MT186e - V1.2 en
MT186e - V1.2 en
MT186e - V1.2 en
Teaching material
i
11/2008
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.4 Operating
characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.1 Pump and system
characteristics . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.3 Alteration of the operating point by restriction and variation
of speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Operating characteristics of multiple interacting pumps . . . . 20
2.4.5 Intake characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . 21
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.1 Static
seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.2 Shaft and piston rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7.3
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.4 Spare parts
ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.5 Gear pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6 Spare parts drawing and spare parts list . . . . . . . . . . . . . . . . . . . . . . 50
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6 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1 Worksheet
1, page 1: Introduction to the gear pump . . . . . . . . . . . . 81
6.2 Worksheet 2, page 1: Design, function and applications of gear
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.3 Worksheet 3, page 1: Identifying causes of faults . . . . . . . . . . . . . . . 85
6.4 Worksheet 4, page 1: Sealing systems . . . . . . . . . . . . . . . . . . . . . . . 86
6.5 Worksheet 5, page 1: Inspection of pumps . . . . . . . . . . . . . . . . . . . . 88
6.6 Worksheet 6, page 1: Servicing pumps. . . . . . . . . . . . . . . . . . . . . . . 90
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7 Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.1 Worksheet
1, page 1: Introduction to the gear pump . . . . . . . . . . . 107
7.2 Worksheet 2, page 1: Design, function and applications of gear
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.3 Worksheet 3, page 1: Identifying causes of faults . . . . . . . . . . . . . . 111
7.4 Worksheet 4, page 1: Sealing systems . . . . . . . . . . . . . . . . . . . . . . 112
7.5 Worksheet 5, page 1: Inspection of pumps . . . . . . . . . . . . . . . . . . . 114
7.6 Worksheet 6, page 1: Servicing pumps. . . . . . . . . . . . . . . . . . . . . . 116
7.7 Worksheet 7, page 1: Repair of pumps . . . . . . . . . . . . . . . . . . . . . . 118
7.8 Worksheet 8, page 1: Wearing parts on gear pump . . . . . . . . . . . . 120
7.9 Worksheet 9, page 1: Assembling the gear pump. . . . . . . . . . . . . . 121
7.10 Worksheet 10, page 1: Changing the floating ring seal. . . . . . . . . . 125
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8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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v
11/2008
1 Introduction
The MT 186 practice kit forms part of the GUNT learning concept for pump
maintenance, which is designed to aid education and training at trade acad-
emies and corporate training centres.
A close link between theory and practice is key to the learning content.
Pumps
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump
MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
Tab. 1.1 Product relating to pump assembly and maintenance
Groups of two or three students working with one kit represents an optimal
way of learning.
1 Introduction 1
11/2008
We very much hope you enjoy using this GUNT assembly practice kit, and
we wish you success in your important task of providing students and
appren-tices with an introduction to the basic principles of the technology.
1 Introduction 2
11/2008
Code Product
Pumps are fluid-flow machines which dictate how processes operate - that
is to say, they ensure that flow takes place within systems.
In practice, pumps are often named after the liquid they pump or their
purpose, such as milk pumps or cooling pumps. However, technicians and
fitters can more easily identify their design when they are named according
to their operating principle.
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Fluid-flow machines
Machines Engines
(Machine drives a (Flowing medium
flowing medium) drives machine)
Pumps Turbines
Positive-displacement Centrifugal pumps
The following table sets out the designs and operating characteristics of the
most common positive-displacement pumps.
The following table sets out the designs and operating characteristics of the
most common centrifugal pumps.
The GUNT Practice Line kits for assembly and maintenance exercises
include the following pumps:
Centrifugal pumps are in widespread use, and are primarily used to pump
fluid media. Their applications include in shipbuilding, industry and water
supply.
curve. The delivery rates are measured on the test stand at the respective
delivery pressures. The pump measurement data is depicted in the form of
a characteristic curve. Usually the delivery head is given in place of the
deliv-ery pressure (as a result the characteristic curves of centrifugal
pumps are not dependent on the density of the pumped liquid).
In the case of centrifugal pumps the dependency of the delivery rate on the
head is marked: As the head rises, the delivery rate decreases significantly.
By contrast, the delivery rate of positive-displacement pumps remains virtu-
ally constant as the head rises.
HeadH
Head H
Delivery Q Delivery Q
Fig. 2.16 Characteristic curve for Fig. 2.17 Characteristic curve for
Delivery Q
Fig. 2.18 System characteristic curve
The actual delivery data result from the interaction of the pump and the
system.
If the pump and system curves are plotted on the same diagram, the point
at which the curves intersect is the operating point.
Head H
Head H
1
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Delivery Q Delivery Q
Fig. 2.19 Operating point (1) of a Fig. 2.20 Operating point (1) of a
normally priming centrifugal positive-displacement pump
pump
should first check and calculate the correct operation of the pump in the
system. This should be done on initial commissioning and every time the
system is modified.
