4. Index of range of Varley gear pumps
Section Title Page Number
1. Introduction 6
2. Features, benefits,
operating range 7
3. Nomenclature and pump sizing 8
. Ordering information 9
5. Pump performance
indication guide 10-13
6. Pump performance curves 1-26
7. Dimension drawings 27-5
8. Section drawing and parts list 6-51
9. Alternative assembly
(mechanical seal and plain cover) 52
www.varleypumps.com
ht_pump_manual NEW.indd 4 7/11/07 15:45:48
5. Section Title Page Number
10. Table of approximate
viscosity comparisons 53
11. Definition of hydraulic terms 54
12. System design
typical fuel oil pumping 55
13. Installation, operating
and maintenance instructions 56-59
1. Service and maintenance 60-63
15. Quotation form 6-65
16. Notepad 66
Sales office ☎ +44 (0) 1582 731144 5
ht_pump_manual NEW.indd 5 7/11/07 15:46:04
6. 1. Introduction
When you use Varley Pumps you benefit from over
50 years of experience and development.
The Varley Double Helical Gear Pump Handbook has the performance indicator guide on pages 10-11. A more
been revised to bring the data into line with customer accurate guide to performance and power curves can be
requirements. found on pages 12-2 taking viscosity into account.
It is a reference book designed to help you select and You can now specify your pump precisely using the
specify a pump precisely. nomenclature system given on page 8. Should you prefer,
our engineers or agents will be only too pleased to make
If you need to pump a liquid with lubricating properties
a suitable selection for you on receipt of full details of your
at flow rates between 0.5 igpm and 200 igpm against
requirements.
pressures varying from 5 p.s.i to 500 p.s.i then Varley
pumps can provide you with robust reliable solutions. Varley Pumps are approved by: NCB power generation
Larger pumps can be supplied for special applications. authorities, British Rail, British Steel, British Gas, Lloyds,
The Post Office, The Admiralty, Bureau Veritas, Norske
With knowledge of the output required and the differential
Veritas and American Bureau of Shipping to name but a few.
pressure (approximately the same as discharge pressure if
inlet pressure low), a provisional choice can be made from
6 www.varleypumps.com
ht_pump_manual NEW.indd 6 7/11/07 15:46:22
7. 2. Features, benefits, operating range
Varley Pumps can give you:
Features Benefits
Compact design Easy fitting
Double helical motors Smooth non-pulsating flow
Balanced rotor Thrust eliminated
Journal roller bearings Long life
High suction lift capability Self-priming
High interchangeability Economic maintenance
Flexible coupling Easy maintenance
Standard metric motors Faster deliveries
All motorised units bracket mounted Saves space/eliminates need for base plate
Pumps custom tested as standard No adjustment required on site
Capacity range: 0.5 igpm (0.1 M3/H) – 200 igpm (55M3/H) Standard Materials
Viscosity range: Up to 15000 secs Redwood No. 1 1. Front cover, body, rear cover
Pressures: Up to 500 p.s.i (35 kg/cm2) Close grained cast iron to B.S.152 (grade 1)
Suction lift: Up to 20+ Hg (5mm)
2. Shafts
Temperatures: Up to 350°F (176°C)
(main and idler) Steel to B.S.970 (EN36B)
3. Double helical rotors
Steel to B.S.970 (EN9)
4. VJournal roller bearings
To B.S.292
5. Bearing housings
Cast iron to B.S.152 (grade 1)
6. Seal
Packed gland or mechanical seal
Other options available, please contact us at
varley@haywardtyler.com or on +(0)1582 7311
Integral by-pass relief valve fitted as standard (can be Other Products
supplied without if not required) (separate publications available)
Standard paint finish Hammer Green (Styrenated Alkyd) VARLEY Tanker Pumps
VARLEY Atex Pumps
VARLEY API 676 Positive Displacement Pumps
VARLEY Engine Pumps
(3D CAD models available)
Sales office ☎ +44 (0) 1582 731144 7
ht_pump_manual NEW.indd 7 7/11/07 15:46:23
8. 3. Nomenclature and pump sizing
The nomenclature used to describe a Varley pump is designed to specify the unit in full as follows:
Example explained below 5M1TR/01
5 M 1 T 4 R/ 01
Pump Size Mounting Motor Motor Speed Relief Valve Relief Valve
Horsepower Enclosure (by-pass) Seal type
Pump size Speed at 50Hz
Corresponds to nominal output in igpm at 120 rpm: pole – 120rpm
1, 2, 5, 7, 10, 20, 30, 35, 50, 75, 100, 150, 200 6 pole – 960 rpm
8 pole – 720 rpm
Mounting Lower speed available using gearbox.
