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YOUR REF.

PURPOSE : Heeling

ORDER NO.: HA-EF/I-149929/2

PROJECT : H32 - NYK

IRON REF.

PUMP NO. : QT0567

ORDER NO.: 3564676

PUMP TYPE: QT 250

,03257$175HDGWKLVPDQXDOEHIRUHPRXQWLQJDQGVWDUWLQJRISXPSV

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1.0 Before start ..............................................................................................................................7

1.1 General instructions.................................................................................................................7
1.2 Mounting instructions..............................................................................................................7
1.3 For pumps delivered without motor - mounting of coupling parts .........................................7
1.4 Alignment of couplings ...........................................................................................................7
1.5 Installation of the pump...........................................................................................................8
1.6 Motor wiring............................................................................................................................8
1.7 Starting of the pump ................................................................................................................8

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2.0 3 Months’ check ....................................................................................................................10

2.1 12 Months’ check ..................................................................................................................10

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3.0 Preservation of bearings ........................................................................................................11

3.1 Preservation of interior parts of the pumps ...........................................................................11
3.2 Preservation procedure ..........................................................................................................11
3.3 Restarting of the pumps.........................................................................................................11

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4.0 Dismounting ..........................................................................................................................12

4.1 Mounting ...............................................................................................................................12

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5.0 Safety precautions .................................................................................................................13

5.1 Mounting ...............................................................................................................................13
5.2 Alignment ..............................................................................................................................13
5.3 Possible misalignments .........................................................................................................13
5.4 Operation ...............................................................................................................................13
5.5 Maintenance ..........................................................................................................................14
5.6 Replacing of flexibles............................................................................................................14
5.7 Table .....................................................................................................................................14
5.8 Instructions drawing for EFLEX-R coupling type RN..........................................................15

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Page 2
 ,5213803$6

6.0 Fitting instructions for mechanical shaft seals ......................................................................16

6.1 Fitting rotating sealing units on shaft ....................................................................................16

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7.0 Error finding ..........................................................................................................................19

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Type : QT 250

Pcs :1

Capacitet : 151 / 420 m3/h

Head :

Total head : 13,50 / 8,00 m.W.c.

Suction head :

Coupling Size : EFLEX-R / RN6

Weight / kg. : 380

Material:

Pump casing : Bronze RG10

Impeller : Ni.Al.Bronze

Casing wear ring : Ni.Al.Bronze

Shaft : AISI-329

Mech.seal : YES

Gland packing :

0RWRU

Type : Alstom AF2S 200 L4

kW : 34,50

Power consumption kW : 35,50 / 24,50 (max 41,80)

RPM : 1770 / 1770

Weight / kg :

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• Check the indications mentioned on the label: Especially the type of grease.
• Mark down the date of commissioning in the place provided for that purpose on the label.
• Pre-lubricateboth the unit to be greased and the grease inlet circuit into the unit. Use a grease that can
be mixed with the grease contained in the SNR dispenser.
• Remove the waterproof plastic cap then the round plug to gain access to the switch panel.
• Engage the switch (or switches) to correspond to the duration chosen (1,2,3 months..) and turn on the
warning light switch. Replace the round plug and the waterproof plastic cap.
• Withdraw the plastic plug from the grease outlet.
Screw the dispenser onto the greasing point (1/4 inch thread) by hand (do not overtighten), Use a cou-
pling (min inner dia 6 mm) or a tubing (max length 1 m), if the dispenser cannot be installed directly on
the greasing point.

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• The SNR dispenser is operational whatever the position (vertical, horizontal, at an angle, or even head
down) and can be submerged.
• After closing the electrical circuit, the chemical reaction starts with controlled production of propel-
lant gas - the gas must reach a given pressure before the grease begins to be ejected. This delay varies
according to the setting:

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If you wish to start straight away, engage all switches at once for 12 hours, then return to the chosen set-
ting.
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Just replace the dispenser when it is empty or when the set running time is over. If the grease level does
not go down while the warning light is flashing, it means that the unit is full of pressurized grease. Inthis
case, the dispenser ensures continuos greasing of the unit to be lubricated by maintaining the grease
under pressure.

