ERI AquaBold Pump

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

2x3x5
3x4x7
4x6x9
Energy Recovery Inc
17608 Commerce Drive, New Boston, MI 48164
Tel: 1-734-639-5000 / Fax: 1-734-639-5001

www.energyrecovery.com

ERI AquaBold Pump Manual

TABLE OF CONTENTS
1

INTRODUCTION .....................................................................................................................1
1.1 About This Manual .......................................................................................................1
1.2 Available Support Resources .......................................................................................1
1.3 Icons Used in This Manual ..........................................................................................1

Safety Precautions ......................................................................................................................3

Critical Startup Checklist ...........................................................................................................4

3.1 Know Your Machine ....................................................................................................4
3.1.1

Driver Instruction: ........................................................................................4

3.1.2

Piping: ..........................................................................................................5

3.1.3

Instrumentation: ...........................................................................................5

3.1.4

Mechanical Seal: ..........................................................................................5

3.2 Before any operation of the pump - CRITICAL ..........................................................6

3.2.1

Check Driver Rotation: ................................................................................6

3.2.2

Starting Pump...............................................................................................6

3.2.3

Once running, check ....................................................................................6

RECEIVING YOUR UNIT .......................................................................................................7

4.1 Inspection .....................................................................................................................7
4.2 Short-Term Storage: 1 day - 6 months .........................................................................7
4.3 Long-Term Storage: 6 months or more .......................................................................7

INSTALLATION ......................................................................................................................8
5.1 Mounting ......................................................................................................................8
5.2 Coupling Installation ..................................................................................................10
5.3 Filtration .....................................................................................................................10
5.4 Guidelines for Installing the Suction and Discharge Piping ......................................10
5.5 Flushing ......................................................................................................................11
5.6 Motor Rotation ...........................................................................................................12

STARTUP ................................................................................................................................13

PUMP OPERATION ...............................................................................................................14

7.1 Suction Conditions .....................................................................................................14
7.2 Discharge Conditions .................................................................................................14

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7.3 Minimum Flow Conditions ........................................................................................15

7.4 Maximum Flow Conditions........................................................................................15
7.5 Drivers ........................................................................................................................15
7.6 Entrained Gases ..........................................................................................................15
8

SERVICING/MAINTENANCE ..............................................................................................16
8.1 Guidelines ...................................................................................................................16
8.2 Mechanical Seal Replacement....................................................................................16
8.2.1

Seal Removal .............................................................................................16

8.2.2

Seal Re-installation ....................................................................................18

8.3 Pump Disassembly .....................................................................................................20

8.4 Pump Reassembly ......................................................................................................26
8.5 Thrust Bearing Inspection/Replacement ....................................................................27
9

TROUBLESHOOTING ...........................................................................................................32
9.1 Pump Troubleshooting ...............................................................................................32
9.2 Mechanical Seal Troubleshooting ..............................................................................35

10 ERI CUSTOMER/FIELD SUPPORT .....................................................................................37

11 REVISION LOG ......................................................................................................................38
12 DRAWINGS AND DATA .....................................................................................................38
Figures
1

Pump Lifting Diagram

Mounting Diagram

Shim Diagram

Temporary Filter Setup During the Flushing Process

Pump Lifting Diagram

Tables
1

Seal Gland Nut Torque Values

Impeller Tolerances

Torque Values

4 Pump Troubleshooting

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Mechanical Seal Troubleshooting

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ERIAquaBold Pump Manual

1 INTRODUCTION
1.1 About This Manual
This manual contains instructions for the installation, operation, and maintenance of Energy
Recovery, Inc.s (ERIs) AquaBold high-pressure, multistage centrifugal pump. This
information is provided to ensure the long life and safe operation of your AquaBold pump.
This manual is intended for use by personnel with training and experience in the installation and
operation of fluid handling systems.
ERIs AquaBold pump is intended for clean water or liquid applications where high efficiency
and low maintenance are important considerations. This pump offers optimal performance,
durability, and reliability, with minimal maintenance. Our superior materials of construction,
enhanced corrosion resistance, and improved bearing and debris management will provide you
with years of service life.
The ERI AquaBold pump features our proprietary Hiperax hydrodynamic water lubricated
thrust bearing, which eliminates the balance drum/disc, balance chamber, and return line. The
Hiperax bearing reduces complexity with its efficient and compact design. All radial bearings,
interstage bushings, and wear rings are constructed to allow closer running clearances and
greater efficiency. A single, unitized mechanical seal is employed on the suction side of the pump
and is designed for easy inspection and maintenance.
Typical uses of the ERI AquaBold pump include reverse osmosis high pressure feed service,
boiler feed, nitrogen oxide (NOx) suppression, pollution control, and hydrocarbon processing.
The ERI AquaBold pump can be used as the high pressure pump for systems utilizing any type
of energy recovery device, including the ERI Turbocharger and PX Pressure Exchanger
devices.
1.2 Available Support Resources
ERI technicians are based worldwide and are available to assist you. ERI provides many
technical services with the goal of making your project a success. ERI technicians are available
for commissioning, process, and instrumentation drawing reviews (P&ID) and technical
consultation. We are always available by phone to answer any system design or operational
questions at 1-510-483-7303 and ask for Technical Support. Please go to our website at
www.energyrecovery.com to find local contact information in your area or e-mail our service
team at support@energyrecovery.com for additional information.
1.3 Icons Used in This Manual
The following icons (symbols) are used to indicate specific types of information

Good ideas to use: A reminder to do something.

