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Multiflo W

Horizontal Multistage Pumps

Multiflo HMW Horizontal Multistage Pumps

INDEX

Section Contents Page

1. General 2

2. Description 2-3

3. Pump Installation 3-4

4. Operation 4-5

5. Maintenance 5-6

6. Dismantling 6-7

7. Rotor Assembly 7

8. Pump Assembly 7-8-9

9. General notes 9

10. Diagram 10

11. Operating troubles and their causes 11 - 12

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Multiflo HMW Horizontal Multistage Pumps

1. GENERAL

1.1 Please read this operating manual carefully, before starting and commissioning the pump.
The warranty and satisfactory service life of the pump depend on the pump being installed and
operated in accordance with our instructions and within the duty parameters specified by us.

1.2 The warranty shall become null and void if any work has been performed on the pump unit
without our prior consent.

1.3 This manual does NOT SUPERSEDE OR OVERRIDE LOCAL SAFETY REGULATIONS.
The owner/user is responsible for adherence to local regulations.

1.4 When ordering spare parts, the serial number of the pump should be quoted as well as the
item number from the parts list.

1.5 These are high pressure units and care must be taken to ensure that connecting flanges,
pipework and valves are suitably rated.

2. DESCRIPTION

2.1 The HMW series pumps are horizontal multistage pumps with radially split casings. The pump
comprises the suction and discharge casings with the requisite number of stage casings
clamped between them by means of tie bolts. The stage casings carry a separate diffuser and
are sealed by an ‘O’ ring. The rotating assembly is supported in bearing frames which are
located on the suction and discharge casings by machined spigots.

2.2 The mounting feet are cast integral with the suction and discharge casings.

2.3 Hydraulic thrust is balanced by means of radial vanes on the back shroud or wear ring and
balance holes. Residual thrust is absorbed by angular contact bearings.

2.4 The shaft is protected by sleeves between the stages and at the stuffing boxes.

2.5 Gland packing or mechanical seals are available and there is provision for either internal or
external flushing.

2.6 The pumps are designed for use on clear and turbid non aggressive liquids.

2.7 Direction of rotation

Clockwise looking on the drive end towards the pump.

2.8 Permissible temperatures

o
Graphite cotton packing 90 C
o
PTFE packing 110 C
o
Mechanical seal 110 C
2.9 Flange connection
Flanges drilled to BS4504 (SABS 1123)
Suction Table 16
Discharge Table 40

2.10 Shaft sealing

Standard packing Graphite / cotton
Optional PTFE packing
Packing size
10 x 10mm
Other seals available on request

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Multiflo HMW Horizontal Multistage Pumps

2.11 Bearing lubrication

Standard NLGI No. 2 (Mobilux No. 2 or equal)

3. PUMP INSTALLATION

3.1 Location
The pump unit should be installed as close to the supply source as possible, so that the
suction line is short and direct. Sufficient space should be allowed around the pump for
inspection and maintenance. There must be sufficient ventilation for cooling of the motor and
aspiration and cooling if the driver is a petrol or diesel engine. On larger units provision should
be made for lifting tackle for maintenance.

3.2 Foundations
For fixed installations, reinforced concrete bases should be used with sufficient mass to
contain vibrations and avoid twisting or cracking under load. The top should be level and free
from loose chippings, sand and protrusions. On larger units, the holding down bolts should be
cast in or grouted into suitable pockets. Sufficient curing time should be allowed before
mounting the pump.

3.3 Levelling
The pump baseplate should be carefully levelled on steel packers to avoid any twisting,
sagging or hogging when the holding bolts are tightened. Preferably a layer of non-shrink
grout should be poured to add support and prevent the seepage of water under the base which
could cause corrosion. If this is done, the final tightening of the holding down bolts should only
be done when the grout is cured.

3.4 Alignment
If the pump leaves our factory with the motor on a common baseplate, the unit will have been
pre-aligned and will have a coupling guard. IT IS STILL ESSENTIAL TO CHECK THE
ALIGNMENT AFTER LEVELLING to ensure that there has been no deformation during
installation or transport.

