................. 14

4-2 Start-Up ......................................................................................................................................................................................... 15

4-2.1 Priming the Pump .................................................................................................................................................................. 15

4-2.2 Starting the Pump .................................................................................................................................................................. 15

4-3 Operation ...................................................................................................................................................................................... 16

4-3.1 General Considerations ......................................................................................................................................................... 16

4-3.2 Break-In Period ........................................................................................................................................................................ 16

4-3.3 Operating at Reduced Capacity ......................................................................................................................................... 16

4-3.4 Operating Under Freezing Conditions ............................................................................................................................. 17

4-4 Shut-Down .................................................................................................................................................................................... 17

4-5 Final Alignment .............................................................................................................................................................................. 17

5. PREVENTIVE MAINTENANCE

5-1 General Comments ...................................................................................................................................................................... 18

5-2 Maintenance Schedule ............................................................................................................................................................... 18

5-2.1 Break-In Period ......................................................................................................................................................................... 18

5-2.2 Routine Maintenance Summary ........................................................................................................................................ 18

5-2.3 Routine Inspection .................................................................................................................................................................. 18

5-2.4 Monthly Inspection ................................................................................................................................................................. 18

5-2.5 Annual Inspection ................................................................................................................................................................... 18

5-3 Maintenance of Bearings ........................................................................................................................................................... 19

5-3.1 Oil Lubricated Bearings ......................................................................................................................................................... 19

5-4 Maintenance of Shaft Seals ...................................................................................................................................................... 20

5-4.1 Mechanical Seals ..................................................................................................................................................................... 20

5-4.2 Packed Back Cover .................................................................................................................................................................. 20

6. BREAKDOWN

6-1 Disassembly ................................................................................................................................................................................... 21

6-1.1 Pump from Baseplate ............................................................................................................................................................ 21

6-1.2 Disassembly of Bearing Housing ....................................................................................................................................... 21

6-2 Reassembly ................................................................................................................................................................................... 21

6-2.1 Inspections ................................................................................................................................................................................. 21

6-2.2 Seal Assembly ........................................................................................................................................................................... 24

6-2.3 Seal Testing ............................................................................................................................................................................... 24

6-2.4 Pump Assembly ....................................................................................................................................................................... 24

6-2.5 Motor and Coupling Assembly ........................................................................................................................................... 25

7. TROUBLE SHOOTING

7-1 Pump Troubleshooting Guide ................................................................................................................................................... 26

7-2 Mechanical Seal Troubleshooting Guide ............................................................................................................................... 27

8. PARTS BREAKDOWN

Sectional View of a Group 1 Pump ................................................................................................................................................. 28

Sectional View of a Group 2 Pump ................................................................................................................................................ 29

Sectional View of a Group 3 Pump ................................................................................................................................................ 30

APPENDIX –GENERAL ALIGNMENT INFORMATION

Set-Up .................................................................................................................................................................................................... 31

Measurement ....................................................................................................................................................................................... 31

Angular Alignment ............................................................................................................................................................................. 31

Parallel Alignment .............................................................................................................................................................................. 32

Complete Alignment ......................................................................................................................................................................... 33

DSP Series ............................................................................................................................................................................................. 33

Common Conversions ........................................................................................................................................................................ 34

1. SAFETY

1-1 NOMENCLATURE

This pump has been designed for safe and reliable operation when properly used and maintained in accordance with

instructions contained in this manual.

A pump is a pressure-containing device with rotating parts that can be hazardous. Operators and maintenance personnel

must realize this and follow safety measures. TRUFLO shall not be liable for physical injury, damage or delays caused by a

failure to observe the instructions in this manual.

Throughout this manual the words Warning, Caution, and Note are used to indicate procedures or situations that require

special operator attention.

WARNING

Warning is used to indicate the presence of danger that can cause severe personal injury, death, or substantial property

damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a danger, which will, or can cause minor personal injury or property damage if

the warning is ignored.

NOTE: Operating procedure, condition, etc. which is essential to observe.

EXAMPLES;

WARNING

Pump shall never be operated without coupling guard

installed correctly.

CAUTION

Throttling flow from the suction side may cause

cavitation and pump damage.

1-2 GENERAL PRECAUTIONS

WARNING

Personal injury will result if procedures outlined in this manual

are not followed.

Never use heat to disassemble pumps due to risk of explosion from trapped liquid.

Never operate pump without coupling guard correctly installed.

Never operate pump beyond the rated conditions to which the pump was sold.

Never start pump without proper prime (sufficient liquid in pump casing).

Never run pump below recommended minimum flow or when dry.

Always lock out and tag out power to the driver before performing pump maintenance.

Never operate pump with discharge valve closed.

Never operate pump with suction valve closed.

Do not change conditions of service without approval of authorized TRUFLO representative.

2. GENERAL INFORMATION

2-1 PUMP DESCRIPTION

The Model DAP is a horizontal overhung, open impeller centrifugal pump that meets requirement of ANSI B73.1. The

model is based on 6 power ends and 31 hydraulic pump sizes. Groupings are as followed.

