Double suction centrifugal split case pumps

Installation and operation instructions

series: DPAS
 EC declaration of conformity

DP-Pumps
Kalkovenweg 13
2401 LJ Alphen aan den Rijn, The Netherlands
Tel: (+31)(0)-172-48 83 88

Hereby declares as manufacturer entirely on his own responsibility, that the products:

Vertical single-stage centrifugal pumps, series: DPNL

Horizontal single-stage centrifugal pumps, series: DPNT and DPNM
Horizontal single-stage split case pumps, series: DPAS

to which this declaration refers, are in accordance with the following standard: EN 809/A1 according to the
provisions of the harmonized standard for pumps and which implies the regulations of Machine Directive
2006/42/EC, EMC Directive 2004/108/EC, Ecodesign Directive 2009/125/EC, Regulation 547/2012 (for
water pumps with a maximum shaft power of 150kW) in the most recent form.

The pump is subject to this declaration of conformity as a stand-alone product. An installation in which the
pump is built in must be declared as compliant to all relevant regulations and standards for the complete
assembly.

Alphen aan den Rijn

14/02/2013

Authorized representative
W. Ouwehand, technical director

2
Table of contents
1 Introduction .......................................................................................... 5
2 Safety precautions............................................................................... 6

3 General ................................................................................................. 7
3.1 Definition of pump and applications ............................................................................ 7
3.2 Performance information ............................................................................................. 7
3.3 Warranty conditions .................................................................................................... 7
3.4 Test ............................................................................................................................. 7
3.5 Pressure limit .............................................................................................................. 7

4 Safe operating conditions ................................................................... 8

4.1 Training of personnel .................................................................................................. 8
4.2 Hazardous conditions that may occur when one does not comply with the safety
instructions .................................................................................................................. 8
4.3 Safety measures for operator ...................................................................................... 8
4.4 Safety measures for maintenance and installation ...................................................... 8
4.5 Spare parts replacement ............................................................................................. 8

5 Technical information ......................................................................... 9

5.1 Design ......................................................................................................................... 9
5.2 Construction of pump group .......................................................................................... 9

6 Transport and storage ....................................................................... 10

6.1 Transport ................................................................................................................... 10
6.2 Storage ..................................................................................................................... 10

7 Assembly / installation ...................................................................... 11

7.1 Installation ................................................................................................................. 11
7.2 Foundation method ................................................................................................... 11
7.3 Foundation ................................................................................................................ 11
7.4 Coupling alignment ................................................................................................... 12
7.5 Piping ........................................................................................................................ 13
7.6 Motor connection....................................................................................................... 15

8 Commissioning, start up and operating ............................................. 16

8.1 Preparations before start-up....................................................................................... 16
8.2 Checking rotation direction ........................................................................................ 16
8.3 Start-up procedure .................................................................................................... 16
8.4 Shut down procedure ................................................................................................ 17

9 Maintenance ....................................................................................... 18

9.1 Checks during operation ........................................................................................... 18
9.2 Service ...................................................................................................................... 19
9.3 Spare Parts ............................................................................................................... 19 3

10 Noise level and vibration .................................................................. 20

10.1 Expected noise values .............................................................................................. 20

11 Disassembly, repair and reassembly ............................................... 21

11.1 Disassembly .............................................................................................................. 21
11.2 Reassembly .............................................................................................................. 21

12 Possible failures, causes, solutions ................................................ 22

 13 Pump dimensions table and weights ............................................... 23

14 Tightening torques ............................................................................ 24

15 Forces and moments at the pump flanges ...................................... 25

16 Sample pipework ............................................................................... 26

17 DPAS series pump - sectional drawing and parts list .................... 27

18 DPAS series pump - exploded view ................................................. 28

4
1 Introduction
This manual contains instructions for the The signs used in this operating manual
installation, operation and maintenance
of the DPAS series non-self-priming Read the instructions carefully in this
centrifugal split case pumps from operating manual and store it for future
DP-Pumps. reference.

x Please read carefully this manual and apply

all the instructions to operate pumps without
problems. Pumps shall be used for their Warning sign against electrical risks.
intended duties. In this manual, there are
information on operating conditions,
installation, starting-up, settings and main
controls of pumps. Sign for the operator’s safety.
x These operating and maintenance
instructions contain DP-Pumps’ suggestions.
The special operating and maintenance
information of the plumbing that a pump is
fitted to is not considered in these
instructions. This information must be given
by plumbing constructors only.
x Please refer to instructions of plumbing
constructors.
x Please pay attention to the warnings in this
manual and ensure that it is read before the
installation-start up process. DP-Pumps is
not responsible for the accidents resulting
from negligence.
x If you cannot find an answer to your
questions in this manual, it is suggested that
you contact DP-Pumps. Please inform us
about the rated value and especially the
serial number of the pump when you get in
contact for help.
x The safety instructions in this manual cover
the current national accident protection
regulations. Beside all of these, an operation,
work and safety measure imposed by the
costumer has to be applied.

