SERVICE MANUAL
Contents
1. 4 4 11 Stator Removal 4 4 12 Drive End Gear Joint Removal 5 4 13 Rotor and Connecting Rod Removal 5 4 14 Drive Shaft and Bearings Remowval 5 4 15 4 16 4 24 4 36 4 39 Page GEEANINQ etie tede tees 5 INSPECTION tacet i certe otn tae 5 4 17 Beatings oneri ai 5 4 18 Drive Shaft innisis 5 4 19 S68l 1 5551 abeat onte denen 5 4 20 Packing rennen hr etes 5 4 21 ROOM iiie creen ted 5 4 22 sen edi ed 5 4 23 All Other 5 ASSEMBLY ensinan 6 4 25 Lubrication During Assembly 6 4 26 Packing 6 4 27 Bearing Housing Suction Housing Assembly seen 6 4 28 Bearing Drive Shaft Assembly 6 4 29 Rotor Stator Assembly 7 4 30 Rotor Gear Joint Assembly 7 4 31 Rotor Stator to Drive End Assembly 8 4 32 Drive End Gear Joint Assembly 9 4 33 Stator Support Discharge Assembly 9 4 34 Final Assembly seen 9 4 35 Packing Adjustment 9 STORAGE deines eam 9 4 37 Short Term 9 4 38 Long Term St2. 891 PK087Q KPK87Q T15261 PK0311 KPK291 PK0331 10762 581 21 771 415 T15423 571 51 PKO0085 932 715021 81 BK085Q 084 AK0932 WK0932 WK0126 256 916 PK113Q PH0335 Moyno Tri Phaze Systems U S Telephone 800 874 7430 Fax 937 327 3055 Canada Telephone 780 448 1938 Fax 780 430 0535 Venezuela Telephone 261 736 3926 MOYNO Always the Right Solution M 2006 by Moyno Inc Moyno Tri Phaze System and Moyno are registered trademarks of Moyno Inc Moyno Inc is a Unit of Robbins amp Myers Inc Printed in U S A
3. 4 14 Drive Shaft and Bearings Removal Note If the space immediately in front of the pump is unob structed for a distance equal to the length of the drive shaft follow steps 1 through 3 1 Complete Sections 4 9 and 4 12 2 Remove six hex head screws A from bearing cover plate 2 Slide bearing cover plate 2 with radial grease seal 1 and O ring 3 off drive shaft 3 Pull drive shaft bearing assembly out of bearing housing taking steps to support the weight of the assembly as the bearings clear the housing Remove grease seal 19 from the bearing housing Note If the space in front of the pump is obstructed and the obstruction is not easily moveable follow steps 4 through 6 Page 5 4 Complete Sections 4 10 and 4 11 and pull the rotor connecting rod assembly from the pump 5 Remove the four cap screws 0 from the clamp ring 28 and the four cap screws fastening the bearing housing 26 to the base Slide the bearing housing shaft assembly out of the suction housing until the quill clears the stuffing box Assembly may now be turned or removed to an area where sufficient space is available to permit removal of the shaft bearing assembly CAUTION The bearings are pressed on the shaft during assembly Care must be taken during disassem bly to avoid damaging the bearings or shaft 6 Remove bearing lock screw 17 from bearing nut 18 Using suitable spanner wrench or soft punch and hammer thread loc
4. the first few hours of operation are recommended in order to compress and seat each ring of packing evenly 1 Upon initial start up of the pump adjust the gland nuts for a leakage rate of 1 2 drops per second until the packing has seated and adjusted to the operating temperature approximately 10 15 minutes 2 If leakage is excessive after 15 minutes of operation tighten the gland nuts until a desired leakage rate is obtained Page 3 CAUTION Do not tighten until zero leakage is obtained Over tightening of the packing gland may result in accelerated wear on the packing and damage to the shaft In those situations where no packing leakage can be tolerated consult your Moyno Tri Phaze System Authorized Service Representative PACKING GLAND PACKING RAN 2 1 LANTERN M RING SNES SSE SEAN cS ys SS DESO SSN NN T TN XPD Figure 4 1 Cross Section of Stuffing Box 4 4 PACKING REPLACEMENT When leakage can no longer be regulated by tightening the gland nuts remove and replace the packing Replace as fol lows 1 Remove packing gland nuts F and slide gland 21 and slinger ring 20 back along drive shaft 14 2 Remove packing gland studs 3 Use a pair of packing extractors see Figure 4 2 to remove four packing rings 22 lantern ring halves 23 and three additional packing rings 22 Figure 4 2 Packing Removal Tool 3 Inspect surface of
5. BH114Q 4 Drive Shaft Head PF0971 PGO0971 PH0971 0971 5 O Ring Shaft Head BE113Q BG114Q BH111Q TJ111Q 6 Primary Thrust Plate PF0981 PG0981 981 PJ0981 7 OY oos epe hber RF0761 RGO0761 RHO0761 RJO761 8 Ring Gear AF0952 AG0952 AH0952 AJ0952 9 LOCK sed RS RF0581 RGO0581 RHO0581 RJ0581 10 AF0951 AG0951 AH0951 AJ0951 Gear Joint Kit See Note C KPF951 KPG951 KPH951 KPJ951 11 Secondary Thrust Plate PF0982 0982 PH0982 PJ0982 12 SealSupport PF0891 PG0891 91 PJ0891 13 Gear Joint Seal PF087Q PG087Q PH087Q PJ087Q Gear Joint Seal Kit See Note D KPF87Q KPG87Q KPH87Q KPJ87Q 14 Drive T30261 T50261 T90261 T11261 15 Tapered Roller Bearing PF0311 PGO0311 PH0311 PJ0311 Bearing Kit See Note KPF291 KPG291 KPH291 KPJ291 16 Bearing Spacer PF0331 PG0331 PH0331 PJ0331 17 Bearing Lock Plug 10762 10762 10762 10762 18 Bearing Lock Nut PF0581 PG0581 581 PJ0581 19 Thrust Grease Seal XK0621 PG0621 PH0621 Al4611 20 Slinger Ring 771 0771 771 PJO771 21 Packing Gland Half PF041S PG041S PH041S PJ041S 22 Packing tn ex LER Pea T30423 T50423 T90423 T11423 23 Lantern Ring Half PF0571 PG0571
