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Ar Manual

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INSTRUCTIONS ON INSTALLATION,

OPERATION AND MAINTENANACE FOR


SAM TURBO PUMP TYPE “AR”

SAM TURBO INDUSTRY LIMITED


NEELAMBUR, COIMBATORE-641 014. INDIA
PH: 0422-3058899(50 LINES), FAX: 3058000, E-MAIL: info@sampumps.com, WEBSITE:
www.sampumps.com
SAM TURBO INDUSTRY LIMITED
NEELAMBUR, COIMBATORE-641 014. INDIA

WARRANTY
We warrant that the pump supplied by us is free from
defective material and faulty workmanship. This
warranty holds good for a period of 12 months from
the date of commissioning of the equipment or 18
months from the date of despatch from our factory,
whichever is earlier.

Our liability in respect of any complaint is limited to


replacing part/parts free of charge ex-works or repairs
of the defective part/parts only to the extent that such
replacement / repairs are attributable to or arise solely
from faulty workmanship or defective material.

We warrant the materials for the chemical composition


and mechanical properties of the relevant standard only
and not for corrosion and erosion.

The warranty holds good only for the products


manufactured by us.

SAM TURBO INDUSTRY LIMITED


STORAGE & PRESERVATION OF PUMPS

Protect the equipment upto 6 months in an indoor environment. The


pump must be protected against damage, dust or any aggressive
environment. Pumps stored for period exceeding one year should be
serviced every 12 months. They should be disassembled, cleaned and
the whole preservation process described below should be repeated.

 All inlet connection in the pump should be closed.


 Suction and discharge flange should be covered to prevent the
entry and kind of foreign material.
 The surface to be preserved should be covered with the
preservatives suitable for the storing environment.
 Mechanical seal should be cleaned by compressed air. No other
liquid of material should be applied to them in order to prevent
damage to the secondary sealing and to o-ring /gasket.
 Oil in the bearing bed should be drained.
 Pumps waiting for the installation or start up should be turned
manually every 15 days. If is difficult to move the shaft by hand,
user a suitable spanner, by protecting the surface of the shaft at
the point of operation.
VERY VERY IMPORTANT INSTRUCTION

Since many times it is difficult to go through the entire manual. We are giving very very important points to be
considered before running the pump. If the points given below are not properly followed (apart from other
points) the pump will get damaged resulting failure of the equipment.

Since the pump is provided with screwed on impeller check direction of rotation of Motor before coupling with
the pump.

Sealing water connection to be given for both inlets of Stuffing Box. This will improve the gland housing life and
shaft sleeve components. If in the event of slurry is seen coming out of stuffing box stop the pump and check
the sealing water line.

The .Rubber Gasket provided in the front door is very very important. Whenever pump is dismantled
reassembled change this again. This avoids recirculation and hence improves the life of above components.
This outer casing should only contain static Liquid

Totally 5 mm clearance is given to the Impeller adjustment. 2.5 clearances are to be maintained on both sides.
If during initial trial running rubbing take place increase the clearance with a gasket of 1.5 mm.

Whenever pump is dismantled or reassembled all the '0' rings and Gasket to be changed to new set with same
original dimension.

!t is very very important that sleeve type coupling are to be used for connection between suction and delivery
pipe line.

For Maintenance purpose provide minimum clearance as specified in the manual.

Never buy Impeller separately from other parties. Impeller is very very important spare parts. it must be
procured from us along with Impeller nut for satisfactory performance.
The original spare is very very important and it is must for satisfactory performance. Never use non standard
spare parts procured from other parties. Use genuine spare parts from us for all the components.

.
ERECTION OF THE PUMP:

Foundation and Alignments:

The foundation 01 the slurry pumps is subject to several 10ads, like Suction and Delivery pipe Loads,
Dynamic Load of the revolving parts, Belt Pull and Static load. To withstand these loads the foundation has to
be casted. To cast the foundation, just the dimension of GAD and F9undation Drawings, are to be Followed,
which will be submitted at the time of execution itself.

In case of direct coupled pumps, pumps and motors are to be mounted on a common Base Plate. Care
should be taken, so that the Foundation Bolts are not tightened too much, which will in turn distort the Base
Plate and result in mis - alignment. After even-tightening 01 the Foundation Bolts, the coupling alignment has
to be checked up. Even if there is small mis - alignment in the Couplings, it will lead to hike in bearing
temperature and pre-mature failure 01 the same. After the alignment, the Shaft should be free to rotate. Alter
doing the above work, the Suction and Delivery Pipes are to be connected and again alignment 01 the
Couplings are to be checked up.