Head H
Head H
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1
1
Delivery Q Delivery Q
Fig. 2.21 Shift in operating point from Fig. 2.22 Shift in operating point from
(1) to (2) by restriction for a (1) to (2) by restriction for a
normally priming centrifugal pump positive-displacement pump
Head H
Head H
n
2
n1 n2
n1
Delivery Q Delivery Q
Fig. 2.23 Influence on the pump Fig. 2.24 Influence on the pump
The pump industry has made use of these properties and developed a
number of designs accordingly.
Multi-flow pumps achieve high delivery rates, multi-stage pumps achieve
high heads.
Fig. 2.27 Multi-flow pump, sectional Fig. 2.28 Multiple-stage pump, sectional
view and delivery principle view and delivery principle
Self-priming pumps include side channel pumps (see chapter 2.2, page 5).
They are capable of pumping gases. However, the pump body must always
be filled with liquid for this to happen. That is why the intake and delivery
ports on side channel pumps always point upwards.
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3.1Definition Maintenance
All pump operators should maintain their pumps in accordance with the
main-tenance and operating instructions issued by the manufacturers.
Mainte-nance is the umbrella term for inspection, servicing and repair (see
Fig. 3.1). A log book or machine file should be set up for each pump unit,
indicating the current status and the repair work carried out to date.
Pumps are required for the operations of many manufacturing systems. If the
pumps are malfunctioning, there is a risk of production outages. Appropriate
maintenance is a key factor determining the productivity of operations.
Complete replacement of the pump is possible in the event of a defect, though
it is not always essential and, especially, is not necessarily cost-effec-tive.
Carrying out preventive maintenance and servicing, as well as repairs, is
advantageous. A number of reasons are cited by way of example.
• The cost of purchasing a mid-sized industrial pump is considerable. The
annual cost of wearing parts amounts to around 10% - 20% of the
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Service life
Fig. 3.2 Total cost, comparison of replacement (1) and maintenance (2)
Fig. 3.2 shows that routine maintenance of pumps (2) results in lower costs in the
medium and long term than complete replacement of pumps (1).
There must always be a liquid film between the contact faces of a floating
ring seal.
During inspection of the pump, checks should be made regularly while the
pump is running to ensure early detection of faults, focussing in particular
on the following points:
• Leakage
• Noise
• Smooth running
• Temperature
• General condition
The reasons for pump faults are many and varied.
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Bearings
The operating instructions specify that the lubricant should be changed on
pumps with an enclosed gear and bearing unit.
Modern-day greased bearings are lifetime-lubricated, and merely need to
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Shaft seals
Packing glands and floating ring seals are checked for leaks and wear.
Glands can be adjusted, if still possible. The gland packing should be
replaced after about 2000 operating hours.
The service lives of the floating ring seals are considerably longer. They are
replaced in full if worn.
Couplings
Pumps coupled to their drives by flexible couplings should be checked for
flush coupling. The power-transmitting components should be checked for
wear and replaced as necessary.
Pump internals
The pumps should be opened and their internals checked for wear and
corrosion at the specified servicing intervals.
In the case of centrifugal pumps, as well as the shaft seal the static seal
ring must be checked and replaced if worn.
The valves of reciprocating pumps, including their sealing faces, should be
checked. Piston rings and packing should be checked for wear, and the
plungers and sleeves checked for scoring.
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BearingCoupling
3.5 Wearing parts in the pumps from the GUNT Practice Line for
assembly and maintenance
It should be stated by way of preamble that, according to the state of the art
in centrifugal pumps, bearings are no longer classed as wearing parts.
Valves
Diaphragm
Valves
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O-rings
3.6 Shutdown
Fig. 3.13 Installation with standby Fig. 3.14 Single pump with stop
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pump valves
3.7 Repairs
Whereas during servicing parts are usually replaced following checking and
as required, during repair complete wearing parts or defective components
are replaced after predetermined operating cycles. These cycles are either
specified by the manufacturers or they are determined by the identified
condition of parts at the various maintenance intervals.
It is advisable to schedule every second to third service as a repair operation.
Flat seals and O-rings used for sealing between metal components and to
prevent escape of liquid from the pump body are replaced completely. Their
locations include at the connection fittings and on the housing covers,
floating ring seals, shaft sleeves and valves.
Procedure:
• Dismount the pump
• Remove the seals and dispose of them
• Clean the parts
• Install the new seals during reassembly
• Avoid mechanical damage. Ensure
cleanliness. Grease seals where necessary.
Static seal
Static seals
Static seals
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The most varied stresses on seals in pump engineering occur in the sealing
of shaft and piston rod feed-throughs. These seals must act between areas
subject to different pressures, and are subject to the demands of a wide
variety of media, as well as having to withstand additional physical strains
caused by rotating shafts or oscillating piston rods. These types of seal are
known in engineering as dynamic seals. Operators expect reliable sealing,
with minimal leakage, over a long service life. The shaft seals in particular
should be preventively replaced during scheduled repair work, because of
the extreme stresses to which they are subject.