M Horizontal motorised unit
V Vertical motorised unit Integral Relief Valve (by-pass)
B Base plate mounted motorised unit R omitted from reference when not required
F Foot mounted bare shaft extension pump
SS Short shaft Relief Valve (by-pass) and Seal type
Temperature range:
Motor Horsepower 0° to 20°F sizes 1 to 100.
Dependant on application ½, ¾, 1, 1 ½ etc. 0° to 120°F sizes 150 and 200.
Enclosure
T totally enclosed fan cooled
FLP flame and explosion proof
Relief Return to Intake Return to Tank Without By-pass
Valve
Seal Type Mechanical Seal Gland Mechanical Seal Gland Mechanical Seal Gland
Packing Packing packing
Anti-
Clockwise 0 01 05 02 06 03
Suffix
Clockwise 5 51 55 52 56 53
suffix
Temperature range: 21° to 360°F sizes 1 – 100. 121° to 360°F sizes 150 and 200.
Anti-
Clockwise 22 19 23 20 2 21
Suffix
Clockwise 72 69 73 70 7 71
suffix
8 www.varleypumps.com
ht_pump_manual NEW.indd 8 7/11/07 15:46:23
9. . Ordering information
Ordering
You are advised to give the following additional information so that we can ensure that the correct unit is supplied:
1. Flow rate
2. Working pressure
3. Fluid details including viscosity at operating temperature and the condition
. Rotation (anti-clockwise looking at shaft end standard)
5. Top or bottom drive (top drive standard)
6. Suction conditions
7. Operating temperature
Standard pumps will be supplied unless otherwise requested
Mechanical seal
The mechanical seal type fitted as standard to the Varley gear pump, is of a single unbalanced design. Standard
construction is of Stainless-Carbon-Viton. Hard face, dual rotation and PTFE seals can be accommodated within the
standard range. Our engineers are on hand to advise you of any requirements.
Gland packing
PTFE impregnated synthetic fibre yarn packing. Max shaft service speed 26 m/s and up to 350 psi.
Viscosity
Varley pumps are suitable for viscosities up to 15,000 secs. Redwood No. 1 and even higher for certain specialised
conditions (in such cases we should be consulted to ensure correct application).
The performance curves contained within this brochure cover the following viscosities: - 75, 310 and 700 seconds
Redwood No. 1. They are intended as a guide to indicate the b.h.p. requirement for each size of pump within the Varley
range. Interpolation is possible but we recommend that you check with the sales office for viscosities very different to
those shown.
Example
A transfer oil pump to handle fuel oil at 75 secs, Redwood No. 1 viscosity from underground storage tank to an elevated
service tank. Rate of flow 6 igpm at 50 p.s.i. The b.h.p absorbed on duty is determined by curve “C” (lower) on the graph
i.e. 0.5 H.P. Thus a nomenclature of 5M1/2 TR is derived if your requirement is a horizontal motorised unit, to which
should be added the appropriate assembly type number e.g. 5M1/2 TR/01.
Should any other type of mounting be required, the type reference would be modified accordingly.
E.g. 5V11/2 TR/01. 5B11/2 TR’/01, 5SR/01, 5FR/01
When ordering please provide precise details of pump duty. Alternatively please complete the form at the back of
the handbook.
Note
Varley Pumps Ltd reserve the right to make additions to or deletions from the Varley pump range, and make dimensional
alterations without notice. The availability of any item shown in this handbook should therefore be checked at the enquiry
stage.