In case 01 Belt Driven pumps, pump pulley end should touch the pump shall step and duly be arrested by the
tie rod, by using tappings provided at the centre 01 the Shaft. In the same manner, the Motor Pulley (Vari Pitch
Pully has to be filled on the Motor shaft, which should also touch the shaft step and duly be arrested by the tie
rods. After putting the Belts, see that the belts are exactly at the centre line with respect to both the pulley. By
utilizing tensioning bolts of the Motor Slide Rail, the motor can be moved and proper tightening of the belts is
achieved.

PIPINGS:

a) Suction Piping:

The pipe line should be properly supported, so that no, pipe thrust should be exerted on the pump. The
suction piping should be as short and direct, as possible with minimum number of bends. Care must be
taken, so that the joints of the pipes are absolutely' air tight and also sound piping should only be used. If
suction pipe is not proper, there is a possibility of entry of air into the suction piping, causing vibration of the
pump, abnormal sound and also less capacity. The suction pipe line should be horizontal or raised
continuously all the way to the pump. The sump should be free from wastes, that is, the solids or particles in
the sump should not be bigger than the size what was committed at the time of placement of order. In
general Strainer is not recommended for slurry application. Around Suction piping, inside the sump, no
disturbance should be allowed in the form of vertes or jelling. If at all, any make up water or jelling is called
for the system, it should be as much away from the suction intake as possible as per the standard practice.
I
b) Delivery Pipe:

In any case the Delivery Pipe should not be closed for longer periods while running. At the time of starting
only, the Delivery Valve should be closed. Proper venting should be given to release the air also.

c) Suction and Delivery Pipes should be started independently and due to this no load should be exerted
on the pump.
OPERATION:

Before starting the pump, for the first time special attention should be paid 10 the following points:-

i) If the pump is of direct coupled arrangement on a common Base Plate, remove the coupling pins and
check the direction of rotation of the running motor. Since the Impeller is screwed on type, if the pump is
run' in a different direction- than that marked in the pedestal, the Impeller will unwind and create serious
damage to the pump. This is a very important precaution. Similarly, in the event of Belt Driven Pump,
remove all the bells and check the direction of rotation of the motor.

ii) Do not run the pump in a dry condition, under any circumstance.

v) Connect Flushing water under pressure for the purpose of flushing the gland and lubricating the
same.

vi) Check the gland nuts and it should be finger tight only.

vii) Check the freeness of the shaft.

viii) Check the alignment of the Belts, if the pump is Belt Driven, or it is Direct coupled, take extra care
in aligning the couplings as specified elsewhere in this manual. Open the Suction Valve and allow
the liquid in the case of flooded suction pump.

ix) Keep the Delivery Valve ¾ closed.

x) Open the Suction Valve to allow the liquid to system.

xi) After checking the above points, start and run the same for one or two minutes and again stop the same.

xii) Since the Impeller is screwed on type, there will be a chance for getting tightened, while running in the
correct direction. Due to tightening of the Impeller, a clearance between the Impeller and Bracket Side Wear
Plate may be reduced or rubbing may take place. So, check up again the freeness of the Shaft. If it is not
free and if it is rubbing over the rear wear plates, move the Impeller towards the Suction Side or vice versa,
to get free rotation of the shaft (Only once during commissioning)

xiii) After starting, again check up the duty requirements.

xiv) Check up daily during operation of the pump

1. Check the bearing Temperature.


2. Check the Gland leakage. It is in the event slurry leakage is observed, stop the pump immediately.
3. Check seal water line so that the required pressure and flow is maintained.
4. Observe if any abnormal sound from the casing as well as in the Bearing Housing.
5. Keep the record of all the information.

If the pumps are in series keep all the delivery valve in 1/4 open before starting the pump. No moment the
first pump is started, within one or two minute open the-delivery valve fully within next one or two minutes
start the IInd and lIIrd pump. Now, do not allow ~ore time gap between the pump starting.

STOPPING THE PUMP:

First stop the IIlrd and lInd pump in tl18 series. Now close the final delivery valve at once. Now without any
delay within a minute stop the first pump. After this, open the seal flushing line allow the flushing water to flow
the IlIrd, IInd and Ist pump so that all the slurry go back to the sump through the Suction valve. This flushing
should continue for 15 minutes, Now at the stage close the suction valve and after this stop flushing· and as
well as seal water line. This type of operation improves the life of pump components. Further pump is now
ready for again starting. Follow the same procedure as above while re-starting the pump.
DISMANTLING PROCEDURE

Procedure for dismantling the Impeller in the event of changing a new Impeller:

i) Remove the Suction pipe connection.