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Shaft seal
1 3
4
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To seal the pump shaft, packing glands (1) are used. These are provided in
a wide range of materials and designs depending on the pump application.
To protect the shaft, a shaft sleeve (2) is installed. Locking rings or ancillary
glands (3) hold the packing in place. The gland press (4) compresses the
packing by way of screw fittings. Correct functioning demands careful
assem-bly and commissioning.
Item Name
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1 Washer
2 Shaft
3 Packing gland packing
4 Locking ring
5 Packing gland press
6 Stud bolt with
hexagonal nut
7 Shaft sleeve
8 Housing cover
• Only tighten up the gland press after a run-in time of about 20-30
minutes with leakage of 50-100 drops per minute
• Adjust the gland to the required leakage rate of 3 drops per minute
3 2 4 1
Floating ring seals are contact seals which create a yielding seal connection
between stationary and rotating contact faces. Between the contact faces is a
film of liquid, which assumes a stable position due to the centrifugal force
occurring during rotation. The floating ring seal is sealed against the housing
by means of static elastomer seals (1). The floating ring (2) rotating with the
shaft is held axially in place relative to the counter-ring (4) fixed in the housing
by a spring (3). The contact faces thus automatically adjust axially. Even high
pressures can be controlled by means of hydraulic relief.
Procedure for replacing the floating ring seal on a centrifugal pump shown
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below:
• Shut down the pump
• Open the pump cover (1)
• Slacken the impeller nut (2)
• Detach the impeller (3) from the shaft
• Remove the floating ring (4) from the shaft
• Pull the counter-ring (5) out of the housing using a suitable implement
• Assemble in the reverse order of removal
1 4
3
5
2
In view of the wide range of floating ring seal designs and pump versions,
methods of removal and fitting vary. The principle illustrated here is that
appli-cable to the most frequently used centrifugal pump.
The piston rod sealing in oscillating motions of the piston rods and
plungers of the piston pumps is achieved by using packing glands, lipped
rings, grooved rings (1) and conical rings held in support rings (2). The
design and materials must always be selected to match the given operating
conditions. Spring-loaded (3) seals, for example, offer uniform pre-tension,
low friction and so longer service lives.
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3 1 2
The method of removal and fitting depends on the specific pump version
and design. The manufacturers’ fitting instructions are useful in this context,
and should be followed.
The same is true of the piston seals. Replacing piston rings and piston
sleeves forms part of the essential scheduled repair routine. Some design
variants are shown in Fig. 3.25.
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Piston with hemp stricks Piston with leather/rubber Piston with metal seal
sleeves rings
3.7.3 Valves
Weighted with conical Spring-loaded with flat Spring-loaded with flat seat
seat seat and seal ring
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The details shown in Fig. 3.29 need to be quoted to the supplier when
order-ing spares, so as to ensure the correct parts are supplied:
1. Pump model
2. Serial number
3. Part name
4. Item number on parts list
Fig. 3.29 Information for spare parts ordering, e.g. identified from rating plate, parts
drawing or parts list
4.1 Description
Gear pumps are rotary positive displacement pumps, which operate on the
positive displacement principle.
They have a clear design and are easy to handle. Gear pumps can
generate operating pressures of up to 40bar and delivery flows of up to 60
3
m /h. Their pulse-free delivery flow increases linearly with the speed. High-
viscosity media (oils, paints, adhesives, etc.) can also be pumped.
Gear pumps are sensitive to hard solid particles in the flow. The stainless
steel material used in the construction of the pump presented here make it
resistant to most corrosive and aggressive chemicals. The plastic / metal
gear wheel pairing results in relatively quiet running.
The gear pump is powered by the drive shaft located below it. The PTFE gear
wheel located above is carried along by the lower stainless steel gear wheel.
Fig. 4.3 Clockwise rotation of drive shaft – right-hand fitting is intake fitting
4.3 Layout
The layout of the gear pump is shown in the drawings. The pump consists
of the following assemblies:
• Bearing flange, closed (1)
• Housing (2)
• Bearing flange, shaft (3)
• Driven shaft (4)
• Drive shaft (5)
• Floating ring seal (7)
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The shafts have a floating design in PTFE plain bearing bushes using wear
discs.
The gear wheels are fastened to the shafts with a feather key and snap ring.
The two bearing flanges are fastened to the housing with through bolts.
O-rings are used to seal the housing.
The shaft seal takes the form of a floating ring seal.
