Varley+pump+selection+handbook

Pump selection handbookfor double helical gear pumps

API 676 Pumps Standard Varley Pump

Diesel Engine Pumps

ht_pump_manual NEW.indd 1 7/11/07 15:45:23


Pump selection handbookfor double helical gear pumps


� www.varleypumps.com

Index of range of Varley gear pumps

1. Introduction 6

2. Features, benefits, operating range 7

3. Nomenclature and pump sizing 8

�. Ordering information 9

5. Pump performance indication guide 10-13

6. Pump performance curves 1�-26

7. Dimension drawings 27-�5

8. Section drawing and parts list �6-51

9. Alternative assembly (mechanical seal and plain cover) 52

Page NumberSection Title


5Sales office ☎ +44 (0) 1582 731144

10. Table of approximate viscosity comparisons 53

11. Definition of hydraulic terms 54

12. System design typical fuel oil pumping 55

13. Installation, operating and maintenance instructions 56-59

1�. Service and maintenance 60-63

15. Quotation form 6�-65

Page NumberSection Title

16. Notepad 66


6 www.varleypumps.com

1. Introduction

The Varley Double Helical Gear Pump Handbook has been revised to bring the data into line with customer requirements.

It is a reference book designed to help you select and specify a pump precisely.

If you need to pump a liquid with lubricating properties at flow rates between 0.5 igpm and 200 igpm against pressures varying from 5 p.s.i to 500 p.s.i then Varley pumps can provide you with robust reliable solutions. Larger pumps can be supplied for special applications.

With knowledge of the output required and the differential pressure (approximately the same as discharge pressure if inlet pressure low), a provisional choice can be made from

the performance indicator guide on pages 10-11. A more accurate guide to performance and power curves can be found on pages 12-2� taking viscosity into account.

You can now specify your pump precisely using the nomenclature system given on page 8. Should you prefer, our engineers or agents will be only too pleased to make a suitable selection for you on receipt of full details of your requirements.

Varley Pumps are approved by: NCB power generation authorities, British Rail, British Steel, British Gas, Lloyds, The Post Office, The Admiralty, Bureau Veritas, Norske Veritas and American Bureau of Shipping to name but a few.

When you use Varley Pumps you benefit from over 50 years of experience and development.


7Sales office ☎ +44 (0) 1582 731144

2. Features, benefits, operating range

Varley Pumps can give you:

Features

Compact design

Double helical motors

Balanced rotor

Journal roller bearings

High suction lift capability

High interchangeability

Flexible coupling

Standard metric motors

All motorised units bracket mounted

Pumps custom tested as standard

Benefits

Easy fitting

Smooth non-pulsating flow

Thrust eliminated

Long life

Self-priming

Economic maintenance

Easy maintenance

Faster deliveries

Saves space/eliminates need for base plate

No adjustment required on site

Capacity range: 0.5 igpm (0.1� M3/H) – 200 igpm (55M3/H) Viscosity range: Up to 15000 secs Redwood No. 1 Pressures: Up to 500 p.s.i (35 kg/cm2) Suction lift: Up to 20+ Hg (��5mm) Temperatures: Up to 350°F (176°C)

Standard Materials1. Front cover, body, rear cover Close grained cast iron to B.S.1�52 (grade 1�)

2. Shafts (main and idler) Steel to B.S.970 (EN36B)

3. Double helical rotors Steel to B.S.970 (EN9)

4. VJournal roller bearings To B.S.292

5. Bearing housings Cast iron to B.S.1�52 (grade 1�)

6. Seal Packed gland or mechanical seal

Other options available, please contact us at [email protected] or on +��(0)1582 7311��

Other Products(separate publications available) VARLEY Tanker Pumps VARLEY Atex Pumps VARLEY API 676 Positive Displacement Pumps VARLEY Engine Pumps

(3D CAD models available)

Integral by-pass relief valve fitted as standard (can be supplied without if not required)Standard paint finish Hammer Green (Styrenated Alkyd)



3. Nomenclature and pump sizing

5 M 1 T 4 R/ 01Pump Size Mounting Motor

Horsepower Motor

EnclosureSpeed Relief Valve

(by-pass)Relief Valve & Seal type

The nomenclature used to describe a Varley pump is designed to specify the unit in full as follows:Example explained below 5M1T�R/01

Pump sizeCorresponds to nominal output in igpm at 1�20 rpm: 1, 2, 5, 7, 10, 20, 30, 35, 50, 75, 100, 150, 200

MountingM Horizontal motorised unitV Vertical motorised unitB Base plate mounted motorised unitF Foot mounted bare shaft extension pump SS Short shaft

Motor Horsepower Dependant on application ½, ¾, 1, 1 ½ etc.