ii) Loosen the Delivery Flange Bolts.
iii) Remove the front suction cover sub-assembly (consisting of part Nos.70.21 and 19). After removing
the nuts marked in the drawing, there is no need for removing the Suction Cover (part No.21) from the flange
suction cover (part number70). This sub-assembly can be dismantled only in the event of changing the
suction side wear plate (part number 19).
iv) After removing the above, you will find '0' Ring on the Suction Side Cover, which is to be preserved
carefully.
v) The Impeller is now visible. Remove the Inner and Outer Casing Assembly (part Nos. 17.15 and 2'0), alter
removing the Nuts from the Bracket Side Cover (part No.25). vii) Give a Lever of sufficient diameter and
length between the vanes of the Impeller (Inside the Suction Bore of the Impeller), thereby preventing the
rotation of the same.
viii) Now rotate the pump pulley (if it is Belt Driven) in the opposite direction, as that of normal running
direction, by hand. This process will make the Impeller to unwind from the shaft at the same time to come
out towards the operator standing before,
ix) Stop in the middle and provide proper holding, before further unwinding, so that the Impeller will come out
and hang on the holding. The above procedure is to be adopted in the reverse fashion for assembling.
x) To remove the Inner Casing (part No.17), the Fasteners provided for tightening 01 the Outer Casing (part
Nos.20 and 15) are to be loosened and the same can be separated. A gasket is provided between two
halves, to withstand the pressure. While assembly also, care must be taken to see that the gaskets of the
same thickness is used.
xi) By loosening the Nuts, which is fixed on the Base (part No 1), the Bracket Cover (part No.25) along with
the Bracket .Side Wear Plate (part No.16) can be removed outside.
xii) Now, after removing the Impeller, Expeller (part No.14) can be taken out and '0' Rings whatever visible
are to be preserved carefully. After removing the Expeller, Gland Housing (part No.9) can be taken outside.
Now the Shaft Sleeve also can be removed very easily. To remove the Assembly a special type equipment
is required

FLUSHING OF OUTER CASING:

During the pump operation with slurry, the gap between Inner Casing and Outer Casing will lead to
sedemented slurry particles. In the event of pump being not operated, the slurry particles will be collected at
the bottom of the Outer Casing and hence flushing is to be carried out. At the delivery side of the pump,
before the Delivery Valve, a by-pass is to be provided with 2" Gate Valve. Provision is to be given for
supplying pure water under pressure of 5 Kg/cm2. At intervals, the Suction and Delivery Gate Valves are to
be closed and the water under pressure is to be injected through this flushing system after opening the drain
plate, provided at the front door of the pump.

While flushing, the following procedures are to be adopted:

i) Close the Delivery valve.


ii) Close the Suction Valve.
iii) Remove Drain Plate at the bottom of the front door, and start flushing the pump.
iv) Open 2" by-pass valve.
v) Now the liquid pass through the Outer Casing and flush away all slurry particles through the drain.
vi) In the event of stopping of pump for maintenance, flushing is to be c3rried out.
IMPELLER:

Impellers are supplied along with Impeller Nut (Part No.38), as one unit and inseparable combination. This
Impeller nut aids the removal of material, while carrying out dynamic balancing. Please do not separate this
Impeller Nut from the main Impeller on any case. While ordering, always indicate the part numbers of the
components and the serial number of the pump.

WORKING PRINCIPLE OF VARI PITCH PULLEY

Most of the Process Industries use pumps, driven by directly coupled motors. Pump head requirements are
met by changing the standard Impeller diameter. When abrasive handling slurry pumps are to be used, this
practice is no longer possible and the method of varying speed is called for. If a pump is directly coupled to
motor, the pump head is determined by the motor speed. If the motor speed is fixed, the only way to alter the
developed head is to change the impeller diameter. Due to abrasive action, the wear on the Impeller takes
place and this results in alter, i.e., reduction in head for a particular capacity.

To avoid this, in fixed speed installation, the pump is usually at a higher speed than the duty requirement, to
allow drop in performance, as parts wear. This means that pumps are running faster that at the optimum
speed. Again wear takes place, performance drops below the duty requirement and replacement of impeller
becomes necessary event though it may not be fully worn out.

In the vari pitch pulley driven pump installation, pumps run at optimum designed speed. As wear takes place,
performance drops as before. However, instead of replacing the Impeller all that is needed is a simple change
to alter the vari pitch pulley, to increase the speed and restore the design duty. This means that the Impeller
can be used until it is severely worn before final replacement becomes necessary. This will reduce
maintenance/ inventory cost during operation of the pump.