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Equipment use alert: Failure to follow these procedures may result in damage to the
equipment.

Safety alert: Failure to follow these procedures can endanger you or others

Electrical hazard: Failure to follow these procedures can endanger you or others.

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2 SAFETY PRECAUTIONS

Suggested Safety Instructions:

During installation, maintenance or repair of ERIs AquaBold pump, safety systems should be
installed prior to initial operation or before attempting any repairs. Failure to take responsibility
for safety may lead to injury of operator or others.
The ERI AquaBold pump has been designed to provide safe and reliable service. However, it
is industrial rotating machinery that creates high pressure. Therefore, operators and personnel
must exercise good judgment and proper safety practices to prevent injury and avoid damage to
the equipment and surrounding areas. It must be understood that the information contained in
this manual does not relieve operation and maintenance personnel of the responsibility of
exercising normal good judgment in the operation and care of this product and its components.
The safety officer at the location where this equipment is installed must establish a safety
program based on a thorough analysis of local industrial hazards. Proper installation and care of
shutdown devices and over-pressure and over-flow protection equipment must be an essential
part of any such program. In general, all personnel must be guided by all basic rules of safety
associated with high-pressure equipment and processes. Operation under conditions outside of
those stated in the pump datasheet can result in damage to the pump.

Lock-Out/ Tag-Out Guidelines:

Follow your companys Lock-Out/Tag-Out procedure when servicing ERIs AquaBold pumps.

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3 CRITICAL STARTUP CHECKLIST

3.1 Know Your Machine
Before servicing and starting up the ERI AquaBold pump, read the entire manual and carefully
review the specification sheet, the outline drawings, and performance curves. It is important to
become familiar with this pump before start-up and operation.
1. Report any external damage to the pump before proceeding.
2. Verify that the pump has been properly installed as specified in this manual.
3. Verify that the feed water quality meets the ERI specifications. Debris in the feed water
can DAMAGE pump bearings and seals.
4. Verify that the feed water supply pressure meets ERI specifications.
5. Verify that all the piping that feeds the pump has been thoroughly flushed.
6. Verify that you have the following information on site and available during start-up.
A. ERI AquaBold Pump Installation and Operations Manual
B. Pump Specification Sheet
C. Pump Curves
D. Driver Manual
E. Coupling Manual
F. Mechanical Seal Manual
3.1.1 Driver Instruction:
Carefully follow the installation and starting instructions provided by the manufacturer of the
driver.
1. Verify that the driver is correctly aligned with the pump.
2. Verify that the correct driver bearing grease is on site.
3. Verify that the electrical connections are correct.
4. Verify all overload protections are in place and functioning properly.
5. Verify that the available electrical power supply meets the system requirements.

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3.1.2 Piping:
1. Verify that there is no strain on the piping connections to the pump. The pump should
NOT carry any loads induced by piping. Piping should be independently supported.
2. Make sure pump flange bolts, seal environment piping, and port connections are properly
secured.
3. Verify that temporary start-up screens, if used, are properly installed, including
differential pressure indicators (recommended).
4. Verify that the auxiliary piping conforms to ERIs drawings.
5. After the pump-motor assembly has been installed at its final location, verify again that
all piping connections are lined up.
6. Verify that the tools required for normal start-up and maintenance activities are on site.
See the ERI Recommended Tool List for your pump.
3.1.3 Instrumentation:
1. Verify the connection points of the instruments and open all root valves.
2. Calibrate and verify the set points of all measurement equipment (flow meters, current or
ampere meters, pressure meters, pressure switches, etc.).
3. Verify that the variable-frequency drive (VFD) configuration, if used, is correct.
4. ERI recommends thatat a minimumthe following instruments are installed before
operation.

Suction pressure indicator

LOW suction pressure switch

Feed water flow meter

Discharge pressure indicator

HIGH discharge pressure switch

Voltage and current indication

3.1.4 Mechanical Seal:

Understand the installed mechanical seal type and how it operates. Some applications require
special systems to control the environment of the seal and some applications require special seal
flush systems. Always ensure that the seal is flooded before operation and that the seal is
properly vented.
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3.2 Before any operation of the pump - CRITICAL

Ensure that the pump has been flooded and that all air has been purged from the system. Air
entering the pump during operation can damage seals and bearings. NEVER operate the pump
dry for ANY length of time. Be sure to thoroughly flush the suction piping to the pump BEFORE
connecting to the pump itself to ensure all construction debris is removed.
3.2.1 Check Driver Rotation:
Driver rotation must be in the same direction as the arrow on the pump casing. If the pump
cannot be flooded during the check, uncouple the pump before checking driver rotation.
3.2.2 Starting Pump
Start pump with suction valve completely open while throttling discharge valve to bring pump to
design operating point. If a VFD is used to control the driver, start the pump at the specified
minimum flow rate and ramp up the pump to normal operating speed.
3.2.3 Once running, check
Check total head, flow rate, and power consumption against pump specification sheet. Check that
specific gravity, viscosity and net positive suction head (NPSH) are in accordance with
specification sheet. These conditions will significantly alter performance of pump. There should
be no abnormal noise or vibration during running.
Please read the entire pump manual for more detailed information. Please contact
support@energyrecovery.com with any questions or to discuss problems.