5
 2 Safety precautions
In order to minimize the accidents during 19. If the pump contains hazardous liquids, one
the mounting and putting into service of must use protective helmet against the risk of
the pump, the following rules have to be splatter. One also must accumulate the liquid
applied: in a proper container against any risk of
leakage.
1. Do not work without taking safety measures
relevant to equipment. Cable, mask and All other health and safety rules, laws and
safety band must be used when necessary. regulations must be applied.
2. Be sure there is adequate amount of oxygen
and there is no toxic gaseous around
3. Before using welding or any electrical
equipment make sure that there is no risk of
explosion.
4. Check the cleanliness of the area to take
care of your help (dust , smoke, etc.).
5. Do keep in mind that there is a risk of having
accidents related to electricity
6. Do not lift the pump before you check the
transport equipment.
7. Be sure you have a by-pass line
8. Use helmet, eye glasses and protective
shoes for your safety
9. Place a protective barrier around the pump
within the necessary safety area
10. Dust, liquids and gaseous that may cause
overheating, short circuit, corrosion and fire
must be kept away from the pump unit.
11. By checking the noise level of the pump unit ,
necessary measures to avoid noisy operation
of the pump that can have harmful effects on
the personnel and environment.
12. Be careful about the direction of transport
and storage.
13. Cover appropriately the moving parts to
avoid possible injury of the personnel. Mount
the coupling guard and belting before
starting-up the pump.
14. All the electrical and electronic applications
must be performed by authorized person
conforming EN60204-1 and /or domestic
instructions.
15. Protect the electrical equipment and motor
6 against overloading.
16. If flammable and explosive liquids are
pumped, ground connection of electricity
should be carried out properly.
17. Do not expose the pump unit to sudden
temperature variations.
18. All personnel who work with the waste water .
system need to be vaccinated in case of
contagious diseases.
3 General
3.1 Definition of pump and 3.2 Performance information
applications
Actual performance of the pump can be obtained
DPAS series pumps are horizontal split case from the order page and/or from the test report.
pumps and are used in: This information is given on the pump label.
x Irrigation pump stations, The performance curves given in the catalogue
x Cooling water and circulation circuits are valid for water whose density and viscosity are
x Tap water pump stations ȡ=1 kg/dm3 and Ȟ=1 cst. respectively. For those
x Oil transmission pipeline stations, liquids whose densities and viscosities are
x Various pumping stations for general different from those of water, please consult with
purpose. DP-Pumps since the performance curves vary
with density and viscosity.
DPAS pumps must be used to transfer non-
abrasive and non-flammable, clean liquids (up to CAUTION
90°C ) which do not contain large solid particles. Do not operate the pump with a motor
that has a different power except for
CAUTION the given catalog and label values.
Please contact DP-Pumps for liquids
that have different chemical and The pump is not to be operated at off-design point
physical specifications. given in the order and supplied from the firm.
It is necessary to ensure that the instructions are
Technical specifications of DPAS type pumps obeyed for the safe running of the pump.
Suction Flange DN 80-DN 400
Discharge Flange DN 65-DN 350 3.3 Warranty conditions
Operating Pressure 16-20 Bar
Capacity 30-3000 m3/hour The entire products in our selling program are
Head 15-160 m warranted by DP-Pumps. The warranty period is
Speed 960-3600 rpm 24 months after delivery.

Pump Label Warranty conditions will only be valid when all the
instructions about installation and start-up
operations of the pump unit are taken into
account.

3.4 Test

All Pumps are dispatched for sale when all the

performance and pressure tests are completed.
Proper assurance of material and fault-free
operation of pumps whose performance tests are
made is under the warranty of DP-Pumps.
7
3.5 Pressure limit

Pressure at the discharge flange must

not exceed 150% of the pump’s head.
4 Safe operating conditions
This manual contains main safety instructions for 4.3 Safety measures for
the installation, operation and maintenance.
operator
It must be read by the personnel who are
responsible for installation and operation.
Dangerous, hot or cold components in the pump
This manual should always be kept near the
area must be covered so that one cannot touch
installation location. It is important to comply with
them.
safety precautions stated in page 1 along with the
Moving components of the pump (such as
general safety instructions as well as preventive
coupling) must be covered so that one cannot
measures repeated in other sections of this
touch them. Those covers must not be
manual.
dismounted while the pump is running. Dangers
that results from electrical connections must be
4.1 Training of personnel removed. To get more information about this
subject, you can refer to VDE and domestic
Installation, operation and maintenance personnel electrical instructions.
must have necessary knowledge in order to
accomplish the given job. The responsibility,
4.4 Safety measures for
adequacies and controlling duties of such
personnel must be determined by the costumer. It maintenance and
has to be certain that these personnel installation
comprehend totally the content of the operating
manual. The costumer must assure that all maintenance,
If the personnel do not have enough knowledge, check and instalment tasks are performed by
required training must be given by the costumer. If qualified personnel. Repair work must only be
training support is needed by the costumer, it will performed while the machine is not running.
be provided by the manufacturer/seller The pump and its auxiliary system must be
cleaned thoroughly if it contains hazardous liquids.
CAUTION At the end of the repair work, all safety and
Untrained personnel and protective equipment must be re-installed.
unwillingness to comply with safety
instructions may be risky for both 4.5 Spare parts replacement
machine and environment. DP-Pumps
is not responsible for this kind of Replacement of spare parts and all modifications
damages. must be done after contacting with the
manufacturer. Spare parts and accessories
4.2 Hazardous conditions that certified by the manufacturer are important for the
may occur when one does safe operation of the system.
not comply with the safety
Notice: DP-Pumps is not responsible for using of
instructions improper spare parts.

Incompliance with safety regulations may put the

personnel, the environment and the machine in
danger and thus may cause damages. 8
Incompliance with safety regulations may give rise
to situations listed below