Alignment checks are carried out in the following manner:

3.4.1 Axial alignment is the alignment of the pump and motor shaft centre lines and is
achieved by inserting suitable packing (brass or stainless steel shimstock) under the
motor feet, and jacking the motor across the base. At the same time, the motor
should be jacked forward to set the distance between shaft ends. The alignment is
o
checked using a clock gauge or a straight edge and feeler gauge at four points 90 C
apart around the periphery of the coupling flange. The straight edge must rest evenly
on the flanges at all four positions with no light showing between the straight edge and
flange when the alignment is correct. The clock gauge would register zero or 0,05 run
out when the alignment is correct.
3.4.2 Radial alignment is the alignment of the coupling faces or the angular alignment of the
pump and motor shafts and is achieved by adding or removing packing under the front
or back motor feet as required.
The alignment is checked using a clock gauge, inside calipers or slip gauges, to
o
measure the distance between the flange faces at four points set at 90 C intervals
around the coupling. The alignment is correct when all readings are equal or within
0,05mm.
3.4.3 A final check should be done on the distance between the shaft ends.

3.5 The above checks are carried out with the flexible element removed and care should be taken to
ensure that the coupling is properly reassembled and the securing screws fully tightened.

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Multiflo HMW Horizontal Multistage Pumps

3.6 Inaccurate alignment will result in vibration and reduced service life. (See Figure 1)

Straight edge Slip gauge

Figure 1 - Coupling alignment using straight edge and slip gauge

3.7 Piping installation

The pipes must align naturally with the pump flanges without the necessity of levering or
pulling to bring the faces evenly together. The flange bolts should be free to move before they
are tightened. THE ALIGNMENT SHOULD BE CHECKED AGAIN after the pipes are fitted to
ensure that the pump has not been moved.
3.7.1 The piping must be properly supported and anchored to avoid stress on the pump
casing.
3.7.2 The suction should be as short as possible and rise continuously to the pump to
prevent the formation of air pockets.
All joints must be airtight and the gaskets must not intrude into the bore of the pipe.
Pipe size must be selected to keep the flow velocity to a minimum, typically in the
order of 1-1,5m/s, and at least one size larger than the pump suction.
Eccentric reducers only shall be used and shall have a minimum overall length of 4 (D-
d).
Bends should be kept to a minimum and should be the long radius type.
Valves should be installed horizontally to avoid air traps and must remain fully open
when the pump is running.
3.7.3 A foot valve in the suction line will keep the pump primed. The free area through the
valve must be at least 1,5 times the area of the suction pipe. A strainer must be fitted
to the foot valve with a free area at least 3 to 4 times the area of the suction pipe.
3.7.4 Any in-line strainer fitted in the suction line must be at least 8 pipe diameters from the
pump flange. If this is not possible a flow straightener must be installed.
3.7.5 The discharge pipe diameter should be at least the same as the pump flange and for
long pipe runs at least a size larger, to reduce pipe friction and the resultant head loss.
3.7.6 A non-return valve and isolating valve are normally fitted in the discharge line. The
non-return valve will protect the pump from reverse rotation when the pump is
stopped. The isolating valve is used for starting and stopping on manual sets,
maintenance and to give a measure of regulation.
3.7.7 Reducers should be of the concentric type on delivery lines.
3.7.8 Before connecting to the pump, all piping must be cleaned to remove construction
debris.

4. OPERATION

4.1 The direction of rotation must be checked. This is best done while the coupling is
disconnected for alignment as the motor can be started without the risk of dry running damage
to the seals. Failing this, check when the pump is fully primed.

4.2 Check that the bearing housing has been greased.

4.3 Check pump for free rotation without undue mechanical noise or resistance.

4.4 Ensure that the suction valve is open.

4.5 On suction lift duties, the pump must be primed. This may be done by filling the suction line
and pump through the vent plug or discharge flange, or, by closing the discharge valve and
mechanically extracting the air from the pump and suction line by means of a vacuum pump.

