VERTICAL CANTILEVER SHAFT SUMP PUMP (PPCS)_ METALLIC INSTALLATION, OPERATION AND MAINTENANCE MANUAL PROCESS PUMPS (INDIA) PVT LTD Plot No.86, III Phase, Peenya Industrial Area, Bangalore 560058 Phone: 91-80-28395327/28 Fax: 91-80-28395807 WEBSITE: www.process-pumps.com E-mail: contact@process-pumps.com
CONTENTS 1.0 INTRODUCTION 2.0 SCOPE OF SUPPLY 3.0 HANDLING 4.0 STORAGE 5.0 INSTALLATION 5.1. ERECTION 5.2. FOUNDATION 6.0 PIPE WORK INSTALLATION 7.0 STARTING THE PUMP 7.1. PRE START CHECK UP 8.0 OPERATION OF THE PUMP 9.0 CORROSION 10.0 STOPPING THE PUMP 11.0 DIRECTION OF ROTATION 12.0 DISMANTLING PROCEDURE 13.0 REASSEMBLING 14.0 ROUTINE MAINTENANCE SCHEDULE 14.1 WEEKLY MAINTENANCE 14.2 BIANNUAL MAINTENANCE 15.0 TROUBLE SHOOTING 16.0 RECOMMENDED SPARE FOR TROUBLE FREE OPERATION Date: 12.12.2010 2
SAFETY PRECAUTIONS Please follow all safety norms as required for assembly of heavy mechanical rotating equipment. Ensure that electric power is not connected to the pump until all preliminary checks have been completed. Before starting the pump ensure that the suction line is clean and completely free of any blockage. 3
1. Introduction The PPCS Pump is a single stage, vertical end suction Centrifugal Cantilever shaft Pump fitted with either a closed or semi open impeller. For handling clear liquids, a closed impeller is used where as for handling liquids containing solids a semi- open type impeller is preferred. The pumps are designed to ISO and API standards. The drive from the electric motor is transmitted to the pump through a spacer type flexible coupling. 1.1 Construction Details a) Impeller Casing: The casing of the PPCS Pump is concentric metallic volute. b) Impeller: The impeller with the PPCS Pump is either full open or closed depending up on the fluid used. The impeller has integral curves vanes and the rear hub of the impeller is attached to the shaft by key way. c) Motor End: This consists of a motor, coupling, motor mount, thrust bearing, Shaft and it is also attached to the mounting plate. d) Bearings: The pump consists of a Double row angular contact ball bearing to take the thrust loads and some of the radial loads. e) Discharge pipe: The discharge pipe is terminated in a circular flange with bolt holes for connection to the customer s equipment. 2. Scope of Supply The pump is supplied with the following accessories as a standard practice a) Gland Packing b) Coupling c) Mounting Plate d) Discharge Pipe 4
3. Handling On receipt of consignment please check and ensure the following: a) That the Tally plate details are in accordance with your order. b) All the accessories are as per the packing list. c) All the components have been received in a good condition. d) The shaft can be turned by hand easily. If heavy resistance is felt or the pump doesn t rotate this means that the equipment is damaged in transportation. e) Discrepancies if any must be immediately reported. f) Packages should not be dropped or rough handled to prevent damage to the pump and motor. 4. Storage The place of storage should be well ventilated and protected from dust, heat, moisture and rain etc. In case the pump is not installed with in a period of three months then please follow the following precautions: a) Check that the bearings are properly lubricated. b) The external surfaces are free from rust peeling of paint etc. c) Rotate the shaft at least once every two weeks to make sure that the shaft and bearings are free. For maintenance of motor please refer to the motor manufacturer s manual for their recommendations and instructions. 5
5. Installation 5.1 Erection All external parts of the pump and motor must be thoroughly cleaned before erection begins. 5.2 Foundation The pump should be installed on a tank flange or a concrete foundation properly fitted with grouted foundation bolts. The foundation must be designed to absorb all the loads forces and vibrations and provide a proper support to the Mounting plate of the pump. This is important in maintaining the alignment of the unit with respect to the pump shaft position, piping and the driver shaft. The Mounting plate of the pump must be leveled using a spirit level by taking readings at 0, 90, 180 and 270 such that the shaft centre line is with in one are minute of the mounting plate. The level can be adjusted by inserting shims between the bed and mounting plate accompanied by a gentle tightening of the foundation bolts. IF THE PUMP IS NOT LEVELED WITH IN THIS TOLERANCE, DO NOT PROCEED UNTIL THIS CONDITION IS RESOLVED Twelve numbers of φ17 holes are provided on the mounting plate for fastening to the bed with M16X50 bolts and nuts. 6
6. Pipe work installation The discharge pipe must be supported independently near the pump to avoid undue loads on the discharge pipe. Care must be taken to ensure that no piping strains are transmitted to the pump as this may cause misalignment. It is preferable to use the suction piping of one size lager diameter than the pump suction size. Don t use a discharge pipe diameter lower than the actual pump discharge pipe diameter. 7. Starting the Pump 7.1 Prestart Check up Rotate the coupling by hand. The shaft should rotate freely, with no resistance in any position. The pump should always be run in the direction indicated by the arrow provided on the bearing housing. The pump has to rotate in the clockwise direction when viewed from the top. If the pump runs in the reverse direction, the lock nut unscrews and which in turn damage the impeller and shaft. Phase sequence motor has to be used to get desired direction of rotation. If motor is operated through Star-Delta starter, then run for a moment in star position to check the direction. Wiring to the motor terminals and starter should be checked. Direction of rotation of incorrect must be corrected by reversing two of the starter leads. Delivery valve should be closed before starting the pump. On acid or organic liquid service the pump should not be run with the delivery valve closed for more than few seconds because the increase in temperature of the liquid may be harmful. The pressure indicated in the delivery gauge should go up steadily. 7