6. REMOVED during assembly of the gear joints to allow excess lubricant to vent from the gear joints 3 Packing Lubricate packing rings during assembly Additional grease can be added after assembly through the zerk fittings installed in the side of the stuffing box 4 Approved lubricants CAUTION Do not mix different brands of lubricants for the same application Area to Lubricate Approved Lubricant or Equivalent Bearings Mobilux EP2 Grease Mobil Chemical Co Gear Joints MPG 2 Multi Purpose Grease amp Packing Dubois Chemical Div 4 26 PACKING INSTALLATION 1 The standard packing set 22 consists of seven braided packing rings Lantern ring halves 23 must be ordered sep arately 2 Install packing and lantern ring halves into the stuffing box area of the suction housing 29 in the following sequence a Wipe a film of lubricant on each packing ring and install three rings Push each ring firmly in place Note Install the packing rings with the splits staggered at 90 degrees to the adjacent ring of packing On initial assembly one ring of packing may not fit in stuffing box This final ring of packing should be installed after pump is started and packing is seated CAUTION Always use a proper packing tamper tool to install packing Do not use a pointed or sharp tool as damage to the packing material or drive shaft could result To assure proper shaft lubrication never use a one piece spiral wrap p
7. on shaft with rollers facing seat in cup Cone should be pressed on until face of cone is flush or even with shoulder on shaft CAUTION Do not press second cone past shoulder on shaft 2 Thread bearing nut 18 on shaft 14 and tighten until it rests against the shoulder on the drive shaft Install brass tip set screw 17 in bearing nut and tighten Note The tapered bearings are designed such that when properly installed there may be a very slight end play in the bearings bearing spacer halves may slip freely out of place or they may have a slight pre load bearing spacer halves held tightly in place and bearings do not turn freely 3 Remove bearing spacer halves 16 Thoroughly pack lubricant around rollers and on bearing races Install one half of bearing spacer Fill area between bearings half full of lubricant and install other half of bearing spacer Note Assuming the bearings are not too hot an alternate method of lubricating bearings is as follows Pack the rollers of the first cone immediately after it is pressed on shaft Lubricate race of first cup before it is installed Place bearing spacer halves in place and fill it full of lubricant Lubricate race of second bearing cup and place on spacer Pack rollers of second cone with lubricant and press on shaft until flush with shoulder Note If too much grease is packed into the bearings during assembly it may seep from the grease seals during the first few ho
8. recess in end of suction housing End 1 8 0 CEA NS Figure 4 6 Gear Joint Installation 3 Move the rotor stator connecting rod assembly in position and insert connecting rod through the suction hous ing and drive shaft Align stator with bore in suction housing and slide stator in place checking to insure that stator gasket 34 remains properly positioned 4 Check the dimension between the end of the connecting rod and face of the drive shaft as shown in Figure 4 6 For proper assembly of the drive end gear joint this dimension should be no less than that shown in column C and should not exceed the amount in column C by more than 1 8 inch Reposition rotor stator assembly in or out of suction housing as required to achieve the proper dimension 5 f the stator is firmly seated against stator gasket in suction housing recess and connecting rod extends beyond face of drive shaft by specified amount stator may be secured to suction housing If the specified dimension cannot be maintained with stator firmly seated do not perform the following step 6 until the drive end gear joint is properly assembled 6 Align holes in clamp ring 36 with threaded holes in suction housing and thread four hex head screws R with lockwashers through holes in clamp ring into threaded holes in suction housing Tighten hex head screws evenly 4 32 Drive End Gear Joint Assembly 1 Check to see that connecting rod
9. stator 4 Remove top half of stator support 31 5 Unbolt stator clamp ring 36A from suction housing 29 Pull stator off rotor Remove stator gasket 34 Use a screw driver tip to carefully remove stator retaining ring 35 see Figure 4 3 Remove stator clamp ring from stator 30 Figure 4 3 Typical Retaining Ring Removal Note On multiple stage pumps or when cleaning checking or changing stator 30 rotor 40 and or gear joint assem bly one of the following procedures is suggested Method 1 Use winch type device anchored directly opposite stator end Attach cable to discharge flange 37 to pull stator 30 off rotor 40 Method 2 Remove stator 30 rotor 40 and connecting rod 38 as a single unit see Section 4 13 Place the stator 80 in an upright position on the discharge flange 37 Remove rotor 40 and connecting rod 38 from the stator 30 It may be necessary to use a chain or sling with a lifting device Anchor discharge flange 37 securely to the floor before lifting Method 3 Hold stator 30 with pipe or strap wrench and turn drive shaft head 4 clockwise to unscrew stator 30 from rotor 40 6 Check rotor 40 and stator 30 for wear See Sections 4 21 and 4 22 for instructions 4 12 Drive End Gear Joint Removal 1 Complete Section 4 9 2 Remove drive coupling or V belts and pulley from drive shaft head 4 3 Remove vent plugs C from drive shaft head 4 and
