SAMCO CP7 Manuel utilisateur

SAMCO PUMPS

TYPE:CP7 Pumps

INSTRUCTIONS

Installation

Operation

Maintenance

TABLE OF CONTENTS

PAGE PAGE

l. INTRODUCTION 3 VII. SERVICING 33

A. PURPOSE OF MANUAL 3 A. DISASSEMBLY 33

B. SAMCO / A-C PUMP – SERVICE 1.WET END 33

ORGANIZATION 3 2. FRAME DISASSEMBLY 34

C. WARRANTY 3 B. PART INSPECTION 35

C. ASSEMBLY 36

II. PUMP IDENTIFICATION (NAMEPLATE) 3 1. FRAME 36

2. WET END 37

III. SAFETY INFORMATION 4 D. ADJUSTMENTS 41

1. IMPELLER CLEARANCE 41

IV. INSTALLATION 4 2. SEALWATER 41

A. RECEIVING PUMP 4

B. STORAGE 5 APPENDIX “A”

1. TEMPORARY 5 ENGINEERING INFORMATION 43

2. LONG TERM 5 A. CASING & IMPELLER DATA

C. LOCATION 5 B. STUFF BOX DATA

D. FOUNDATION 5 SEAL LUBRICATION PRESSURE 45

E. SETTING BASEPLATE 6 C. SHAFT AND BEARING DATA 46

F. ALIGNMENTPROCEDURE 7 D. PUMP WEIGHTS 47

G. DOWELING 11

H. SUCTION AND DISCHARGE PIPING11 APPENDIX “D”

I. STUFFING BOX LUBRICATION 15 IMPELLER TRIMMING 47

V. OPERATION 19 ASSEMBLY SECTION (PACKING) 49

A. PRE-START CHECKS 19

B. PRIMING 19 ASSEMBLY SECTION

C. STARTING 20 (STD. STUFF. BOX, MECH. SEAL) 53

D. OPERATIONAL CHECKLIST 20

E. SHUTDOWN 21 ASSEMBLY SECTION (OVERSIZE

F. FREEZE PROTECTION 21 STUFF. BOX, MECH. SEAL) 55

G. FIELD TESTS 21

ASSEMBLY SECTION

VI. MAINTENANCE 23 (DYNAMIC SEAL F4-G1 FRAME) 58

A. GENERAL MAINTENANCE AND

PERIODIC INSPECTION 23 ASSEMBLY SECTION

B. MAINTENANCE OF FLOOD (DYNAMIC SEAL F4-H1 FRAME) 59

DAMAGED PUMPS 23

C. LUBRICATION 24 ASSEMBLY SECTION

1. BEARINGS 24 (DYNAMIC SEAL F4-J1 FRAME) 60

2. COUPLINGS 26

D. SEAL INFORMATION 26

1. PACKING 26

2. MECHANICAL SEALS 27

E. MAINTENANCE TIMETABLE 28

F. TROUBLE SHOOTING 28

NOTE

The information contained in this book is intended to assist operating personnel by providing information on the

characteristics of the purchased equipment.

It does not relieve the user of their responsibility of using accepted engineering practices in the installation,

operation, and maintenance of this equipment.

Any further questions, contact SAMCO / A-C Pump.

SECTION I. INTRODUCTION

A. PURPOSE OF MANUAL:

This manual is furnished to acquaint you with the easiest and most practical way to install, operate, and

maintain this pump. Read it completely before doing any work on your unit and keep it handy for future

reference.

Equipment cannot operate well without proper care. To keep the unit at top efficiency, follow the recom-

mended installation and servicing procedures outlined in this manual. The S.A.M. Engineering (Pty) Ltd

Customer Service Department is available to expertly guide the installation of the pump for maximum

operating life and minimum downtime.

B. S.A.M. Engineering (Pty) Ltd Service organisation:

Experienced, factory trained servicemen offer prompt, efficient service at reasonable rates. These

servicemen can find and correct costly errors such as poor grouting, misalignment, pipe stresses

transmitted to the pump casing, or improperly sized piping. A serviceman may be requested through your

nearest S.A.M. Engineering Pump Sales Representative.