Sales office ☎ +44 (0) 1582 731144 9
ht_pump_manual NEW.indd 9 7/11/07 15:46:23
45. 8. Section Drawing and Parts List 1-2S
Sales office ☎ +44 (0) 1582 731144 45
ht_pump_manual NEW.indd 45 7/11/07 13:04:40
46. 8. Section drawing and parts list 5-7S
46 www.varleypumps.com
ht_pump_manual NEW.indd 46 6/11/07 12:31:58
47. Section Drawing and Parts List 10-20S
Sales office ☎ +44 (0) 1582 731144 47
ht_pump_manual NEW.indd 47 6/11/07 12:32:00
48. Section drawing and parts list 30S
48 www.varleypumps.com
ht_pump_manual NEW.indd 48 6/11/07 12:32:02
49. Section Drawing and Parts List 35-100S
Sales office ☎ +44 (0) 1582 731144 49
ht_pump_manual NEW.indd 49 6/11/07 12:32:04
50. Section drawing and parts list 150S
50 www.varleypumps.com
ht_pump_manual NEW.indd 50 6/11/07 12:32:06
51. Section Drawing and Parts List 200S
Sales office ☎ +44 (0) 1582 731144 51
ht_pump_manual NEW.indd 51 6/11/07 12:32:08
52. 9. Alternative assembly
(mechanical seal and plain cover)
52 www.varleypumps.com
ht_pump_manual NEW.indd 52 6/11/07 12:32:09
53. 10. Table of Approximate
approximate
viscosity comparisons
Viscosity Comparisons
The following table lists several commonly used viscosity measurements for quick, easy conversion from one to another.
Although the values are only approximate, they are sufficiently accurate for most pump calculations. The tables are
especially useful because all values may be compared directly with each other.
Sales office ☎ +44 (0) 1582 731144 53
ht_pump_manual NEW.indd 53 6/11/07 12:32:11
54. 11. Definition of hydraulic terms
Head: Static discharge head:
The hydraulic pressure is expressed in pounds per square Is the hydraulic pressure exerted at the pump discharge
inch (psi) gauge using atmospheric pressures as the by the liquid at rest, commonly measured as the difference
datum. It can be determined by use of pressure gauges or in the elevation between the pump discharge port and the
can be computed by using pipe friction tables and static delivery point.
head measurements.
Total discharge head:
Friction head: Is the total hydraulic pressure at the discharge port with the
This is the hydraulic pressure exerted to overcome frictional pump in operation (the sum of the static discharge head
resistance of a piping system to the liquid flowing through it. and the friction head of the discharge piping).
Static suction lift: Total pumping head
The hydraulic pressure below atmospheric at the intake (or dynamic head):
port with liquid at rest. It is usually expressed in or Is the sum of the total discharge head and the total suction
converted to inches of mercury (Hg) vacuum. lift; or the difference between the total discharge head and
the total suction feet.
Total suction lift:
Is the total hydraulic pressure below atmospheric at the Head expressed in feet:
intake port with the pump in operation (the sum of the static Although the foregoing definitions refer to the “head”
suction lift and the friction head of the suction piping). as expressed in psi, it is also proper to specify the total
pumping head in feet of liquid or water. Conversions can be
made between these expressions of psi to feet but since
Flooded suction: there will normally be an appreciable difference between
Is a very indefinite term which has been carelessly used
the feet of head or a particular liquid and the feet of head
for so many years that its meaning is no longer clear. More
of water, it is extremely important to specify which term is
often than not, it merely indicates that suction conditions
being used.
have not been accurately determined. One point to
remember is that a static suction head may become a
suction condition when the pump goes into operation, due Pressure (psi) = head(ft) x Specific Gravity
to friction in the suction pipe work. 2.31
Total suction head:
Is the hydraulic pressure above atmospheric at the intake
port with the pump in operation (the difference between
the static suction head and the friction head of the suction
piping).
54 www.varleypumps.com
ht_pump_manual NEW.indd 54 6/11/07 12:32:11
55. 12. System Design
12. System Fuel Oiltypical fuel oil pumping
Typical design Pumping
System arrangements (for light fuel oils)
The main criteria is to maintain a constant pressure and correct flow to the burners
2. Dead leg system
A dead leg system may extend to many hundreds of feet.
1. Daily service tank systems Constant pressure is maintained by incorporating a relief
Constant pressure to within a few inches water gauge, may valve in the by-pass.
be maintained at the burners.
Note: By-pass line should return to tank – not to intake. If
Note: An overflow, size to handle full flow from the pump, returned to intake any entrapped air will re-circulate and
should be incorporated to limit problems in the event of a cause burner ignition problems.
float switch failure.
3. Main ring system 4. Underground tank system
For feeding burners placed around the perimeter of a Suction lifts should be kept to a minimum.
factory. Pipe sizing must be such as to ensure that losses
do not adversely affect burner performance. Note: The return line should not be fed into the intake but
back to tank. Failure to do so can result in entrapped air
Note: Pump is normally sized to give a circulation flow re-circulating.
around the ring equal to 2 ½ times the total burner
requirements.
