ISF End-Suction Pumps Operating Instructions
Description
Single stage end-suction top discharge centrifugal
pump for general service, in accordance with ISO
2858 standard.
The pump is of back-pull-out construction and is
fitted with mechanical seal.
Important notes
Read these instructions before putting the
pump into service.
Installation and operation should be car-
ried out by qualified personnel only.
Danger of electrocution. Electric supply
must be isolated before working on the
pumpset.
Electrical work should only be carried out
by qualified personnel
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DECLARATION OF CONFORMITY
Section 1.0 Machinery description
Make: APEX PUMPS
Type: ISF centrifugal pump
Serial No: Refer to pump nameplate
Description: Horizontal centrifugal pump
Section 2.0 Applicable directives / regulations
Machinery directive 89/392/EEC
Section 3. Applicable standards / specifications
Section 4.0 Declaration
We Apex Fluid Engineering Ltd declare that as manufacturer of the machinery de-
fined in section 1.0 above, the machinery complies with the directives and regulations
set out in section 2.0 above.
Signed:
Authorised / responsible person
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General of suitable load capacity round the suction flange
Apex ISF pumps are single stage end suction pumps and bearing housing as indicated. For new installa-
supplied bareshaft, suitable for connection to an tions, keep the pump on its original pallet while
electric motor, diesel engine or other driver, or sup- moving around site or on transport. If the original
plied as a complete pumpset with electric motor and pallet is not available, the pump should be securely
coupling. The complete range comprises 26 different bolted to a pallet of generous size to ensure stabil-
pump sizes, providing good coverage across a wide ity.
range of applications and duties. Details of the pump
type and model, serial number and operating data
are indicated on the pump nameplate.
The pump must be installed and operated in full
compliance with these instructions. The pump may
not be operated outside the limits specified on the
nameplate and within this manual. The pump should
only be operated by skilled trained personnel. The
manufacturer will not accept liability if these instruc-
tions are not followed. This manual does not take
into account any specific local regulations or bylaws
that may be applicable, and it is the responsibility of
the installer to ensure compliance with such regula-
tions.
Application
Apex ISF pumps are suitable for continuous pump-
ing of clean water and liquids with properties similar
to water, with fine solids content not exceeding 200
ppm.
For standard pumps, the maximum temperature of Fig 1. Attaching a sling to the pumpset
the pumped liquid is 90 deg C. Pumps fitted with spe-
cial seals are suitable for temperatures up to 130 deg
C. Storage
If the pump is controlled by level devices, pressure If not to be used immediately, the pumpset should
switches etc, ensure that the pump does not switch be stored in a dry warm and vibration free environ-
on and off more than 10 times per hour. Damage to ment. Do not remove flange covers until the pump
the motor may occur with repeated starting. is ready to be connected to it’s pipework.
Area of operation Drivers
May be installed within a building or externally. Apex ISF pumps may be driven by an electric mo-
Wherever installed, protect the pump from frost, tor or engine, through a shaft-to-shaft coupling or
snow and flooding. Care must be taken to ensure via a belt drive system.
that cold weather will not cause the pump or pipes to
freeze, and installers may wish to consider lagging While it is outside the scope of this manual to in-
or trace heating. clude instructions on the driver and power drive ar-
rangement, there are particular points which can
Spare parts affect the pump:
Spare parts are available from Apex distributors and
stockists throughout the United Kingdom. Please • Shaft-to-shaft flexible couplings must be prop-
quote the pump model and serial number for all erly aligned, as poor alignment will cause high
spares enquiries. loads on the pump bearings. Couplings must
The pump user is strongly recommended to carry re- be suitably rated, and provide sufficient flexi-
placement spares for parts which are wearing items: bility to prevent shock forces and oscillating
loads from being transmitted to the pump
• Mechanical seal shaft. This is particularly important for diesel
• Casing wear ring engine drives.
• Shaft sleeve
• Belt drives using a system of pulleys and belts
• Casing gasket
must be aligned with care. Over-tensioning of
• Glandplate gasket
the belts will cause unacceptable loads on the
pump bearings. Generally larger pulleys will
Transport
impose lower forces on the pump bearings.