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4 RECEIVING YOUR UNIT

4.1 Inspection
When you receive the ERI AquaBold pump, check for any damage. If you find any, inform the
carrier and ERI immediately.
Check the outline drawings and bill of material to ensure that all auxiliary items are properly
included.
Check the pump shaft. Seal drag may cause it not to turn freely at first; this is normal.
4.2 Short-Term Storage: 1 day - 6 months
If the pump is to be stored near strong chemicals or salt water, protect it immediately. To do this,
follow the steps from the long-term storage procedures below.
Protect the unit from moisture and dust.
Make sure that the factorys shipping covers the housing flanges and the seal ports are securely in
place.
Carefully follow the storage instructions provided by the manufacturer of the motor or turbine.
4.3 Long-Term Storage: 6 months or more
If you store the ERI AquaBold pump for a long period of time, the following procedures are
very important. If you require further instructions, please contact ERI.
Be sure the storage area is indoors.
Do not allow contact of airborne chemicals with the internal components of the unit.
If the unit is being stored near strong chemicals or salt water, protect it immediately.
Protect the unit from moisture and dust.
Turn pump shaft by hand approximately 1-2 turns every 1 to 2 months to prevent brinelling of
motor bearings particularly if pump is stored in high vibration environment.
Make sure that the factorys shipping covers for housing flanges and seal ports are securely in
place.
Prevent corrosion of the non-stainless steel components of the motor, and coupling.
After long-term storage, have an authorized ERI service engineer inspect all components and
supervise any necessary repair to be sure that they work properly. Any components not made by
ERI (except mechanical seals) must be inspected or replaced as determined by the

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manufacturers authorized personnel, at the purchasers expense. Any Field Service work must
be clearly stated at the time of purchase.
5 INSTALLATION
5.1 Mounting
A. Be sure to lift the pump hydraulic end in the proper fashion. NEVER lift the pump by its
shaft as this will cause internal damage.

Figure 1: Pump Lifting Diagram

B. During pump installation, ensure that adequate surrounding space is available for inspection,
operation and maintenance requirements.
C. The pump and driver for the frame mounted units should be bolted to a concrete foundation
or an adequately supported structure substantial enough to absorb any vibration and to
provide a rigid support.
D. Failure to provide adequate mounting per this manual can result in damage to the pump and
therefore void the product warranty.
1. ERI recommends to choose a solid ground location and build the foundation form 3
inches larger overall than the bedplate.
2. Use bedplate anchor bolts of the same size specified in the outline drawing. Provide pipe
sleeve with an internal dimension (I.D.) 2.5 to 3.0 times the bolt diameter. Provide flat
washers between the bolt head and pipe sleeve to keep the bolt from slipping through the
pipe sleeve. See Figure 2.

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Figure 2: Mounting Diagram

3. Bolts should be of sufficient length so that they will project at least -inch or 6.35 mm above
the nuts after allowing for bedplate, shim and nut thickness. Locate the bolts accurately
according to the outline drawing.
4. Pour concrete and tamp or vibrate during the pouring process to ensure no hollow spot forms.
This is especially important around the anchor bolts. Do not allow any concrete to fall inside
the pipe sleeves.
5. Level off the concrete surface. Leave a rough finish to provide a good base for grout. Allow
the foundation to cure for one week before installing.
6. Hoist the bedplate above the foundation and lower into position over the anchor bolts.
Anchor bolts can be moved laterally in the hollow of pipe sleeve for ease of alignment with
the holes in the base plate.
7. Using a precision level across the bedplate (front-to-rear and side-to-side), insert steel shims
as required next to each bolt until the bedplate is level in all directions. See Figure 3. Secure
the anchor bolt nuts finger tight only.

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Figure 3: Shim Diagram

8. Provide a wood dam around the base perimeter of the bedplate and thoroughly wet the top
surface of the foundation. The use of non-shrink grout is recommended. Grout should be of a
consistency to flow out under the bedplate against the wood dam. Grout should be puddled
continuously as it is poured to expel air and to completely fill the space under the bedplate.
Fill to the level of the grout hole.
9. Allow the grout to harden for at least 48 hours. Tighten the anchor bolts.
5.2 Coupling Installation
Please refer to coupling manufacturers instructions included with your shipment.
5.3 Filtration
The thrust bearing of the ERI AquaBold pump is a hydrodynamic bearing. This bearing works
on a fluid film layer. Debris infiltration into the pump can break this fluid film layer and cause
damage to the bearing. Nominal filtration of 10 microns is required in order to protect the
bearing from debris damage.
5.4 Guidelines for Installing the Suction and Discharge Piping
A. Good installation practice dictates that there should be a minimum straight length of pipe on
the suction of the pump equal to three (3) times the suction pipe diameter. This is to allow
the liquid to flow into the pump casing/impeller without turbulence. Furthermore, good
installation practice dictates the use of suction piping at least one size larger than the pump
flange and reduction of the pipe diameter at the pump flange. Never use suction piping of a
smaller diameter than the pump suction inlet.