EnclosureT totally enclosed fan cooledFLP flame and explosion proof

Speed at 50Hz� pole – 1�20rpm6 pole – 960 rpm8 pole – 720 rpmLower speed available using gearbox.

Integral Relief Valve (by-pass)R omitted from reference when not required

Relief Valve (by-pass) and Seal typeTemperature range: 0° to 2�0°F sizes 1 to 100. 0° to 120°F sizes 150 and 200.

Relief Valve

Return to Intake Return to Tank Without By-pass

Seal Type Mechanical Seal Gland Packing

Mechanical Seal Gland Packing

Mechanical Seal Gland packing

Anti- Clockwise

Suffix0� 01 05 02 06 03

Clockwise suffix

5� 51 55 52 56 53

Temperature range: 2�1° to 360°F sizes 1 – 100. 121° to 360°F sizes 150 and 200.

Anti- Clockwise

Suffix22 19 23 20 2� 21

Clockwise suffix

72 69 73 70 7� 71


9Sales office ☎ +44 (0) 1582 731144

OrderingYou are advised to give the following additional information so that we can ensure that the correct unit is supplied:

1. Flow rate2. Working pressure3. Fluid details including viscosity at operating temperature and the condition�. Rotation (anti-clockwise looking at shaft end standard)5. Top or bottom drive (top drive standard)6. Suction conditions7. Operating temperatureStandard pumps will be supplied unless otherwise requested

Mechanical sealThe mechanical seal type fitted as standard to the Varley gear pump, is of a single unbalanced design. Standard construction is of Stainless-Carbon-Viton. Hard face, dual rotation and PTFE seals can be accommodated within the standard range. Our engineers are on hand to advise you of any requirements.

Gland packingPTFE impregnated synthetic fibre yarn packing. Max shaft service speed 26 m/s and up to 350 psi.

Viscosity Varley pumps are suitable for viscosities up to 15,000 secs. Redwood No. 1 and even higher for certain specialised conditions (in such cases we should be consulted to ensure correct application).The performance curves contained within this brochure cover the following viscosities: - 75, 310 and 7�00 seconds Redwood No. 1. They are intended as a guide to indicate the b.h.p. requirement for each size of pump within the Varley range. Interpolation is possible but we recommend that you check with the sales office for viscosities very different to those shown.

Example A transfer oil pump to handle fuel oil at 75 secs, Redwood No. 1 viscosity from underground storage tank to an elevated service tank. Rate of flow 6 igpm at 50 p.s.i. The b.h.p absorbed on duty is determined by curve “C” (lower) on the graph i.e. 0.5 H.P. Thus a nomenclature of 5M1/2 T�R is derived if your requirement is a horizontal motorised unit, to which should be added the appropriate assembly type number e.g. 5M1/2 T�R/01.Should any other type of mounting be required, the type reference would be modified accordingly. E.g. 5V11/2 T�R/01. 5B11/2 T�R’/01, 5SR/01, 5FR/01When ordering please provide precise details of pump duty. Alternatively please complete the form at the back of the handbook.

NoteVarley Pumps Ltd reserve the right to make additions to or deletions from the Varley pump range, and make dimensional alterations without notice. The availability of any item shown in this handbook should therefore be checked at the enquiry stage.