Operation of Vari Pitch Pulley:

(Refer Drawing NO.201 0-06 and its Part list). In the Vari Pitch Pulley, Belts run over the tappered Pulley Plates
(part No.1). Tappered angle of the plates suits 5mly 'D' Suction Belts. To get different speeds, the PCD of the
vari pitch pulley should be altered. To get this alteration, the pulley plates are to be moved axially, so that the
gap between the tappered portion is altered, thus either Belt is run at the edge of the tapper or inner side of the
tapper which gives the alter in PCD. At the same time, the plate should be held properly and tightened to
withstand the Belt Pressure. To achieve this, all the plates are keyed on to the longitudinal M.S.Sleeve which is
going to be mounted (part No.6) and this can be properly fixed on the sleeve by tightening the
PART LIST

V.P.PULLEY

S. NO. PART NAME MAT. QTY/ PULLEY

1. Pulley Plate CI nx2

2. Sleeve Steel 1

3. Bush En-8 nx8

4. Long Stud En-8 4

5. Retaining Bolt En-8 1

6. Ring M.S. 1

7. Retaining Plate En-8 1

8. Hex. Nuts M.S. 24

9. Lock Nuts M.S. 8

10. Clamping Bolt M.S. 1

11. Key for Motor Shaft En-8 1

12. Key for Sleeve En-8 2

13. Short Stud En-8 4

NOTE: n = number of V-Grooves.

.
'0' RINGS CHART (NEOPRINE RUBBER CARD):
PART 11 LOCATION
NO.
In between
03 suction side wear
plate and Suction
cover

0 Between
1 suction and
Bracket side
cover with
Outer casing.

Between Inner
0 Casing and Wear
2 Plates,

Between Gland
Housing and Bracket
0
5 side Wear Plate.

Between Gland
Housing and Bracket
Side cover.
0
6
Between Impeller
and Impeller Nut.

0
7

Between Impeller nut


and Expeller
Between Sleeve
and Expeller
Between
Sleeve and shaft.

0
1
0

0
AP side g and outer
PLI the casing. If this
CA '0' Ring does
TI pum
ON p not perform
and properly, pre-
also matured
T
by- failure of Inner
h
pass Casing
i
ing and wear plates
s
of will result.
' slurr This 'O' Ring
0 y
from prevents
'
the the flow of slurry
r oute from the Outer
i r Casing to the
n casi Expeller zone or
g ng to vice versa.
the
This prevents
p sucti
leakage of the
r on.
slurry tram the
e This '0' Outer
v Ring Casing to the
e prevents atmosphere.
n the
t leakage of This '0' Ring prevents
s Slurry the entry of slurry into
Fro the Impeller and hence
t m the slurry does not
h the touch the shaft at all.
e Out
er
e Casi
n ng,
t whic This '0' Ring
r h is prevents
y und the shaft away
er from the slurry.
o pres
f sure This '0' Ring also
to prevents the shaft
a the away from the
t atm slurry.
m osp This '0' Ring
o here
s . prevents
p the entry of
This '0'
h slurry into the
e Ring Bearing
Housing.
r prevents
i the
c intern
al
a circula
i tion
r betwe
en
i Inner
n Casin
ALIGNMENT AND TENSIONING – VEE BELT DRIVES

General

Whether direct coupled or vee belt driven, the pump and motor shafts should be accurately aligned.

In vee belt drives, non-parallel shafts cause excessive belt wear.

Alignment

Before fitted to the belt drive ensure the following details are adhered to.

Always use a set of new belts.

Clean any oil or grease form pulleys. Remove any rust or burns from the grooves.

Reduce the centre distance by jacking the motor towards the pump using the jacking bolts supplied, until the
belts can be put onto the pulley grooves without forcing.

Use a good straight edge across both motor and pump pulley faces. It is important to align the two pulleys to
a tolerance whereby daylight is non existent or at a minimum between the pulleys and the straight edge.

Tensioning

Proper tensioning of belts ensures a longer life for both the belts and the roller bearings.

The high performance required form modern belts cannot be achieved without correct tensioning. To check
the belt for correct tensioning refer to fig. 2 below and proceed as follows:-

(a) Measure the length of span.


(b) Apply a force at right angles to the belt at the centre of the span sufficient to deflect one belt by 16mm
per metre of span
(c) Compare the force required with the value stated in the table.

If the measured force is within the values stated in the table the belt tensioning should be satisfactory. If
the force measured is below or above the value stated the belt should be tightened or slackened
respectively. Provision should be made for periodic checking of belt wear during the life of a belt and
adjusting the belt to correct tension as necessary.
Note: New belts should be tensioned at the higher level stated to allow for a drop in tension during the
normal running in period. New belts should be checked and adjusted for the correct tension after a
period of 2 hours. During the first 24 hours running, it is recommended that a further check is carried
our and the belts adjusted as necessary.

TENSIONING FORCES

Force required to deflect belt


Belt 16mm per metre of span
Section Small Pulley Diameter Newton (N) Kilogram Force
(mm) (Kgf)

224 to 355 60 to 90 6.1 to 9.2


SPC
375 to 560 90 to 120 9.2 to 12.2

Under Tensioning:

Under tensioning of the drive belts can cause vibration resulting in damage to the bearing cartridge, as well as
the loss of transmission efficiency. Under tensioning also causes the belts to slip and overheat, resulting in
belt fatigue and subsequently a shortening of the belt life.