When hoisting the complete pumpset, secure a sling
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support the pipes. Locate pipe supports close to
• When designing the drive system and prime the pump.
mover, take into account that the pump dis- Never force the pipes into place to align with the
mantles by removing the rotating element out pump flanges, as this will impose unacceptable
from the back of the pump casing. Sufficient loads on the pump. Where necessary, flexible
space should be allowed to facilitate disman- jointed pipework should be fitted to accommodate
tling of the pump. small movement of the pipe and eliminate strain on
the pump.
It is usual practice to fit pipes of one or two sizes
Installation larger than the bore of the pump's suction and dis-
charge. For short pipe runs, it may be economical
to fit pipes of the same diameter as the pump
No special tools are required for installation of the flanges. Do not fit pipes of a smaller bore than the
pump. pump flange size.
Foundations
The pumpset should be mounted on a level hori-
zontal base. The base should be of sufficient rigid- DISCHARGE VALVE
ity to prevent flexing. When bolting the pump down,
insert shims as necessary under the pump feet to
NON RETURN VALVE
level the pump using a spirit level on the suction
and discharge flanges of the pump. Use all six bolt
holes to mount the pump.
CONCENTRIC TAPER
ECCENTRIC TAPER
When coupling the pump to its driver, select a flexi-
SUCTION VALVE
ble coupling of sufficient size to transmit the drive
power. Ensure that the driver is set in true align-
ment with the pump, and to ensure alignment with
its driver.
The pumpset must rotate freely by hand. Excessive
pipe loads on the pump flanges can cause the
pump to distort, which will affect the close clear-
ances within the pump.
Fig 3. Connecting the pipework
Most systems require the installation of suction and
discharge valves, and a non-return valve on the
discharge pipeline. We would recommend fitting
such valves for ease of maintenance. If the flowrate
is to be regulated or initially set with the discharge
valve, fit a gate valve in preference to a wafer type
discharge valve.
Before final connection of the pump on a new sys-
tem, thoroughly clean and flush all suction pipes
and tanks to eliminate weld debris and scale, which
can become dislodged and block the suction of the
pump. A temporary strainer can be fitted to the suc-
tion line to prevent debris from entering the pump.
Fig 2. ISF pump mounting.
Auxiliary pipes
For pumps handling hazardous, harmful or hot liq-
Pipe connections uids in excess of 60 deg C, the drain and vent tap-
Pipes must be independently supported, and ar- pings in the pump casing should be piped away to
ranged in such a way that expansion or contraction a safe place for disposal.
along the length of the pipe does not impose strain
on the pump flanges. Never use the pump itself to
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Electrical connection
Starting the pump
Before the pump is started for the first time, it im-
Isolate the supply before commencing
work on the pump. portant to check the following points:
• Check that the pump rotates freely by hand.
• Open the suction valve fully and evacuate all the
Where the pump is to be driven by an electric mo- air inside the pump casing to prime the pump.
tor, observe the instructions provided by the elec- • Close the discharge fully for the first start after in-
tric motor manufacturer. Electrical installation stallation or service.
should only be carried out by a skilled electrician. • Momentarily start and stop the electric motor or
The installation should be earthed at the motor, engine driver to check that the rotation is correct.
pipes, support frame and pump as appropriate. • The pump may now be run. On starting, observe
the discharge pressure.
Vibration isolation • Slowly open the discharge valve: the pressure will
Pumps installed in buildings may require isolation gradually fall as the flowrate through the pump
from the floor and pipes using anti-vibration mounts increases.
and flexible pipe connectors.
• Open the discharge valve only until the required
pressure is indicated on the pressure gauge.
Operation Over-pumping
When correctly installed and operated, this Apex When pipework system losses are estimated, an
pump will give many years of trouble free service. extra allowance in head is often made for pipe de-
In operation, the pump should be free from vibra- terioration, or the pump is oversized to allow for fu-
tion and run smoothly. Any changes to smoothness ture expansion. In these circumstances, it is likely
of operation should be investigated immediately. that the pump will operate at a higher flowrate than
The pump should be visually checked periodically. intended, which may result in excessive loads on
the pump bearings and driver overload.
Priming the pump The operator should limit the flow by adjustment of
Pumps operating on flooded suction conditions the discharge valve, referring to the discharge
(where the liquid source is higher than the pump) pressure gauge to obtain the design conditions. For
are easily primed by opening the suction valve, re- pumps driven by electric motor, the operator should
leasing air vent on the pump discharge, and allow- verify that the motor nameplate current is not being
ing the pump casing to fill with liquid. exceeded.