�. Ordering information



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11Sales office ☎ +44 (0) 1582 731144

Spe

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13Sales office ☎ +44 (0) 1582 731144

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6. Pump performance curves


15Sales office ☎ +44 (0) 1582 731144

Pump Performance Curves



Pump performance curves


17Sales office ☎ +44 (0) 1582 731144






19Sales office ☎ +44 (0) 1582 731144






21Sales office ☎ +44 (0) 1582 731144






23Sales office ☎ +44 (0) 1582 731144






25Sales office ☎ +44 (0) 1582 731144






27Sales office ☎ +44 (0) 1582 731144

7. Dimension Drawings Spigot Mounted Pump Sizes 1-2S7. Dimension drawings



Dimension drawings spigot mounted pump sizes 5-7S


29Sales office ☎ +44 (0) 1582 731144

Dimension Drawings Spigot Mounted Pump Sizes 10-20S



Dimension drawings spigot mounted pump size 30S


31Sales office ☎ +44 (0) 1582 731144

Dimension Drawings Spigot Mounted Pump Size 35-100S



Dimension drawings spigot mounted bare shaft pumpsizes 150S & 200S


33Sales office ☎ +44 (0) 1582 731144

Dimension Drawings Foot Mounted Bare Shaft Sizes 1-2F



Dimension drawings foot mounted bare shaft sizes 5-7F


35Sales office ☎ +44 (0) 1582 731144




Dimension drawings foot mounted pump size 30F


37Sales office ☎ +44 (0) 1582 731144




Dimension drawings foot mounted pump sizes 150F & 200F


39Sales office ☎ +44 (0) 1582 731144

Dimension Drawings Horizontal Motorised Pump Sizes 1-2M



Dimension drawings horizontal motorised pump sizes 5-7M


41Sales office ☎ +44 (0) 1582 731144




Dimension drawings horizontal motorised pump sizes 10-30Mlarger bracket size


43Sales office ☎ +44 (0) 1582 731144




Dimension drawings horizontal motorised pump sizes 75-200M


45Sales office ☎ +44 (0) 1582 731144

8. Section Drawing and Parts List 1-2S



8. Section drawing and parts list 5-7S


47Sales office ☎ +44 (0) 1582 731144

Section Drawing and Parts List 10-20S



Section drawing and parts list 30S


49Sales office ☎ +44 (0) 1582 731144

Section Drawing and Parts List 35-100S



Section drawing and parts list 150S


51Sales office ☎ +44 (0) 1582 731144

Section Drawing and Parts List 200S



9. Alternative assembly (mechanical seal and plain cover)


53Sales office ☎ +44 (0) 1582 731144

10. Table of Approximate Viscosity Comparisons

The following table lists several commonly used viscosity measurements for quick, easy conversion from one to another. Although the values are only approximate, they are sufficiently accurate for most pump calculations. The tables are especially useful because all values may be compared directly with each other.

10. Table of approximate viscosity comparisons



11. Definition of hydraulic terms

Head: The hydraulic pressure is expressed in pounds per square inch (psi) gauge using atmospheric pressures as the datum. It can be determined by use of pressure gauges or can be computed by using pipe friction tables and static head measurements.

Friction head: This is the hydraulic pressure exerted to overcome frictional resistance of a piping system to the liquid flowing through it.

Static suction lift: The hydraulic pressure below atmospheric at the intake port with liquid at rest. It is usually expressed in or converted to inches of mercury (Hg) vacuum.

Total suction lift: Is the total hydraulic pressure below atmospheric at the intake port with the pump in operation (the sum of the static suction lift and the friction head of the suction piping).

Flooded suction: Is a very indefinite term which has been carelessly used for so many years that its meaning is no longer clear. More often than not, it merely indicates that suction conditions have not been accurately determined. One point to remember is that a static suction head may become a suction condition when the pump goes into operation, due to friction in the suction pipe work.

Total suction head: Is the hydraulic pressure above atmospheric at the intake port with the pump in operation (the difference between the static suction head and the friction head of the suction piping).

Static discharge head: Is the hydraulic pressure exerted at the pump discharge by the liquid at rest, commonly measured as the difference in the elevation between the pump discharge port and the delivery point.

Total discharge head: Is the total hydraulic pressure at the discharge port with the pump in operation (the sum of the static discharge head and the friction head of the discharge piping).

Total pumping head (or dynamic head): Is the sum of the total discharge head and the total suction lift; or the difference between the total discharge head and the total suction feet.

Head expressed in feet: Although the foregoing definitions refer to the “head” as expressed in psi, it is also proper to specify the total pumping head in feet of liquid or water. Conversions can be made between these expressions of psi to feet but since there will normally be an appreciable difference between the feet of head or a particular liquid and the feet of head of water, it is extremely important to specify which term is being used.