Group 1 ------------ 7 Pump sizes

Group 2 ------------ 14 Pump sizes

Group 3 ------------ 10 Pump sizes

Casing:

The pump casing is an end-suction and top discharge ANSI B73.1 design with 150lb ANSI raised face flanges as standard

inlet and outlet connections. Inlet and outlet connections are available in 150lb or 300lb flanges with raised or flat face

configurations. The casing is configured with a back pull out design, which allows complete disassembly without

disturbing the piping or motor. A rigid foot mount for maximum resistance to unanticipated load supports the casing.

Confined gasket between casing and back cover plate insures positive seal. Unit is also supplied with 1/4" NPT tap on the

discharge flange.

Impeller:

The impeller is an open design for maximum efficiency, hydraulically balanced, with the best wear characteristics and no

axial adjustments. The impeller is attached to the shaft by means of a MNPT bore on reverse side. The impeller has rear

pump out vanes to minimize back cover plate pressure. The impeller clearances can be set externally via jack bolts on

outboard side of the pump. Standard material for the impeller is 316 stainless steel (CF8M) unless the pump material is of

higher grade alloy. All impellers are dynamically balanced.

Back Cover Plate:

Standard design is cylindrical bore and oversized for increased circulation. Back cover plate can accept a variety of

mechanical seals, such as single, double (inside and out) unbalanced or balanced in any materials available. Flush plans

are available.

Bearing Housing:

The bearing housing shall be sealed with labyrinth style bearing isolators to prevent contamination of the bearing

lubricant. A large and easy to read 1” NPT sight glass and a magnetic filter shall be used.

Shaft:

Shaft is a heavy duty, solid shaft design with maximum diameter in critical areas and with minimum shaft overhang.

Maximum shaft deflection is less then 0.002” at the face of the back cover plate. Shaft is also stepped to fit a variety of

seal types. Standard shaft material is 316 stainless steel (CF8M) unless the pump material is of higher grade alloy.

Bearings:

The inboard bearing carries only radial load, it is free to float axially in the frame. The outboard bearing is shouldered and

locked to the shaft and housing to enable it to carry radial and thrust loads. All fits are precision machined to industry

standards. The inboard bearing is a single row deep groove ball bearing. The outboard bearing is a double row angular

contact bearing.

Shaft Sealing:

The back cover plate is available to fit a component seal, cartridge seal or packing.

Direction of Rotation:

Counterclockwise as viewed from casing, looking at the driver shaft.

2-2 ATTACHED INFORMATION

2-2.1 Pump Nameplate

Every pump has a TRUFLO nameplate that provides information about the pump. The nameplate is located on the bearing

adaptor.

The nameplate provides information about the pump’s characteristics. Note the format of the pump size: Suction Diameter

x Discharge Diameter - Impeller Diameter (inches). (Example: 3 x 1.5 - 6)

When ordering spare parts you will need to identify pump model, size, serial number, and the item number of required

parts. Information can be taken from the pump nameplate. Item numbers can be found in this manual.

2-2.2 Included Information

Each pump is sent with the following information in the form of attached tags, stickers and manuals:

1. Installation, Operation and Maintenance Manual

2. Stainless Steel Nameplate

3. Direction of Rotation Sticker

4. Label stating that the pump has been shipped without oil and requires oil before start up

5. Label stating that the pump needs to be realigned & rotation checked before start-up.

2-3 TRANSPORTATION & STORAGE

Inspect the pump as soon as it is received. Carefully check that everything is in good order. Make notes of damage or

missing items on the receipt and freight bill. File any claims with the transportation company as soon as possible.

2-3.1 Storage Requirements

Short Term: (less than 6 months) TRUFLO’s normal packing procedure is designed to protect pump during

shipping. Upon delivery of equipment, store in a covered and dry location.

Long Term: (more than 6 months) Preservative treatment of bearings and machined surfaces will be required.

Rotate shaft several times every 3 months. Refer to driver and coupling manufacturers for their long-term storage

procedures. Store in a covered dry location.

2-3.2 Handling / Lifting

WARNING

CAUTION

Pump and components are heavy. Failure to properly lift

and support equipment could result in serious physical

injury or damage to the equipment. Steel-toed shoes

must be worn at all times.

Use a forklift or an overhead crane with sufficient

capacity to move the equipment. Failure to do so

can result in physical injury or equipment damage.

WARNING:

All applicable regulations and standards must be followed when lifting equipment.

Assembled equipment and their components are very heavy. Failure to properly lift and support equipment can

result in serious physical harm and/or damage to the equipment.

Lift equipment only at the identified lifting points. Devices such as hoist rings, shackles, slings, straps, chains,

spreaders, etc. must be rated to support the entire weight of equipment.

Equipment and their components can be heavy. Use proper lifting methods and wear steel-toed shoes at all

times.

Do NOT lift equipment by shaft ends.

Do NOT combine or interchange different lifting methods.