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Move all switches to “OFF” then start again when yuo wish. It is also possible to alter the setting during
operation.

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Check the pump immediately after receipt. In case of damages or defects - complain immediately.
All pumps are marked with indication of type and number, stamped into the plate as well as into the
pump itself - as for centrifugal pumps, usually in the suction flange - as for other pumps, at an easily
visible place.
If the pump is not mounted immediately after receipt it should be protected during storage (see storage
instructions).

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When calculating the piping system, special regard should be paid to minimizing pressure losses in the
suction line (short pipe lengths, large diameter, few bendings, no valves). If valves are necessary, then
use valves with min. pressure losses, e.g. slide valves, butterfly valves, flap non-return valves etc.
Static suction lift + total pressure losses in suction line + NPSH value of the pump + steam pressure of
the liquid must not exceed 10 mWC at sea level (and 760 mm Hg.).

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Before mounting, shaft and coupling parts must be carefully cleaned. Grease shaft ends and check that
key fits. Heat coupling parts to 80oC. and push them on to the shaft ends by hand or by a light pressure.
By dismounting a puller will have to be applied.

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Flexible couplings will absorb small deviations in the relative positions of the shaft ends to be connected,
however, a careful and accurate alignment will prolong the life of the coupling flexibles - see instructions
for coupling.

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The entire piping must be pressure and leakage tested and flushed clean before it is connected to the suc-
tion and discharge side of the pump. If the pressure test takes place with the pump installed the testing
pressure must not exceed the testing pressure of the pump, which is stamped into the pump, usually in the
suction flange. Otherwise, the pump packings or flanges for the mechanical shaft seal might be dama-
ged. Connection of the pipes to the pump must take place without using force as this might interfere with
the alignment of the pump.
Precautions must be taken to ensure that the pipe connections to the pump are supported in a way that
prevents tensions from being transmitted to the pump, e.g. owing to thermal expansion. Check that all
other connections to the pump are in working order, such as lubrication, priming, heating, cooling med-
ium outlet, etc., and that the various measuring equipment has been correctly connected. Take care that
no parts obstruct the easy access to the pump for inspection or replacement of important parts. If the
pump is equipped with venting device (item 672), then this must be placed upwards.

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Electric motors should be connected by means of sufficiently long cables to permit the motor to be
moved a little without dismantling the connections. A control unit (emergency stop) should be installed
close to the pump. The motor and the valve must be electrical connected so the valve starts opening,
when the motor is started and the valve starts closing, when the motor is stopped.
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When the preceding preparations and installations have been completed incl. the lubricator dispenser and
it has been controlled that the pump shaft can be turned by hand, the pump can be started. The pump can
be started against closed discharge valve, but the valve must be opened immediately after start, not to
damage the motor. The pump will use a lot of power when it is running against closed valve, and the
motor is normally not big enough to run constant at that power. Pumps with mechanical shaft seal must
be protected against impurities and dry running. Please note that clogged filters will cause considerable
friction losses, which may decisively affect the suction capacity and output of the pump. check also when
starting the pump that the direction of rotation is correct (shown with an arrow on the pump), and open
slowly the valve on the discharge side of the pump. At normal discharge head the pump should run
smoothly without abnormal noises and vibrations after abt. 1 minute of operation.
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PDOO\PD[PLQ During the first hours of operation bearings, packings and mechanical shaft seal
should be checked for heating and leakage. Normal bearing temperature is 40-75 hr.C. max temperature
for normal ball and roller bearings is up to 105 gr.c.