Pressure (psi) = head(ft) x Specific Gravity 2.31


55Sales office ☎ +44 (0) 1582 731144

1. Daily service tank systemsConstant pressure to within a few inches water gauge, may be maintained at the burners.

Note: An overflow, size to handle full flow from the pump, should be incorporated to limit problems in the event of a float switch failure.

The main criteria is to maintain a constant pressure and correct flow to the burners

12. System DesignTypical Fuel Oil PumpingSystem arrangements (for light fuel oils)

3. Main ring systemFor feeding burners placed around the perimeter of a factory. Pipe sizing must be such as to ensure that losses do not adversely affect burner performance.

Note: Pump is normally sized to give a circulation flow around the ring equal to 2 ½ times the total burner requirements.

4. Underground tank systemSuction lifts should be kept to a minimum.

Note: The return line should not be fed into the intake but back to tank. Failure to do so can result in entrapped air re-circulating.

2. Dead leg systemA dead leg system may extend to many hundreds of feet. Constant pressure is maintained by incorporating a relief valve in the by-pass.

Note: By-pass line should return to tank – not to intake. If returned to intake any entrapped air will re-circulate and cause burner ignition problems.

12. System design typical fuel oil pumping



Installation, operating and maintenance instructionsMost pump problems occur at start up! These notes have been prepared to help you prevent problems as well as deal with them.

All Varley pumps are covered by a one year warranty against defects in manufacture. The commencement date of the warranty is the date of despatch of the unit from our factory unless otherwise agreed. The warranty also covers damage sustained in transit, provided both carrier and ourselves receive written notification of any damage within 48 hrs from date of despatch.

Notes for the guidance of installers

1. The pump should be installed first and the pipe work built away from the pump. This should avoid strain being imposed upon the pump by poorly aligned pipe work. Such strain may result in rapid seal breakage, bearing failures or broken pipe ports.

On pumps, which have threaded ports, care should be taken to see that the pipe does not bottom into the port, or the threads will be damaged and the port broken. Support the pipe to prevent strain due to its weight being imposed upon the pump.

2. Determining the suction port: Provided that the build of the pump has not been altered after despatch from our factory, the correct direction of rotation is indicated by an arrow on the pump front cover. This same arrow has marked upon it the suction port position (namely the tail of the arrow) and discharge port (the head of the arrow). In any case, a positive check may be obtained by observing the domed protrusion on the side of the non-drive end cover of the pump – the suction port is always on the same side of the pump as that protrusion (see diagram 4).

3. Ensure that on suction pipe work there is no possibility of any leakage, which could result in air being drawn into the pump.

4. Filter: A full flow filter on micron mesh should be fitted on the suction side of the pump. If this is not provided, check to see whether or not one is to be fitted. In cases where the fluid to be pumped is guaranteed to be free from foreign matter, no filter need be fitted but it is desirable to insert a piece of fine gauze between flanges in the pipe work so that weld slag, thread cuttings, sand, etc. will be trapped by the gauze and prevented from entering the unit. This gauze should be removed once the pipe-work system is totally clean.

Start upBefore start up it is wise to check the following points:

1. Check that the pump shaft turns freely. If the pump is jammed solid, it is likely that already some foreign matter has been introduced into the pump and the gears are jammed. This must be rectified immediately.

2. If the pump will turn but is rather stiff it is likely that the pump is gland packed and the packing has dried out somewhat on the shaft. In this case, slacken off the two setscrews a couple of turns and continue to turn by hand until the pump frees.

13. Installation, operating and maintenance instructions


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N.B. the pump should not spin freely, but should have a very slight resistance to movement with a gland packed unit. If it is still stiff after adjusting setscrews, lightly tap the pump with a soft hammer in case the material parts have been forced together during installation.

3. Although Varley pumps are self- priming, it is much easier and safer, on an initial start, to hand prime the pump with a thin lubricating oil. This guarantees that all parts are well ‘wetted’ and will result in rapid pick up of fluid being pumped. (This procedure is unnecessary where the pump is beneath the level of the liquid in the tank).