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B. Both the suction and discharge piping should have no unnecessary elbows, bends and fittings
as they increase friction losses in the piping. The size of pipe and fittings should be selected
carefully to keep the friction losses as low as practical.
C. Suction and discharge block-and-bleed valve designs are recommended to isolate the pump
during shutdown and to drain the process piping when removal of the pump is necessary.
D. Under no circumstances should the suction pipe be forced in order to align it to the pump
suction inlet. The flange bolts should slip into the aligned flange holes without straining the
piping.
E. If the ERI AquaBold pump is provided with flanges, gasket surfaces should be parallel and
flange bolts should slip into the aligned flange holes without straining the pipe to fit the
pump.
F. Piping layouts should be designed to provide sufficient support and flexibility to minimize
forces and moments induced by the piping onto the pump.
G. The suction line should be cleaned thoroughly and a temporary strainer made of a corrosion
resistant material of approximately 40 mesh must be installed during initial startup to protect
the pump internals from damage by mill scale, welding slag, or other foreign particles.
Failure to adequately clean the piping system prior to startup can void the pump warranty and
cause severe internal damage to the pump.
H. All piping must be supported independently of the pump. Proper support for the suction and
discharge piping is essential in order to avoid pipe strain on the pump casing.
I. Always provide a suction pressure gauge on all installations to monitor suction conditions.
Install the gauge as close as possible to the suction flange. When temporary suction strainers
are used, ensure that the gauges are installed on both sides of the strainer.
J. Always provide a discharge pressure gauge on all installations to monitor discharge
conditions. Install the gauge as close as possible to the discharge flange.
K. Check valves should be placed on all the installations where back flow through the pump is
possible. If a check valve is installed in the discharge line, provisions should be made to vent
the space between the pump and the check valve or the pump may not prime.
5.5 Flushing
Suction piping must be flushed while disconnected from the pump. Flushing through the pump
can introduce debris that can damage the pump internals.
The suction line should be clean and a temporary suction strainer of approximately 40 mesh
made of a corrosion resistant material must be installed during initial startup to protect the pump
from damage by mill scale, welding slag or other foreign particles during initial startup
(Figure 4).

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Figure 4: Temporary Filter Setup During the Flushing Process

1. Differential pressure gauge

2. Filter

Use a filter with a length 3 times the diameter of the piping.

Conical filters have proved suitable.

5.6 Motor Rotation

Reverse rotation of your ERI AquaBold pump may damage the unit. Ensure that the motor
shaft rotation is in the same direction as the arrow on the pump marked rotation.

A. Decouple the pump and motor shafts.

B. Be sure that the motor shaft turns freely by hand.
C. Determine that the motor is wired for the correct rotation by jogging the motor for one
second. The motor direction can be verified by observing the motor shaft or fan.
D. If the motor rotation is in the incorrect direction, reverse the rotation by changing any two of
the motor leads.

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6 STARTUP
A. Review the pump specification sheet noting design parameters and possible seal system
requirements.
B. Check to ensure that the driver has been serviced per the instructions supplied by the driver
manufacturer.
C. Check to ensure that the screen has been installed in the temporary suction strainer with
proper orientation
D. If a buffer fluid or external seal flush is required, ensure that this system is pressurized prior
to flooding the suction. Failure to pressurize the buffer system will allow the process fluid to
contaminate the buffer fluid and may also allow contaminants in the process stream to
damage the seal face.

Starting your ERI AquaBold pump against a completely closed discharge valve will dead-head
the pump and may damage the process seal and bearings.

E. Fully open the suction and discharge valves to flood the suction. If there is a check valve in
the discharge piping, ensure that the space between the pump and check valve is vented.
F. Purge or vent all high points in the suction and discharge lines.
G. After the suction is flooded, adjust the control valve to approximately 50% of normal flow.
This is necessary to prevent overloading of the driver and to prevent the pump from
operating off the end of the curve at startup.