VENT CONNECTION
Minimum flowrate
Apex ISF pumps should not be operated at
flowrates below 15% of the peak efficiency flowrate
unless otherwise specifically agreed by the Manu-
facturer. If the system is such that zero flow or less
than 15% of peak efficiency flow will occur, a return
line must be fitted.
Thermal shock
Apex ISF pumps are not designed to withstand
rapid changes in temperature. Where a pump is
handling hot liquids, the liquid should be introduced
slowly allowing the pump to gradually increase in
temperature.
Thermal hazards
Pumps handling hot liquid in excess of 68 deg C
Fig 4. Air vent location present a hazard to personnel if the hot surface of
the pump casing or associated pipework is
For pumps operating on a suction lift, the usual touched. The installer is responsible for warnings
practice is to fit a foot valve to the suction pipe. and means of protection.
This foot valve retains liquid within the suction pipe
and pump casing when the pump is idle. Materials compatibility
The materials of construction of this pump have
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been selected by agreement between the Manufac- Mechanical seal
turer and the Buyer, to be compatible with the The mechanical seal is a wearing item. Life of a
pumped liquid as specified. The installer is respon- seal depends on the erosive properties of the
sible for ensuring that the liquid actually handled on pumped liquid, and the temperature and pressure
site is as specified. Should there be any doubt, the of operation.
installer is to seek advise before proceeding. The seal is self-adjusting, and requires no periodic
maintenance.
Controlling solids
Where solids may be present, a strainer may be Strainer
fitted to the pump suction line to prevent entry into If a strainer is fitted to the suction pipe before the
the pump impeller, preventing possible damage to pump, periodically check and clean the strainer ele-
the impeller. A regular schedule should be estab- ment. A blocked or leaking strainer will cause cavi-
lished to check and clean the strainer. A blocked tation damage to the impeller.
strainer will cause the pump to cavitate resulting in
damage to the impeller. Free rotation
The pump should rotate freely by hand. Having iso-
Dry running lated the supply, remove one of the guards and ro-
The pump must never be allowed to run dry. Possi- tate the shaft by hand to check freedom of rotation.
ble seizure of the internal close clearances, and Replace all guards prior to operating the pump.
failure of the mechanical seal may result. The op-
erator should regularly check that the pump suction Flooding
source is adequate. In some installations, it may be If the pump is accidentally subjected to flooding, on
prudent to fit a level device or other means of auto- no account operate the pump until it is thoroughly
matic protection to prevent the pump from dry run- dry and checked.
ning. If water has entered the pump‘s bearing housing, it
is likely that the bearings will need to be cleaned or
replaced.
Automatic operation For pumps driven by an electric motor, check that
Pumps operating on an automatic control system the motor fan is cleared of debris and is free to ro-
must not be allowed to run at zero flow or flow be- tate. Inspect the pump shaft for debris.
low 15% of the peak efficiency flowrate. Interlocks
should be fitted appropriate to the system. The
pump should not be started more than 10 times per
hour, as damage to the shaft coupling and driver
may result. Installation of a pressure tank or timers
on the electrical control should be considered as
required to reduce the frequency of starts.
Protection from freezing
Where the pumpset may be exposed to cold
weather, ensure that the pump and associated Disassembly
pipework is lagged or trace heated to prevent frost
damage. Special tools
No special tools are required for disassembly of the
pumpset.
Maintenance
Preparation for dismantling
Supply isolation The pump should be allowed to cool to ambient
For pumps driven by electric motor, always isolate temperature before commencing any work. Close
the supply before working on the pump. Affix a no- the suction and discharge valves and drain the
tice on the electrical isolator to inform others that pump of liquid by releasing the casing drain plug. If
the work is being carried out on the installation. If the pump is driven by an electric motor, ensure the
possible lock closed the supply isolator. power supply is isolated. Disconnect the electric
cables from the electric motor terminal box.
Lubrication
The pump bearings are provided with sealed for life Removing the rotating element
grease lubricated bearings. No maintenance is re- The rotating element, which includes the motor and
quired on these bearings. pump impeller, may be removed without disturbing
the suction and delivery pipework.