4. A gland packed pump may leak along the shaft on initial start up, but it is wise to allow a short time of running in this condition for it to bed in before any effort is made to adjust the gland, Adjustment should then be carried out until there is just an occasional drip of liquid from the gland area, adjustment should be done carefully over a period of hours taking each nut down evenly a little at a time.

On some units, and especially on hot oil units, a slight leak may develop across the pump end cover joints. Should this occur, all the nuts on the end covers of the pump should be checked for tightness.

5. All units have had their relief valves set with respect to discharge pressure, but should this set pressure prove to be unsuitable on site, it can be varied by screwing the relief valve setting screw on the non drive end cover of the pump in or out, depending on whether the pressure needs to be increased or decreased. If the correct pressure cannot be set an alternative spring available from our spares department, may be required.

Fault finding and correction: 1. Failure to prime a. Check that all valves are in open position b. Check for leaks in suction line and seal c. Check that the by-pass valve is not blocked in the open position – clean if necessary d. Check that the filter is not blocked – change or clean if necessary. 2. Reduction in flow rate a. Check that the by-pass valve is closed – clean and reset as required b. Check that there are no leaks in the pump or in the system c. Check the any regulating valves in both the suction and discharge lines are correctly set d. Check for increased pressure in discharge line.

Installation, operating and maintenance instructions



3. Noisy running a. Check both suction and discharge lines for blockages b. Strip the pump down and look for damaged parts or foreign matter. 4. Pump has seized and will not turn a. Dismantle and clean b. Replace damaged parts

Varley Pumps has an integrated Service and Spares Section, that will undertake fieldwork and manages the repair section at our works. The spares section will be pleased to help you identify spare parts and supply replacements.

For those who wish to carry out their own maintenance, please refer to the following notes on servicing the units:

DismantlingRemove pump from bracket, or base plate and proceed as follows:

1. Withdraw the coupling half from the pump shaft (first slackening the grub screw). 2. Carefully remove the key from its keyway. 3. Examine the shaft extension and keyway for cleanliness and carefully remove any burrs. 4. Remove setscrews (or nuts) and washers securing the front cover to the pump body. Break the joint by lightly tapping the cover with a soft hammer and withdraw the cover. 5. Detach rear cover in the same fashion as for the front cover removal. 6. If fitted, withdraw the spacing collar from the main shaft at the front cover end. 7. Remove any circlips and withdraw the complete rotating assemblies with bearings from the body. 8. In the case of pump size 1 to size 20, the housings will part from the rotor end faces sufficiently to allow the insertions of extractors for drawings the bearing inner races off the shafts. In the case of pumps size 35 and above the bearing housings complete with bearing outer races and rollers will slide freely off the shafts leaving the inner races still in position. 9. Do not attempt to press shaft through the rotors on any of the pump sizes, rotors are permanently secured to the shafts and they must be considered as one unit. Keep all bearing inner and outer races as sets. 10. Remove the outer races of the bearing from their housings. 11. On a gland packing pump, fully unscrew the gland adjustment setscrews and remove the gland retainer. Remove all the old packing and then clean and smooth the bore using a fine emery cloth or a small soft wire brush. 12. By-Pass valve Remove dome nut and release locknut. Screw out the setting screw, making sure the number of turns are counted. Remove the setting screw housing, spring and valve. 13. Mechanical seal The mechanical seal-rotating element should be removed from the pump, before the shaft assembly is pressed out. In removing this seal, it is advisable to use a dummy - shaft key to prevent the seal ring being cut when it passes over the keyway (see diagram 5).

The seal collet should be removed by opening up the slot and sliding it off the shaft. The static seal face is in the front cover; this should be removed by light finger pressure.



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InspectionExamine all parts for wear and damage and clean up or replace with new parts as necessary. It is unwise to rebuild a pump with worn components, and we fully recommend the replacement of bearings, gaskets, packing and mechanical seal. It is important to note that a mechanical seal is very unlikely to re-sit in the same place once the two seal faces have been split.

Reassembly 1. Carefully press the outer races of the roller bearings into the bearings housings. 2. On sizes 1 to 20:

Carefully press the bearing housing and bearing assemblies on to the shaft, ensuring that they are square to the shaft. Note that in this case the load should be placed on both the inner race of the bearing and the bearing housing at the same time.