During startup, pay close attention to the discharge pressure gauge. The pressure should rise
quickly and remain steady. If the pressure rise is sluggish and drops back to a lower level, stop
the pump. The erratic pressure behavior is a sign that air and/or vapors are in the pump and
suction line. The pipe system and pump should be purged of all air and gases prior to startup.
J. Start the driver. Adjust the control valve or VFD to the desired flow and check the head,
flow, and motor horsepower against the anticipated conditions.
L. Continually check the pressure drop across the suction strainer. Never allow the suction
pressure to drop below the minimum design pressure that would ensure adequate NPSH).
This minimum suction pressure should be established before commissioning.
M. When the pressure drop across the strainer increases, the temporary screen is becoming
clogged with particles and must be cleaned out. The pump should be shutdown and the

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discharge and suction valves blocked in to isolate the pump and screen. After the strainer has
been cleaned and reinstalled, the pump must be primed just as during the initial start up.
N. Examine the debris and/or particles removed from the strainer each time it is cleaned.
Typically, the strainer contents will be matter foreign to the process and it will take longer
and longer for the strainer to clog up. If no new debris shows up for a reasonable period of
time, the temporary strainer and pressure gauge can be removed.
O. If the temporary strainer keeps clogging up at a relatively steady pace and the clogging
material is process oriented particles, such as undissolved crystals, high boiler compounds
or other entrained particles which are expected to continue forming in the pumpage at about
the same constant rate, some permanent modification in the pumping system may be
required.
7 PUMP OPERATION
While the application of the ERI AquaBold pump in any particular system is not within the
scope of this instruction manual, the importance of proper application to successful pump
operation cannot be ignored. Several factors must always be considered.
7.1 Suction Conditions
A. The most common reasons for improper centrifugal operation are those relating to proper
flow of liquid into the impeller. To avoid turbulence at the eye of the impeller, the suction
pipe should be straight for at least 3 pipe diameters beyond the suction inlet of the casing.
Suction piping size should be equal to or larger than the pump suction inlet.
ERI recommends that the margin between the required and available NPSH be at least 3 feet
(1 meter).
B. The pressure of the liquid reaching the impeller eye must or should have sufficiently high
pressure to prevent flashing in the impeller. The result of this liquid flashing is a
phenomenon called cavitation. Cavitation can cause damage to the impeller and inducer and
is caused by insufficient NPSH. Cavitation is sometimes noticeable as a pumping gravel
noise in centrifugal pumps. The easiest way to prevent cavitation is to maintain suction
pressure at a high enough level to overcome the effects of high vapor pressure and excessive
friction losses in the suction piping. Careful design of the pump suction conditions will
ensure that the available NPSH exceeds the NPSH required by the ERI pump.
7.2 Discharge Conditions
A. Ensure that the pipe system is not over pressurized and that the discharge pressure of the
pump does not exceed the design rating of the equipment.
B. Care must be exercised in the fitting of non-return valves to discharge pipe work as this may
prevent correct venting of the pump prior to start up.

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C. When operating your ERI AquaBold pump, always vary the flow with a valve installed in
the discharge line. Never throttle flow from the suction side. Attempting to throttle flow from
the suction side may result in Failure of the pump due to inadvertent dry run of the seals or
cavitation.
7.3 Minimum Flow Conditions
A. Centrifugal pumps can also experience vibrations from internal flow separation and
recirculation at low flow conditions. The minimum flow of your ERI AquaBold pump is
shown on the pump data sheet. The pump data sheet is provided during the proposal process.
While a pump can operate without harm with some noise due to recirculation, excessive
noise and vibration are signs that the pump may be subject to damage if operation is
continuous.
B. Protection against operation below minimum flow is possible by use of either a continuous
bypass or by a flow controlled bypass. Any bypass designs must return the liquid to the
suction tank or to a location with a similar heat sink capability. If a bypass design is used,
part of the total flow through the pump is never pumped to the process. Therefore, the
operator must consider the combined process flow and bypass flow requirements when
specifying the pump for an application.
C. Noise and vibration may be accentuated by resonance in the discharge line, especially when a
control valve is located well down-stream from the pump. Optimum performance will be
achieved when the control valve is located within 5 feet (1.5 meters) from the pump
discharge.
7.4 Maximum Flow Conditions
Maximum flow of the ERI AquaBold pump should be limited to the value on the pump data
sheet. This maximum flow limitation assumes that the driver horsepower and NPSH
requirements of the unit are not exceeded.
7.5 Drivers
A. The equipment should only be used with the driver specified at the time of order. The driver
horsepower rating has been specifically designed for the design conditions. An engineering
review is recommended before making any changes. The driver size should not be changed
without consulting ERI.
B. The driver bearings should be greased in accordance with the bearing lubrication
recommendations provided by the driver manufacturer.
7.6 Entrained Gases
A. Entrained gases in the fluid will reduce the head and capacity of a centrifugal pump.
Entrained gases in the process stream may also damage the process seals.

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B. During the design of the suction vessel and piping, ensure that sufficient submersion of the
pipe work is maintained and that air entrainment and vortices do not occur. Failure to do so
will allow vapors and undissolved gases into the pump and may cause a seal failure. Tanks
should be designed to allow sufficient residence time for the gases and vapors to disengage
from the liquid.
8 SERVICING/MAINTENANCE
8.1 Guidelines
The normal operating routine, including both minor and major overhaul intervals, depends to a
great extent upon the pump service and duty cycle. The operating life of a piece of equipment is,
under normal circumstances, determined by the action of the operator. All operating parameters
should be frequently observed and recorded. Any deviation from normal range of operating
values should be immediately investigated to determine the cause and to take corrective actions.
The following items should be serviced at the intervals indicated.
Driver: Service the driver according to the manufacturers recommendations.
Seal Leakage: Seal leakage out of the seal drain port should be periodically checked. Seals
should be replaced if leakage increases to an unacceptable level. With a double seal system, the
buffer pressure and usage should be monitored to ensure that the seals are functioning properly.
Coupling: If a flexible coupling is used, refer to the manufacturers recommendations for
service intervals.
8.2 Mechanical Seal Replacement
One of the benefits of the ERI AquaBold pump is that the mechanical seal can be replaced
without disturbing the pump-motor alignment. Follow these steps to replace the mechanical seal.
8.2.1 Seal Removal
1. Remove the motor adapter protection screen.
2. Drop out the coupling spacer (if applicable) and the pump side coupling hub.
3. Remove the four (4) seal gland nuts.