1 3
2
7
Fig. 4.4 Exploded drawing with gear pump assemblies
4 Technical description Gear pump 48
11/2008
• Pump materials:
Housing: Stainless steel 316 (1.4401)
Gear wheels: Stainless steel 316 (1.4401)/PTFE
Wear discs: PTFE
Bearings: PTFE
• Speed-dependent viscosity:
n=300rpm: 10000mPas
n=1750rpm: 3000mPas
11/4" BSPT
105,8
35
54
ø15,7
32 66,6
190 81 ø7,1
265 101,6
Tools:
• Combination wrench, size 11
• Hexagon socket wrench SW 3/32”
• Screwdriver
11
2
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Item Name
10
2 Bearing flange, closed
11 Locking pin
10
11
Bearing flange,
closed
(2)
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Locking pin
(11)
Bearing flange,
closed
(assembly unit 1)
16
Germany11/2008
1
Barsbüttel,
15 Item Name
1 Housing
Gerätebau,
16 O-ring
15 Housing pin
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15
16
Housing
(1)
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O-rings
(16)
Housing pins
(15)
Assembly unit 2
11
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10
Item Name
3 Bearing flange, shaft
10 Plain bearing bush
3
11 Locking pin
3
10
11
Locking pin
(11)
Bearing flange,
shaft
(assembly unit 3)
9 17
23
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Item Name
6 Driven shaft
17 Feather key
9 Driven gear
23 Snap ring
6 9
17
23
Feather key
(17)
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Driven gear
(9)
Driven shaft
(assembly unit 4)
8 17
5
23
Item Name
5 Drive shaft
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17 Feather key
8 Driving gear
23 Snap ring
8
5
17 23
Drive shaft
(5)
Feather key
(17)
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Driving gear
(8)
Assembly unit 5
20 22 21 13
5
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1 2 3
Item Name
1 Assembly unit 1
2 Assembly unit 2
3 Assembly unit 3
4 Assembly unit 4
5 Assembly unit 5
13 Wear disc
21 Hexagon screw
22 Spring washer
20 Hexagon nut
2 3
4
13
21 20
22
Housing
(assembly unit 2)
Drive shaft
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(assembly unit 5)
Driven shaft
(assembly unit 4)
Wear disc
(13)
Bearing flange,
closed
(assembly unit 1)
Bearing flange,
shaft
(assembly unit 3)
Hexagon
screw fitting
(20, 21, 22)
Housing
• Slide one wear disc (13) over each end of the shaft with the smooth side
towards the gear into the housing. The cut sides point towards one
another.
• Place the closed bearing flange (assembly unit 1) onto the left side of the
housing (1). Carefully insert the shaft ends into the floating bearing bushes
(10) without sliding the shaft out of the housing. The housing pins (15)
engage in the holes in the bearing flange.
• Place the shaft bearing flange (assembly unit 3) onto the right side of the
housing (1). Carefully insert the shaft ends into the floating bearing bushes
(10) without sliding the shaft out of the housing. The continuous bearing
bush is placed over the long end of the shaft. The housing pins (15)
engage in the holes in the bearing flange.
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• Run the four hexagon screws (21) through the holes in the bearing
flange and the housing and fit with spring washers (22) and hexagon
nuts (20). Tighten the screws crosswise.
18 4
14
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12
7 19, 22
Item Name
1 Housing assembly 6
12 Solid ring
14 Housing seal
4 Seat ring
19 Hexagon screw
22 Spring washer
7 Screw plug
Teflon strip
12
14
18
22 19 4
Housing
Housing seal
(14)
Solid ring
(12)
Seat ring
(4)
Hexagon
screw fitting
(19, 22)
Teflon tape
Screw plug
(7)
Gear pump
5 Assembly and dismantling Gear pump 70
11/2008
Hexagon screw on floating ring seal Tightening the floating ring seal
• Slide a housing seal (14) onto each side of the solid ring (12).
• Slide the solid ring (12) over the shaft against the shaft bearing flange (3).
• Slide the seat ring (4) over the shaft and solid ring (12) against the shaft
bearing flange (3).
• Screw the seat ring against the bearing flange with hexagon screws (19)
and spring washer (22). Tighten the screws uniformly.
• Wind two to three layers of Teflon tape around the thread of the screw
plugs (7).
• Twist the screw plugs (7) into the threaded hole on the shaft bearing
flange and tighten lightly.
Tools:
• Combination wrench, size 11
• Hexagon socket wrench SW 3/32”
• Screwdriver
• Loosen the hexagon screws (19) and spring washer (22) and uniformly
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• Loosen the four hexagon screw fittings (20, 21, 22) and remove the
hexagon screws from the bearing flange and housing holes.
• Carefully detach the shaft bearing flange (assembly unit 3) from the right
side of the housing with a screwdriver. Remove assembly unit 3 from the
shaft.
• Carefully detach the closed bearing flange (assembly unit 1) from the left
side of the housing with a screwdriver. Remove assembly unit 1 from the
shaft.
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• Remove the wear discs (13) from the ends of the shaft.
• Remove the driven shaft (assembly unit 4) from the upper half of the
housing (assembly unit 2).
