Gear Pump Installation

Installation Location Guidelines

• Install the pump in a clean, dry, and well-lit area.
• Ensure the pump is easily accessible for maintenance.
• Avoid damp locations for motor-driven units unless proper protection is provided.
• Keep suction piping short, direct, and of full diameter.

Foundation Setup

• Use a solid concrete base for vibration-free and rigid support.
• Include space for grouting beneath the baseplate.
• When installing on steel structures, place the pump directly over beams to avoid distortion.
• Follow mounting drawings carefully for correct bolt positioning.

Factory Alignment

• All Unique Pumps are factory-aligned using surface plates.
• Shims may be used under feet for precise leveling.

Field Alignment

• Position the pump and motor on wedges near bolt holes.
• Use a spirit level to align machined pads on the base.
• Align coupling halves with a straight edge or by rotating the coupling and checking at quarter turns.

Important : Recheck alignment after piping installation. Misaligned piping can distort the pump, leading to hot bearings, noise, and reduced performance.

Grouting

• Grout the baseplate before connecting piping.
• Recommended mix: 1 part cement + 2 parts sand, add water until the mix flows freely.
• Ensure complete support underneath the baseplate.

Suction Piping Guidelines

• Suction line should be of equal or larger diameter than the pump’s suction port.
• Maintain a uniform upward slope from the fluid source to the pump.
• For high viscosity liquids, use oversized suction lines to reduce friction.
• Ensure airtight sealing to avoid capacity loss.
• Install a strainer with 3-4x the area of the suction pipe to prevent foreign particles.
• Discharge should rise vertically (approx. 5x pipe diameter) to prevent airlock.
• Always use a relief valve set slightly above max discharge pressure (no more than +10%).

Stuffing Box and Seals

• Pumps usually come with neoprene oil seals.
• If gland packing is provided, avoid over-tightening. Minimal leakage assists lubrication.

Priming Before Startup

• Never run the pump dry. Always prime with liquid before starting.
• If internal oil is present from testing, clean and refill with process fluid if needed.

Direction of Rotation

• Follow the arrow marked on the pump.
• For reverse operation, rotate the back cover 180°, reposition bolts and grub screw accordingly.

Starting the Pump

• Prime the pump fully.
• Check all electrical connections and control circuits.
• Confirm suction and discharge pressures are within specifications.
• Start under low load and gradually increase to full operation.
• Lubricate bearings periodically if external grease fittings are present.

Routine Maintenance Checklist

Periodic Checks :

• Confirm pump-motor alignment.
• Inspect for suction air leaks or clogged strainers.
• Adjust relief valve if pressure drop occurs.
• Check and tighten end cover bolts if leakage is noticed.

Annual Inspection :

• Replace worn gears, wear plates, or seals.
• Inspect and replace oil seals, bearings, or the entire body if needed.
• Ensure proper lubrication and part alignment.

Troubleshooting Tips

• If pump jams, loosen bolts slightly and use a pipe wrench to rotate the shaft.
• Allow overheated pumps to cool before restarting.
• Never dismantle without first consulting Unique Pump System.
• Use caution during commissioning—tight shafts may still be normal due to tight tolerance.

Rebuilding Pumps with Bush Bearings

• Remove side covers and rotors.
• Check bush face wear; replace or machine if required.
• Maintain equal bush widths and appropriate packing.
• Inspect and eliminate burrs on body and rotors.
• Reassemble and ensure free shaft rotation with pipe wrench.
• Replace seals and check tightness.

Rebuilding Pumps with Antifriction Bearings

• Unbolt covers and use jacking holes if needed.
• Remove rotors, bearings, and wear plates.
• Inspect wear plates and gear faces; regrind or replace if necessary.
• Remove burrs and reassemble components precisely.
• Re-check free shaft rotation, replace seals, and tighten all bolts evenly.

Recommended Spare Parts List - Unique Rotary Gear Pump

Important : When requesting spares, provide:

Pump serial number and nameplate details
Purchase order number and date

Conclusion

Proper handling of your Unique Rotary Gear Pump ensures long-lasting performance, minimal downtime, and operational efficiency. Following this guide during installation, operation, and maintenance will reduce the chances of equipment failure and maximize productivity.