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Lubricate the thrust roller bearings with normal ball bearings grease - Mobiltemp SHC 100.
The bearings are lubricated with 25 gram grease for every 2000 hours. Check that not too much grease is
pressed into the bearings as this will cause generation of heat. All bearings are provided with sealing
rings in order to prevent humidity and impurities from entering. The grease must no be pressed through
these sealing rings. For bearings which are exposed to higher pressure or humidity a heat resisting and
water-repelling grease will apply (Molypan LT-1 or similar quality).

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BP ENERGREASE LS-EP2

CASTROL SPHEEROL AP 2/3

CHEVRON DURA LITH GREASE EP2

ESSO BEACON EP2

MOBIL MOBILTEMP SHC 100

Q8 REMBRANDT EP2

SHELL ALVANIA GREASE EP2

TEXACO MULTIFAK ALL

PURPOSE EP2

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Set the lubricator dispenser rate to 12 months.

See the “Fitting and setting instructions” for the SNR lubricator.
A new lubricator dispenser must be mounted when the old is emty (after apr.12 month)

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Check the pump for false noises, vibrations and leakage. pumps with mechanical shaft seal must not
leak, neither during standstill with inlet pressure on the pump, nor during operation. The bypass pipe to
the mechanical shaft seal must be intact and permit free flow. In case of defects they must be corrected
immediately as they may greatly influence the operation and life of the pump.

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Disassemble the pump (see instructions). Check the components of the rotary element and perform all
necessary replacement.

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All pumps which are taken out of operation for some time should be protected against corrosion and frost
and kept in a dry place. The following directions should be observed:

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Both ball / roller bearings and slide bearings should be lubricated all over with their normal lubricant.

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The interior parts of the pumps should be protected against aggressive pumping media, for instance by
using a water-repelling solvent containing at the same time corrosion inhibiting nitrides. We recommend
“Mobil oil - Arma 245” or similar quality.

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Flush the pump with pure. hot water (does not apply to be screw pumps and gear pumps) and let it airdry.
Close the valves on both sides of the pump and flush the pump with “Mobil Arma 25” or similar quality.
Flushing can take place through the manometer connections.

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When restarting pumps it is advisable to fill the pump with hot water through the manometer connections
(does not apply to screw pumps and gear wheel pumps) and to turn the pump shaft by hand before
starting the pump. Watch the operation of the pump for abt. 10 minutes and open the valve in the normal
way. Bearings, gearboxes etc. should be lubricated with normal oil or grease if a change of oil has taken
place.

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• Remove the motor.

• Remove the pump from the pipe system.
• Unscrew and remove the suction elbow item 139 and pull out the wear ring item 512.
• Remove the impeller hub cap item 260.
• Pull the impeller item 230 of the shaft.
• Unscrew and remove the pump bowl item 112.
• Unscrew the seal cover item 471 - ZDWFKRXWIRUWKHVKDIWVHDO
• Unscrew the bearing housing item 350.
• The shaft and bearing housing can now be pulled out of the pump - ZDWFKRXWIRUWKHVKDIWVHDO
• Dismantle the bearing housing when the coupling has been removed.

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Clean the pump casing inside and if necessary paint it (for instance with Apexior No.3 or with a more
resistant product as Hempadur No.1513 “Hempel marine paints”).
Control all pump parts and replace damaged parts.