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Multiflo HMW Horizontal Multistage Pumps

4.6 Ensure that the gland packing is only lightly tightened at this stage. Excessive tightening must
be avoided.

4.7 Start the pump and ensure that the pump comes up to speed and registers the anticipated
closed valve pressure.

4.8 Slowly open the discharge valve until the required service pressure is reached. DO NOT
operate for prolonged periods with the discharge valve closed as this will cause damage to the
pump.

4.9 Check that there is leakage from the gland packing. After a minimum of 30 minutes running,
adjust the gland nuts slowly and evenly to reduce the leakage to 1 or 2 drips per second. DO
NOT overtighten or stop the leakage entirely, or the gland will run hot and damage the packing
and sleeve.

4.10 Check that the motor overload is set to the correct value, the phases are balanced and the
voltage correct.
4.11 Check that there is no vibration and that the bearing temperatures are normal.

4.12 Before stopping the pump, close the discharge valve. This will help to prevent water hammer.
Do not close the suction valve unless the pump is being stopped for maintenance.

4.13 If there is a danger of freezing, the pump should be drained.

5. MAINTENANCE

5.1 A properly installed and commissioned centrifugal pump requires little maintenance. It does
require regular checks to ensure that everything is in order. Faults which are detected and
attended to in the early stages will prevent serious breakdown at a later stage.

5.2 Recommended inspection schedule:

5.2.1 Check gland leakage and running pressure daily or whenever the pump is started.
Listen for unusual noises and check that bearing temperatures are normal.
5.2.2 Alignment - check every 6 months or 1000 hours, whichever is the earlier.
5.2.3 Grease the bearings every 2000 hours at running speeds and temperatures of
o o
1450rpm and 60 C. At running speeds and temperatures above 1450rpm and 60 C
and in high humidity and extremely dusty areas, grease every 1000 hours.
Before greasing carefully, clean the grease nipples and the grease gun connector.
CARE MUST BE TAKEN TO AVOID OVERGREASING, as this may cause
overheating.
Every 10000 hours, or at the latest after 2 years, the bearings should be removed,
replaced if necessary or cleaned and repacked with grease.

5.3 Pump Glands

If the gland leakage is excessive and is not reduced by tightening the gland nuts gradually and
evenly, then the packing is worn and must be replaced. When the gland packing is removed,
the sleeve should be checked. If the surface is grooved the sleeve must be replaced.
5.3.1 Repacking the gland
• Remove the gland nuts, backing plate and gland follower halves.
• Remove the old packing. This procedure is simplified by using packing
pullers.
• Check the condition of the sleeve.
• If the packing is not pre-cut, cut the packing into suitable lengths to suit the
shaft sleeve diameter. Insert the rings one at a time pushing them fully home
and staggering the joints.
• Replace the lantern ring under the flush inlet and insert additional rings to the
full depth of the stuffing box.

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Multiflo HMW Horizontal Multistage Pumps

• Fit the gland follower halves into place, ensuring that they enter the stuffing
box properly, push the backing plate into position and tighten the gland nuts
lightly and evenly.
• When the pump is restarted, the packing will leak appreciably. This should
gradually be reduced, over a period of 30 - 60 minutes, by tightening the gland
nuts evenly in stages until the leakage is reduced to 1 - 2 drips per second.
• DO NOT overtighten the gland.
5.4 Mechanical Seals
5.4.1 If a mechanical seal leaks, both the rotating and stationary elements must be
replaced.
5.4.2 The seal setting instructions are normally included with the seal and care must be
taken to ensure that the parts are assembled under clean conditions.
5.4.3 After fitting a new seal, the pump must be primed to ensure that there is water at the
seal. Running the seal dry, even for a few seconds, can cause damage.

5.5 Recommended Lubricants

Grease - HLGI No. 2 (Mobilux No. 2 or equal)

6. DISMANTLING

6.1 Before dismantling the pump, read the manual and acquaint yourself with the sequence of
steps and the relevant drawing.

6.2 Close suction and discharge valves and drain casing by removing the casing drain plug.

6.3 Disconnect the suction and discharge flanges.

6.4 Remove coupling guard.

6.5 Disconnect the coupling and remove the flexible element. If a spacer is used, match mark the
parts to ensure correct reassembly.