Sales office ☎ +44 (0) 1582 731144 55
ht_pump_manual NEW.indd 55 6/11/07 12:32:14
56. 13. Installation, operating
and maintenance instructions
Installation, operating and maintenance instructions
Most pump problems occur at start up!
These notes have been prepared to help you prevent problems as well as deal with them.
All Varley pumps are covered by a one year warranty against defects in manufacture. The commencement date of the
warranty is the date of despatch of the unit from our factory unless otherwise agreed. The warranty also covers damage
sustained in transit, provided both carrier and ourselves receive written notification of any damage within 48 hrs from date
of despatch.
Notes for the guidance of installers
1. The pump should be installed first and the pipe work built away from the pump. This should avoid strain being
imposed upon the pump by poorly aligned pipe work. Such strain may result in rapid seal breakage, bearing failures
or broken pipe ports.
On pumps, which have threaded ports, care should be taken to see that the pipe does not bottom into the port, or
the threads will be damaged and the port broken. Support the pipe to prevent strain due to its weight being imposed
upon the pump.
2. Determining the suction port: Provided that the build of the pump has not been altered after despatch from our
factory, the correct direction of rotation is indicated by an arrow on the pump front cover. This same arrow has
marked upon it the suction port position (namely the tail of the arrow) and discharge port (the head of the arrow).
In any case, a positive check may be obtained by observing the domed protrusion on the side of the non-drive
end cover of the pump – the suction port is always on the same side of the pump as that protrusion (see diagram 4).
3. Ensure that on suction pipe work there is no possibility of any leakage, which could result in air being drawn into the
pump.
4. Filter: A full flow filter on micron mesh should be fitted on the suction side of the pump. If this is not provided, check
to see whether or not one is to be fitted. In cases where the fluid to be pumped is guaranteed to be free from foreign
matter, no filter need be fitted but it is desirable to insert a piece of fine gauze between flanges in the pipe work so
that weld slag, thread cuttings, sand, etc. will be trapped by the gauze and prevented from entering the unit. This
gauze should be removed once the pipe-work system is totally clean.
Start up
Before start up it is wise to check the following points:
1. Check that the pump shaft turns freely. If the pump is jammed solid, it is likely that already some foreign matter has
been introduced into the pump and the gears are jammed. This must be rectified immediately.
2. If the pump will turn but is rather stiff it is likely that the pump is gland packed and the packing has dried out
somewhat on the shaft. In this case, slacken off the two setscrews a couple of turns and continue to turn by hand
until the pump frees.
56 www.varleypumps.com
ht_pump_manual NEW.indd 56 6/11/07 12:32:15
57. Installation, operating
and maintenance instructions
N.B. the pump should not spin
freely, but should have a very
slight resistance to movement with
a gland packed unit. If it is still stiff
after adjusting setscrews, lightly tap
the pump with a soft hammer in
case the material parts have been
forced together during installation.
3. Although Varley pumps are self-
priming, it is much easier and safer,
on an initial start, to hand prime
the pump with a thin lubricating oil.
This guarantees that all parts
are well ‘wetted’ and will result in
rapid pick up of fluid being pumped.
(This procedure is unnecessary
where the pump is beneath the level
of the liquid in the tank).
4. A gland packed pump may leak along the shaft on initial start up, but it is wise to allow a short time of running in this
condition for it to bed in before any effort is made to adjust the gland, Adjustment should then be carried out until
there is just an occasional drip of liquid from the gland area, adjustment should be done carefully over a period of
hours taking each nut down evenly a little at a time.
On some units, and especially on hot oil units, a slight leak may develop across the pump end cover joints. Should
this occur, all the nuts on the end covers of the pump should be checked for tightness.
5. All units have had their relief valves set with respect to discharge pressure, but should this set pressure prove to be
unsuitable on site, it can be varied by screwing the relief valve setting screw on the non drive end cover of the pump
in or out, depending on whether the pressure needs to be increased or decreased. If the correct pressure cannot be
set an alternative spring available from our spares department, may be required.
Fault finding and correction:
1. Failure to prime
a. Check that all valves are in open position
b. Check for leaks in suction line and seal
c. Check that the by-pass valve is not blocked in the open position – clean if necessary
d. Check that the filter is not blocked – change or clean if necessary.