Important operational functions of the factory

may stop.
Maintenance may get difficult.
One may get injured by electrical, mechanical
or chemical hazards.
5 Technical information
5.1 Design Since the impeller is double suction type, the axial
force balances automatically. To prevent the
DPAS pumps are double suction, horizontal split leakage flow into bearing housing, there are
case pumps. Since the upper cover of the pump is deflectors in front of the bearing covers.
removable, all internal components can be easily
replaced without disassembling the pump from the 5.1.6 Seals
piping.
Stuffing box is cooled with water. Seals are easily In DPAS type pumps gland squeezed, Teflon knit
dismountable, which makes replacing and fitting soft packing are used. There is a lantern ring in
up additional seals easy. Since the impeller is a the stuffing box.
double suction type, the axial force is balanced x Non-cooled packing is standard. (It is
automatically. acceptable up to 90°C ).
See Figure 11: Design with soft packing.
5.1.1 Locations of flange – flanges
5.2 Construction of pump group
Pumps have normally clockwise rotation when
viewed from the driver side. In this case, suction 5.2.1 Drive
opening is on the right and discharge opening is on
the left. Suction and discharge flanges are A hermetic, 3 phase, fan cooled, squirrel caged in
concentric. Suction and discharge flanges are in according to DIN 42673-IM 1001B3 type electrical
accordance with DIN 2533-PN 16. It is possible to motor which complies with DIN IEC and VDE is used
manufacture pumps with counter clockwise rotation. to drive the pump in proper speed and power.
Specifications of electrical motor
5.1.2 Auxiliary fittings Isolation class F
Protection class IP 54-IP 55
Please refer to the technical drawing of the pump Frequency 50 Hz.
for necessary auxiliary fittings. Running type S1
Start-up type
5.1.3 Impeller x 3x380 V(Y) up to 4 kW
x More than 4 kW, 3x380(ǻ) + (Y/ǻ)
Specially and carefully designed impellers are There is another possible application to drive the
closed type and have Francis type blades. They pump with a diesel engine.
are balanced both statically and dynamically.
5.2.2 Coupling and coupling cover
5.1.4 Shaft
A flexible shaft coupling with or without secondary
The shaft is longer for standard DPAS type pumps component in accordance with DIN 740 is used. A
which have soft packing applications. coupling cover is given in accordance with EN 294
Alternatively, the mechanical seal option may also in case of the pump group includes the coupling
be used. DPAS type pumps are also available with and chassis.
mechanical seal and shorter shaft length.
Pump can only be run with a coupling
5.1.5 Bearing and lubrication guard in accordance with EN 294 9
according to safety instructions.
Rolling bearings are used in DPAS type pumps. If there is no coupling cover, it is
They support radial load caused by the impeller. provided by the operator.
A NU series cylindrical bearing at the motor side
of the pump and a 63-C3 series ball bearing on 5.2.3 Base plate
the other side of the shaft are used. They are all
long life rolling bearings. Rolling bearings are It is manufactured from U profile steel in
lubricated with grease. accordance with DIN 24259.
 6 Transport and storage
Suction, discharge and all auxiliary fittings must be 6.2 Storage
closed during transport and storage. Dead-end
covers must be removed while the pump unit is
being installed. Please keep the unit clean and dry
area during storage.
6.1 Transport
If the pump is out of use for a long time, please
Pump and pump group must be carried safely to consider the instructions below.
the installation location by lifting equipment. 1. If there is water inside the pump, drain it.
2. Clean the pump casing and impeller by
Current general lifting safety jetting clean water for a short time.
instructions must be applied. Please 3. Empty water inside the pump casing, suction
use a suspension system shown in line and discharge line.
figure while you are carrying and 4. Add small amount of antifreeze inside the
lifting the pump unit. The suspension pump casing if it is not possible to empty it
rings may be broken because of the completely. Rotate the pump shaft by hand
excessive load and may result in a to mix the antifreeze.
damage of the pump. Prefer fabric 5. Close the suction and discharge exits with
cable for suspension. gasket
6. Spray an anti-corrosive into the pump casing.
7. Rotate the pump shaft by hand once in every
month, in order to protect it from freezing and
to lubricate the bearings.

Figure 1 Transport of pump group

Incorrect lifting may damage the

pump unit and cause injuries.

Damages caused in transport

Check the pump when it is delivered to you.
Please let us know of there is any damage.

10
7 Assembly / installation
7.1 Installation CAUTION
If base plate is supported from only
In our standard production, the pump and the four points, pump group will stay in
motor have been installed in a common base the middle, causing misalignment of
plate. the coupling and increasing the noise
level.
7.1.1 Location of installation
7.3.3 Foundation Properties
Pump shall be installed in a location where the
control and the maintenance of the pump are The foundation shall be horizontal, flat and clean
easily made. The pump room shall be suitable for and shall support all the weight.
operation of lifting systems such as freight
elevator, forklift, etc. NOTE
The pump group should be installed in the lowest Reinforced concrete bases are
possible location of the pumping system in order constructed from standard concrete
to achieve the highest suction pressure. with at least B 25 resistance class.

7.1.2 Location of installation- local

ambient temperature

When the local ambient room temperature

exceeds +40°C in a pumping system, suitable Mortar

ventilation should be provided in order to remove Base

Key

Mn. 20mm
Mould
the heat dissipated to the environment and supply
fresh air.

7.2 Foundation method

Type of connection depends on the design type

and the size of the pump and the motor, as well as
the local installation conditions. Foot-mounted
horizontal pump-motor units have been installed in
a common base plate.
Leave a min. 20mm space under the base
Leave the surface of the base rough and
7.3 Foundation make wet before applying mortar
Concrete base

7.3.1 General

Base plate of the pump must be grouted. The

foundation shall be of concrete or steel framework.

NOTE 11
The foundation shall distribute the
weight of the pumping group evenly.

7.3.2 Main Properties of the Steel

Framework Bases Figure 2 A typical concrete foundation

Foundations with steel framework shall be

designed in such a way that the base plate is
bolted or welded contacting to all area.
 7.3.4 Fixing (securing) of pump group For alignment, the gauge stick shall be in contact
with both of the halves at the same time.
After the alignment of the pump group on the This procedure shall be repeated for four sides of
foundation has been made, the mutual securing the coupling (i.e., top, bottom, left and right sides
bolt screws should be used alternately to fix the of the coupling). When all four sides give
pump group. reasonably accepted results, alignment of the
All of the area of the base plate should be filled coupling has been ensured.
with gout as much as possible.
2. Angular Misalignment (Figure 5 - 7)
NOTE In order to control the angular misalignment, the
While securing pump group with the distance between the two halves of the coupling is
mortar bonding agents and molding, measured in both horizontal and vertical planes.
one has to make sure that the base Measurements taken at four points shall be in
plate contacts completely with the base agreement for the alignment
with no cavities between the surfaces.
Inside of the chassis (frame) should be Misalignments can be in horizontal or vertical
completely filled with concrete planes. Misalignments in horizontal plane can
be fixed by placing sheet iron at the bottom of
7.4 Coupling alignment the pump or motor base, while misalignments
in vertical plane can be fixed by sliding the
7.4.1 General pump or the motor in horizontal plane.