6.6 Loosen motor holding down bolts (if necessary) and move motor aside.

6.7 Loosen holding down bolts and remove pump to a suitable working area.

6.8 Before stripping, match mark and number the stages to ensure re-assembly in the correct
order.

6.9 Loosen set screws and remove discharge end bearing housing cover.

6.10 Remove shaft end nut.

6.11 Loosen set screws and remove discharge end bearing housing and bearing.

6.12 Undo the gland follower nuts and pull back the follower.

6.13 Remove thrower and spacer ring and ‘O’ ring.

6.14 Support stages to prevent collapse when discharge is removed.

6.15 Loosen and remove tie bolts.

6.16 Remove discharge housing complete with final diffuser and ‘O’ ring.
6.17 Remove in succession each casing, ‘O’ ring, diffuser, spacer, impeller and key.

6.18 Mark each component relative to the stage casing.

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Multiflo HMW Horizontal Multistage Pumps

6.19 Loosen set screws and remove suction end bearing housing cover.

6.20 Remove shaft end nut.

6.21 Loosen set screws and remove discharge end bearing housing and bearing outer ring.

6.22 Undo the gland follower nuts and pull back the follower.

6.23 Remove shaft.

6.24 Remove bearing inner ring and sleeve, spacer ring, thrower and ‘O’ ring.

7. ROTOR ASSEMBLY

7.1 When new rotating parts are fitted, the following procedure should be followed before
assembly in the pump.

7.2 Fit drive end circlip (42) onto the shaft and slide sleeve (18) up against the circlip.

7.3 Push ‘O’ ring (38) over the shaft, against the spacer sleeve and fit spacer (20) with the ‘O’ ring
groove towards the ‘O’ ring.

7.4 Fit the impeller key (14) and slide the impeller (8) over the key ensuring that the impeller slides
smoothly without interference.

7.5 Fit the stage sleeve (19) behind the impeller ensuring that the sleeve locates on the key.

7.6 Repeat the above for the required number of stages.

7.7 Fit the discharge protection sleeve (21) against the last stage impeller, ensuring that the sleeve
locates on the key.

7.8 Fit ‘O’ ring (38) into the groove on sleeve (21). Slide the spacer sleeve (18) into position and fit
circlip (42) into the circlip groove.

7.9 The shaft assembly should now be held firmly between the circlips without axial movement. If
there is axial movement or if the circlip (42) cannot be fitted, the spacer sleeve (18) should be
adjusted accordingly.

7.10 Rest the motor assembly on vee blocks positioned at the bearing journals and check for run
out at the impeller eyes and back and front shaft sleeves (max run out 0,03mm).
7.11 The rotor should be dynamically balanced to =/-0,02g.

7.12 After balancing, check all match markings are still clear and new components match-marked
to maintain the original; assembly positions.

8. PUMP ASSEMBLY

8.1 Before commencing assembly, all parts should be carefully cleaned and old packing removed.
The parts should be examined for wear and worn or damaged parts replaced. The shaft
should be checked between vee blocks for runout.

8.2 Re-assembly is carried out in the reverse sequence. Care should be taken to ensure that the
assembly conditions are clean. The cross sectional drawing should be available for reference.

8.3 When fitting new bearings, ensure that only the type recommended are used. The bearings
o
should be preheated to 80 C before fitting.

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Multiflo HMW Horizontal Multistage Pumps

8.4 Stand the suction casing (1) on the bench and clamp down.

8.5 Slip the protecting sleeve (20), spacer sleeve (18) and ‘O’ ring (38) onto the shaft.

8.6 Fit circlip (42).

8.7 Push the thrower (23), gland follower (22) and lantern ring (36) onto the shaft and slip the shaft
into the suction casing.

8.8 Bolt the bearing bracket (6) onto the suction casing.

8.9 Fit the impeller key (14) and slide the first stage impeller (8) and spacer sleeve (19) onto the
shaft. Push the impeller firmly against sleeve (20). The impeller must slide smoothly over the
key without interference and the sleeve keyway locates on the key.

