Flow Range:  20~2500 m³/h

Head Range: 60~ 1200m

Operating Temperature: -40~200 ℃

Design Pressure: 16 MPa

Design Speed: 2980 rpm / 1480 rpm

Transported Media: Clean water, oil products, chemical solvents, wastewater and other liquids with solid content ≤ 3% (subject to material selection)

API-BB3 Series MDK Horizontal Split-case Multistage Centrifugal Pump Outline Drawing

Installation Procedures

1. Foundation Construction & Inspection

Cast a solid concrete foundation according to the pump dimensions and weight. The length, width and height of the foundation shall comply with design requirements, and be capable of bearing the maximum load and vibration generated during pump operation.

Check the flatness of the foundation surface. The horizontal deviation shall be within 0.05 - 0.1 mm per meter. Ensure the foundation is free from cracks, honeycombs, pitting and other defects. Meanwhile, reserve anchor bolt holes with position and dimensions precisely matching the pump anchor bolts.

2. Pump Positioning & Preliminary Alignment

Use suitable lifting equipment to place the pump steadily onto the foundation, and align the pump anchor bolts with the reserved holes. Place shims under the pump base to preliminarily adjust the level and elevation. Measure the levelness via the pump suction/discharge flanges or machined surfaces of the pump casing to keep it within allowable range.

Install anchor bolts and fasten nuts loosely. Do not fully tighten them to reserve space for precise alignment and secondary grouting.

3. Piping Connection

Before pipe installation, thoroughly clean the flange faces of the pump and pipelines to remove burrs, oil stains and debris, ensuring smooth and flat sealing surfaces.

Install gaskets and select proper gasket materials such as oil-resistant rubber and PTFE based on the properties of conveyed media. Connect pipelines to pump flanges and tighten bolts evenly in compliance with specified torque. Uneven force shall be avoided to prevent flange deformation and poor sealing.

Ensure no external forced stress is applied to the pump during connection. The weight and stress of pipelines shall not be transmitted to the pump body. Adjust pipe supports and hangers as required, and adopt cold drawing or thermal compensation for pipelines when necessary.

4. Motor Installation & Shaft Alignment

For split-coupled pump and motor units, keep the motor shaft and pump shaft concentric within specified tolerance. When connected via a coupling, the radial runout deviation between two shafts shall not exceed 0.05 - 0.1 mm, and the axial deviation shall not exceed 0.05 - 0.15 mm.

Use dial indicators for accurate measurement and alignment by adjusting the motor position and shim thickness. After alignment, fully tighten the motor anchor bolts and recheck the alignment to confirm no displacement occurs during fastening.

5. Lubrication & Cooling System Installation

For pumps equipped with lubrication and cooling systems, install the lube oil piping and cooling water pipelines correctly. Keep the lubrication piping clean and well sealed to prevent foreign matter from entering the lubrication system.

Make sure cooling water flows in the correct direction, with water flow rate and pressure meeting operational requirements. Install necessary valves and gauges on cooling pipelines for regulation and condition monitoring.

6. Electrical Connection & Grounding

Connect power cables and control cables in accordance with the rated voltage, power and other parameters of the pump and motor. Ensure cables comply with specifications, with firm connection and good insulation.

Install the grounding wire for the motor. The grounding resistance shall be no more than 4 Ω to guarantee equipment and personal safety. Use dedicated grounding cables with reliable connection to prevent looseness and poor contact.

7. Post-installation Inspection & Cleaning

Conduct a comprehensive inspection: verify all anchor bolts and connecting bolts are fully tightened, pipelines are securely connected, sealing performance is intact, and lubrication & cooling systems work properly.

Clear away sundries and tools around the pump to keep the site tidy. Rotate the pump rotor manually to check flexible rotation, and confirm no jamming or abnormal noise exists.

Operation Procedures

1. Pre-start Preparation

Recheck all connecting parts for looseness and sealing surfaces for leakage.

Inspect the lubricant level and quality. The oil level shall stay within the marked range, and the oil shall be clean without impurities or emulsification. Replace the lubricant immediately if it fails to meet requirements.

Open the pump suction valve to fill the pump with conveyed medium, and vent internal air via the air vent valve until no air escapes.

Verify the motor rotation direction by inching the motor. Adjust the phase sequence if the rotation is incorrect to ensure the impeller runs in the right direction.

Check the normal operation of gauges including pressure gauges, thermometers and flow meters to ensure accurate readings for operational monitoring.

2. Pump Start-up

Start the motor and gradually raise the speed to the rated value. During start-up, closely monitor operating conditions including noise, vibration, current and pressure.

After the pump reaches rated speed, check whether discharge pressure and flow rate meet standard values. Shut down the pump immediately if any abnormality occurs, troubleshoot the faults before restarting.

3. In-operation Maintenance & Monitoring

Regularly monitor operating parameters such as suction/discharge pressure, flow rate, motor current, temperature and vibration, and keep detailed records. Perform inspection every 1 to 2 hours for timely fault detection.

Listen for abnormal noise and vibration from the pump and motor. Stop operation for maintenance if abnormalities are found, which may be caused by unbalanced impellers, damaged bearings, pipeline resonance and other issues.

Check sealing leakage. Minor leakage is acceptable as long as it is within the permitted range. Replace sealing components or conduct repairs in time if excessive leakage occurs.