10. 000 15000 29000 Figure 4 4 Rotor Installation ROTOR 40 WHEN ROTOR THRUST PLATE IS FULLY SEATED INDICATED SURGACES MUST BE FLUSH Figure 4 5 Rotor Thrust Plate Seating Detail Page 8 5 Apply a film of grease to the splines on the inside of the gear ball 10 Install gear ball on connecting rod 38 with counterbored end end without splines first on con necting rod Gear ball should slide freely against shoulder on connecting rod Place lock nut 9 on connecting rod and tighten against gear ball Apply grease to spherical surfaces and teeth of gear ball 6 Apply grease to the teeth of the ring gear 8 and slide ring gear onto the gear ball When ring gear is in place key ways should be facing the lock nut end of connecting rod 7 Apply a thin coating of grease to the spherical surface of the thrust plate 6 already installed in the rotor head Fill the recessed area in the rotor head with grease 8 Slide the gear joint shell 39 over the connecting rod and assembled gear joint components being careful to seat the outside diameter of the gear joint seal 13 in the end of the gear joint shell 39 The two tapped holes in the gear joint shell should be in line with one of the keyways in the ring gear 9 Place keys 7 in the keyways in the ring gear Check to insure the tapped holes in the side of the gear joint shell are aligned with one of the keyways 10 Align the keys in the ring gear with the
11. 571 PJ0571 26 Bearing Housing PF0051 0051 51 PJ0051 27 Retaining 0085 PGO0085 AHO0085 0085 28 Clamp Ring AG0932 PG0932 AH0932 PJ0932 29 Suction Housing T30021 T50021 T90021 T11021 30 Stator See Note A Order Using Pump Model Number and Serial Number 31 Stator Support BF0381 BGO0381 BJ0381 34 Stator BF085Q BG085Q BH085Q BJ085Q 35 Retaining Ring AF0085 AG0085 AH0085 AJ0085 36A Stator Clamp Ring Clip AF0932 AG0932 AH0932 AH0932 36B Stator Clamp Ring AF0993 AG0993 AH0993 AH0993 37 Discharge Flange BF0127 0127 BH0127 BJ0127 38 Connecting Rod PF0256 PGO0256 PH0256 PJ0256 39 Gear Joint Shell PF0916 PG0916 916 PJ0916 40 Rotor See Note A Order Using Pump Model Number and Serial Number 41 PF113Q PG113Q PH113Q PJ113Q 42 Head Ring See Note E PF0335 PGO0335 PH0335 PJ0335 Note A Order Rotors and Stators in sets Note B Bearing Kit includes items 1 15 2 19 Note C Gear Joint Kit includes items 6 7 2 8 10 11 12 Note D Gear Joint Seal Kit includes items 5 13 41 Note E Model 11000 2 Head Ring part number is PHO34S 15000 29000 PK0611 PK0341 PK110Q 971 BK114Q 981 RK0761 AK0952 RK0581 AK0951 KPK951 982
12. MOYNO bes PHAZE SYST EM SERVICE MANUAL TABLE OF CONTENTS Page 1 1 INTRODUCTION 1 1 2 GENEBAL tee ect i te d 1 1 3 NAMEPLATE 1 1 4 Pump Rotation 1 2 1 1 2 2 GENERA a tede eed 1 2 9 PIPING ii nth t 1 2 4 Suction Piping 1 2 5 Suction Housing Rotation 1 2 6 Discharge Piping 1 2 7 FOUNDATION eese 2 2 8 SHAFT ALIGNMENT 2 2 9 On Coupling Connected Units 2 2 10 On Belt Drive Units 2 2 11 PACKING 2 3 1 OPERATION tet cede d eee 2 3 2 INITIAL 2 3 3 START UP cete ttt e e 2 3 4 PACKING LEAKAGE 3 4 1 MAINTENANCE 3 4 2 GENERA As eec 3 4 3 PACKING ADJUSTMENT 3 4 4 PACKING REPLACEMENT 3 4 5 LUBRICATION seen 4 4 6 8 mtn 4 4 7 Joints ene nes 4 4 8 DISASSEMBLY 4 4 9 Disconnect 4 4 10 Packing
13. RATION MAY DAMAGE PUMP COM PONENTS Never allow the pump to operate without fluid as dry operation will cause premature wear and possible damage of the stator The stator is lubricated by the fluid which is being pumped 1 Before operating the pump for the first time fill the pump suction with fluid The fluid will lubricate the stator for the initial start up If the installation has a by pass line as recommended and fluid is bypassing the pump the suction and discharge valves can be slowly opened allowing fluid to flow to the pump 2 Once the suction and discharge valves have been opened and fluid is in the pump check for the direction of rotation by momentarily starting and stopping the drive and observing the pump shaft rotation Rotation should be clockwise when viewing the pump from the drive shaft end 3 If applicable turn on the mechanical seal flush system On packed pumps ensure the packing has been lubricated with a suitable grease and the packing gland adjusting nuts are a little more than finger tight 4 With VFD in manual mode start the pump at a slow operating speed Over time slowly increase the pump speed until the pump suction pressure has been decreased to the desired pressure Slowly close the valve in the by pass piping while observing the pump suction pressure If the pump suction pressure increases above the desired pressure then the pump speed should be increased as needed Once the system has stabilized