2. Reduction in flow rate
a. Check that the by-pass valve is closed – clean and reset as required
b. Check that there are no leaks in the pump or in the system
c. Check the any regulating valves in both the suction and discharge lines are correctly set
d. Check for increased pressure in discharge line.
Sales office ☎ +44 (0) 1582 731144 57
ht_pump_manual NEW.indd 57 6/11/07 12:32:16
58. Installation, operating
and maintenance instructions
3. Noisy running
a. Check both suction and discharge lines for blockages
b. Strip the pump down and look for damaged parts or foreign matter.
4. Pump has seized and will not turn
a. Dismantle and clean
b. Replace damaged parts
Varley Pumps has an integrated Service and Spares Section, that will undertake fieldwork and manages the repair
section at our works. The spares section will be pleased to help you identify spare parts and supply replacements.
For those who wish to carry out their own maintenance, please refer to the following notes on servicing the units:
Dismantling
Remove pump from bracket, or base plate and proceed as follows:
1. Withdraw the coupling half from the pump shaft (first slackening the grub screw).
2. Carefully remove the key from its keyway.
3. Examine the shaft extension and keyway for cleanliness and carefully remove any burrs.
4. Remove setscrews (or nuts) and washers securing the front cover to the pump body. Break the joint by lightly
tapping the cover with a soft hammer and withdraw the cover.
5. Detach rear cover in the same fashion as for the front cover removal.
6. If fitted, withdraw the spacing collar from the main shaft at the front cover end.
7. Remove any circlips and withdraw the complete rotating assemblies with bearings from the body.
8. In the case of pump size 1 to size 20, the housings will part from the rotor end faces sufficiently to allow the
insertions of extractors for drawings the bearing inner races off the shafts.
In the case of pumps size 35 and above the bearing housings complete with bearing outer races and rollers will
slide freely off the shafts leaving the inner races still in position.
9. Do not attempt to press shaft through the rotors on any of the pump sizes, rotors are permanently secured to the
shafts and they must be considered as one unit. Keep all bearing inner and outer races as sets.
10. Remove the outer races of the bearing from their housings.
11. On a gland packing pump, fully unscrew the gland adjustment setscrews and remove the gland retainer. Remove
all the old packing and then clean and smooth the bore using a fine emery cloth or a small soft wire brush.
12. By-Pass valve
Remove dome nut and release locknut. Screw out the setting screw, making sure the number of turns are counted.
Remove the setting screw housing, spring and valve.
13. Mechanical seal
The mechanical seal-rotating element should be removed from the pump,
before the shaft assembly is pressed out. In removing this seal, it is
advisable to use a dummy - shaft key to prevent the seal ring being cut
when it passes over the keyway (see diagram 5).
The seal collet should be removed by opening up the slot and sliding it
off the shaft. The static seal face is in the front cover; this should be
removed by light finger pressure.
58 www.varleypumps.com
ht_pump_manual NEW.indd 58 7/11/07 15:48:12
59. Installation, operating
and maintenance instructions
Inspection
Examine all parts for wear and damage and clean up or replace with new parts as necessary. It is unwise to rebuild a
pump with worn components, and we fully recommend the replacement of bearings, gaskets, packing and mechanical
seal. It is important to note that a mechanical seal is very unlikely to re-sit in the same place once the two seal faces have
been split.
Reassembly
1. Carefully press the outer races of the roller bearings into the bearings housings.
2. On sizes 1 to 20:
Carefully press the bearing housing and bearing assemblies on to the shaft, ensuring that they are square to the
shaft. Note that in this case the load should be placed on both the inner race of the bearing and the bearing housing
at the same time.
On sizes 35-200:
Place the bearing spacers on the shaft, and press on the inner races. The bearing housings will now slide over the
inner races. NB do not mix up inner and outer races.
3. Where supplied refit the circlips into the grooves in shafts. Check to see that the rotor turns freely in its bearings.
4. Match the main shaft assembly and the idlershaft assembly together and place them in the body from the rear
towards the front of the pump.
5. Very carefully insert the assembly into the body ensuring square entry and that both assemblies are entering the
pump together. Ensure the pressing is done on the outer race to prevent damage to rotors and bearing housings.
6. The assembly is correct when the housings are flush to the body. Fit locating washer and spacing collar, when
provided, replace front and rear cover gaskets and fit the covers. Line up with a suitable bush between the shaft and
front cover bore.