Over Tensioning:

Over tensioned belts also shorten the drive belt life. Further more bearings will tend to overheat due to
excessive radial forces on the rolling elements and this will lead to premature bearing failure.

Adjustment:

After new belts have been fitted or a new installation has been completed, when the drive has been running
for approximately 2 hours the tension of the belts should be re-checked and re-adjusted. The drive should be
subsequently checked at regular maintenance intervals.

ALIGNMENT - DIRECT COUPLED DRIVE

General

In direct coupled drive misalignment causes unnecessary vibration and wear on the bearings. Rigid
couplings should be avoided and used not be used without consultation.
The following procedures outline the recommended practice given in BS 3170 1972 (Appendix) for checking
shaft alignment. This method is independent of the truth of the coupling or shaft and is therefore not affected
by canted coupling faces or eccentricity of the outside diameter of the coupling.

CAUTION: CHECK THAT NO DAMAGE CAN BE CAUSED WHEN THE SHAFT OF THE DRIVEN UNIT IS
TURNED.

Before commencing alignment rotate each shaft independently to check that the shaft and bearings turn
without undue friction and that the shaft is true to within 0.04 mm or better as measured on a Dial Test
indicator (DTI).

Couplings should be loosely coupled, each half must be free to move relative to the other or the resulting Dial
indicator gauge indications can be incorrect. Where tightly fitting pins or springs prevent loose coupling, the
pins or springs should be removed, a line scribed across both half couplings and readings taken only when
the two are aligned. On couplings with a serrated rim, ensure that as the couplings are rotated, the gauge
plungers do not fall in to a groove and become damaged.

Angular Shaft Alignment:

To ensure correct Angular Shaft alignment proceed as follows:-

(a) Isolate the driving unit from the power supply.


(b) Refer to Fig. 3 and clamp two Dial Test Indicators (DTI) at diametrically opposite points (180 0) on one
half coupling, with the plungers resting on the back of the other half coupling.
(c) Rotate the couplings until the gauges are in line vertically, and set the gauges to read zero.
(d) Rotate the couplings through half a revolution (180 0) and record the reading on each DTI. The
readings should be identical though not necessarily zero because of possible end float. Either positive
or negative readings are acceptable provided they are equally positive or equally negative. Refer to
the paragraphs headed TOLERANCES for the maximum allowable tolerance and adjust the position
of one of the units if necessary.
(e) Rotate the couplings until the gauges are in line horizontally and reset the gauges to read zero.
(f) Repeat operation (d) and adjust the unit position until the correct tolerance is achieved and no further
adjustment necessary.

Radial Shaft Alignment

To ensure that the Radial Shaft Alignment is correct proceed as follows

(a) Clamp a DTI to one half coupling or to the shaft, as shown in Fig. 4, with the plunger resting on the
rim of the other half coupling.
(b) Set the gauge to read zero.
(c) Rotate the couplings and note the reading at each quarter revolution (90 0). Any variation in the
readings indicates a deviation form alignment and the position of one of the units must be adjusted
until the readings at each quarter revolution are identical or within the tolerances given. (Refer to
paragraphs headed TOLERANCES).

Note: Provisional alignment can be carried out with the unit cold however, where the working temperature
of the pump has the effect of raising the centre line of one machine relative to the other allowances must
be made. The units should then be realigned when each have attained their correct operating
temperature.

Tolerances:

The limits of accuracy within which adjustments must be made cannot be specifically defined because of
differences in the size and speed of units, but the following variations which can be tolerated when
checking alignment, are suggested.

(1) Angular Alignment:

Couplings up to 300 mm dia….0.05 mm.


Couplings more than 300 mm…..0.07 mm.
(2) Radial Alignment:

Not to exceed 0.1 mm on micrometer dial gauge ( i.e. 0.05 mm eccentricity).

When both the bedplate level and the shaft alignment are satisfactory the final grout can be run.

OPERATIONAL CHECKS

Running:

When the pump has attained its full operating speed the following checks must be made:-

That the pump is rotating in the correct direction as indicated by the directional arrow.

That the pump is generating not less than its rated delivery pressure.

If the pump fails to generate at least its rated delivery pressure it must be stopped immediately, the cause
ascertained, the fault rectified and the pump re-primed before re-starting. If the foregoing checks are proved
to be satisfactory, open the delivery valve slowly and bring the pump gradually up to load. Ensure that the
bearings are not overheating. The ideal running temperature of a bearing is between 40 0C and 600C.
However, this figure may be slightly increased as long as the reading is constant. A constant reading of 68 0C
is satisfactory however a reading of 680C and still rising should be investigated.

Overheating of roller bearings is frequently caused by over packing them with grease. An increase in running
temperature after adding grease is normal, but if one or two shots of grease form a grease gun are applied,
the temperature should return to its previous level as the grease is distributed.