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Seal Before Removal

Remove the seal gland.

Remove rotating seal and spring.

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8.2.2 Seal Re-installation

Press non-rotating seal component into the seal gland. The shiny side of the seal should face up.

Separate the two parts of the rotating seal.

Slide the seals spring onto the shaft.

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Slide the portion of the rotating seal with the metal ring onto the shaft. It will take some force to
push it on.

Press the other portion of the rotating seal onto the shaft.

Install the seal gland onto the shaft.

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Be sure to press the gland all the way in until it meets the suction housing. Re-install the gland
nuts to the following torque values listed in Table 1.

Table 1: Seal Gland Nut Torque Values

ERI AquaBold Pump Model
2x3x5
3x4x7
4x6x9

Torque, ft-lbs (N-m)

40 (54)
40 (54)
90 (122)

8.3 Pump Disassembly

Before disassembling the pump, remove the mechanical seal according to the instructions in
Section 8.2. The pump must be disassembled in the vertical position. Place the pump vertically
on a clean and level table with a hole in the table large enough to allow the pump shaft to pass
through. If a table is not available, the pump should be stood up on the bell housing motor
adapter.
Important note: Do not use the shaft as a lifting point for the pump. This can damage the internal
parts.

Figure 5: Pump Lifting Diagram

Follow the steps below to completely disassemble the pump hydraulic end. Please see
Section 8.4 for steps to inspect the thrust bearing in the horizontal position.
When it is desired to inspect or repair the internal parts of the AquaBold pump, please follow
the following instructions. A complete inspection will require precision measurements of outer
and inner diameters. Suitable measuring equipment such as OD micrometers and ID micrometers
or telescoping bore gauges should be available.
The pump to be worked on needs to be shut down and secured for maintenance following the
plants approved safety procedures. Motor controllers need to be tagged out of service and/or
locks placed on circuit breakers or motor starters to ensure there will be no inadvertent startup of
the pump while undergoing service. The pump and piping system should be depressurized and
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isolated from the pump by valves that are secured and tagged or by isolation flange blanks.
Failure to properly secure the pump may result in damage to the equipment and possibly severe
injury to personnel.
Once the pump is in the vertical position, the bare shaft end must be supported.

Remove end cap nuts and end cap

Before

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After

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Remove impeller retaining sleeve nut and sleeve. You must prevent opposite end bare shaft
from turning while removing the nut.

Remove final diffuser stage

Remove final impeller

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Remove final impeller key and interstage sleeve

Remove thrust bearing

Remove radial positioning stage retaining screws. There are two (2) screws per hole.

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Remove the motor end containment shell nuts

Remove the containment shell

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Remove the radial positioning stage (RPS)

Before

After

Remove the next impeller

Remove the impeller key and interstage sleeve

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Continue this process until all diffuser stages, impellers, keys, and sleeves have been removed.
You may then lift the shaft out of the suction housing. Once all of the components are removed,
measurements can be taken to check clearances. Refer to Table 2 below for tolerances.

Table 2: Impeller Tolerences

Maximum Allowable Diametrical Clearance
AquaBold Pump Model
Impeller Wear Ring
Interstage Bearing
2x3x5
.014
.007
3x4x7
.016
.007
4x6x9
.019
.009
2x3x5
3x4x7
4x6x9

Drive End Radial Bearing

.006
.007
.008

End Radial Thrust Bearing

.007
.007
.009

8.4 Pump Reassembly

To re-assemble the pump, follow the disassembly instructions in the reverse order. Be sure to reinstall impellers in the same order that they were removed. Make sure that all o-rings and seals
are properly installed during re-assembly. ERI recommends replacing all o-rings and seals when
the hydraulic pump end is serviced.
Additional Measuring

There are two additional steps during re-assembly. After installing the RPS, check that the RPS
is perpendicular to the shaft. The measurement must be within 0.003 around the entire RPS
stage.
When re-installing the shaft retaining nut, refer to Table 3 below for torque values.