8.10 Fit the first stage diffuser (9) and align the centre of the first stage impeller outlet with the
centre line of the diffuser inlet. (See Figure 2)

Figure 2 - Typical cross section through the first stage impeller

8.11 Measure and record the distance from the shaft end to the bearing housing face.

8.12 Fit the diffuser and stage casing (2) with ‘O’ ring (39). Support the casing and tap the
components into close contact, with a soft head mallet.

8.13 The remaining stages are fitted in the same manner.

8.14 Fit the shaft protection sleeve (21) and ‘O’ ring (38) and push on the discharge casing (3) and
stage ‘O’ ring (40).

8.15 Insert the tie bolts (8) and tighten the nuts (32) evenly across the diagonals until all stages are
closed (no gap between stages).

8.16 Push the gland follower (22), spacer (18) and thrower (23) onto the shaft and fit circlip (35).
Check that the shaft assembly turns freely.

8.17 Mount the bearing frame (4) and bolt firmly to the discharge housing.

8.18 Pull the rotor backwards as far as possible and again measure from the shaft end to the
bearing housing. The difference between the two dimensions gives the total shaft float and
should be between 1,5 and 3,5mm depending on the number of stages.

8.19 Set the shaft at the mid-point between the two readings. This should give a dimension within ±
0,5mm of the dimension recorded under 8.11.

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Multiflo HMW Horizontal Multistage Pumps

8.20 Measure from the drive end shaft to the circlip (35) and to the thrust bearing location face. The
difference will give the thickness of spacer (17).
o
8.21 Insert the spacer and pre-heat the thrust bearing (24) to 80 C. Push the bearing onto the shaft
and into the housing against the locating face and immediately tighten up locknut (25).

8.22 Ensure that the drive end shaft position is unchanged and fit the drive end radial bearing and
taperlock assembly (25) (26). Check that the full roller width is in contact with the races.
Locate the lock washer tag in the slot and tighten the locknut. Flatten lock washer into lock nut
slot.

8.23 Fit the drive end bearing housing cover (7) and gasket (28) and tighten firmly across the
diagonals.

8.24 Fit the non-drive end bearing housing cover (5) and gakset (27) and tighten firmly across the
diagonals.

8.25 Fit gland flushing piping.

8.26 Fit gland packing ensuring that the lantern ring is correctly positioned in the suction gland (See
5.3).

GENERAL

When the pump is returned to service, the alignment must be re-checked (See Section 3) and the
gland packing adjusted (See Section 5.3). If the motor has been removed the rotation should be
checked.

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 Multiflo HMW Horizontal Multistage Pumps

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION

1 1 SUCTION CASING ASSEMBLY 23 2 THROWER
2 A/R STAGE CASING ASSEMBLY 24 1 BEARING
3 1 DISCHARGE CASING ASSEMBLY 25 1 NUT
4 1 BEARING HOUSING 26 1 BEARING
5 1 BEARING COVER DISCHARGE 27 1 BEARING COVER GASKET
6 1 BEARING HOUSING SUCTION 28 1 BEARING COVER GASKET
7 1 BEARING COVER SUCTION 29 1 CLAMPING SLEEVE ASSEMBLY
8 A/R IMPELLER 30 8 TIE BOLT
9 A/R DIFFUSER ASSEMBLY 31 16 WASHER FLAT M24
10 1 DIFFUSER ASSEMBLY LAST STAGE 32 16 NUT HEX
11 1 SHAFT 33 12 NUT HEX M12
12 1 KEY 34 4 BOLT HEX M10 X 30 LG
13 1 KEY 35 1 EXTERNAL CIRCLIP
14 A/R KEY 36 1 LANTERN RING
15 1 KEY 37 8 GLAND PACKING
16 1 SPACER RING 38 2 ‘O’ RING
17 1 SPECER RING 39 1 ‘O’ RING
18 2 SPACER SLEEVE 40 A/R ‘O’ RING
19 A/R STAGE SLEEVE 41 2 GREASE NIPPLE M6
20 1 PROTECTION SLEEVE SUCTION 42 1 EXTERNAL CIRCLIP
21 1 PROTECTION SLEEVE DISCHARGE 43 2 ELBOW
22 2 44 1 FLUSHING PIPE

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Multiflo HMW Horizontal Multistage Pumps

OPERATING TROUBLES AND THEIR CAUSES

Symptoms
capacity

Pump loses prime after

leaks

and
Pump does not deliver

Pump requires excessive

pressure

Pump vibrates or is noisy

Bearings have short life

Packing has short life

overheats
box

Cause
excessively
Insufficient

Insufficient
developed
delivered

Stuffing
starting

seizes
power

Pump
water

* * 1 Pump not primed.