Gland leakage check (Oil and Sealed)

If leakage is excessive tighten gland nuts until flow is reduced to required level. If leakage is insufficient and
gland shows signs of heating, then loosen the gland nuts. If this is ineffective and the gland continues to heat
up, the pump should be stopped and the gland allowed to cool. Gland nuts should be loosened to such an
extent that the gland follower is allowed to disengage form the stuffing box.
At low pressure (single stage operation) very little leakage is required and it is possible to operate with only a
small amount of water issuing form the gland.

Note: It is normal for gland leakage water to be hotter than the supply because it is conducting away the heat
generated by friction in the gland.

It is not essential to stop a pup because of gland heating unless steam or smoke is produced. This difficulty is
normally only experienced on initial start up on gland sealed pumps. When initial heat up of the gland is
encountered it is usually only necessary to start up – stop – cool and start the pump two or three times before
the packing beds in correctly.

It is preferable at start up to have too much leakage than not enough.

After the pump has run for some 8-10 hours, gland bolts should be adjusted to give optimum leakage. If
heating of the gland persists, the packing should be removed and the gland repacked.

Gland leakage check (Centrifugal Seal):

During operation no gland leakage should occur to a centrifugally sealed pump. A sight drip will occur from
the gland during normal shutdown. Should the leakage be excessive during the shutdown period, first
lubricate the gland by rotation of the grease cup, if the gland still leaks adjust the gland nuts to the required
tightness. If the gland leakage still persists repack the complete stuffing box.

OPERATIONAL FAULTS

Abnormal Start Up:

If the pump fails to prime, one or more of the following faults may be the cause.

Blocked Suction Pipe:

When the pump has been inoperative for some time it is possible for slurry to settle in or around the suction
pipe. This prevents the water rising to the pump impeller.

Air Entering Gland:

Air may be induced into the pump through the gland for one or more of the reasons listed below. This may
prevent the pump “picking up” its prime or cause it to lose its prime during operation.

(a) Sealing water pressure too low.


(b) Packing is excessively worn.
(c) Shaft sleeve is excessively worn.
(d) Gland sealing water connection into stuffing box is blocked.

Inspection of gland will readily reveal if above faults are occurring and remedial action is self evident.
Overloading may occur when the pump is discharging into an empty system when the delivery head will be
temporarily lower and the throughput in excess of that for which the pump is deigned. Careful regulation of the
delivery valve until the system is fully charged will prevent this.

WARNING: PUMPS THAT ARE NOT FITTED WITH A LEAK OFF DEVICE SHOULD NOT BE RUN FOR A
LONG PERIOD AGAINST A CLOSED DISCHAREGE VALVE. CHECK THAT THE DRIVING UNIT IS NOT
BEING VERLOADED – REFER TO DRINVING UNIT AND PUMP DELIVERY PRESSURE GAUGE.

OPERATING – FAULTS

Blocked Suction Pipe:

It is possible during pumping operations for foreign matter to be drawn across the bottom of the suction pipe
thereby causing a partial obstruction. Such an obstruction may not be sufficient to stop operation completely
by will result in a reduced output form the pump. It will also cause a drop in discharge pressure and will
increase the vacuum reading on the pump suction. Rough running and vibration of the pump may also occur
due to the high induced suction causing cavitation within the pump.

Blocked Impeller:

Impellers are capable of passing a certain size particles. If a particle larger in size enters the suction pipe it
may become lodged I in the eye of the impeller thereby restricting the output of the ump. Such an obstruction
will usually result in a drop of current and a drop in both discharge pressure and suction vacuum readings
pump vibration may also occur due to the out of balance effects.

Blocked Discharge Pipe:

Blocked discharge pipe may be caused by abnormally high concentration of coarse particles in the pump
discharge pipe or by the velocity in the discharge pipe being too low to adequately transport the solids. Such
a blockage will be shown up by a rise in discharge pressure, and a drop in both current and suction vacuum
readings.

Shutting Down Procedure:

On shutting the pump down the pump should be allowed to operate on water only for a short period to ensure
the system is clear before shut down. Then proceed as follows:-

(a) Close the delivery valve to reduce the load on the driving unit.
(b) Depress the appropriate ‘STOP PUMP’ push-button on the control panel.
(c) On gland seal pumps sealing water must be left on during all operations. Including shutdown and run
back. Only then should all ancillary supplies be isolated.
(d) When all ancillary supplies have been isolated it is advisable to close the suction valve.

PERIODIC LUBRICATION

Bearing lubrication:

A correctly assembled and lubricated bearing assembly will have a long trouble-free life, provided it is
protected against ingress of water or other foreign matter and that it is adequately maintained.