8. Operation of the Pump The desired capacity is to be set by throttling the discharge valve. Operating the pump at the point other than the specified duty point have an adverse effect on the performance of the pump. The running of the pump can be checked by observing the Voltage (by volt meter), Pressure (by Pressure Gauge), Current (by Ammeter) and Speed (by Tachometer). Before stopping the pump discharge valve must be closed. Then motor is switched off. 9. Corrosion The material of construction of the pump has been selected after careful study of the liquid to be handled, its composition, its corrosiveness, specific gravity, ph, temp, solid content, particle size, viscosity, etc. A slight variation in any of the above factor can cause severe corrosion of the wetted parts. Therefore it is necessary that ample care be taken to ensure with every fresh batch of liquid that its properties are the same for which the pump originally is meant. When number of pumps with different materials of construction have been supplied for different duty conditions great care must be taken to ensure that the right pump is put to in service. Operating the pump at the point other than the specified duty point might also have an adverse effect as far as the corrosion is concerned. Spare parts of the same original material are to be used while parts are replaced to avoid the formation of galvanic cell, which initiates corrosion. 8
10. Stopping the Pump Before stopping the pump the discharge valve must be closed. The motor is switched off. 11. Direction of Rotation The pump should always be run in the direction indicated by the arrow provided on the bearing housing. The pump has to rotate in the clockwise direction when viewed from the motor fan side. 9
12. Dismantling Procedure Total Assembly of the Pump is shown in Figure 12.1 Figure 12.1 10
Step 1: a) Remove the coupling between the pump shaft and motor b) Remove the Motor as shown in Figure 12.2 below Figure 12.2 Step 2: Lift the Pump along with Mounting Plate keep it horizontally on the table 11
Figure 12.3 Step 3: Disconnect the delivery pipe and remove the Impeller Casing by loosening the bolts. Figure 12.4 12
Step 4: Hold the shaft tightly at the coupling end and loosen the Impeller Nut by rotating in anticlockwise direction. Figure 12.5 Step 5: Pullout the Impeller and Backplate. 13
Figure 12.6 Step 6: a) Unscrew the bolts holding the Mounting plate and column pipe. b) Unscrew the bolts holding the column pipe and Intermediate support. c) Unscrew the bolts holding the column pipe and Gland housing. d) Unscrew the bolts holding the Intermediate support and Housing support. e) Unscrew the bolts holding the Intermediate support and Bearing housing. f) Unscrew the bolts holding the Bearing housing and housing support. g) Unscrew the bolts holding the Housing support and coupling chamber. 14
Figure 12.7 Step 7: a) Separate the Mounting plate from column pipe. b) Separate the column pipe from Intermediate support. c) Separate the Intermediate support from Housing support. d) Separate the Housing support from coupling chamber. 15
Figure 12.8 Step 8: Pull out the shaft along with the bearing housing Figure 12.9 16
Step 9: a) Unscrew the align bolts of gland housing cover & gland housing. b) Remove the gland cover and remove the gland packing. c) Separate the drive end oil seal and bearing cover from drive end bearing housing. d) Unscrew the bearing lock nut and push the bearing housing down. This will expose the Bearing. Figure 12.10 17
Step 10: a) Separate the far end oil seal and bearing cover from far end bearing housing. b) Separate bearing housing from the far end bearing. Figure 12.11 Step 11: a) Separate the bearing housing b) Separate the bearing from the shaft 18
13. Reassembling: For reassembly we have to do the reverse of the above procedure. 14. Routine Maintenance Schedule 14.1 Weekly Maintenance The pump has to be checked weekly for bearing temperature, discharge, pressure, undue noise or vibration. 14.2 Biannual Maintenance For every Two years the pump has to be dismantled and the following checks should be carried out to avoid any extensive damage or replacements or total breakdown at a later stage. Pumps are supplied with the grease-lubricated bearings. Proper grade of grease should be provided at intervals. 19
15. Trouble Shooting In the event of failure of any component or assembly, the primary cause of failure should be established before renewing the defective parts. Symptoms Possible cause Remedy 1. Pump fails to start. No supply to motor or power failure. Seizure of motor or Check power supply. Dismantle and overhaul as necessary. Pump 2. Pump fails to lift liquid. Clogging of the suction strainer or discharge line Clean the suction strainer or discharge line. 3. Pump fails to maintain discharge Pressure. Pump running at low speed. Suction strainer choaked. Check the speed. Clean the suction strainer. 4. Pump delivers Low speed. Check the speed. insufficient capacity 5. Excessive Motor vibration. Foreign material trapped in the pump cavity. Remove the foreign material. Check the pipeline. Incorrectly supported pipeline. 6.Bearing over heating Insufficient lubrication. Bearing defect Misalignment Check the bearing lubrication. Renew the bearing. Check the alignment. 20
16. Recommended Spare for Trouble Free Operation 1) Impeller Casing (Part No 1) 2) Impeller (Part No 2) 3) Shaft Coupling Unit (Part No 25) 4) Gasket (Part No 15) 5) Oil seal (Part No 18, 20, 21 and 24) 21