14. acking b Install the two lantern ring halves with the flat side against the packing c Install final four packing rings firmly pushing each ring into place 3 Install packing gland studs H packing gland halves 21 and gland adjusting nuts F Tighten nuts finger tight at this time 4 27 Bearing Housing Suction Housing Assembly This procedure may be performed now or after the bearing drive shaft assembly is installed in the bearing housing 1 Place clamp ring 28 on suction housing 29 and install retaining ring 27 in groove on suction housing 2 Slide turned diameter of suction housing into bore on end of bearing housing 26 Align holes in clamp ring 28 with four threaded holes in bearing housing 26 and thread four hex head screws O with lock washers into threaded holes Tighten finger tight 3 Rotate suction flange to desired position if not already fastened to piping and tighten four hex head screws O 4 28 Bearing Drive Shaft Assembly 1 Bearings must be pressed on the shaft in the following sequence Larger units 5000 BFD models and larger require heating of the bearings to 250 F before assembly a Press bearing cone on shaft 14 making sure rollers face in proper direction to receive cup step b Cone should be pressed firmly against shoulder on shaft b Place cup on rollers c Place bearing spacer 16 halves on cup d Place second cup on spacers e Press second bearing cone
15. drive shaft 7 Place keys 7 in keyways of the ring gear A small amount of grease may be used to hold the keys in place The flat face of the ring gear should be approximately flush with the face of the drive shaft 8 Place primary thrust plate 6 in drive shaft head 4 aligning slot in outside diameter of thrust plate with pin in drive shaft head When the thrust plate is properly seated the face of the thrust plate should be flush with the face of the drive shaft head 9 Lubricate the spherical surface of the thrust plate and fill the recess in the drive shaft head with grease 10 Place O ring 5 in the groove on drive shaft head 4 Align the keyways in the drive shaft head with the keys in the ring gear and insert the head into the drive shaft assembly Note If the threaded holes in the drive shaft do not align with the holes in the drive shaft head a strap wrench or pipe wrench may be used to turn the drive shaft slightly 11 Thread the six socket head screws E through the drive shaft head into the drive shaft Tighten them evenly until face of drive shaft head is tight against face of drive shaft Excess grease in the gear joint assembly will be purged from the holes in the drive shaft and drive shaft head Page 9 Note If the standard socket head screws are not long enough initially to engage the threads in the drive shaft two longer screws may be used 180 degrees apart to pull the drive shaft head close eno
16. drive shaft 14 Remove set screw D from drive shaft 14 Remove six socket head screws E from drive shaft head 4 and remove drive shaft head Remove primary thrust plate 6 from drive shaft head and remove two keys 7 4 Remove lock nut 9 from end of connecting rod 38 Remove ring gear 8 gear ball 10 secondary thrust plate 11 seal support 12 and gear joint seal 13 Note It is recommended that each time the drive end gear joint is disassembled the drive shaft O ring 5 and gear joint seal 13 should be replaced 4 13 Rotor and Connecting Rod Removal 1 Complete Sections 4 9 4 11 and 4 12 2 Pull the rotor connecting rod assembly from the pump Remove the vent plug C and set screw S from the gear joint shell 39 3 Remove six socket head screws T from head ring 42 and remove head ring and O ring 41 Slide connecting rod gear joint assembly off rotor head Remove gear joint keys 7 and primary thrust plate 6 from rotor 40 4 Slide gear joint shell 39 off gear ball connecting rod assembly Slide ring gear 8 off gear ball 10 5 Clamp connecting rod 38 in vice or hold with pipe wrench and remove lock nut 9 Remove gear ball 10 sec ondary thrust plate 11 seal support 12 and gear joint seal 13 from connecting rod Note It is recommended that each time the rotor end gear joint is disassembled the rotor head O ring 41 and gear joint seal 13 should be replaced
17. drive shaft for wear or grooves If shaft is worn through the chrome plating into the base metal or is badly scored or grooved it should be replaced 4 f the drive shaft is not worn install three rings of packing the lantern ring halves and four more rings of packing lubricating them before installation with a good grade of packing grease Be sure to stagger the packing ring joints at 90 increments see Section 4 26 Page 4 CAUTION Always use a proper packing tamper tool to install packing Do not use a pointed or sharp tool as damage to the packing material or drive shaft could result To assure proper shaft lubrication never use a one piece spiral wrap packing 5 Replace packing gland 21 and secure with packing gland nuts see Figure 4 1 6 Adjust packing per Section 4 3 4 5 LUBRICATION 4 6 Bearings The bearings are lubricated at the factory and will only need to be relubricated when the shaft bearing assembly is removed from the pump 4 7 Gear Joints Both gear joints are packed with lubri cant during assembly and will only need to be relubricated when gear joints are disassembled 4 8 DISASSEMBLY CAUTION Be aware that although the pump is isolated from the pipeline by valves there could still be fluid under high pressure in the pump Therefore after closing the suction and discharge valves carefully remove the suction housing drain plug and loosen the discharge flange connection to relieve any o