Replacement and spare parts, including special attention to your individual problems, may also be

obtained through the same Sales Representative.

C. WARRANTY:

Refer to your sales contract for coverages.

SECTION II. PUMP IDENTIFICATION (NAMEPLATE)

These pumps are designated by serial number, model, size, and M.O.C. This information is stamped on

an identification plate and affixed to the pump frame or casing.

Permanent records are kept by the factory and filed by serial number.

The pump nameplate contains the following information:

(1) SERIAL NUMBER –Composed of certain groups of numbers. All groups are necessary for

identification. TYPICAL EXAMPLE: P 2081 / 98

(2) MODEL – CP7, followed by SIZE – Composed of three (3) groups of number.

EXAMPLE: 4 x 3 x 11 – First number (4) is the ASA suction flange size in inches, second number

is the ASA discharge flange size in inches, the third number (11) is the nominal maximum impeller

diameter in inches.

(3) IMPELLER DIAMETER – This number is the impeller diameter in millimeters as supplied by the

factory. EXAMPLE: 265

(4) FLOW – design flow rate in cubic metres per hour.

(5) HEAD – design head in metres.

(6) MAX. DESIGN PRESSURE – This refers to factory standard hydrostatic test pressure for hydraulic

end of pump.

(7) M.O.C. – Material of construction of pump shown in abbreviated form and in four parts.

EXAMPLE: CI/SS/CI/EN8 – where casing, stuff box and wearplate (if fitted) are in Cast Iron /

impeller in Stainless Steel / frame is in Cast Iron / shaft is in EN8

(8) RPM – Design speed of pump to achieve design flow and head.

SECTION III. SAFETY INFORMATION

WARNING: Unit weights are given on page 31. Failure to follow all instructions may result in serious

injury, death, or property damage.

Read all warning & caution decals on the pump.

Never use motor lifting lugs or pump casing lugs to lift entire unit.

When field hydro testing pump or system, do not exceed maximum field hydro test pressure given on

pump nameplate. Vent all air from pump and piping.

CAUTION: Pump damage will occur if rotation is reversed. Check rotation of driver with coupling

disconnected. Failure to follow these instructions could result in severe personal injury or property

damage.

WARNING: Do not operate at or near zero flow (closed shutoff valve). Explosion could result due to

large temperature rise in the fluid being pumped. Failure to follow these instructions could result in

property damage, severe personal injury, or death.

WARNING: If pump is to be used on process fluids above 49°C pump surface temperatures could be

warm enough to cause burns. We recommend pump surfaces be insulated. Failure to follow these instruc-

tions could result in severe personal injury or death.

SECTION IV. INSTALLATION

A. RECEIVING PUMP:

Check pumps for shortages and damage immediately upon arrival. (An absolute must!) Prompt reporting

to the carrier's agent, with notations made on the freight bill, will expedite satisfactory adjustment by the

carrier.

Pumps and drivers are normally shipped from the factory mounted on a base plate. Couplings may either

be completely assembled or have the coupling hubs mounted on the shafts and the connecting members

unfastened.

Shafts are in alignment when the unit is shipped; however, due to shipping, the pumps may arrive mis-

aligned and, therefore, alignment must be established during installation. S.A.M. Engineering (Pty) Ltd

has determined that proper and correct alignment can only be made by accepted erection practices. Refer

to the following paragraphs on "Foundation", "Setting Base plate", "Grouting Procedure", "Alignment

Procedure" and "Doweling".

B. STORAGE:

1. Short term (less than 6 months): S.A.M. Engineering normal packaging procedure is designed to

protect the pump during the shipping. Upon receipt, store in a covered and dry location.

2. Long term (more than 6 months): Preservative treatment of bearings and machined surfaces will

be required. Rotate shaft several times every 3 months. Refer to driver, coupling and seal

manufacturers for their long term storage procedures. Store in a covered dry place.