• Remove the drive shaft (assembly unit 5) from the lower half of the
housing (assembly unit 2).
• Prise the two snap rings (23) out of the groove with a screwdriver and
remove from the relevant end of the shaft.
• Remove the driving gear (8) from the drive shaft (5) and feather key (17).
• Remove the feather key (17) from the groove on the drive shaft (5).
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• Prise the two snap rings (23) out of the groove with a screwdriver and
remove from the relevant end of the shaft.
• Remove the driven gear (9) from the shaft (6) and feather key (17).
• Remove the feather key (17) from the groove on the shaft (6).
• Remove the plain bearing bush (10) from the shaft bearing flange (3).
• Remove the locking pin (11) from the groove.
• Repeat this procedure for the second bearing bush
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• Carefully remove the two O-rings (16) from the ring grooves in the housing
(1) with a screwdriver. If the O-rings are to be re-used, make sure that
they are in sound condition.
• Remove the four housing pins (15) from the relevant holes on the front of
the housing (1).
Housing dismantled
• Remove the plain bearing bush (10) from the closed bearing flange (2).
• Remove the locking pin (11) from the groove.
• Repeat this procedure for the second bearing bush
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6 Tasks
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembling the gear pump
Worksheet 10 Changing the floating ring seal
Worksheet 11 Parts identification using the parts drawing
Worksheet 12 Spare parts ordering
6 Tasks 78
11/2008
6 Tasks 79
11/2008
6 Tasks 80
11/2008
Objective:
To obtain an overview of the design and function of the gear pump.
Exercise:
You are provided with an assembled pump. Dismantle the pump so that all
the component parts are laid out before you.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Take the pump drawings and the associated parts list. Locate the actual
components in the drawing.
Refer to the parts list to identify the correct names of the components.
6 Tasks 81
11/2008
Worksheet 1, page 2
You are now familiar enough with the overall design of the pump to be able
to answer the following questions:
1. How is the lead-through of the free end of the shaft sealed on this pump?
6 Tasks 82
11/2008
Objective:
To explain the design of the pump. To understand and describe its method
of operation and usage.
Exercise:
1. Describe the design of the pump.
Use the drawings.
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6 Tasks 83
11/2008
Worksheet 2, page 2
6 Tasks 84
11/2008
Objective:
To identify or suspect likely causes of faults in response to specific
malfunctions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table below. Note down your
assumptions in the right-hand section of the table.
You can exclude system-related disturbances.
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6 Tasks 85
11/2008
Objective:
To divide sealing systems into basic categories and identify them based on
the example of the gear pump.
Information on classification of sealing systems
Sealing systems
Exercise:
1. Here you see the sectional drawing of the pump.
In the sectional drawing, mark the static seals as S and the dynamic
seals as D.
What respective functions do they perform?
6 Tasks 86
11/2008
Worksheet 4, page 2
Once you have identified the sealing systems used in the gear pump, move
on to the following exercise.
2. Describe the design and method of operation of a shaft seal based on
the floating ring principle.
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3. The drawing below represents a shaft seal based on the packing gland
principle. Describe the design and function of this shaft seal.
6 Tasks 87
11/2008
Objective:
To know what the term “inspection” involves, and to draw up an inspection
plan.
Exercise:
1. What does the term “inspection” mean in the context of technical
maintenance?
Mark the statements you consider to be true or false in the Yes or No
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Activity Yes No
The object of servicing is to record and assess the current actual status of a
pump
Components such as impellers or seals are replaced as a preventive
measure
Shaft bearings are lubricated and couplings re-aligned
During an inspection, operating data for the pump system is measured (read)
and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair
6 Tasks 88
11/2008
Worksheet 5, page 2
When you have established what the term “inspection” means, move on to
the following exercise.
2. Imagine you are discussing a large gear pump which is of crucial
importance to the operation of a refinery.
Let us also assume that this large pump is similar in design to the small
pump from our MT 186 exercise project.
Draw up an inspection plan to be used to document/log an inspection
carried out.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Inspection plan/log
Item Comments
6 Tasks 89
11/2008
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technical
maintenance?
Mark the statements you consider to be true or false in the Yes or No
column of the following table as appropriate.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Activity Yes No
Components such as impellers, shaft seals and other seals are replaced as
a preventive measure
The object of servicing is to record and assess the current actual status of a
pump
Servicing of a pump is a routine operation, carried out at predefined intervals
6 Tasks 90
11/2008
Worksheet 6, page 2
When you have established what the term “service” means, move on to the
following exercise.
2. Do you think that routine servicing is useful and necessary for the gear
pump from our MT 186 kit?
Give reasons for your decision.
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3. Let us assume that two gear pumps with the conventional differing shaft
seals are being used in a chemical process. What servicing operations
need to be carried out on the packing gland type shaft seal and on the
floating ring seal?