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Table 3: Torque Values

Model
2x3x5
3x4x7
4x6x9

Retaining Nut Size

3/4 - 10
7/8 - 9
1-8

Torque, ft-lbs (N-m)

130 (176)
202 (274)
271 (367)

Check end thrust tolerence

After assembly is complete but before the seal is re-installed, check the end thrust of the pump.
The end thrust must be within the following tolerance before proceeding.
Total thrust should be in the range indicated in 0.0150.030 inches or 0.3810.762 mm.
If the end thrust is out of tolerance, there was an error during re-assembly and the procedure
must be repeated. All parts should be checked to ensure they were installed properly.
The seal may now be installed per the instruction in Section 8.2. After seal installation, re-install
the coupling and follow the normal startup procedures.
8.5 Thrust Bearing Inspection/Replacement
The pump can remain in the horizontal position.

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Remove suction and discharge piping.

Remove end cap retaining nuts

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Remove final diffuser stage

Remove shaft retaining nut. Be sure to secure the opposite end of the shaft to prevent the shaft
from rotating.

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Remove final impeller retaining sleeve

Remove final impeller

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Remove thrust bearing

Thrust bearing removal is now complete. To re-install, follow these instructions in reverse order.
No precision measurements are required during removal or installation of the thrust bearing.

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9 TROUBLESHOOTING
9.1 Pump Troubleshooting
Table 4: Pump Troubleshooting
Problem
No flow, no pressure
at startup.

Possible Cause

Investigative/Corrective Action

Pump not completely

primed.

Bleed all vapors and gases from system. Also

bleed vapor or air from the seal flush port.
Allow more cool-down time if pumping a low
temperature fluid.
Verify that pump and suction line are full of
liquid.

NPSH available is lower

than requirement shown
on pump specification
sheet.

Suction line blocked. Check suction strainer

and valves.
Excessive pressure drop through suction
piping.
Flow restricted by vapor pockets in high points
of suction and discharge piping.
Inability to vent past a check valve in the
discharge piping.
Suction tank pressure too low.
Entrained gases in pumped liquid.
NPSH reduced by a more volatile process
liquid.

Failure of drive
component, impeller key,
high-speed shaft bearing,
or coupling.

Replace as necessary.

Wrong direction of rotation Direction of driver shaft rotation is shown by

on motor.
arrow on gearbox housing.
Note: Impeller and driver rotate in different
directions. Rotation can be check by viewing
driver fan (or input shaft on frame-mounted
units). Reverse any two leads on motor to
change direction of rotation.
Pump starts and then Improperly primed pump.
stops pumping.

Attempt to prime pump. If priming is not

possible, inspect suction piping for
obstructions.
Determine if there is a check valve on the
discharge. If so, determine if the vapors
between the pump and the check valve are
properly vented.

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Suction screen plugged.

Suction line blocked. Check suction strainer

and valves.

Air or vapor pockets in

suction line.

Vent suction piping at the highest point.

Determine if the piping must be redesigned to

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Table 4: Pump Troubleshooting
Problem

Possible Cause

Investigative/Corrective Action
eliminate the formation of air or vapor
pockets.
Note: An eccentric reducer with Belly side
on top will create a vapor pocket.

Insufficient flow or
pressure.

Flow rate is higher than

pump design allows.

Check head rise and flow rate against

performance curve.

Wrong direction or driver Direction of driver shaft rotation is as shown by

arrow on gearbox housing.
shaft rotation.
Note: Impeller and driver rotate in different
directions. Rotation can be checked by
viewing driver fan or input shaft on framemounted units. Reverse any two leads on
motor to change direction of rotation.
Air trapped in pump or
pumping entrained vapors
or gases.

Check shutoff pressure. If deficient, vent

pump.
Determine if there is a check valve on the
discharge. If so, determine if the vapors
between the pump and the check valve are
properly vented.

Impeller damage by
passage of solid particles.

Inspect impeller for nicked, bent, or worn

blades. Replace impeller if damaged.

Available NPSH is lower

than required as shown on
pump specification sheet.

Refer to solutions provided under No Flow,

No Pressure at Startup.

Flow too low, causing

overheating of fluid and
loss of NPSH after a short
period of satisfactory
operation.

Increase pump flow rate.

Increase bypass flow rate or use seal cavity
bypass to continuously increase inlet flow
rate. Vent to the highest point of the pump.
Install bypass to recirculate portion of pump
discharge back to the supply tank.

Pressure gauges or flow

meters in error.

Remove and replace with calibrated

instrument.

Corrosion pitting on pump

Minor pitting may be polished with emery
casing.
cloth. Major pitting indicates a failed part and
should be replaced.
Inspect remainder of pump to determine if
other areas of pump are damaged from
corrosion. Replace damaged parts.
Identify source of corrosion mechanism.
Determine if process conditions can be
changed. Consult your authorized ERI sales
representative for assistance on alternative
pump materials of construction.
Corrosion and/or erosion of If edge of throat has opened in size, head rise
diffuser throat (may also be may be reduced. Opening the throat will

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Table 4: Pump Troubleshooting
Problem

Possible Cause

Investigative/Corrective Action

increase flow rate and horsepower

accompanied by corrosion
and/or erosion of diffuser consumption. Corrosion and/or erosion of the
diffuser and cover surfaces will significantly
surface adjacent to the
increase horsepower consumption.
impeller).

Driver overloaded.

Pump discharge throat

partially plugged.