18. extends beyond face of drive shaft by amount specified in column C of Figure 4 6 see Section 4 31 step 4 2 Fit the gear joint seal 13 on the connecting rod 38 Push the seal firmly in place on the connecting rod so that the neck on the seal seats in the recess in the seal retainer component of the connecting rod 3 Apply a film of gear joint grease to the inside of the gear joint seal and to the flat face of the seal support 12 Slide the seal support 12 onto the connecting rod such that the flat face fits against the seal 4 Apply a film of grease to the concave spherical surface of the secondary thrust plate 11 and slowly push the thrust plate into the drive shaft until it rests firmly against the seal 5 Apply a film of grease to the gear ball 10 splines and spherical surfaces and install gear ball on connecting rod counterbored end first end without spines Gear ball should slide freely on rod until it contacts shoulder on rod Install connecting rod lock nut 9 and tighten against gear ball While tightening lock nut prevent connecting rod from turning by carefully holding with pipe wrench or vise grips through inspection ports in suction housing 6 Apply liberal amount of grease to gear ball teeth and ring gear 8 teeth and slide ring gear into the drive shaft assembly Keyways in ring gear should be facing out and one of the keyways should be aligned with drilled and tapped holes in outside diameter of
19. f the pressure in the pump before proceeding with disassembly of the pump Note The following instructions cover ONE procedure for disassembling all pump components Major pump components can be disassembled in various ways since specific installation location limitations will deter mine method of component removal 4 9 Disconnect Pump 1 Flush the pump preferably with clean water to remove the pumpage from the unit 2 Shut off pump 3 Close suction and discharge valves 4 Disconnect power source 5 Drain any fluid in the pump by removing the drain plug 4 10 Packing Removal 1 Shut off the pump 2 Complete Section 4 9 steps 3 6 3 Remove gland adjustment nuts F gland studs H and gland halves 21 from stuffing box 4 Remove packing rings 22 This is best done by using flexible packing extractors see Figure 4 2 Use two extractors simultaneously on opposite sides of each ring Pull evenly 5 Remove lantern rings 23 in similar fashion Twist split rings to remove from shaft 6 Remove additional packing rings 4 11 Stator Removal 1 Complete Section 4 9 2 Remove section of discharge pipe attached to discharge flange 37 3 Remove discharge flange by unbolting from stator clamp ring 36B and remove stator gasket 34 Remove sta tor retaining ring 35 and stator clamp ring from stator 30 Note Omit above step 3 when using alternate methods 1 or 2 see Page 5 to separate rotor and
20. from the driven end of the pump 2 1 INSTALLATION 2 2 GENERAL Moyno pumps are lubricated and tested at the factory prior to shipment and require minimum pre start up maintenance Packing however is not lubricated at the factory Accessibility to the pump and adequate clearance should be a prime consideration in any installation Enough space should surround the unit so that maintenance can be carried out with ease PROGRESSING CAVITY PUMPS ROTATION v gt MODEL NO MFG SERIAL DO NOT START OR RUN PUMP WHEN DRY MOYNO Always the Right Solution Figure 1 1 Typical nameplate showing rotation arrow model and manufacturing serial numbers 2 3 PIPING 2 4 Suction Piping should be as short as possible and is normally the same size as the suction flange However actual wellhead or satellite conditions may warrant a different pipe size It is recommended the pump be installed with a bypass loop around the pump to the discharge piping This bypass loop will facilitate bringing the Tri Phaze System online and can also be used to permit the well or satellite to remain in operation when the pump is being serviced 2 5 Suction Housing Rotation to any position 360 about the centerline of the pump is possible To rotate loosen the hex head bolts holding the clamp ring to the bearing housing Remove the packing gland halves and the packing studs Loosen the stator support caps and rotate the suction hou
21. hed by loosening the mounting bolts on either the pump or driver and moving the loosened component into alignment with the fixed component On couplings with equal diameter hubs it may be possible to lay a straight edge axially across the coupling halves to check alignment 2 10 On Belt Drive Units check to ensure that sheaves or sprockets are in alignment Check belts for proper tension Tension requirements will vary with the type of belt center distances and belt speeds Consult the belt manufacturer for specific recommendation 2 11 PACKING LUBRICATION The packing is grease lubricated through a grease fitting in the stuffing box Packing is not grease lubricated at the factory prior to shipping If mechanical seal is used consult the seal manufac turer s instructions for seal flush requirements 3 1 OPERATION 3 2 INITIAL CHECK Before putting the pump into operation the following items should be checked to ensure that each piece of equip ment is installed correctly Pump driver coupling or sheave alignment Electrical connections Gauges and other instruments Pump rotation Rotation is indicated on the name plate on the bearing housing All valves should be open on both suction and discharge sides of pump See START UP VFD should be in manual mode CAUTION This is a positive displacement pump Do not operate it against a closed valve 3 3 START UP CAUTION DRY OPE