C. LOCATION:

The pump should .be installed as near the suction supply as possible, with the shortest and most direct

suction pipe practical. The total dynamic suction lift (static lift plus friction losses in suction line) should

not exceed the limits for which the pump was sold.

The pump must be primed before starting. Whenever possible, the pump should be located below the

fluid level to facilitate priming and assure a steady flow of liquid. This condition provides a positive

suction head on the pump. It is also possible to prime the pump by pressurizing the suction vessel.

When installing the pump, consider its location in relation to the system to assure that sufficient Net

Positive Suction Head (NPSH) at pump suction is provided. Available NPSH must always equal or

exceed the required NPSH of the pump.

The pump should be installed with sufficient accessibility for inspection and maintenance. A clear space

with ample head room should be allowed for the use of an overhead crane or hoist sufficiently strong to

lift the unit.

NOTE: Allow sufficient space to be able to dismantle pump without disturbing the pump inlet and

discharge piping.

Select a dry place above the floor level wherever possible. Take care to prevent pump from freezing

during cold weather when not in operation. Should the possibility of freezing exist during shutdown

period, the pump should be completely drained, and all passages and pockets where liquid might collect

should be blown out with compressed air.

Make sure there is a suitable power source available for the pump drive. If motor driven, electrical

characteristics should be identical to those shown on motor data plate.

D. FOUNDATION:

The foundation must be substantial enough to absorb vibration. (Hydraulic Institute Standards

recommend the foundation weight at least five (5) times the weight of the pump unit.) It must form a

permanent and rigid support for the base plate. This is important in maintaining the alignment of a

flexibly coupled unit.

Foundation bolts 6 mm smaller in diameter than the clearance holes in the base plate should be embedded

in the concrete to a depth of eight (8) times the diameter of the bolt and locked with either a hook around

a reinforcing bar or alternatively, a nut and washer at the bottom. The bolts should have a sleeve around

them at least six (6) times the bolt diameter long and at least two (2) bolt sizes larger in I.D. If a nut and

washer are used for locking, the washer should have an O.D. two (2) sizes larger than the sleeve.

The foundation should be poured within 20-40 mm of the finished height. (See Figure I) Freshly poured

foundations should be allowed to cure for several days before the unit is set in place and grouted.

E. SETTING BASEPLATE:

Pump units are checked at the factory for alignability to required tolerances.

Due to flexibility of an ungrouted base and handling in shipment, it should not be assumed that the unit is

in alignment when it is placed on the rough foundation. If these directions are followed, the required

alignment should be readily achieved.

Initial or rough alignment must be done prior to grouting of base plate. Rough alignment is designated as

0.51 mm TIR parallel alignment and 0.23 mm TIR per 25.4mm of radius angular alignment (See

"Alignment Procedure" on page 4). Use blocks at anchor bolts and midway between to position bottom of

base at finished height (See Figure II) with foundation bolts extending through holes in the base plate.

Metal wedges with a small taper may be used in lieu of blocks and shims.

If the unit has a non-flexible coupling, the coupling halves should be disconnected; this is generally not

necessary on flexible type couplings.

Tighten up all pump and motor bolts to assure they have not loosened or a "soft foot" has occurred due to

base distortion in shipment.

If driver is being field installed, it should be centered in its bolt holes with shims added to bring the motor

into rough alignment with the pump.

NOTE: Do not exceed six (6) shims, using as thick a shim as possible, otherwise "sponginess" or "soft

foot" will result.

Level and plumb the pump shaft, coupling faces and flanges by adding or removing shims between the

blocks and bottom of the base. Hand tighten the anchor bolt nuts at first. Being very careful not to distort

the base, snug down the nuts with a wrench. The nonflexible coupling should not be reconnected until the

alignment operation has been completed.

NOTE: The base plate does not have to be level.

After foundation bolts are lightly torqued, recheck alignment requirements once more. Follow require-

ments outlined at the beginning of this section. Add or remove shims under the base and snug anchor

bolts until rough alignment tolerances are met.

Then the unit can be grouted in (See Figure II.)