Pump Type

Lifting Method

Bare Pump Only

Use a suitable sling attached properly to the casing, flanges, and/or frame.

Base Mounted Pump

Use suitable slings attached properly to the casing and the motor or baseplate. Use

lifting lugs or rings on the baseplate when available.

For concrete polymer baseplates, see the baseplate IOM manual for additional lifting

instructions.

Proper Lifting Method Examples

Figure 1:

Bare Pump Lifting Method

Figure 2:

Pump and baseplate lifting method.

Figure 3:

Pump, base and motor lifting method.

Figure 4:

Lifting method for baseplates

using lifting lugs or rings.

3. INSTALLATION

3-1 SITE / FOUNDATION

A pump should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection.

1. Baseplate mounted pumps are normally grouted on a concrete foundation, which has been poured on a solid

footing. The foundation must be able to absorb any vibration and to form a permanent, rigid support for the

pumping unit.

2. The location and size of foundation bolts are shown on the outline assembly drawing provided with the pump

data package.

3. Foundation bolts most commonly used are sleeve type and J-type. Bolt designs permit movement for final bolt

adjustment.

3-2 LEVEL BASEPLATE

1. After mounting on the foundation examine the baseplate and make sure it is as level as possible.

2. Place 2 sets of wedges or shims on the foundation, one set on each side of every foundation bolt.

3. The wedges should extended 3/4 in (20mm) to 1.5 in (40mm) above foundation, to allow for adequate grouting.

This will provided even support for the baseplate once it is grouted.

4. Remove water and/or debris from anchor bolt holes/sleeves prior to grouting. If the sleeve type bolts are being

used, fill the sleeves with rags to prevent grout from entering.

5. Carefully lower baseplate onto foundation bolts.

6. Level baseplate to within 1/8 inch (3.2mm) over length of the baseplate and to within 0.088 inch (1.5mm) over the

width of the base by adjusting wedges.

7. Tighten bolts by hand.

3-3 GROUT BASEPLATE

1. Clean areas of baseplate that will contact grout. Do not use oil-based cleaners because grout will not bond to it.

(Refer to grout manufacturer’s instructions)

2. Build a dam around foundation. Thoroughly wet pump foundation.

3. Pour grout through grout hole in the baseplate, up to level of dam. Remove air bubbles from grout as it is poured

by patting, using a vibrator, or pumping the grout into place. Non-shrink grout is recommended.

4. Allow grout to set.

5. Fill remainder of baseplate with grout. Again remove air.

6. Allow grout to set at least 48 hours.

7. Tighten foundation bolts.

3-4 ALIGNMENT PROCEDURE

WARNING

Before beginning any alignment procedure make sure that

drive power is shut down. Failure to shut down driver power

will result in serious physical injury.

Alignment is achieved by adding or removing shims from under the feet of the driver/motor and adjusting equipment

horizontally as needed.

Note: Even though the pump was aligned after assembly prior to shipment, proper field alignment is the

responsibility of the installer and user of the unit.

Accurate alignment of the equipment must be attained. Trouble free operation can be accomplished by following these

procedures.

3-4.1 Alignment Check

Proper total alignment calls for alignment checks several times during the installation/start-up process. Below are

recommended points for which alignment is performed.

Before Grouting Baseplate –To ensure alignment can be obtained.

After Grouting Baseplate –To ensure no changes have occurred during grouting process.

After connecting pipe –To ensure pipe strains have not altered Alignment. If changes have occurred, alter piping to

remove pipe strains on pump flanges.

Final Alignment -Hot Alignment with pump heated to normal operating temperature.

Break In Period –Alignment check at this point will determine if pump system has moved out of alignment.

Obtain alignment when both pump and driver are at operating temperature. Thereafter, alignment should be

checked periodically according to plant operating procedures.

Note: Alignment check must be made after a process temperature change, piping changes and or pump

service is performed.

Note: Please refer to Appendix for Alignment Procedures and Guidelines

3-5 PIPING

3-5.1 General Notes

Guidelines for piping are given in the “Hydraulic Institute, Standards” available from: Hydraulic Institute, 30200 Detroit

Road, Cleveland, OH. 44145-1967 and must be reviewed prior to pump installation.

WARNING

Never draw piping into place by forcing at the flanged

connections of the pump. This may impose dangerous strains

on the unit and cause misalignment between pump and driver.

Pipe strain will adversely effect the operation of the pump

resulting in physical injury and damage to the equipment.

1. All piping must have an adequate number of pipe hangers and be aligned both axially and radially with the pump

flanges.

2. Piping runs should be as short as possible to minimize friction loss.

3. Do not connect piping to pump until grout has hardened and pump and driver hold-down bolts have been

tightened.

4. It is suggested that expansion loops or joints be properly installed in suction and/or discharge lines when handing

liquids at elevated temperatures, so linear expansion of piping will not draw pump out of alignment.

5. The piping should be arranged to allow pump flushing prior to removal of the unit on services handling corrosive

liquids.

6. Carefully clean all pipes, parts, valves and fittings, and pump branches prior to assembly.

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