7.3. Start-Up Procedure
Check if the suction valve is open and the discharge valve is closed.
Start the motor
Wait until the motor reaches sufficient speed. (In Star-delta
connections, wait until the engine passes to delta connection.)
Keeping an eye on the amperage shown on the panel, open the
discharge valve slowly.
In the primary operation, if the discharge pipe is empty, do not open the
valve completely. By keeping an eye on the amperage, open the valve
with care regarding that it should not exceed the value indicated on
pump’s label.
After opening the valve completely, check the pressure from the pump
exit manometer and make sure that this value is the pump operating
pressure value and is indicated on pump’s label.
If the value one reads is less than the pump label value when the valve
is completely open, it means that the height is miscalculated. Increase
the value by narrowing the valve and bring it to pump’s label value.
If the value one reads is greater than the pump label value when the
valve is completely open, it means that the height is calculated less
than what it should be in reality. The device is pumping less than what
is requested. Check the installation and the calculations.
Minimum flow rate: If the pump is working with zero flow rate (closed
valve) from time to time during its operation, the water inside the pump
may endanger the pump by getting warmed up. In such cases, a
minimum flow valve must be connected to the pump exit.
Stop the motor if the pump gets too hot. Wait until it gets cold.
Then start the system up again carefully.
7.4. Shut Down Procedure
During sudden start ups and stops, a pressure reducing valve must be
placed at the exit section of high flow rate pumps whose discharge
pipelines are long, in order to reduce water hammer effect. Water
hammer may explode the pump.
In normal conditions (apart from sudden power shut down, etc), stop the
pump as below:
Close the discharge valve slowly
Switch the power off, stop the motor. Notice that the rotor slows down.
Do not start up the motor at least before 1 to 2 minutes.
If the pump will be out of use for a long time, close the suction valve
and auxiliary circuits. If the pump is outside and if there exists a danger
of frost, remove all drain taps and empty all the water inside the pump.
(5.2. Storage)
If the pump is outside and if there exists a danger of frost, remove
all drain taps and empty all the water inside the pump.
8. MAINTENANCE
Maintenance operations must be done by authorized personnel with
protective clothing only. The personnel must also beware of high
temperatures and harmful and/or caustic liquids. Make sure that the
personnel reads carefully the manual.
The instructions in Safety Precautions must be executed during
maintenance and repair
Continuous monitoring and maintenance will increase the engine’s and
pump’s lives.
8.1. Checking During Operation
Pump must never be operated without water.
Pump must not be operated for a long time with the discharge valve
closed (zero capacity).
Bearing temperature must never exceed 80C if the ambient
temperature is 30C
Precautions must be taken against flare up when the component
temperatures are over 60C. “Hot Surface” warnings must be placed
over necessary areas.
All the auxiliary systems must be in use while the pump is operating.
Water must drop from the glands of stuffing boxes (20-30 drops per
minute)
Gland nuts must not be tightened too much. If the amount of water
increases after a long operation time, the nuts may be tightened by 1/6
turns
If the system consists of a substitute pump, keep it ready by operating it
once a week. Check also the auxiliary systems of the substitute pump.
Check the elastic components of the coupling. Replace them when
necessary.
8.1.1. Component Check
To make possible the visual control, one must be able to reach the pump
from any direction. Especially, to be able to dismount the internal units of
the pump and the engine, sufficient free space must be created around
them for maintenance and repair. Furthermore, one must make sure that
the piping system can easily be dismounted.
8.1.1.1. Bearing and Lubrication
Ball bearings are used in YPSP type fire pumps. Long-life, NU series
cylindrical bearings and one row, 63..-C3 series ball bearings are used
respectively on the motor and the shaft sides, in order to balance axial
forces acting on the impeller. Bearings are lubricated with grease oil.
8.1.2. Shaft Seal Maintenance
8.1.2.1. Soft Packing
Before replacing the soft packing, the gland must be dismounted first.
Used packing rings may be taken off by a sharp pointed tool. Take off
the lantern ring if it exists, then clean the interiors of the sealing box, the
gland and the lantern ring.
Wrap a proper sized, good quality sealing over the shaft bush and
make sure that the bush tip is completely covered.
Place the first ring, its joint facing upwards and push it to its bed by
using the gland
If it exists push the watering ring to its bed.
Place also the other rings to their beds alternating, i.e., their joints
facing upwards and downwards.
After placing the last ring, position the gland and tighten it completely.
Thus, the squeezed sealing rings take the shape of the sealing box.
Then un-tighten the nuts. Rotating the shaft tighten them slowly again.
When you feel that the shaft is put on a brake, stop the tightening.
Water must come from the seals drop by drop as soon as the pump is
started. The number of drops must not be less than 10 and not more
than 30 per minute. Find the proper setting by tightening and un-
tightening the opposite gland nuts.
Ensure that the water leaking from the sealing is collected and/or
discharged in a manner which is appropriate in terms of safety and
environmental criteria.
Check the sealing temperature two hours after the gland adjustment is
made. For a system which pumps water at ambient temperature, the
sealing temperature must not exceed 80C.
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