Grout compensates for the uneven foundation. Together with the base plate, it makes a very rigid inter-

face between the pump and foundation distributing the weight over the length of the base and prevents

shifting.

Use an approved, non-shrinking grout.

Grouting procedure:

1. Build a strong form around the foundation to contain the grout.

2. Soak the top of the foundation thoroughly, then remove surface water.

3. The base plate should be completely filled with grout and if necessary, temporarily use air relief

tubing or drill vent holes to remove trapped air.

4. After the grout has thoroughly hardened (approximately 24 hours) tighten the foundation bolts

fully.

5. Check the alignment after the foundation bolts are tightened.

6. Approximately fourteen (14) days after the grout has been poured and the grout has thoroughly

dried, apply an oil-based paint to the exposed edges of the grout to prevent air and moisture from

coming in contact with the grout.

F. ALIGNMENT PROCEDURE:

1. Standard couplings:

Proper rough alignment must be made during unit setting and grouting. See previous section.

There are two forms of misalignment between the pump shaft and the driver shaft as follows:

a. Angular misalignment - shafts have axis concentric at intersection, but not parallel.

b. Parallel misalignment - shafts have axis parallel, but offset.

The necessary tools for checking alignment are (1) a straight edge and caliper or micrometer, or (2) a dial

indicator with mounting magnet and extension bars.

Method 1 - Straight Edge

Proceed with this method only if satisfied that face and outside diameters of the coupling halves are

square and concentric with the coupling bores. If this condition does not exist or elastomeric couplings do

not make this method convenient, use Method 2.

Check for angular alignment with micrometer or caliper at 90° intervals. The unit is in angular alignment

when these four (4) measurements are the same. (Figure IIIa.)

Check for parallel alignment by placing a straight edge across both the coupling rims on all four sides.

The unit is in parallel alignment when the straight edge rests evenly across both coupling rims in all four

(4) positions. (Figure IIIb.)

Method 2: Dial Indicators

A dial indicator can be used to attain more accurate alignment. Fasten the indicator to the pump half of

the coupling and adjust the assembly until the indicator button is resting on the other half coupling

periphery.

The following steps are used to measure indicator assembly sag:

Take indicator assembly as is and mount it on any short section of the pipe. Holding the pipe

horizontally with indicator assembly on top, set the dial to zero. Rotate the pipe 180° so the indicator

assembly is on the bottom and read the dial. This reading represents indicator assembly sag and must be

considered in the alignment readings.

Set the indicator back on the pump as before. Set the dial to zero and chalk mark the coupling half where

the button rest. (Chalk is not necessary on the elastomeric couplings that have not been disconnected.)

Rotate both shafts by the same amount; i.e., all readings must be made with the button on the chalk mark.

The dial readings will indicate whether the driver has to be raised, lowered or moved to either side. After

each adjustment, recheck both parallel and angular alignments. Accurate alignment of shaft centers can be

obtained with this method even where faces or outside diameters of the coupling are not square or

concentric with the bores. For angular alignment, change the indicator so it bears against the face of the

same coupling half and proceed similarly to above. See Figure IVa & IVb.

NOTE: Gross deviation in squareness or concentricity may cause unbalance problems and if so must be

corrected.

NOTE: Permissible misalignment will vary with the type of coupling. Consult coupling manufacturer's

data.

Parallel: 0.4 mm TIR

Angular: 0.004 mm/25.4mm of Radius

Check and correct for angular misalignment before correcting parallel alignment. Final alignment should

be made by moving and shimming the motor on its base until the coupling hubs are within the

recommended tolerances measured in total runout. All measurements should be taken with the pump and

motor bolts tightened. The shaft of a sleeve bearing motor should be in the centre of its mechanical float.

2. MOUNTING C-FACE MOTORS

When mounting C-face motors in the field to pumps equipped with C-face motor adapters, the following

steps must be followed in the sequence given:

a. Slide coupling hubs on pump and motor shaft.

b. Be sure C-face adapter is bolted tight to frame and locating fit is clean.

c. Then mount C- face adapter support foot and tighten.

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