7. After tightening down the covers check that the mainshaft turns freely: if it does not it is probable that the bearings
housings have closed up on the rotors. It is possible to ease them off, by lightly tapping the body with a hide hammer.
8. By-pass valve
Assembly of by-pass should be effected in reverse order to the dismantling.
Note on repacking the gland:
The gland should be repacked using only moulded rings supplied by Varley pumps.
Make sure that the ring joins are staggered to prevent a leakage path for the liquid. Then refit the gland retainer, and screw
in the setscrews until the shaft has just the slightest resistance to movement, (though it should still be quite free to turn).
Sales office ☎ +44 (0) 1582 731144 59
ht_pump_manual NEW.indd 59 7/11/07 15:48:12
60. 14. Service and maintenance
Note on assembly of mechanical seal
Again, the mechanical seal should be assembled in a dummy key in the coupling keyway.
The stationary carbon ring should be carefully pressed into the recess in front cover, care being taken to see that the
carbon is pressed in squarely.
N.B Great care must be taken to see that the carbon is not chipped or cracked during this operation (the carbon is a
brittle component).
It is wise to lightly smear the rotating face with clean lubricating oil before assembly of the front cover.
It should be possible to reassemble a pump satisfactorily, provided normal fitting skill is exercised.
Points to bear in mind when designing the installation.
1. Location of pumps
Wherever possible the pump should be located close to the supply tank. This avoids the necessity for long suction
pipe runs, which can often be troublesome. This is because no pump can literally ‘suck’, it normally requires
atmospheric pressure to ‘push’ liquid into the pump.
2. Sizing of the pipe work
Resistance to flow is reduced as pipe work size is increased, and consequently requires less motive power. We,
therefore, do not apply a limitation to the maximum discharge pipe work that can be employed. It should be noted,
however, that at no time should this be less than the port size of the pump.
NB Care must be taken when choosing the diameter of suction pipe work when the pump is operating under suction lift.
Should the diameter be too large, the pump will spend much of its time, on start up, evacuating the large volume of
air in the pipe, and we strongly recommend the pipe size be kept to the same size as that of the suction port.
3. Noise
Noise may be airborne, structure-borne, pipe-borne, or fluid-borne. The siting of the unit will take care if airborne
noise and steps should be taken to mount the unit on a noise/vibration absorbing base if structure-borne noise
could be a serious problem.
Most fluid and pipe borne noise results from numerous changes of direction causing turbulent flow of the fluid and
vibration of the pipe work. The number of bends should, therefore be kept to a minimum. This form of noise is
frequently the most troublesome as pipe work often runs through a building and the noise is distributed throughout.
The pipe work should also be firmly clipped to the wall, with some anti vibration material between clip and pipe.
When pipe work is not near a wall it must be firmly supported.
4. Suction lifts
It has already been mentioned that pumps should be mounted as closely as possible to the tank. Where this is
impossible the imposition of a suction lift on the pump is often necessary. In such cases, it is essential that the pipe
work be free from all air leaks. Therefore joints should be kept to a minimum. Even though the pump unit is self-
priming a foot valve should still be fitted to the suction line in the tank. Without this the pump is called upon to
60 www.varleypumps.com
ht_pump_manual NEW.indd 60 7/11/07 15:48:13
61. 14. Service and Maintenance
prime the total length of the line at each start up which means longer periods of dry running before the fluid
reaches the pumps and rapid wear can occur.
5. Filter
New pumps rely on the maintenance of fine working clearances for efficient operation, so if there is any possibility
of foreign matter finding its way into the tank and thence to the pump, a full-flow suction filter or 60-80 micron
mesh must be installed to ensure long life. The mesh size will depend on both fluid and application e.g. plain
bearings will require 20 mesh or less.
6. Valving
Isolating valves should always be provided
on either side of the pump to avoid the messy
task of clearing lines before removal of the
pump for maintenance. (See diagram 1 for
suggested layout).
Where two units pump the same line (especially
on an automatic standby system), non-return
valves should be fitted in the discharge from
each unit to prevent back-flow of the unit through
the stationary pump. A satisfactory valving
arrangement is shown in diagram 2.
7. Effect of fluid viscosity
Very careful attention must be paid to the pipe work layout when viscous fluids are being pumped. Suction lifts
should be avoided if possible and all pipe work runs kept as short as possible to avoid large pipe work losses.