On sizes 35-200: Place the bearing spacers on the shaft, and press on the inner races. The bearing housings will now slide over the inner races. NB do not mix up inner and outer races.

3. Where supplied refit the circlips into the grooves in shafts. Check to see that the rotor turns freely in its bearings.

4. Match the main shaft assembly and the idlershaft assembly together and place them in the body from the rear towards the front of the pump.

5. Very carefully insert the assembly into the body ensuring square entry and that both assemblies are entering the pump together. Ensure the pressing is done on the outer race to prevent damage to rotors and bearing housings.

6. The assembly is correct when the housings are flush to the body. Fit locating washer and spacing collar, when provided, replace front and rear cover gaskets and fit the covers. Line up with a suitable bush between the shaft and front cover bore.

7. After tightening down the covers check that the mainshaft turns freely: if it does not it is probable that the bearings housings have closed up on the rotors. It is possible to ease them off, by lightly tapping the body with a hide hammer.

8. By-pass valve Assembly of by-pass should be effected in reverse order to the dismantling.

Note on repacking the gland:The gland should be repacked using only moulded rings supplied by Varley pumps.

Make sure that the ring joins are staggered to prevent a leakage path for the liquid. Then refit the gland retainer, and screw in the setscrews until the shaft has just the slightest resistance to movement, (though it should still be quite free to turn).



Note on assembly of mechanical sealAgain, the mechanical seal should be assembled in a dummy key in the coupling keyway.

The stationary carbon ring should be carefully pressed into the recess in front cover, care being taken to see that the carbon is pressed in squarely. N.B Great care must be taken to see that the carbon is not chipped or cracked during this operation (the carbon is a brittle component).It is wise to lightly smear the rotating face with clean lubricating oil before assembly of the front cover.It should be possible to reassemble a pump satisfactorily, provided normal fitting skill is exercised.

Points to bear in mind when designing the installation.

1. Location of pumps Wherever possible the pump should be located close to the supply tank. This avoids the necessity for long suction pipe runs, which can often be troublesome. This is because no pump can literally ‘suck’, it normally requires atmospheric pressure to ‘push’ liquid into the pump.

2. Sizing of the pipe work Resistance to flow is reduced as pipe work size is increased, and consequently requires less motive power. We, therefore, do not apply a limitation to the maximum discharge pipe work that can be employed. It should be noted, however, that at no time should this be less than the port size of the pump.

NB Care must be taken when choosing the diameter of suction pipe work when the pump is operating under suction lift. Should the diameter be too large, the pump will spend much of its time, on start up, evacuating the large volume of air in the pipe, and we strongly recommend the pipe size be kept to the same size as that of the suction port.

3. Noise Noise may be airborne, structure-borne, pipe-borne, or fluid-borne. The siting of the unit will take care if airborne noise and steps should be taken to mount the unit on a noise/vibration absorbing base if structure-borne noise could be a serious problem.

Most fluid and pipe borne noise results from numerous changes of direction causing turbulent flow of the fluid and vibration of the pipe work. The number of bends should, therefore be kept to a minimum. This form of noise is frequently the most troublesome as pipe work often runs through a building and the noise is distributed throughout.

The pipe work should also be firmly clipped to the wall, with some anti vibration material between clip and pipe. When pipe work is not near a wall it must be firmly supported.

4. Suction lifts It has already been mentioned that pumps should be mounted as closely as possible to the tank. Where this is impossible the imposition of a suction lift on the pump is often necessary. In such cases, it is essential that the pipe work be free from all air leaks. Therefore joints should be kept to a minimum. Even though the pump unit is self- priming a foot valve should still be fitted to the suction line in the tank. Without this the pump is called upon to

14. Service and maintenance


61Sales office ☎ +44 (0) 1582 731144

14. Service and Maintenance

prime the total length of the line at each start up which means longer periods of dry running before the fluid reaches the pumps and rapid wear can occur.

5. Filter New pumps rely on the maintenance of fine working clearances for efficient operation, so if there is any possibility of foreign matter finding its way into the tank and thence to the pump, a full-flow suction filter or 60-80 micron mesh must be installed to ensure long life. The mesh size will depend on both fluid and application e.g. plain bearings will require 20 mesh or less.