6 Tasks 91
11/2008
Objective:
To know what is meant by the term “repairs” in this context and to draw up
a preventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technical
maintenance? Mark the statements you consider to be true or false in
the Yes or No column of the following table as appropriate.
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Activity Yes No
Repair involves replacing well-used parts with new ones: e.g. impellers,
seals
Repairs are carried out when damage has occurred to the pump
6 Tasks 92
11/2008
Worksheet 7, page 2
Once you have established what the term “repairs” means, move on to the
following exercise.
2. Let us assume that our gear pump is a key component in a chemical
process, where a failure of the pump would shut down the entire system.
In view of this, the pump is inspected and serviced at regular intervals.
To achieve an absolutely reliable operating condition, the plant
management decides to carry out routine preventive repairs on the unit.
Draw up a repair plan / order to be used as a basis for carrying out and
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Repair plan/order
Procedure Comments/Status
Parts to be replaced:
Parts to be checked:
6 Tasks 93
11/2008
Objective:
To identify the wearing parts on the gear pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them.
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2. Of what material are the wearing parts of the gear pump made? Enter
the wearing parts you have identified in the table along with the relevant
material.
6 Tasks 94
11/2008
Objective:
To structure the assembly process. To identify which assembly units can be
put together before overall assembly is carried out.
Exercise:
You have laid out all the component parts of the gear pump in front of you.
Your task is to assemble the gear pump.
First of all, individual assembly units are pre-assembled, and are then
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
6 Tasks 95
11/2008
Worksheet 9, page 2
•
Item Name
Item Name
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Item Name
Item Name
Item Name
6 Tasks 96
11/2008
Worksheet 9, page 3
2. Once you have put together the various assembly units, the next step is
to assemble the body of the pump.
In doing this, set out the procedure in a structure as shown in the
schematic diagram.
Assembly of the floating ring seal should not yet be documented.
Assembly unit 2
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(Housing)
Parts x, y, ...
Parts x, y, ...
Pump housing
6 Tasks 97
11/2008
Worksheet 9, page 4
Assembly unit 2
(Housing)
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Pump housing
6 Tasks 98
11/2008
Objective:
Planning and carrying out a change of floating ring seal on the gear pump.
Exercise:
1. Your task is to change the floating ring seal on the gear pump.
Set out your planned method in the pre-compiled work plan. Use the
drawings.
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6 Tasks 99
11/2008
6 Tasks 100
11/2008
6.11 Worksheet 11, page 1: Part identification using spare parts drawing,
familiarity with technical terms
Objective:
To assign items from a spare parts list to a spare parts drawing.
Exercise:
You will be given a spare parts drawing without item numbers.
Refer to the supplied spare parts list. Enter the item numbers specified in
the first column in the relevant fields on the spare parts drawing.
11/2008
Standard
6 Tasks 101
11/2008
6 Tasks 102
11/2008
Objective:
Identifying technical data for clear spare parts ordering.
Exercise:
You are going to carry out a repair, and need spare parts for your gear pump.
Select three parts you suspect are worn. Note the technical information for
these three parts that is necessary for a clear spare parts order.
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Spare part:
6 Tasks 103
11/2008
7 Solutions
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembling the gear pump
Worksheet 10 Changing the floating ring seal
Worksheet 11 Parts identification using the parts drawing
Worksheet 12 Spare parts ordering
7 Solutions 104
11/2008
7 Solutions 105
11/2008
7 Solutions 106
11/2008
Objective:
To obtain an overview of the design and function of the gear pump.
Exercise:
You are provided with an assembled pump. Dismantle the pump so that all
the component parts are laid out before you.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Take the pump drawings and the associated parts list. Locate the actual
components in the drawing.
Refer to the parts list to identify the correct names of the components.
7 Solutions 107
11/2008
Worksheet 1, page 2
You are now familiar enough with the overall design of the pump to be able
to answer the following questions:
1. How is the lead-through of the free end of the shaft sealed on this
pump? With a floating ring seal.
7 Solutions 108
11/2008
Objective:
To explain the design of the pump. To understand and describe its method
of operation and usage.
Exercise:
1. Describe the design of the pump.
Use the drawings.
The shafts have a floating design in PTFE plain bearing bushes using
wear discs.
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The gear wheels are fixed to the shafts with a feather key and snap
ring. The two bearing flanges are secured to the housing with through
bolts. O-rings are used to seal the housing.
The shaft seal takes the form of a floating ring seal.
7 Solutions 109
11/2008
Worksheet 2, page 2
7 Solutions 110
11/2008
Objective:
To identify or suspect likely causes of faults in response to specific
malfunctions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table below. Note down your
assumptions in the right-hand section of the table.
You can exclude system-related disturbances.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
7 Solutions 111
11/2008
Objective:
To divide sealing systems into basic categories and identify them based on
the example of the gear pump.
Information on classification of sealing systems
Sealing systems
Exercise:
1. Here you see the sectional drawing of the pump.
In the sectional drawing, mark the static seals as S and the dynamic
seals as D.