Monitor the temperature and level of lubricant. The oil temperature shall be maintained between 40 ℃ and 60 ℃. Check the cooling system and other potential faults if the oil temperature is too high. Top up lubricant regularly to keep the oil level normal.

Confirm the properties and temperature of conveyed media comply with operating requirements. Avoid performance degradation and service life reduction caused by corrosive media, viscosity change or extreme temperature.

4. Shutdown Procedures

Gradually close the discharge valve to minimize flow rate, then stop the motor. This operation prevents water hammer that may damage the pump and pipelines.

Close the suction valve. Drain the medium inside the pump as needed. Complete drainage is recommended if the medium is corrosive or prone to crystallization.

For long-term shutdown, perform maintenance work: clean the pump casing, apply anti-rust oil, inspect and replace wearing parts, so as to prevent component rust and damage and extend service life.

1. Pump fails to start or runs at low speed

Causes

Power supply faults: power outage, blown fuse, poor cable connection, etc.

Motor faults: winding short circuit, open circuit, motor shutdown due to overload protection.

Foreign objects inside the pump jam the impeller.

Misaligned coupling causing misalignment between motor shaft and pump shaft and excessive resistance.

Insufficient starting torque caused by low voltage or improperly selected motor.

Solutions

 Inspect power supply, restore power, replace fuses and repair cable connections.

Repair or replace the motor; identify and eliminate overload causes.

Dismantle the pump casing and remove foreign objects.

Realign the coupling to ensure concentricity of motor shaft and pump shaft.

Check power voltage to keep it within the rated range, or select a proper motor.

2. Insufficient flow rate

Causes

Blocked suction pipeline or partially closed valve restricting medium intake.

Severely worn impeller leading to excessive clearance between impeller and pump casing and medium backflow.

 Worn wear ring causing increased internal leakage and reduced flow.

Pump speed below rated value due to motor or transmission faults.

Increased medium viscosity resulting in higher flow resistance.

Solutions

Clean the suction pipeline and fully open the valve.

Replace the worn impeller.

Replace the wear ring.

Inspect the motor and transmission to restore rated speed.

Select a suitable pump model or pre-treat the medium to reduce viscosity according to medium properties.

3. Insufficient head

Causes

Damaged or reversely installed impeller reduces hydraulic work output.

Entrapped air inside pump causes air binding and impedes liquid transportation.

Excessive discharge line resistance from overlength piping, excessive elbows or throttled discharge valve.

Sub-rated rotating speed lowers hydraulic head generated by impeller.

Solutions

Repair or replace the impeller and ensure correct installation.

Re-vent the pump to remove all internal air.

Optimize discharge pipeline layout to reduce unnecessary resistance and fully open valves.

Inspect the motor and transmission system to restore rated speed.

4. Pump fails to start or runs at low speed

Causes

Power supply faults: power outage, blown fuse, poor cable connection, etc.

 Motor faults: winding short circuit, open circuit, motor shutdown due to overload protection.

Foreign objects inside the pump jam the impeller.

Misaligned coupling causing misalignment between motor shaft and pump shaft and excessive resistance.

Insufficient starting torque caused by low voltage or improperly selected motor.

Solutions

Inspect power supply, restore power, replace fuses and repair cable connections.

Repair or replace the motor; identify and eliminate overload causes.

Dismantle the pump casing and remove foreign objects.

Realign the coupling to ensure concentricity of motor shaft and pump shaft.

Check power voltage to keep it within the rated range, or select a proper motor.

5. Excessive vibration or abnormal noise

Causes

Misalignment between pump shaft and motor shaft.

Unbalanced impeller caused by uneven wear or attached foreign matter.

Damaged bearings leading to shaft runout and vibration.

Unstable foundation or loose anchor bolts causing pump shaking during operation.

Pipeline resonance resulting from poorly fixed or improperly arranged pipes.

Solutions

Realign the coupling to ensure shaft concentricity.

Conduct dynamic balance test on the impeller, remove foreign matter or replace the impeller.

Replace damaged bearings.

Reinforce the foundation and tighten anchor bolts.

Re-fix pipelines and optimize layout to eliminate resonance.

6. Leakage at shaft seal

Causes

Damaged mechanical seal, such as worn seal faces or aged sealing rings.

 Worn shaft sleeve leading to enlarged clearance between seal face and sleeve.

Insufficient or interrupted seal flush fluid supply.

Excessive shaft axial play affecting stable operation of the mechanical seal.

Solutions

Replace the mechanical seal assembly.

Replace the worn shaft sleeve.

Inspect the seal flush system and ensure normal fluid supply.

Check and adjust shaft axial play to the specified range.

7. Overheated motor

Causes

Motor overload caused by excessive flow, excessive head or medium viscosity beyond design range.

Poor heat dissipation due to excessive dust or blocked ventilation openings on the motor.

Abnormally high or low power voltage.

Motor winding short circuit or ground fault leading to increased current.

Solutions

Adjust pump operating conditions to match design parameters, or replace with a suitable motor.

Clean dust on the motor and clear ventilation openings to improve heat dissipation.

Stabilize power voltage within the rated range.

Repair winding short circuit or ground fault; replace the motor if necessary.