6. Valving

Isolating valves should always be provided on either side of the pump to avoid the messy task of clearing lines before removal of the pump for maintenance. (See diagram 1 for suggested layout).

Where two units pump the same line (especially on an automatic standby system), non-return valves should be fitted in the discharge from each unit to prevent back-flow of the unit through the stationary pump. A satisfactory valving arrangement is shown in diagram 2.

7. Effect of fluid viscosity Very careful attention must be paid to the pipe work layout when viscous fluids are being pumped. Suction lifts should be avoided if possible and all pipe work runs kept as short as possible to avoid large pipe work losses. Particular care must be taken when heat is required to bring the viscosity to an acceptable level. At start-up the liquid is often cold, resulting in a severe overloading of the pump and possibly a motor failure. If there is the possibility of cold starts, you should let us know and we can take it into account when specifying the unit.

8. By-pass valve The by-pass valves fitted to pumps of our manufacture are intended entirely as pressure relief valves to protect the pump and system against over-pressure should blockage occur in the discharge pipe work, or should the imposed load rise too high. It should not, therefore, be used as a pressure regulating valve in normal circumstances (and it will not normally give adequate regulation if any attempt is made to use it in this way).



A system should not be designed using a return-to-inlet by-pass valve if the discharge is to be kept closed for long periods, since the fluid will then circulate around the pump and cause overheating. In this case the alternative return to tank system should be utilised. To avoid aeration of oil, the return line back to tank should be installed as far away as possible from suction line, then entry of this line into the tank must go below the oil level at all times (see diagram 3).

Notes for the guidance of designersBecause the pumping unit is relatively simple and inexpensive, its siting is sometimes given little thought. It is in fact the ‘heart’ of an installation and therefore the sizing and location are worthy of careful attention.

MotorsMotors are normally trouble free as long as they are kept in clean dry conditions. Where greasing points are fitted they should be given one shot of grease every few months running – but not more than one shot.

FiltersFilters should be cleaned regularly.

Pump storageIt sometimes happens that a unit must be obtained well before the plant is to be put into operation. If it should become necessary to store a pump, or to leave it on site for a lengthy period before operation, the following precautions should be taken.

1. On gland-packed pumps, loosen off the gland retainer set screws. 2. Liberally coat the pump shaft coupling and motor shaft with a protective oil. 3. Ensure that the motor windings are kept dry either by storing in warm, dry, clean conditions or install heaters in the motor. 4. Fill the pump body with a corrosion-inhibiting oil and, where the pump is in storage, seal off pump ports. About once a month give the pump shaft a couple of turns to prevent any standing corrosion effects.

Service and maintenance


63Sales office ☎ +44 (0) 1582 731144

Recommended SparesWe are frequently asked to provide a list of recommended spares for units of our manufacture. To assist the user to assess his requirements we break out our recommendations into two headings – namely, ‘normal’ usage spares (those normally required to be replaced during the overhaul of a unit which has been maintained and operated correctly) and ‘strategic’ breakdown spares (those spares which should be held against breakdown when the unit is of strategic importance to the operation of a system).

We give below our normal recommendation for a spares holding:

1 – set gaskets1 – set gland-packing or mechanical seals1 – set bearings and housings

Strategic breakdown sparesAll those for normal repair, plus all the following:

One complete set of internals, namely: -

Main shaft asseyIdler shaft asseyBearing housingsBy-Pass valve

Obviously, if there are many pumps of the same type operating in a system it would be wise to hold spare pumps, together with sets of normal usage spares.

Service and Maintenance



Please complete the form below and we will send you a quotation by return. If we require any more information we will be in touch.

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Fluid

Name:

Viscosity:

Operating Temperature:

Contamination:

Suction

Flooded

Lift metres

Discharge Pressure:

Relief Valve

Yes Internal External

No

Drive

Motor Volt Frequency Phase

Other Details:

Mounting

Standard

Horizontal

Vertical

Tank Top

Environment

Safe

Hazardous

Indoors

Outdoors

Notes:



16. Notepad



Revision 3© Varley Pumps Ltd

Varley Pumps Ltd is a division of the Hayward Tyler Group


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