What respective functions do they
perform? The static seals seal the housing.
The dynamic seals seal the shaft feed-through.
D S D
7 Solutions 112
11/2008
Worksheet 4, page 2
Once you have identified the sealing systems used in the gear pump, move
on to the following exercise.
2. Describe the design and method of operation of a shaft seal based on
the floating ring principle.
Floating ring seals are contact seals which create a yielding seal
connection between stationary and rotating contact surfaces. Between
the contact surfaces is a film of liquid, which assumes a stable position
due to the centrifugal force occurring during rotation. The floating ring
seal is sealed against the housing using static elastomer seals. The
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floating ring rotating with the shaft is held axially in place relative to the
counter ring fixed in the housing by a spring.
3. The drawing below represents a shaft seal based on the packing gland
principle. Describe the design and function of this shaft seal.
7 Solutions 113
11/2008
Objective:
To know what the term “inspection” involves, and to draw up an inspection
plan.
Exercise:
1. What does the term “inspection” mean in the context of technical
maintenance?
Mark the statements you consider to be true or false in the Yes or No
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Activity Yes No
The object of servicing is to record and assess the current actual status of a X
pump
Components such as impellers or seals are replaced as a preventive X
measure
During an inspection, operating data for the pump system is measured (read) X
and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair X
7 Solutions 114
11/2008
Worksheet 5, page 2
When you have established what the term “inspection” means, move on to
the following exercise.
2. Imagine you are discussing a large gear pump which is of crucial
importance to the operation of a refinery.
Let us also assume that this large pump is similar in design to the small
pump from our MT 186 exercise project.
Draw up an inspection plan to be used to document/log an inspection
carried out.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Inspection plan/log
Item Comments
Pump capacity
Delivery pressure
Leakage
Noise
Smooth running
Temperature
General condition
7 Solutions 115
11/2008
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technical
maintenance?
Mark the statements you consider to be true or false in the Yes or No
column of the following table as appropriate.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Activity Yes No
Components such as impellers, shaft seals and other seals are replaced as X
a preventive measure
The object of servicing is to record and assess the current actual status of a X
pump
Servicing of a pump is a routine operation, carried out at predefined intervals X
A service is usually carried out with the system stopped X
7 Solutions 116
11/2008
Worksheet 6, page 2
When you have established what the term “service” means, move on to the
following exercise.
2. Do you think that routine servicing is useful and necessary for the gear
pump from our MT 186 kit?
Give reasons for your decision.
Yes! Servicing checks the condition of the wearing parts. On the gear
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pump from the MT 186 these are the floating ring seal, the housing
seals, the bearing bushes and the wear discs. Damaged wearing parts
are replaced.
3. Let us assume that two gear pumps with the conventional differing shaft
seals are being used in a chemical process. What servicing operations
need to be carried out on the packing gland type shaft seal and on the
floating ring seal?
Packing glands must be repositioned depending on the leakage rate.
Their general condition must be checked and they must be repacked as
necessary.
Floating ring seals do not have to be adjusted. However, their condition
must be checked at each service. Preventive replacement of the floating
ring seal is advisable if very high reliability is required for operation of the
pump.
7 Solutions 117
11/2008
Objective:
To know what is meant by the term “repairs” in this context and to draw up
a preventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technical
maintenance? Mark the statements you consider to be true or false in
the Yes or No column of the following table as appropriate.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Activity Yes No
Repair involves replacing well-used parts with new ones: e.g. impellers, X
seals
Repairs are carried out when damage has occurred to the pump X
Repairs may also be carried out as routine and preventive measures to X
prevent damage and stoppages from occurring in the first place
Entire pump units are replaced X
7 Solutions 118
11/2008
Worksheet 7, page 2
Once you have established what the term “repairs” means, move on to the
following exercise.
2. Let us assume that our gear pump is a key component in a chemical
process, where a failure of the pump would shut down the entire system.
In view of this, the pump is inspected and serviced at regular intervals.
To achieve an absolutely reliable operating condition, the plant
management decides to carry out routine preventive repairs on the unit.
Draw up a repair plan / order to be used as a basis for carrying out and
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
Repair plan/order
Pump: Inspected by:
Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Floating ring seal (18)
Solid ring (12)
Housing seal (14)
Wear discs (13)
Plain bearing bush (10)
Locking pin (11)
Driven gear (9)
O-ring (16)
Parts to be checked:
Housing components
Driving gear
Shafts
7 Solutions 119
11/2008
Objective:
To identify the wearing parts on the gear pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them.
Housing seal
2. Of what material are the wearing parts of the gear pump made? Enter
the wearing parts you have identified in the table along with the relevant
material.
7 Solutions 120
11/2008
Objective:
To structure the assembly process. To identify which assembly units can be
put together before overall assembly is carried out.
Exercise:
You have laid out all the component parts of the gear pump in front of you.