Disassemble pump and inspect pump casing

for an obstructions. Replace damaged
hardware with genuine ERI parts.

Driver speed too low.

Check driver speed against value provided

on the pump specification sheet.

Fluid specific gravity or

viscosity is exceeds original
pump design.

Decrease specific gravity and/or viscosity.

Reduce pump flow to the level that will
reduce driver power consumption to an
acceptable level.

Electrical failure in motor. Check circuit breaker heater size and setting.
Check motor voltage.
Check motor current in each phase. The
current should be balanced within 3%.
Mechanical failure of
pump

Rotate shaft assembly and check for ease of

rotation.
Inspect thrust and journal hearings. Replace
failed parts.

Excessive discharge
pressure pulsations
(may sound like
hammering or
gravel being
pumped).
Excessive noise and
vibration.

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Pump operating beyond

capacity.

Check actual pump flow and head against

the values provided on the pump
specification sheet.

Flow rate too low.

Increase flow through pump. Add bypass if

required.

Insufficient NPSH

Refer to solution for insufficient NPSH under

No Flow, No Pressure at Startup.

Defective flow control

valve.

Repair or replace valve.

Rotation incorrect.

Direction of driver shaft rotation is shown by

arrow on pump housing. Note: Reverse any
two leads on motor to change direction of
rotation.

Worn or damaged
bearings.

Disassemble pump and replace damaged

components with genuine ERI parts.

Insufficient NPSH.

Refer to solution for insufficient NPSH under

No Flow, No Pressure at Startup.

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9.2 Mechanical Seal Troubleshooting

Table 5. Mechanical Seal Troubleshooting
Problem

Possible Cause

Investigative/Corrective Action

Sudden increase in seal Severe cavitation or loss of

leakage.
suction pressure causing
vibration and bouncing of
seal face.

Correct pump suction condition causing

cavitation. Bleed vapor from seal cavity and
restart pump. Install double seal system if loss
of suction cannot be prevented.
Replace seal and rotating face with genuine
ERI parts if either part shows wear or damage.

Seal icing on low

temperature pumps or icing
when handling fluids which
have high vapor pressures
at a temperature of less
than 32F (0C).

Purge dry nitrogen gas into seal drain area.

Install double seal system and use a
compatible, non-aqueous, nonvolatile
external seal drain area.

Solid particles in seal cavity

or seal spring area.

Replace seal and rotating face.

Seal stationary spring action

is rough and sticky.

Supply clean, external seal flush or install

double seal system if particles cannot be
removed by a separator or filter.
If parts are corroded, check for material
compatibility.
Check for the accumulation of solids in the
seal retainer area. If solids are found, consider
the installation of a double seal system.

Worn or damaged seal.

Disassemble high speed shaft assembly and

replace worn or damaged components with
genuine ERI parts.

Inspect shaft sleeve and impeller hub for high

Wear pattern on seal
rotating faces not uniform in spots. Replace if necessary. Install new seal
the circular direction.
and rotating face.
Shaft sleeve not parallel causing rotating face
to be cocked. Check for dirt or debris caught
between sleeve, rotating face, or adjacent
parts.

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Wear pattern on stationary

face of seal is smooth but
not uniform.

Replace seal and rotating face.

Edges of stationary face

chipped and seal face is
worn (usually caused by
vapor formation in the seal
cavity).

Prevent loss of pump suction. Install double

seal system if loss of suction cannot be
prevented.

Seal rotating face is

cracked or broken. ( May
be caused by damage

Prevent loss of pump suction. Install double

seal system if loss of suction cannot be
prevented.

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Supply cool seal flush. Consult with your

authorized ERI sales representative to
determine if a heat exchanger is required.

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Table 5. Mechanical Seal Troubleshooting
Problem

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Possible Cause

Investigative/Corrective Action

during assembly or by
thermal shock from running
the seal dry.)

Supply cool seal flush. Consult with your

authorized ERI sales representative to
determine if a heat exchanger is required.

Seal rotating face is worn in

area of contact stationary
face (usually caused by
icing from air in drain).

Install nitrogen purge in drain area.

Chemical degradation of
seal faces, seal parts, or orings.

Investigate process fluid properties and

change seal and o-ring materials if needed.

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Install a double seal system.

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10 ERI CUSTOMER/FIELD SUPPORT

The Technical Services staff of ERI offers complete and commissioning support for all products,
including field installations and at the location of the RO system manufacturer. Although
commissioning service is not a requirement, some customers might feel more comfortable with
the offered service. Please contact your ERI representative to request a rate quote.
Should a problem develop with any ERI product, our Technical Services Group is prepared to
handle customers concerns whether the location is domestic or overseas. An ERI representative
can provide service rates upon request.
Energy Recovery, Inc.
1717 Doolittle Drive
San Leandro, California 94577
USA
Tel: +1 510 483 7370
Fax: +1 510 483 7371
Email: support@energyrecovery.com
Web: www.energyrecovery.com

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11 REVISION LOG
Revision

Description

Date
Initial Release

Approval
4/14/11

ERK

12 DRAWINGS AND DATA

1. ERI AquaBold Pump Assembly Drawings

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