For a proper operation of a pump group, a good Install the coupling guard only when
alignment of the coupling is necessary. Vibration, the alignment of the coupling is
noise, overheating of the bearings, overcharge checked.
problems can be attributed to the misalignment of
coupling or using an improper coupling.

Flexible coupling does not correct the

axial misalignments between the pump
and the motor axes. However, it allows
pinpointing the misalignments.
In order to avoid overheating, vibration,
noise and wearing of the rolling
bearings, alignment of the coupling has
to be made properly and checked often.
Do not use a different coupling other
than the original type installed on
pumping group.

7.4.2 Method of coupling alignment

In order to make the alignment of the coupling, it is

required to have at least two smooth edged metal
pieces (e.g. a steel ruler or a gauge stick) and one
precision calipers (Figure 3).
12 (For more precision alignments, special apparatus
can be used).
Coupling misalignments in general are of two kinds:

1. Parallel axis misalignment (Figure 4 - 6)

In order to control parallel axis misalignment, a Figure 3 The control of the coupling alignment in
smooth edged gauge stick is pressed axially over horizontal and vertical planes
the upper half of the coupling. Then, the gauge
stick is checked for the other half of the coupling.
Figures below illustrate the possible coupling 7.4.3 Pump and motor mounting
misalignments and the methods to correct them. (coupling)

If the coupling of the pump group is to be mounted

on site, the following procedure should be
followed.

e
1. Coat the shaft tip of the pump and the motor
sides with a sheet of molybdenum disulfide.
2. Push the coupling halves with a driving
e e apparatus towards the pump and the motor
shafts, until the shaft is fit to snag to the hub
Figure 4 Parallel axis misalignment in vertical of the coupling. If a driving apparatus is not
plane and its correction available, heating coupling halves (with
coupling rubbers off) to an approximately
100°C may help the pushing. It is important
b that axial force is prevented from occurring
while mounting the coupling. Support pump
shaft from the impeller side, and motor shaft
a from the fan side while mounting the
coupling. If necessary, dismantle the fan
cover.
3. Screw the two bolts in coupling hub.
4. Make sure that a suitable spacing is left
between the coupling halves while mounting
Figure 5 Angular misalignment in vertical plane pump and the rotor.
and its correction 5. Horizontal pump groups mounted on the
base plate or directly mounted on the base,
alignment of the coupling shall be as
described in chapter 7.4.2.
6. Put into place the coupling guard.
f

According to the accident prevention

regulations, all preventions and
protective devices should be in their
intended place and in operational form.

Figure 6 Parallel axis misalignment in horizontal 7.5 Piping

plane and its correction
7.5.1 General

Do not use the pump as the hinged

c
support for the piping system.

d
x Do not use the pump as the hinged support 13
for the piping system.
x Put enough supports under the piping
system in order to carry the weight of the
pipe and fittings.
Figure 7 Angular misalignment in horizontal
x Avoid piping system loads on pump by
plane and its correction
installing flexible components (compensator)
to suction and discharge of the pump.
x By mounting flexible supporting items, take
into consideration the fact that these items
may elongate under the pressure.
 x Suction pipe shall be in a constantly x When all installation and welding process is
increasing slope to the pump. Air in the done and the heat dissipated by welding is
suction pipe shall be arranged to move into removed, dismantle all the bolted
the pump. connections from the suction tank to
x Discharge piping shall be in a constantly discharge pipe. Take out all demountable
increasing slope to the reservoir or discharge parts.
point, without up and downs which can cause x Clean these parts and then paint body coat
air pockets in the piping system. At locations completely inside and outside.
where forming of air pockets is possible, x Mount the parts again in their intended
special items like air valve and air cock are places. However, this time start from the
mounted to evacuate the trapped air. discharge line and move downward to the
x It is important that pipe diameter and fittings pump. In this instance, do not forget to check
are at least as much as the pump opening the flange gaskets. If needed, (for example
diameter or preferable one or two size deformation during welding) replace them.
higher. One should never use fittings with x Concerning the connection of the pump
smaller diameters than the pump exit flanges to piping, in case of misalignment of
diameter. In particular, preferred fittings like axis and flange holes, do not force the
foot valve, strainer, filter, check valves and system to eliminate the misalignment.
valves shall have large free passing area, Forcing the system may cause difficult-to-
and low friction loss coefficient. correct problems.
x For piping systems with hot liquids, thermal x If there is an axial misalignment between the
expansions are to be taken into account and flanges of the pump and the pipe, due to the
compensators shall be mounted in welding or any other reasons, cut the pipe
accordance with these expansions. Caution from a suitable location in order to fix the
shall be exercised to avoid the loading of problem. Connect the pipe (pump side) to the
pump in this installation. pump. After carrying out the necessary
correction, connect the parts again by
7.5.2 Specification of work in piping welding.
installation x Dismantle and clean the last welded part.
Repaint again and mount on its place.
x After all these processes are accomplished,
In installation of pipes, follow the remove the rubber gasket from the suction
procedures below certainly. and discharge openings. Open their holes
and mount them again on their intended
place.
x Install the pump on the concrete base as
illustrated in Figure 2. 7.5.3 Specification of work after
x Take out the guards (placed by the installation of piping and piping
manufacturer) from suction and discharge system
openings of the pump.
x Close the suction and discharge flanges with
rubber gaskets. This precaution is important
Upper side entry line
to avoid the undesired substances (weld
crust, weld slag, sand, stone, wood piece Pump entry
etc.) get into the pump. Do not take off this flange
gasket until the installation is completed.
14 x Start the installation of piping from the pump
side. Do the necessary assembling and
Pump entry
welding of the parts in a successive order. flange
x In these operations, do not neglect to put the
necessary supports in their respected lower side entry line
locations.
x Following above procedure, complete all
piping system at suction side up to the Installing Pipes
suction tank (or foot valve if available), at
discharge side up to do discharge collector Figure 8 Piping system
and discharge pipe.
An illustrative piping system is shown in Figure 10.
Appropriate manometers shall be mounted on
suction and discharge pipe lines.