* * * * 2 Pump or suction pipe not completely filled with liquid.
* * * * 3 Suction lift too high.
* * 4 Suction pipe too small.
* * * * 5 Insufficient margin between suction pressure and
vapour pressure.
* * * 6 Excessive amount of air or gas in liquid.
* * * 7 Air pocket in suction line.
* * 8 Air leaks into suction line.
* * 9 Air leaks into pump through stuffing boxes.
* * 10 Foot-valve too small.
* * 11 Foot-valve partially clogged.
* * * 12 Inlet of suction pipe insufficiently submerged.
* * 13 Water-seal pipe plugged.
* * * 14 Seal cage improperly located in stuffing box, preventing
sealing fluid entering space to form the seal.
* * * 15 Horizontal bend at suction inlet.
* * 16 Speed too low.
* 17 Speed to high.
* * * 18 Wrong direction of rotation.
* * * * 19 Total head of system higher than design head of pump.
* 20 Total head of system lower than pump design head.
* 21 Specific gravity of liquid different from design.
* * * 22 Viscosity of liquid differs from that for which designed.
* * 23 Operating at very low capacity.
* * * * 24 Parallel operation of pumps unsuitable for such
operation.
* * * * 25 Foreign matter in impeller.
* * * * * * 26 Misalignment.
* 27 Foundations not rigid.
* * * * * 28 Shaft bent.
* * * * 29 Rotating part rubbing on stationary part.

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Multiflo HMW Horizontal Multistage Pumps

OPERATING TROUBLES AND THEIR CAUSES

Symptoms
capacity

leaks
Pump does not deliver

Pump loses prime after

Pump requires excessive

and
pressure

Pump vibrates or is noisy

Bearings have short life

Packing has short life

overheats
box

Cause
excessively
Insufficient

Insufficient
developed
delivered

Stuffing
starting

seizes
power

Pump
water

* * * * 30 Bearings worn.
* * * 31 Wearing rings worn.
* * * 32 Impeller damaged.
* * 33 Casing gasket defective permitting internal leakage.
* * 34 Shaft or shaft sleeves worn or scored at the packing.
* * * 35 Packing improperly installed.
* * * 36 Incorrect type of packing for operating conditions.
* * * * 37 Shaft running off centre because of worn bearings or
misalignment.
* * * * * 38 Rotor out of balance resulting in vibration.
* * 39 Gland too tight resulting in no flow of liquid to lubricate
packing.
* * 40 Failure to provide cooling liquid to water-cooled stuffing
boxes.
* * 41 Excessive clearance at bottom of stuffing box between
shaft and casing, causing packing to be forced into
pump interior.
* * 42 Dirt or grit in sealing liquid, leading to scouring of shaft
or shaft sleeves.
* * * 43 Excessive thrust caused by a mechanical failure inside
the pump or by the failure of the hydraulic balancing
device, if any.
* * 44 Excessive grease or oil in anti-friction bearing housing
or lack of cooling, causing excessive bearing
temperature.
* * 45 Lack of lubrication.
* * 46 Improper installation of anti-friction bearings (damage
during assembly, incorrect assembly stacked bearings,
use of unmatched bearings as pair, etc).
* * 47 Dirt getting into bearing.
* * 48 Rusting of bearings due to water getting into bearing.
* * 49 Excessive cooling of water-cooled bearing resulting in
condensation in the bearing housing of moisture from
the atmosphere.

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Multiflo HMW Horizontal Multistage Pumps

NOTES

Page 13