Particular care must be taken when heat is required to bring the viscosity to an acceptable level. At start-up the
liquid is often cold, resulting in a severe overloading of the pump and possibly a motor failure. If there is the
possibility of cold starts, you should let us know and we can take it into account when specifying the unit.
8. By-pass valve
The by-pass valves fitted to pumps of our manufacture are intended entirely as pressure relief valves to protect
the pump and system against over-pressure should blockage occur in the discharge pipe work, or should
the imposed load rise too high. It should not, therefore, be used as a pressure regulating valve in normal
circumstances (and it will not normally give adequate regulation if any attempt is made to use it in this way).
Sales office ☎ +44 (0) 1582 731144 61
ht_pump_manual NEW.indd 61 7/11/07 15:48:14
62. Service and maintenance
A system should not be designed using a return-to-inlet
by-pass valve if the discharge is to be kept closed for long
periods, since the fluid will then circulate around the pump
and cause overheating. In this case the alternative return
to tank system should be utilised. To avoid aeration of
oil, the return line back to tank should be installed as far
away as possible from suction line, then entry of this line
into the tank must go below the oil level at all times
(see diagram 3).
Notes for the guidance of designers
Because the pumping unit is relatively simple and
inexpensive, its siting is sometimes given little thought.
It is in fact the ‘heart’ of an installation and therefore the
sizing and location are worthy of careful attention.
Motors
Motors are normally trouble free as long as they are kept in clean dry conditions. Where greasing points are fitted they
should be given one shot of grease every few months running – but not more than one shot.
Filters
Filters should be cleaned regularly.
Pump storage
It sometimes happens that a unit must be obtained well before the plant is to be put into operation. If it should become
necessary to store a pump, or to leave it on site for a lengthy period before operation, the following precautions should
be taken.
1. On gland-packed pumps, loosen off the gland retainer set screws.
2. Liberally coat the pump shaft coupling and motor shaft with a protective oil.
3. Ensure that the motor windings are kept dry either by storing in warm, dry, clean conditions or install heaters
in the motor.
4. Fill the pump body with a corrosion-inhibiting oil and, where the pump is in storage, seal off pump ports.
About once a month give the pump shaft a couple of turns to prevent any standing corrosion effects.
62 www.varleypumps.com
ht_pump_manual NEW.indd 62 7/11/07 15:48:15
63. Service and Maintenance
Recommended Spares
We are frequently asked to provide a list of recommended spares for units of our manufacture. To assist the user to
assess his requirements we break out our recommendations into two headings – namely, ‘normal’ usage spares (those
normally required to be replaced during the overhaul of a unit which has been maintained and operated correctly)
and ‘strategic’ breakdown spares (those spares which should be held against breakdown when the unit is of strategic
importance to the operation of a system).
We give below our normal recommendation for a spares holding:
1 – set gaskets
1 – set gland-packing or mechanical seals
1 – set bearings and housings
Strategic breakdown spares
All those for normal repair, plus all the following:
One complete set of internals, namely: -
Main shaft assey
Idler shaft assey
Bearing housings
By-Pass valve
Obviously, if there are many pumps of the same type operating in a system it would be wise to hold spare pumps,
together with sets of normal usage spares.
Sales office ☎ +44 (0) 1582 731144 63
ht_pump_manual NEW.indd 63 7/11/07 15:48:15
64. 15. Request for quotation
PLEASE COPY THIS FORM AND FAX TO
+44 (0) 1582 402563
Please complete the form below and we will send you a quotation by return. If we
require any more information we will be in touch.
First Name: ......................................................................................................
Last Name: ......................................................................................................
Job Title: ..........................................................................................................
Company: ........................................................................................................
Address: ..........................................................................................................
City: .................................................................................................................
Country: ..........................................................................................................
Postcode / Zip: ................................................................................................
Telephone No: .................................................................................................
Fax:..................................................................................................................
Email:...............................................................................................................
64 www.varleypumps.com
ht_pump_manual NEW.indd 64 7/11/07 15:48:15
65. Fluid Environment Mounting
Name: Safe Standard
Viscosity: Hazardous Horizontal
Operating Temperature: Indoors Vertical
Contamination: Outdoors Tank Top
Suction
Flooded
Lift metres
Discharge Pressure:
Relief Valve
Yes Internal External
No
Drive
Motor Volt Frequency Phase
Other Details:
Notes:
Sales office ☎ +44 (0) 1582 731144 65
ht_pump_manual NEW.indd 65 7/11/07 15:48:15