22. k nut off drive shaft Do not use a pipe wrench to remove the lock nut 7 Remove both halves of bearing spacer 16 from shaft and using suitable bearing press and adapters press bearings off shaft 4 15 CLEANING Clean all parts in a suitable cleaning solvent being careful to observe all safety precautions regarding the use of solvent 4 16 INSPECTION 4 17 Bearings After cleaning rotate bearings very slowly under hand pressure to feel for smoothness and even action Never spin a dry bearing Check for cracks galling pitting burrs etc Replace bearing if there is any doubt con cerning complete serviceability 4 18 Drive Shaft Inspect drive shaft 14 for scoring burrs cracks etc Replace as necessary 4 19 Seals It is sound practice to always replace grease seals 1 and 19 whenever drive shaft and tapered roller bearings are removed Apply Locktite 690 to outside diameter of both grease seals 4 20 Packing It is sound practice to always replace packing 22 whenever the pump bearing housing is disassembled 4 21 Rotor Check for excessive wear of rotor 40 4 22 Stator A worn stator may appear pitted and gouged or may appear smooth similar to when new Performance is the best measure of rotor to stator fit If unable to measure performance adequately suspected stator wear can be evaluated by a Moyno Tri Phaze System sales or factory representative 4 23 Other Parts Check for cracks excessi
23. keyways in the rotor head Slide assembled gear joint shell onto the rotor head checking to be sure the keys are properly engaged in the rotor head and ring gear The shallow hole in the rotor head should be aligned with the first threaded hole in the outside of the gear joint shell Thread the set screw S into the threaded hole in the shell until light contact is made with the hole in the rotor head 11 Place O ring 41 into step in gear joint shell Align holes in head ring 42 with six threaded holes in end of gear joint shell and install stainless socket head screws T Tighten the six socket head screws evenly checking to insure O ring 41 remains in place When tightened proper ly a small gap of a few thousandths of an inch may exist between the shell 39 and head ring 42 12 Excess grease in the assembly will be purged from the vent hole while the socket head screws are tightened Tighten the set screw S in the shell Move the free end of the connecting rod in a circular motion to assure that the joint is free and assembled properly This will also help to purge excess grease from the assembly 13 Install the stainless steel pipe plug C in the second hole in the shell and tighten 4 31 Rotor Stator to Drive End Assembly 1 If not already in place slip stator clamp rings 36 on both ends of stator 30 and install retaining rings 35 in grooves provided on both ends of stator 2 Place stator gasket 34 in
24. orage 10 PARTS LIST ttc tenet ge 12 MOYNO BRNZI FPHAZE SYSTEM Page 1 Date January 30 1997 SERVICE MANUAL 1 1 INTRODUCTION 1 2 GENERAL The Moyno Tri Phaze System is the culmination of over 60 years of experience in manufacturing and marketing fluids handling equipment This system includes a special Moyno Pump a drive a variable frequency drive and instrumentation The rugged pump is based on the Moyno 2000 Pump design which has been engineered to be the most reliable product ever sold under the Moyno name It has been painstakenly tested to assure consistent perfor mance in the most difficult applications The variable frequency drive should have a 115 VAC control interface and a 4 to 20 ma input speed isolator module to accept a suction pressure signal This permits the pump speed to be automatically varied in response to variable well or satellite conditions 1 3 NAMEPLATE DATA The pump nameplate located on the bearing housing contains important information relating to the operation and servicing of the pump This information includes the direction of rotation arrow and the pump model and serial numbers see Figure 1 1 The pump model number and serial number must be used for reference when ordering spare parts 1 4 Pump Rotation The direction of rotation is indicated by a rotation arrow on the nameplate Rotation of Moyno pumps is clockwise when viewed
25. owever to insure the best possible protection the following is advised 1 Store pump inside whenever possible or cover with some type of protective covering Do not allow moisture to collect around pump 2 Remove drain plug to allow the pump body to drain and dry completely 3 Loosen the packing gland and inject a liberal amount of grease into the stuffing box Tighten the gland nuts only hand tight Page 10 4 See drive manufacturer s instructions for motor and or drive storage 5 See OPERATION Sections 3 1 through 3 4 before start up Be sure all lubricants are in good condition 4 38 Long Term Storage If pump is to be in storage for more than 6 months perform the above short term storage procedures plus the following 1 Occasionally rotate the pump manually a few revolu tions to avoid a set condition of rotor in stator elastomer This will prevent hard starting and excessive torque requirements when pump is again put into operation 2 Apply rust inhibitor to all unpainted cast iron and machined carbon steel surfaces 3 Remove drive belts if applicable Page 11 06 Q um e Ly Page 12 4 39 PARTS LIST DRIVE END SIZE REF 3000 5000 9000 11000 4 NO 7000 11000 2 12000 1 Radial Grease Seal PF0611 PG0611 PHO0611 PJ0611 2 Bearing Cover Plate PF0341 PG0341 PH0341 PJ0341 9 ee nsi REDE BJ112Q BK110Q PH110Q