Remove the eight or twelve casing bolts, and the
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four motor feet bolts. Withdraw the rotating element Pumps operating on hot water duties are particu-
from the casing by drawing the complete assembly larly prone to this failure, if the static pressure in
backwards. The rotating element may now be re- the system is insufficient to prevent local vapouri-
moved to a workshop or clean area for further dis- sation.
mantling. Failure of a seal may also indicate worn bearings,
hence it is good practice to inspect and if neces-
sary replace the shaft bearings when a seal is
changed.
If a failed seal exhibits excessive wear, caused by
hard particles in the pumped liquid, consider
changing the seal for one with harder faces, of Sili-
con Carbide or Tungsten Carbide.
Fitting a new casing wear ring
The casing is provided with a wear ring which may
be replaced after prolonged service, to restore the
close clearances with the impeller.
The standard clearance for a new pump is 0.4-0.5
mm diametrically, between the bore of the wear
ring and the outside diameter of the impeller neck.
Fig 5. Removing the rotating element from the casing The efficiency of the pump will deteriorate as the
clearance increases through normal wear.
Removing the impeller To extract the casing wear ring, it will be necessary
Prevent the impeller from rotating by holding in to remove the casing from the pipework. A drift can
gloved hands, and undo the impeller nut using a then be passed through the suction bore to tap out
long spanner and mallet. Take care not to damage the wear ring.
the impeller vanes, if a lever is inserted to prevent A new ring may be fitted by gently and evenly tap-
impeller rotation. The impeller may be drawn off by ping into place.
levering equally on both sides behind the impeller.
After a prolonged period of operation, the impeller
may be hard to pull off the shaft, and a penetrating Casing gasket
oil may assist to free the impeller hub. Whenever the rotating element is withdrawn from
the pump casing, the casing gasket should be re-
Inspecting the impeller placed. If a gasket is cut on site, ensure that the
Check the impeller hub and keyway. If the keyway gasket paper used is of the correct thickness, 0.5
is rounded, this indicates that the impeller is loose mm, and that the gasket material is compatible with
on the key, which will cause eventual fracture of the liquid being pumped.
the impeller hub. Replace with an oversize key, fil-
ing to fit the enlarged impeller keyway.
Impeller passages should be free from debris.
Check for cavitation damage to the eye of the im-
peller, where the liquid enters. Cavitation is caused
when there is insufficient suction pressure to the
pump. Pitting or spongified surfaces to the impeller
vanes may be seen.
Removing the mechanical seal
Remove the gland nuts, withdraw the gland along
to the end of the shaft, and remove the eight bolts
securing the backcover to the bearing housing.
The backcover may now be lifted off, revealing the
mechanical seal, mounted on the shaft. Slide the
rotary head of the mechanical seal off the shaft, fol-
lowed by the glandplate and stationary seal ring.
Mechanical seal problems
Mechanical seals will fail if allowed to run dry. This
can occur even if the pump is seemingly full of liq-
uid, if a vapour pocket builds up in the seal area.
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Typical cross section
P1
12.2 04 07 F2 42 41.1 06 03 50 41.2 45.1 13.2
01
02
12.1
13.1
08
P2
08.1
P3
61.1 F1 48 61.2 49 46.1 11 F3 45 46.2
Ref Description Ref Description
01 Casing 13.2 Coupling key
02 Impeller 41.1 Ball bearing
03 Shaft 41.2 Ball bearing
04 Backcover 42 Bearing end cover
06 Bearing housing 46.1 Lip seal
07 Mechanical seal 46.2 Lip seal
08 Impeller nut P1 Vent/gauge plug
08.1 Impeller washer P2 Suction gauge plug
10.1 Casing gasket P3 Casing drain plug
11 Support foot F1 Casing bolts
12.1 Casing wear ring F2 Bearing housing bolts
12.2 Backcover wear ring F4 Support foot bolt
13.1 Impeller key F5 Bearing end cover bolts
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Apex Fluid Engineering Ltd,
Unit 4 Morley Road,
Staple Hill,
Bristol BS16 4QT
Tel 0117 907 7555 Fax 0117 907 7556
Email [email protected]
Website www.apexpumps.com
International Tel: +44 117 907 7555 Fax +44 117 907 7556
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