• Produce new 1 mm. packings for the pump casing item 400.1 + 2 + 3.
• Press the bearing bush item 545 and the shaft seal ring item 420.3 into the bearing carrier item 382
and mount it in the pump bowl item 112, and lock them whit the lockring disc item 552.
• Press the wear rings item 512 into position.
• Push the spacer ring item 504, shaft seal item 433, seal cover item 471 with mounted seal ring, bear-
ing housing item 350 with shaft seal ring and 1 loose collar item 505 into the shaft in the order men-
tioned - ZDWFKRXWIRUWKHVKDIWVHDODQGWKHVHDOULQJ
• Preheat the bearings to 80 gr.C. and place them on the shaft, place the other 2 loose collar item 505,
the lockwasher item 931 and the bearing nut item 923 on the shaft. Tighten and lock.
• Push the bearing housing over the bearings and place the bearing cover item 360 with shaft seal ring -
Tighten the screws for the bearing cover with a torque of 30 Nm. - There will be a gap between the
bearing cover and the bearing housing.
• Push the shaft with shaft seal, seal cover and the complete bearing housing into the pump and fasten
the bearing housing with screws.
• Mount and fasten the pump bowl item 112 - EHFDUHIXOWKDWWKHE\SDVVSLSHLVSODFHGFRUUHFWO\
• Mount the impeller item 230 on the shaft, mount the impeller hub cap item 260, fasten and secure the
screws.
• Mount the suction elbow item 139.
• Mount the bypass pipe. Mount the venting device item 672, if any.
• Mount the pump in the pipe system - if the pump is equipped with venting device item 672, then this
must be placed upwards.
• Preheat the coupling half and mount it on the shaft.
• Mount the motor.
• Lubricate the bearings, and check that the shaft can be turned by hand, before starting the pump.

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• Rotating parts should be guarded by the buyer to prevent accidents, taking account of applicable local
accident prevention regulations.

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• Before mounting the hubs, carefully clean shaft ends and coupling parts.
• Inside hubs to be in level with the shaft ends. Tighten set screw to secure hubs axially.
• Tighten set screw only with hexagon socket wrench according to DIN 911 without extension piece.
• Heating of coupling parts till approx. 80oC. will facilitate mounting, but the flexible elements must be
removed first from the female part.
• Check that the flexible elements are turned correct when they are mounted again - se instructions
drawing.
• Bring the coupling hubs together, taking care to observe dimension S1 according to the table.
• Check all screw connections with screw tightening torques of the table.

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• EFLEX-R couplings will absorb deviations in the relative position of shafts to be connected (see pos-
sible misalignments).
• When aligning the coupling halfs , the angular and parallel offset misalignments of shaft relative to
each other should be as small as possible. Alignment to be carried out in two planes as shown in fig.1
with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dail indicator will
give greater accuracy.
• The gap dimension S1 must be within the limits listed in the table.

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• The permissible axial distance Ka (fig.2) must be within the limits for S1 (see the table).
• Angular misalignment Kw (fig.3) is measured as the difference between Smax. and Smin. possible val-
ues are calculated with values from the table.
• Parallel offset misalignment Kr (fig. 4) see the table.
• Angular and parallel offset misalignment can occur at the same time. The sum of both alignments
should not exceed the values Kr respectively Kw.
• Kw and Kr apply in a shock free operation at ambient temperature - 30oC to 80oC.

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• Before commencing initial operatings check alignment and gap dimension S1and if necessary make
corrections. Further check screw connections.

Page 11
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• EFLEX-R couplings do not require any regular maintenance except for an occasional check on the
• torsional play or backlash between the driving and driven halves. When EFLEX-R couplings are used
in drives which do not require a minimum of torsional play or backlash in the coupling, the coupling
flexibles can be allowed to wear down 2/3 of their original thickness before they need replacing.

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• Uninterrupted torque transmission and reliability of operation cannot be guaranteed unless original
• EFLEX-R flexibles are used.
• After fitting new flexibles, be shure they are turned correct.
• Before starting up control the mounting.