Your task is to assemble the gear pump.
First of all, individual assembly units are pre-assembled, and are then
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
7 Solutions 121
11/2008
Worksheet 9, page 2
• Assembly unit 1 – Bearing flange, closed
Item Name
2 Bearing flange, closed
10 Plain bearing bush
11 Locking pin
1 Housing
16 O-ring
15 Housing pin
7 Solutions 122
11/2008
Worksheet 9, page 3
2. Once you have put together the various assembly units, the next step is
to assemble the body of the pump.
In doing this, set out the procedure in a structure as shown in the
schematic diagram.
Assembly of the floating ring seal should not yet be documented.
Assembly unit 2
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(Housing)
Parts x, y, ...
Parts x, y, ...
Pump housing
7 Solutions 123
11/2008
Worksheet 9, page 4
Assembly unit 2
(Housing)
Assembly unit 5
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(Drive shaft)
Assembly unit 4
(Driven shaft)
Wear disc
(13)
Assembly unit 1
(Bearing flange,
closed)
Assembly unit 3
(Bearing flange,
shaft)
Hexagon
screw fitting
(20, 21, 22)
Pump housing
7 Solutions 124
11/2008
Objective:
Planning and carrying out a change of floating ring seal on the gear pump.
Exercise:
1. Your task is to change the floating ring seal on the gear pump.
Set out your planned method in the pre-compiled work plan. Use the
drawings.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
7 Solutions 125
11/2008
Dismantling
1 Loosen hexagon screws (19) and spring washer (22) and uniformly screw out of Combination
shaft bearing flange (3). wrench 11
2 Remove seat ring (4) from drive shaft (5) and solid ring (12).
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3 Remove solid ring (12) with housing seal (14) from drive shaft (5).
4 Remove housing seal (14) from solid rind and bearing flange.
5 Loosen screw plugs (7) and twist out of threaded hole on shaft bearing flange. Combination
wrench 11
6 Turn shaft manually until the hexagon screws for the floating ring seal (18) are Hexagon
visible through the threaded hole for the screw plug (7). Loosen all four screws. socket wrench
7 Carefully slide floating ring seal out of bearing flange with a slotted screwdriver Slotted
through screw plug hole. Remove the floating ring seal from the shaft. screwdriver
Assembly
8 Slide the floating ring seal (18) over the shaft into the shaft bearing flange (3) until
the hexagon screw is visible through the threaded hole for the screw plug (7).
9 Tighten the screw with the hexagon socket wrench. Turn the shaft manually until Hexagon
the other hexagon screws are visible. Tighten to fasten the floating ring seal on socket wrench
the shaft.
10 Slide a housing seal (14) onto each side of the solid ring (12).
11 Slide the solid ring (12) over the shaft against the shaft bearing flange (3).
12 Slide the seat ring (4) over the shaft and solid ring (12) against the bearing flange
(3).
13 Screw the seat ring against the bearing flange with hexagon screws (19) and Combination
spring washer (22). Tighten the screws uniformly. wrench 11
14 Wind two to three layers of Teflon tape around the thread of the screw plugs (7). Teflon tape
15 Twist the screw plugs (7) into the threaded hole on the shaft bearing flange and Combination
tighten lightly. wrench 11
7 Solutions 126
11/2008
7.11 Worksheet 11, page 1: Part identification using spare parts drawing,
familiarity with technical terms
Objective:
To assign items from a spare parts list to a spare parts drawing.
Exercise:
You will be given a spare parts drawing without item numbers.
Refer to the supplied spare parts list. Enter the item numbers specified in
the first column in the relevant fields on the spare parts drawing.
11/2008
Standard
7 Solutions 127
11/2008
1018
13
17
16
9
23
7 Solutions 128
11/2008
Objective:
Identifying technical data for clear spare parts ordering.
Exercise:
You are going to carry out a repair, and need spare parts for your gear pump.
Select three parts you suspect are worn. Note the technical information for
these three parts that is necessary for a clear spare parts order.
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
7 Solutions 129
11/2008
8 Index
A
C
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 8, 29
Centrifugal pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
Characteristic curve, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Characteristic curve, system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
D
Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 11, 30
Dynamic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F
Floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 48
G
Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14, 32, 46, 52
Gear pump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Gear pump spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Gear pump spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Gear pump technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
H
Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Index 130
11/2008
I
Inline centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13, 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Intake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Multi-flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multiple-stage pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multi-stage centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
O
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Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
P
Packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Parallel configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 12, 31
Piston rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 41
Piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Positive-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14
Pump characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump, multi-flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
R
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 34
Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S
Screw pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 10, 30
Seals, dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seals, floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 48
Seals, packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Seals, static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Series configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Standard centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Index 131
11/2008
Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
V
Valves in pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 11/2008
8 Index 132
11/2008
9 Drawings
9 Drawings 133