26. retaining rings 35 3 Coat the rotor 40 contour with waterless hand cleaner glycol or other lubricant compatible with the stator elastomer Insert rotor into stator so that rotor head is at the specified distance from the end of the stator Dimension A Figure 4 4 Note Turning the rotor counterclockwise while inserting into stator will ease assembly Page 7 4 30 Rotor Gear Joint Assembly 1 Slip O ring 41 over the rotor head and allow to hang loose with head ring Insert primary thrust plate 6 into rotor head flat side first Thrust plate and rotor head surfaces must be flush to assure proper assembly and operation of the pump see Figure 4 5 2 Assemble the rotor end gear joint by first fitting a gear joint seal 13 onto the connecting rod assembly 38 The seal must be positioned so that the flat face of the seal neck fits into the seal retainer component of the connecting rod assembly Apply a small coating of approved gear joint lubri cant to the inside surfaces of the seal 3 Apply a small amount of lubricant to the flat face of the seal support 12 and slide it onto the connecting rod so that the flat face and radius of the support is against the seal 13 4 Grease the concave spherical surface of the rear thrust plate 11 and position thrust plate against the seal 13 with the lip on the outside diameter of the seal fitting the step on the back side of the thrust plate Number s 11000 4 12
27. sing stator and discharge flange together Replace the packing gland studs in the threaded hole provided CAUTION Rotating the suction flange by any other method may tear the stator gaskets causing a leak Once the gaskets have been com pressed it is virtually impossible to rotate any one of the two compressing surfaces without tearing the gasket 2 6 Discharge Piping diameter should generally be as large as the pump ports unless fluid conditions indicate otherwise An easily removable section of piping one to two times longer than the connecting rod should be mated to the dis charge port This will allow the stator to be removed without having to disassemble the complete pump Page 2 2 7 FOUNDATION Each unit is mounted on a strong fabricated steel base plate Skid mounted units may be furnished where applicable but for most installations the base plate should be mounted on a concrete foundation The foundation should be approx imately 4 to 8 longer and wider than the base for which it is built see Figure 2 1 Anchor bolts for the base plate should be located in the foundation FOUNDATION DIMENSION BASE PLATE 100 200 BASE PLATE DIMENSION gt ANCHOR BOLTS BASE PLATE SHIM AS a 7 QONCRET FOUNDATION lt Figure 2 1 Typical Foundation Example Check the base plate surface with a carpenter s level and place shims under the base plate at
28. the VFD can be Switched to automatic mode and the pump speed will be varied as needed to maintain the desired suction pressure 3 4 PACKING LEAKAGE A packed stuffing box is designed to control leakage not stop it completely Leakage is generally necessary to reduce friction and dissipate heat The amount of leakage necessary will depend on the fluid pumped the installation and pump speed and type Refer to Section 4 3 for packing adjustment Moyno pumps have been designed for minimum stuffing box leakage when properly maintained If leakage cannot be tolerated then a mechanical seal should be used 4 1 MAINTENANCE Note In this section the first reference to each pump part will be followed by a number or a letter in parentheses These numbers and letters are those used to identify the pump parts and hardware items in the Exploded View see Figure 4 7 4 2 GENERAL The Moyno pump has been designed for a minimum of maintenance the extent of which is routine adjustment and lubrication of packing The pump is one of the easiest to work on in that the main elements are very accessible and require few tools to disassemble 4 3 PACKING ADJUSTMENT Packing gland nuts should be evenly adjusted so they are little more than finger tight see Figure 4 1 Overtightening of the packing gland may result in premature packing failure and possible damage to the shaft and gland When packing is new frequent minor adjustments during