It must be left to the good judgement of maintenance personnel, to open bearing housings at regular intervals
(not longer than twelve months) to inspect bearings, lubricant and to determine each time the course of action
and the period for the next inspection.

The figure shows the labyrinth seal assembly without grease purge. If a regular addition of greasing is
necessary the nipples on the bearing housing can be used. It is preferable to lubricate often but sparingly than
to add large amounts of grease. Bearings should never be over lubricated.

Use only recommended clean lubricant, see page WP 3.02 Lubricants and recommended alternatives.
Excess Grease

The immediate effect of an excess of grease within a bearing is overheating due to the churning effect. This
should be avoided, if bearings tend to overheat after a change of grease the trouble is normally due to over
greasing. Never add more lubricant to overcome over heating.

Most pump bearings operate in the lower speed range, however, there is still a risk of damage due to over
lubrication, this is especially apparent in the smaller pumps having smaller sized bearings. However, although
over lubrication should be avoided this does not imply that bearings can be neglected. Experience should be
the final determining factor in establishing routine lubricating procedure. It is advisable to inspect the bearings
frequently at the start of operations an dot note any unusual conditions regarding both cleanliness and
temperature.

Under normal conditions when the temperature of bearings does not go above normal, the guidelines set out
in the text can be used; in humid conditions more frequent greasing may be required.

SUPPLEMENTARY LUBRICATION INSTRUCTIONS

The frequency and amount of lubricant to be added depends upon a number of factors, including speed, size
of bearing, extent of on-off operation, and the environmental conditions including, splash and the presence of
contaminants.

PERIODIC LUBRICATION

Bearing lubrication:

A correctly assembled and lubricated bearing assembly will have a long trouble-free life, provided it is
protected against ingress of water or other foreign matter and that it is adequately maintained.

It must be left to the good judgement of maintenance personnel, to open bearing housings at regular intervals
(not longer than twelve months) to inspect bearings, lubricant and to determine each time the course of action
and the period for the next inspection.

The figure shows the labyrinth seal assembly without grease purge.

To improve the sealing properties of the labyrinth at both the wet end and the drive end of the bearing
assembly, a grease nipple and radically drilled hole in the End Cover allows grease to be forced through the
labyrinth to the piston rings, thus purging out grit and moisture to the outside of the bearing cartridge. Less
contaminants entering the bearing assembly will result in linger bearing life an ultimately considerable cost
saving. Therefore careful attention paid to labyrinth purging is an essential maintenance requirement.

The bearings cannot be over greased as approximately 95% if every shot of grease entering the grease purge
nipple exits at the labyrinth and only the remaining 5% enters the bearing assembly.
Under normal conditions 2 shots of grease per 24 hours is recommended to be injected into each grease
nipple on the end cover to maintain labyrinth sealing.
If site conditions are unfavorable i.e. high humidity, dusty or dirty conditions around the bearing
assembly, then the frequency of greasing should be increased to 3 shots per 24 hours.

Use only recommended clean lubricants,


- Lubricants and recommended alternatives

Excess Grease

The immediate effect of an excess of grease within a bearing is overheating due to the churning effect. This
should be avoided. if bearings tend to overheat after a change of grease the trouble is normally due to over
greasing. Never add more lubricant to overcome over heating.

Most pump bearings operate in the lower speed range. However there is still a risk of damage due to over·
lubrication. This is especially apparent in the smaller pumps having smaller sized bearings. However,
although over lubrication should be avoided this does not imply that bearings can be neglected. Experience
should be the final determining factor in establishing routine lubricating procedure. It is advisable to inspect
the bearings frequently at the start of operations and to note any unusual conditions regarding both
cleanliness and temperature.

Under normal conditions when the temperature of bearings does not go above normal, the guidelines set
out in the text can be used; in humid conditions more frequent greasing may be required.

LUBRICATION

Bearings are grease/lubricated. Following grades of grease available in the market are suitable.

Grease Specifications
Name of the firm
Speed 1450 rpm Speed 2900/3600 rpm
INDIAN OIL SERVOGEM 3 SERVOGEM 2
CALTEX STARFAK 3 STARFAK 2
HINDUSTAN PETROLEUM NATRA 3 or NATRA 2 or
LITHON 3 LITHON 2

Fitting Grease Retainers and Bearing Cones

Bearing and shaft should be kept clean at all times.. Mild steel drifts only should be used when tapping
bearings into position. Brass or Copper drafts should NOT be used.

1. Check that shaft and shoulders are clean and free from burns.
2. Apply a smear of clean light lubricating oil to the bearing landings on the shaft.
3. Slide on one grease retainer, with flange up to the shaft shoulder.
4. Pre-heat bearing cone by placing the cone in a container of clean lubricating oil. Ensure that the
cones do not touch the bottom of the container as this will cause local softening. Heat the cones and
oil to 1000C.