Complete the auxiliary pipe

connections in piping system if exist
(cooling to bearing housing, and
stuffing box (seal), relief pipe, oil pipe
etc.).

star
7.6 Motor connection delta U1 V1 W1 U1 V1 W1

W2 U2 V2 W2 U2 V2

Motor shall be connected by an electrical

technician according to the connection (switch)
Figure 9 Electric Connection Diagram
diagram. Local electricity policies and current VDE
regulations have to be applied.
El. line Motor
U (Volt) 230/400V 400V
x Electrical connections have to be 3 x 230V Delta -
made by authorized electricians. 3 x 400V Star Delta
x In dismantling the pump, make
sure the electricity is cut off 7.6.2 Motor Protection
before taking the motor cover out.
x Use the appropriate electrical x Three phased-motor shall be connected to
connection to the motor. power supply.
In environments where there is a x Wait the motor to cool down when thermic
risk of explosion, prescribed protected motor breaks in circuit due to the
protective law and regulations overheating. Make sure the motor does not
shall be applied by competent start automatically until it cools completely.
authorities. x In order to protect the motor from
overcharging and short circuit use a thermic
7.6.1 Motor connection diagram or thermic-magnetic relay. Adjust this relay to
the nominal current of the motor.
x Motors requiring high moments at start up
shall not be connected star-delta. Electrical equipment, terminals and
x Frequency controlled motors, require high the components of the control
moment at start up and have to be cooled systems may carry electric current
properly at low speeds. Provide the even though they are not operating.
necessary cooling for the motors. They may cause deadly and serious
injuries or irreparable material
damages.

15
8 Commissioning, start up and operating
8.1 Preparations before start-up Continue opening the valve until you read the
amperage on the electrical panel.
Oil Check: Ball bearings are used in DPAS type x One should always check the labels which
pumps. Long-life, NU series cylindrical bearings show the direction of rotation and the
and one row, 63..-C3 series ball bearings are used direction of fluid flow. If you dismount the
respectively on the motor and the shaft sides, coupling protection to monitor the direction of
which balance the axial force acting on the rotation, do not restart the engine before
impeller. Bearings are lubricated with grease. remounting the protection.
x Check pump seals.
x Make sure that the pump and the suction 8.3 Start-up procedure
pipe is completely filled with water before the
starting. If the pump operates on a positive x Check if the suction valve is open and the
suction head, no problem will be discharge valve is closed. Start the motor
encountered. Suction valve is opened and air x Wait until the motor reaches sufficient speed
drains are un-tightened. (in star/delta connections, wait until the
x Pumps with foot valve are filled with water by engine passes to delta connection).
opening the pump filling tap or, one takes x Keeping an eye on the amperage shown on
advantage of the water accumulated in the the panel, open the discharge valve slowly.
discharge pipe and by using a small valve x In the primary operation, if the discharge pipe
the check valve is bypassed and the pump is is empty, do not open the valve completely.
filled. By keeping an eye on the amperage, open
x In vacuum pump driven pumps, by operating the valve with care regarding that it should
the vacuum pump one achieves to fill the not exceed the value indicated on pump’s
pump via increasing the water level in the label.
suction pipe. x After opening the valve completely, check
the pressure from the pump exit manometer
and make sure that this value is the pump
CAUTION operating pressure value and is indicated on
Do not start your pump dry pump’s label.
x If the value one reads is less than the pump
label value when the valve is completely
8.2 Checking rotation direction open, it means that the height is
miscalculated. Increase the value by
CAUTION narrowing the valve and bring it to pump’s
The direction of rotation is indicated label value.
on the pump label with an arrow. x If the value one reads is greater than the
Apart from special cases, it is pump label value when the valve is
clockwise direction when looking completely open, it means that the height is
from the motor end. Observe if the calculated less than what it should be in
pump is rotating in the expected reality. The device is pumping less than what
sense by starting the motor for a very is requested. Check the installation and the
short instant. If it is turning in the calculations.
opposite sense, interchange any of x Minimum flow rate: If the pump is working 16
two motor leads. with zero flow rate (closed valve) from time to
time during its operation, the water inside the
x If the motor connection is delta, open the pump may endanger the pump by getting
discharge valve slowly. warmed up. In such cases, a minimum flow
x If the motor connection is star-delta, set the valve must be connected to the pump exit.
time relay to maximum 30 seconds.
Monitor the passage from star to delta by CAUTION
pressing the start button. As soon as you are Stop the motor if the pump gets too
assured that the connection is delta, open hot. Wait until it gets cold. Then start
the discharge valve slowly. the system up again carefully.
8.4 Shut down procedure

CAUTION
During sudden startups and stops, a
pressure reducing valve must be
placed at the exit section of high flow
rate pumps whose discharge
pipelines are long, in order to reduce
water hammer effect. Water hammer
may explode the pump.

In normal conditions (apart from sudden power

shut down, etc.), stop the pump as below:
x Close the discharge valve slowly.
x Switch the power off, stop the motor. Notice
that the rotor slows down.
x Do not start up the motor at least before 1 to
2 minutes.
x If the pump will be out of use for a long time,
close the suction valve and auxiliary circuits.
If the pump is outside and if there exists a
danger of frost, remove all drain taps and
empty all the water inside the pump. See
chapter 6 Storage.

CAUTION
If the pump is outside and if there
exists a danger of frost, remove all
drain taps and empty all the water
inside the pump.

17
 9 Maintenance
CAUTION 9.1.1 Component check
Maintenance operations must be done
by authorized personnel with CAUTION
protective clothing only. To make possible the visual control,
The personnel must also beware of one must be able to reach the pump
high temperatures and harmful and/or from any direction. Especially, to be
caustic liquids. Make sure that the able to dismount the internal units of
personnel reads carefully the manual. the pump and the engine, sufficient
free space must be created around
x The instructions in Safety Precautions must them for maintenance and repair.
be executed during maintenance and repair. Furthermore, one must make sure that
x Continuous monitoring and maintenance will the piping system can easily be
increase the engine’s and pump’s lives. dismounted.