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6 2...6 2,4 0,48 0,50 0,10
7 2...6 2,9 0,58 0,60 0,12
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9 2...6 3,7 0,76
10 2...6 4,2 0,84
11 3...7 4,5 0,95
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A mechanical shaft seal is a very highly precision made product and should be treated with the utmost
care before and during fitting. Do not unpack until ready for use. The rotating wear ring and the seat have
been lapped to a great degree of accuracy. care should be taken when unpacking especially when remov-
ing the plastic protection not to scratch the surfaces.
• Fitting the seat into the housing
• The machined place where the seat fits must be cleaned very carefully.
• Edges that are passed by rubber components should be rounded so they do not act sharp or penetrat-
ing.
• The bore in the housing and the seat must be lubricated, with ethylen-propylen rubber only liquid
soap, soapy water or glycerin should be used as this type of rubber cannot withstand mineral oil or
other connections to it. One must never use thinner or the like when cleaning the seal.
• Seals that are furnished with rubber components made of synthetic rubber such as nitrile can tolerate
mineral oil. To avoid any mistakes one should use soap products only.
• Lubrications containing silicone must never be used.
• Press the seat into position with your fingers. If the space is scarce one can use a bush when pressing
the seat into position care being taken not to scratch the surface of the seat. As an example, one can
use a piece of plastic for protection between the bush and seat. After pressing the seat in its position,
make sure that it is fully in its place by measuring the depth with a depth calliper. care should be taken
when fitting seat types that are held in position with the help of a pin. If the pin does not engage in the
hole in the seat it will not be at right angles to the shaft.

6.1 Fitting rotating sealing units on shaft

• Check that the shaft diameter corresponds with the dimension of the seal within a tolerance of ± 0,05
mm.
• The compressed length after fitting must answer to the working length of the size of seal in question
given in the table of measurements.
• Be aware of changes that can take place when bearing arrangements and gaskets etc. are replaced.
• The surface of the shaft must be free from dirt and burrs before fitting a new seal. All sharp edges that
the seal is to pass over must be rounded and not just chamfered.
• The shaft must be lubricated as mentioned above. Furthermore the elastomer is to be lubricated on the
inside where it slides on the shaft. Now the complete and clean unit can be pressed onto the shaft
while its components are sitting in their positions and while the elastomer still slides easily along the
shaft the pump can be assembled.

Page 14
 ,5213803$6

127(

Before the pump is started it must be filled with liquid and the air allowed to escape. Air escape should
be repeated frequently during the first period of time after starting.
Safety precautions.
When fitting shaft seals the instructions should be read carefully especially when the media is dangerous
(poisonous, hot, ignitable etc.).
The fitter should ensure that the material combination supplied is suitable for the job and also see if
screens are needed for the seal arrangement.
If you are in doubt, please contact the supplier.
To obtain the longest lifetime for mechanical shaft seals, they are constructed to maintain a film of liquid
between the 2 surfaces that rotate against each other. The function of the film of liquid is to reduce the
friction and thereby wear and tear under working conditions, this causes some of the liquid to escape into
the atmosphere, but as it is a very small amount that is in question, one will not normally notice this
minor leakage as it will evaporate into the atmosphere.

Page 15
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This list below shows possible trouble sources if the pump does not function correctly.
If you are unable to find the source of interruption or if you cannot repair the fault, Please contact our
service section.

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A.1 Impeller or shaft blocked.

A.2 Motor fault.

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B.1 Motor rotation is not transmitted through coup-

ling.
B.2 Discharge valve closed.
B.3 Non-return valve or other valves are closed.
B.4 Suction line closed.
B.5 Air in pump casing.
B.6 Suction line leaking.
B.7 Shaft seal leaking.
B.8 Bottom valve defective.
B.9 Suction lift too high.
B.10 Priming pump defective.

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C.1 Wrong direction of rotation.

C.2 Number of revolutions too low.
C.3 Counter-pressure too high.
C.4 Suction line or impeller partly clogged.
C.5 Air in pump casing.
C.6 Air in pumping medium.
C.7 Suction lift too high (inlet pressure too low).
C.8 Cavitation.
C.9 Suction line leaking.
C.10 Shaft seal leaking.
C.11 Pump worm out.

'3XPSSUHVVXUHWRRKLJK

Page 17
 ,5213803$6

D.1 Number of revolutions too high.