29. the places necessary to make it level Then check the pump drive shaft and the pump ports to ensure that they are level Complete base mounted units supplied by Moyno including pump and drive are leveled with respect to the base at the factory Shifting may occur during shipment The pump and drive should be realigned Care should be exercised to ensure that all components are level and mounted in a direct line For maximum rigidity and lower noise levels the base plate should be grouted to the foundation after the anchor bolts have been evenly tightened A good grade of nonshrink grout is recommended The spaces between the base plate and the foundation around the shims should also be filled with grout Allow the grout to dry according to manufacturer s instructions Then fully tighten the anchor bolts 2 8 SHAFT ALIGNMENT Although the base mounted units supplied by Moyno are leveled with respect to the base before shipment most of the larger pump and drive units are shipped with the flexible coupling disconnected After the base has been bolted down to the foundation check the following conditions 2 9 On Coupling Connected Units be sure that the pump and drive shafts are realigned before the coupling is connected Care should be exercised to ensure that all com ponents are level and mounted in a direct line Check gap between coupling halves refer to coupling manufacturers recommendations Adjustment can usually be accomplis
30. ugh to the drive shaft to engage the standard screws 12 After the six socket head screws E are secured and the grease has been purged from the assembly install the pipe plugs C in the drive shaft head and drive shaft Also install the locking set screw D in the drive shaft in the threaded hole nearest the bearing housing 13 If the stator was not previously tightened to the suction housing Section 4 31 step 5 it should be tightened at this time 4 33 Stator Support Discharge Assembly 1 Place top of stator support s 31 over stator and fasten to bottom half of stator supports using hex head screws L 2 Place stator gasket 34 in recess in discharge flange 87 and position discharge flange on end of stator Align holes in stator clamp ring 36B with threaded holes in dis charge flange and install and tighten hex head screws M 4 34 Final Assembly 1 Install inspection plates 32 to suction housing 29 with gaskets 33 using hex head screws P and lockwashers 2 Install pipe plugs Q and J and zerk fittings K in appropriate threaded holes in suction housing Install pipe plugs N in threaded holes in bearing housing or attach drain lines if preferred 3 Connect power source Open suction and discharge valves and start pump 4 35 Packing Adjustment For packing adjustment refer to Section 4 3 4 36 STORAGE 4 37 Short Term Storage Storage of 6 months or less will not damage the pump H
31. urs of operation until the proper lubricant level is achieved This lubricant should be wiped from the seal area when the pump is not operating to pre vent contaminants from collecting in the seal area 4 Install light press grease lip seals 1 and 19 into bearing cover plate 2 and bearing housing 26 with Locktite The lip of the radial grease seal 1 should be facing outward with spring visible The lip of the seal 19 should be facing the bearings The lips of both seals should be wiped with grease 5 Install drive shaft with bearings in bearing housing being careful to avoid damaging the grease seal 19 6 Place O ring 3 on bearing cover plate and bolt bear ing cover plate to bearing housing using six hex head screws A and lock washers The six screws should be tightened evenly and care should be taken to insure the O ring becomes seated in the step in the bearing housing When the bearing cover plate is fully secured to the bearing hous ing a small gap of 0 010 to 0 020 inch will exist between the bearing cover plate and the bearing housing 4 29 Rotor Stator Assembly 1 Slide head ring 42 over rotor 40 contour to the rotor head The side of the head ring with the smallest diameter holes should be facing the rotor head Note On some models the head ring is a two piece compo nent which eliminates this step 2 Slide stator clamp rings 36 on both ends of the sta tor 30 and secure in position with
32. ve wear damage to threaded holes burrs etc Replace as neces sary Replace O rings and all gaskets at each disassembly and reassembly Page 6 4 24 ASSEMBLY The Moyno pumps are reassembled in the reverse order of dismantling The following suggestions are offered 1 While pump is dismantled check all gaskets seals packing and O rings Replace all worn items It is recom mended that the gear joint seals 13 gear joint O ring 41 and drive shaft O ring 5 be replaced each time either of the gear joints is disassembled 2 During the assembly process cleanliness is important To avoid premature failure bearings and gear joint compo nents must be handled with care and kept clean 4 25 Lubrication During Assembly Note The bearings are lubricated at the factory and will only need to be relubricated when the shaft bearing assembly is completely removed from pump 1 Bearings Pack bearings after installation on shaft see Section 4 28 Lubricant should be packed around all of the rollers and should completely cover the faces of the races The void inside the spacer between the bearings should be filled approximately half way with lubricant 2 Gear Joints Both gear joints should be packed with lubricant during assembly see Sections 4 30 and 4 32 DO NOT use zerk fittings to lubricate gear joints after assembly The pipe plugs C in the drive shaft head drive shaft and gear joint shell are vent plugs and MUST BE
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