9.1 Checks during operation 9.1.1.1 Bearing and lubrication

x Pump must never be operated without water. Ball bearings are used in DPAS type pumps.
x Pump must not be operated for a long time Long-life, NU series cylindrical bearings and one
with the discharge valve closed (zero capacity). row, 63..-C3 series ball bearings are used
x Bearing temperature must never exceed respectively on the motor and the shaft sides, in
80°C if the ambient temperature is 30°C. order to balance axial forces acting on the
x Precautions must be taken against flare up impeller. Bearings are lubricated with grease oil.
when the component temperatures are over
60°C. “Hot Surface” warnings must be placed 9.1.2 Shaft seal maintenance
over necessary areas.
x All the auxiliary systems must be in use while 9.1.2.1 Soft Packing
the pump is operating.
x Water must drop from the glands of stuffing x Before replacing the soft packing, the gland
boxes (20-30 drops per minute). must be dismounted first. Used packing rings
x Gland nuts must not be tightened too much. may be taken off by a sharp pointed tool.
If the amount of water increases after a long Take off the lantern ring if it exists, then
operation time, the nuts may be tightened by clean the interiors of the sealing box, the
1/6 turns. gland and the lantern ring.
x If the system consists of a substitute pump, x Wrap a proper sized, good quality sealing
keep it ready by operating it once a week. over the shaft bush and make sure that the
Check also the auxiliary systems of the bush tip is completely covered.
substitute pump. x Place the first ring, its joint facing upwards
x Check the elastic components of the and push it to its bed by using the gland
coupling. Replace them when necessary. x If it exists push the watering ring to its bed.
x Place also the other rings to their beds
alternating, i.e., their joints facing upwards
and downwards.
18 x After placing the last ring, position the gland
and tighten it completely. Thus, the
squeezed sealing rings take the shape of the
sealing box.
x Then un-tighten the nuts. Rotating the shaft
tighten them slowly again. When you feel that
the shaft is put on a brake, stop the tightening.
x Water must come from the seals drop by 9.2 Service
drop as soon as the pump is started.
The number of drops must not be less than Our Customer Service Department offers after-
10 and not more than 30 per minute. Find the sale service. Manager should employ authorized
proper setting by tightening and un-tightening and trained personnel for mounting/dismounting
the opposite gland nuts. procedures. Before these procedures, one must
make sure that pump interior is clean and empty.
x Ensure that the water leaking This criterion is also valid for the pumps which are
from the sealing is collected sent to our factory or to our service points.
and/or discharged in a manner
which is appropriate in terms of Maintain the safety of the personnel
safety and environmental and the environment in every field
criteria. procedure.

x Check the sealing temperature two hours

after the gland adjustment is made. For a 9.3 Spare Parts
system which pumps water at ambient
temperature, the sealing temperature must
The spare parts of DPAS type pumps are
not exceed 80°C.
guaranteed for 10 years by DP-Pumps.
In your spare parts requests, please indicate the
CAUTION
below listed values that are indicated on your
When tightening the gland nuts do not
pump’s label.
work with long sleeve shirts.
Otherwise it is possible to get caught
Pump type and size:
by the turning shaft and get injured.
Motor power and speed:
Pump serial number:
9.1.3 Coupling
Capacity and head:

As mentioned in chapter 7.4, the coupling

If you wish to keep spare parts in store, depending
adjustment must be checked regularly.
on the number of same type of pumps, for two
operation years, the quantities which are listed in
the table below are recommended.
Worn out elastic bands must be
replaced. Component The number of equivalent pumps
name in the installation
1-2 3 4 5 6-7 8-9 10 +
9.1.4 Drive Shaft (Wedge
1 1 2 2 2 3 % 30
included) quantity
Apply to the operating instructions of the motor ømpeller (quantity) 1 1 1 2 2 3 % 30
Casing wear (kit) 1 1 1 2 2 3 % 30
manufacturer.
Ball bearing (kit) 1 1 2 2 3 4 % 50
O-Ring for casting
9.1.5 Auxiliary components 1 1 1 2 2 3 % 40
(kit+1)
O-Ring for shaft
1 1 2 2 3 4 % 50
Check regularly the fittings and the gaskets, (if exist) (kit)
replace the worn out pieces. Soft packing (kit) 2 2 2 3 3 4 % 50
Sealing bush
1 1 1 2 2 3 % 30
(if exist)
Coupling rubber 19
1 2 2 3 3 4 % 50
sleeves (kit)
 10 Noise level and vibration
The reasons which increase the noise level are
indicated below:

x Touch of coupling halves due to worn rubber

sleeves (incorrectly aligned).
x Noise level increases due to the fact that the
pump is not founded properly (vibration).
x If the installation does not have compensator
noise and vibration increases.
x Wearing in ball bearing also increases noise
level.

Check if there is any noise increasing

elements in your installation.

10.1 Expected noise values

Sound Pressure Level (dB) *
Mpower of Motor
Pump with Motor
PN (KW)
1450 rpm/min. 2900 rpm/min.
< 0.55 63 64
0.75 63 67
1.1 65 67
1.5 66 70
2.2 68 71
3 70 74
4 71 75
5.5 72 83
7.5 73 83
11 74 84
15 75 85
18.5 76 85
22 77 85
30 80 93
37 80 93
45 80 93
55 82 95
75 83 95
90 85 95
110 86 95
132 86 95
160 86 96

20 (*) Without protective sound hood, measured at

a distance of 1 m directly above the driven
pump, in a free space above a sound
reflecting surface.

The above values are maximum values.