D.2 Impeller oversized.
D.3 Too many pressure stages.
D.4 Specific gravity of pumping medium too high.
D.5 Viscosity of pumping medium too low.
D.6 Inlet pressure too high.
D.7 Manometer defective.

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E.1 Number of revolutions too high.

E.2 Impeller diameter too big.
E.3 Counter-pressure too low.

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F.1 Number of revolutions too low.

F.2 Impeller diameter too small.
F.3 Too few pressure stages.
F.4 Specific gravity of pumping medium too low.
F.5 Viscosity of pumping medium to high.
F.6 Manometer defective.

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G.1 Motor too small.

G.2 Motor fault.
G.3 Capacity too large.
G.4 Counter-pressure too low.
G.5 Stuffing-box tightened too much.
G.6 Shaft ends out of alignment.
G.7 Electricity supply incorrect.-Volt-amp-frequency

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H.1 Suction line leaking.

H.2 Shaft seal leaking.
H.3 Increasing suction lift.
H.4 Filter clogged.
H.5 Cavitation.

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I.1 Bearings defective.

I.2 Motor fault.

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Page 18
 ,5213803$6

J.1 Beginning cavitation.

J.2 Air in pumping medium.
J.3 Capacity too large.
J.4 Clamping to base loosened.
J.5 Base bolts loosened.
J.6 Influences from pipe connections or base.

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K.1 Cracks in pump casing.

K.2 Faulty assembly of pump.
K.3 Pipe connections leaking.
K.4 Shaft seal leaking (in case of soft stuffing-box)
packing minor leaks are necessary).

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L.1 Faulty lubrication or wrong lubricant.

L.2 Deficient pump alignment.
L.3 Influences from pipe line.
L.4 Coupling distance wrong.
L.5 Shaft bent.
L.6 Foreign bodies or impurities in bearings.

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M.1 Wrong materials in relation to pumping medium

M.2 Cavitation.
M.3 Stuffing-box tightened too much.
M.4 Shaft bent.
M.5 Deficient alignment.
M.6 Influences through pipe line.

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N.1 Impurities in pump.

N.2 Motor not properly balanced.
N.3 Influence from other factors.

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 Maskinfabriken IRON A/S

Instructionsdrawing for pump

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 IRONPUMP A/S

Instructionsdrawing for pump

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 Maskinfabriken IRON A/S

2799624-1e

Parts list for pump

Pump type: QT 250 + QT 300 - Drawing No.: 2799624

Pos No Description Productions No. Pcs Material

112 Pump bowl 1 RG-10 Bronze

115 Delivery casing 1 RG-10 Bronze

139 Suction elbow 1 RG-10 Bronze

210 Shaft 1 AISI 329

230.1 Impeller 1 NiAl-bronze

260 Impeller hub cap 1 Bronze

323 Thrust ball bearing 2

350 Bearing housing 1 Cast iron

360 Bearing cover 1 Cast iron

382 Bearing carier 2 Bronze

400.1 Gasket 2 Klingerit

400.2 Gasket 1 Klingerit

400.3 Gasket 1 Klingerit

420.1 Shaft seal ring 1

420.2 Shaft seal ring 1

420.3 Shaft seal ring 2

433 Mech.seal 1

471 Seal cover 1 Bronze

504 Spacer ring 1 NiAl-bronze

505 Loose collar 3 Steel

512 Wear ring 1 NiAl-bronze

545 Bearing bush 2 Thordon

552 Locking disc 2 Bronze

630 Lubricator dispenser 1

636 Grease nippel 1

672 Venting device (Option) 1

743 Cock (Option) 1

900 Screw 3 Stainless steel

923 Bearing nut 1 Steel

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 Maskinfabriken IRON A/S

Parts list for pump

Pump type: QT 250 + QT 300 - Drawing No.: 2799624

Pos No Description Productions No. Pcs Material

931 Lockwasher 1 Steel

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