5. With the shaft in a vertical position fit the heated bearing cone on the shaft with the large diameter
towards the retainer. Allow the bearing cone to cool.
6. Invert the shaft and fit the other grease retainer and bearing cone as above.
7. When the bearings are cool check that they are hard up against the grease retainers by ensuring that
the retainers cannot be rotated by hand. If necessary use a mild steel drift to drive the bearings tight
against the retainers.

Fitting Impeller End Bearing Cup to Housing

Inspect the bore of the bearing housing for sore marks and clearances. Apply clean lubricating oil or light
grease to the bore at each end of the bearing housing.

Support the bearing housing impeller end uppermost in a vertical position and carefully press or tap the
bearing cup with the larger bore diameter facing inwards, into one end of the housing until the cup is
slightly below the end face.

Fit end cover with the thickest shim to the housing and insert end cover set screws
Tighten the set screws evenly; the end cover will now push the bearing cup into the correct position.

Note: In the following instructions, the bearing housing may differ in appearance on different pump types.
Assembly instructions remain identical.

Fitting shaft to Bearing Housing

1. Fit the shaft, impeller end first, into bearing housing.


2. Press or tap the second bearing cup into the housing.
3. Fit end cover to the housing without using shims, and insert end cover set screws.
4. Rotate the shaft slowly by hand whitst gradually tightening the set screws. Observe that a gap exists
between the end cover and housing face when the screws become tight and the shaft begins to drag
CAUTION: Do not overtighten set screws or damage may result.

End Play Measurement

Remove end cover and end cover set screw from the keyway end of the shaft. Select shims form shim set
having thickness equal to the average gap measured above, plus regular end play, see table below.

Fit shims, replace the end cover and insert end cover set screws leaving approximately 3 mm gap
between the end cover and bearing housing.

Press or gently tap shaft at impeller end until bearing cup at keyway end has moved back to the loosely
fitted end cover. Care must be taken not to damage the thread on the shaft end.

Tighten set screws at keyway end evenly to move bearing cup into correct position, both bearing cups
should now be hard against their respective end covers with the correct end play.

Checking End Play

Attach mounting bracket with dial gauge securely to housing by one of the end cover set screws and
position dial gauge actuating pin against end of the shaft.
1. Rotate the shaft and push it hard backwards and forwards by hand several times to establish
maximum and minimum dial readings, note the difference between the two readings i.e., the total
movement.

2. Should the end play be outside the regular limits (see Table of Permissible End Play) shims must be
added or removed as required from the keyway end.

(a) If shims have to be removed, re-position the end cover and tighten end cover set screws after
removal of shims.
(b) If shims have to be added follow the procedure for fitting shims as described under ‘End Play
Measurement’
3. After re-adjustment of end play with shims, the actual end-play must again be measured with the dial
gauge.

Lubrication

Work the recommended lubricant by hand into the bearing, while rotating the shaft. To ease this operation
each end cover should be removed, in turn, then be end covers refitted.

Fitting Labyrinths, Piston Rings and Locknut

Smear piston rings with light grease and fit two rings to the grooves of each labyrinth, position the piston
ring gaps diametrically opposite.

Smear the shaft adjacent to the end covers with light grease.

Slide one labyrinth over the shaft at each end and push into the end covers until the piston rings prevent
further entry. Compress the piston rings with piston ring compressor, then push labyrinths fully into end
covers. Fit labyrinth locknut and tighten with C-spanner.

NOTE:

The labyrinth locknut is screwed on anti-clockwise when looking at the drive end.

Fit grease nipples.

The bearing assembly is now called ‘Bearing Cartridge Assembly’


Assembly of Stuffing Box Components – Full Flow Gland

1. Place stuffing box flat on the bench, gland side upwards.


2. Drop lantern restrictor into bore to rest on the retaining lip, small diameter first.
3. Stand shaft sleeve on end through the lantern restrictor.
4. Fit packing rings until the chamber is full, stagger the packing ring joints and press each one firmly
into place.
5. Assemble the two halves of the gland, insert gland clamp bolts and fully tighten.
6. Place the assembled gland over the shaft sleeve and push down to compress the packing rings.
7. Insert gland bolts and tighten the nuts sufficiently to hold the shaft sleeve.

Assembly of Stuffing Box – Low Flow Gland

1. Place the stuffing box flat on the bench, gland side upwards.
2. Fit the neck ring into the bore of the stuffing box to rest on the retaining lip.
3. Stand the shaft sleeve on end through the neck ring.
4. Insert one packing ring into the bore, follow this with a lantern ring and press firmly into place.
5. Fit packing rings into the bore, stagger the packing ring joints and press each one firmly into place.
6. Assemble the two halves of the gland, insert the gland clamp bolts and fully tighten. Fit the
assembled gland loosely to the stuffing box with gland bolts.

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