The surface noise pressure level at dB(A) unit is
shown as (LpA).
This complies with TS EN ISO 20361.
11 Disassembly, repair and reassembly
CAUTION 11.2 Reassembly
Before starting work on the pump set,
make sure it is disconnected from the x Reassembly proceeds in reverse sequence
mains and cannot be switched on to dismantling as described in chapter 11.1.
accidentally. You may find the attached drawing useful.
The following points should be noted more
Follow the safety precaution measures particularly:
outlined in "safety instructions". x Never use old O-rings and make sure the
new O-rings are the same size as the old
11.1 Disassembly ones.
x Before mounting the shaft protecting sleeves
x Close all valves in the suction and discharge (70) inspect the condition of their rubbing
lines, and drain the pump by opening the faces. Use new sleeves if the old ones are
drain plug (260) and the air plug (261). badly worn, scored or rough.
x Remove coupling guard and other safety x Place ball bearings on their places on the
guards. shaft by slightly heating or by using press.
x Remove all casing main joint nuts (300) x The joint faces of the casing halves are
dowel pins and bearing housing (30) sealed with liquid sealing compound. The
connecting bolts. joint faces should be thoroughly cleaned
x Separate the casing halves, lifting off the before reassembly and coated over again
upper half casing (02).This reveals the pump with sealing compound. Never use a paper
internals (impeller, wear rings) for inspection. gasket between the two faces.
x Unscrew the bolts which are connecting the
bearing housings (30) to the bottom half
casing (1).
x Lift the rotor out of the bottom half casing.
x Pull off the pump end coupling half from the
shaft (60) using a pull-off device and remove
the coupling key (211).
x Remove bearing covers (034) and bearing
end covers.
x Unscrew the shaft nuts (74) Pull the bearing
housings (30) and bearings off the shaft (60).
x Pull out stuffing boxes (50) from the shaft.
x Remove impeller (25) and sleeves (70-73) by
using a suitable device.
x Clean all the parts, replace damaged or
worn-out ones.

21
 12 Possible failures, causes, solutions
Possible failures and solution strategies are listed
in the table below. Please apply to the Customers’
Service Department of our company when a
generic solution is not found to your problem.

While the failures are repaired the

pump must always be dry and un-
pressurized.

POSSIBLE FAILURE CAUSES SOLUTIONS

1) The pump delivers x Discharge head too high x Readjust the operating point
insufficient capacity x Very high counter pressure x See if there is any undesired
material inside the pipe
x Pump and/or pipe cannot x Vent completely the pump and the
discharge air, cannot suck pipe
x Occurrence of air pockets inside x Change the piping configuration
the pipe
x NPSH is too low x Increase the liquid level
2) Motor overload x System pressure is lower than the x Adjust the operating pressure to the
requested pressure level label value
x Speed too high
x Liquid pumped of different specific x Decrease the speed
gravity and viscosity than that for x Increase the engine power
which pump is rated
x Engine works at two phases x Replace the fuse and control the
electrical connections
3) Pump head is too high x System pressure is higher than the x Set the operating pressure to the
requested pressure level label value
4) Bearing temperatures x Worn out coupling x Replace the coupling
are high x Too much, too little or improper x Change the oil, decrease or
lubrication increase its quantity
x Increase in axial forcing x Clean the balance holes on the
impeller disc
5) Excessive leakage x Worn out gland x Use brand new gland
from the stuffing box x Change the stuffing bush
x Loose gland x Tighten the gland nuts
6) Noisy operation x Worn out motor or pump ball x Replace
bearings
x Cavitation x Close the delivery partially in order
to reduce the capacity.
x Worn out or misaligned coupling x Replace the coupling or align it
x Operation in the far left or right of x Operate the pump at its label setting
the performance curve
7) Excessive increase in x Pump and/or pipe can neither x Bleed completely the pump and the
pump temperature discharge, nor aspirate air pipe
x Too low capacity x Open more the valve
8) Vibration x Pump and/or pipe can neither x Bleed completely the pump and the
22 discharge, nor aspirate air pipe
x NPSH is too low x Increase the liquid level
x Internal components of the pump x Replace the worn out components
are worn out
x System pressure is lower than the x Adjust the operating pressure to the
requested pressure level label value
x Coupling is misaligned x Align the coupling
x In case of continuous overload,
decrease the impeller diameter
x Too much, too little or improper x Change the oil, decrease or
lubrication increase its quantity
x Rotor unbalanced x Balance the impeller again
x Improper bearings x Use new bearings
13
3 Pum
mp dim
mensiions ta
able and
a weeights
s

Flanges
Weight
No P
Pump Type DN
N DN Lp
p e f h1 h2 b m1 m2 n1 n2 s(ø) A B l d(ø) Hp G GROUP
(Kg)
Suctiion Discharge
1 D
DPAS 65-250 100
0 65 585 260 325 250 1115 90 240 200 350 275 18 275
5 225 60 28 4432 500 A 105
2 D
DPAS 80-250 125
5 80 280 1140 0
300 4482 575 145
3 D
DPAS 80-360 125
5 80 674
4 294 380 1135 234 190 5555 600 165
4 DP
PAS 100-250 150
0 100 2 312 400 315 1155 80 270 225 400 340
712 19 325
5 275 80 35 5525 600 B 180
5 DP
PAS 100-315 150
0 100 820 350 470 355 1145 110 290 230 435 350 22 365
5 325 5587 690 330
6 DP
PAS 150-250 200
0 150 870 375 495 375 340 270 500 400 400
0 325 45 6640 725 C
6 DP
PAS 125-400 150
0 125 600 500 450
0 400 6695 850 485
8 DP
PAS 150-315 200
0 150 375 1175 500 400 400
0 350 6645 750 410
9 DP
PAS 150-400 200
0 150 400 2200 600 500 475
5 400 7730 875 515
10 DP
PAS 150-500 200
0 150 942
2 412 530 450 2250 370 300 650 550 550
0 500 8870 1050 590
11 DP
PAS 200-315 250
0 200 500 400 450
0 375 7735 825 565
12 DP
PAS 200-400 250
0 200 972
2 427 545 430 2205 430 360 600 500 23 5 425 110
525 55 7788 950 D 645
13 DP
PAS 200-500 250
0 200 104
42 447 595 475 2220 460 390 0 500
550 8876 1050 760
14 DP
PAS 250-315 300
0 250 106
62 457 605 480 410 525
5 425 8841 950 750
15 DP
PAS 250-400 300
0 250 42 447 595 500 2225
104 460 390 550
0 450 8873 1000 700
16 DP
PAS 250-500 300
0 250 62 457 605 525 2240 100 480 410 650 550
106 23 0 500 140
600 65 9952 1100 E 850
17 DP
PAS 350-400 400
0 350 610 2295 500 750 600 28 600
0 500 11010 1100
18 DP
PAS 350-500 400
0 350 129
90 570 720 630 3315 600 28 0 550
650 11055 1200 1750
19 DP
PAS 500-500 500
0 500 38 694 844 760 3370 150 700 600 800 650
153 28 0 600 140
750 75 11280 1350 F 2170

23
 14 Tightening torques
Tightening Torque Max (Nm)
Thread Diameter Property Classes
8.8 10.9
M4 3.0 4.4
M5 5.9 8.7
M6 10 15
M8 25 36
M10 49 72
M12 85 125
M14 135 200
M16 210 310
M18 300 430
M20 425 610
M22 580 820
M24 730 1050
M27 1100 1550
M30 1450 2100
M33 1970 2770
M36 2530 3560

24
15 Forces and moments at the pump
flanges

∑F ∑M
2 2
All of the applied loads if not reached the
maximum allowable value, to provide that the
actual
+ actual
≤2
following additional conditions, one of these loads ∑F maximum allowable ∑M maximum allowable

may exceed the normal limit:

Any component of a force or a moment, must be In here, 6 6

|F| and |M| are arithmetic sum of
limited 1.4 times of the maximum allowable value. the loads for each flange at the pump level,
The actual forces and moments acting on each without regard of the algebraic signs of the actual
flange, should provide the following formula and maximum allowable values.

Forces Moments
Suction Flange Discharge Flange Suction Flange Discharge Flange
DN Flange
Pump Type
N N Nm Nm
Suction Discharge Fy Fz Fx Fy Fz Fx My Mz Mx My Mz Mx
DPAS 65-250 100 65 1276 1029 1143 800 648 705 476 552 667 419 457 571
DPAS 80-250
125 80 1505 1219 1352 952 781 857 571 724 800 438 495 610
DPAS 80-360
DPAS 100-250
100 1276 1029 1143 476 552 667
DPAS 100-315 150 1905 1543 1714 667 781 952
571
DPAS 125-400 125 1505 1219 1352 724 800
DPAS 150-250
DPAS 150-315
200 150 2552 2057 2286 1905 1543 1714 876,2 1010 1238 667 781 952
DPAS 150-400
DPAS 150-500
DPAS 200-315
DPAS 200-400 250 200 3181 2571 2838 2552 2057 2286 1200 1391 1695 876 1010 1238
DPAS 200-500
DPAS 250-315
DPAS 250-400 300 250 3810 3067 3410 3181 2571 2838 1638 1886 2305 1200 1391 1695
DPAS 250-500
DPAS 350-400 400 350 5067 4095 4552 4438 3581 3981 2629 3029 3695 2097 2422 2956

Forces at the pump flanges were calculated according to TS EN ISO 5199 standard. The calculations are
valid for the materials of cast iron and bronze. Forces and moments at the flanges that made of stainless
material will be approximately twice as moments in the table.

25
 16 Sample pipework

B
A D O
J

N
O G
I K

H E
B

D C
L

Figure 10 Sample pıpework

A. Tank I. Discharge valve

B. Long radius elbow J. Electrical connection
C. Minimum slope is 2 cm/m K. Insulated cable
D. Fittings, flanges etc. L. Concrete foundation
E. Non-return valve M. Dirty water groove
F. Foot valve N. Compensator
G. Suction valve O. Compensator
H. Reducer

26
17 DPAS series pump - sectional
drawing and parts list

Figure 11 Soft Packing Design

Part List

No Name of the part No Name of the part

01 Casing-Lower Half 88 Deflector
02 Casing-Upper Half 200 Ball Bearing
05 Casing Ring 201 Roller Bearing
25 Double Suction Impeller 210 Impeller Key
30 Bearing Housing 211 Coupling Key
34 Bearing Cover (Coupling Side) 240 Soft Packing
50 Stuffing Box 260 Plug
55 Gland 270 Grease Thrower
56 Lantern Ring 276 Valve
60 Shaft 300 Casing Stud And Nut
70 Stuffing Box Bush 310 Gland Stud And Nut
73 Secondary Bush 320 Hex-Bolt
74 Shaft Adjusting Nut 400 O-Ring (For Casing)

27
 18 DPAS series pump - exploded view

PART LIST

Part No Part Name Part No Part Name

01 Casing Lower Part 201 Roller Bearing
02 Casing Upper Part 210 Key for Impeller
05 Wear Ring 211 Key for Coupling
20 Impeller 220 Oil Seal
30 Bearing Housing 240 Soft Packing
34 Bearing Cover (Dead Side) 260 Plug
35 Bearing Cover (Motor Side) 270 Greaser
36 Bearing Housing Cover 276 Adjusting Tap
50 Stuffing Box 300 Casing Stud
54 Gland 301 Stud for Gland
56 Lantern Ring 320 Hexagonal Bolt
60 Pump Shaft 321 Bolt
70 Seal Sleeve 360 Nut for Casing Stud
72 Ring 361 Nut for Gland
73 Space Sleeve 363 Washer for Bearing
74 Nut for Bearing 400 O-Ring (Stuffing Box)
28 88 Water Thrower 401 O-Ring (Shaft Sleeve)
200 Ball Bearing
29
30
31
dp pumps
dp pumps
P.O. Box 28
2400 AA Alphen aan den Rijn
The Netherlands

t +31 172 48 83 88
f +31 172 46 89 30

dp@dp.nl
www.dp.nl

03/2013

Can be changed without prior notice

Original instructions