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SAMCO CP7 Instructions Manual

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SAMCO PUMPS
TYPE:CP7 Pumps
INSTRUCTIONS
Installation
Operation
Maintenance

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Summary of Contents for SAMCO CP7

  • Page 1 SAMCO PUMPS TYPE:CP7 Pumps INSTRUCTIONS Installation Operation Maintenance...

  • Page 2: Table Of Contents

    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.

  • Page 3: Introduction

    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.

  • Page 4: Safety Information

    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.

  • Page 5: Storage

    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"...

  • Page 6: Setting Baseplate

    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.

  • Page 7: Alignmentprocedure

    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.
  • Page 8 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.
  • Page 9 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.
  • Page 10 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.

  • Page 11: Doweling

    d. Mount motor to C-face adapter again making sure locating fits are clean. e. Attach support studs to motor feet as shown on following page. f. Connect coupling and verify alignment is within 0.2mm TIR parallel. g. Replace all guards. After installing motor to "c"...
  • Page 12 3. Both the suction and discharge piping should be independently anchored near the pump and properly aligned so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe hangers or other supports at necessary intervals to provide support. When expansion joints are used in the piping system they must be installed beyond the piping supports closest to the pump.
  • Page 13 3. Where two or more pumps are connected to the same suction line, install gate valves so that any pump can be isolated from the line. Gate valves should be installed on the suction side of all pumps with a positive pressure for maintenance purposes. Install gate valves with stems horizontal to avoid air pockets.

  • Page 15: Stuffing Box Lubrication

    I. STUFFING BOX LUBRICATION: NOTE: CP7 Plus pumps can be furnished with a standard stuff box or oversize seal chamber. Oversize seal chambers are available as either cylindrical bore or tapered bore designs. Consider using oversize seal chamber or Dynamic Seal on difficult sealing applications. Standard stuffing box can be furnished with a mechanical seal or packing arrangement.
  • Page 16 3. Suction pressure is below 5 bar g. 4. Liquid has lubricating qualities. 5. Liquid is non-toxic and non-volatile. When the liquid being pumped contains solids or is otherwise not compatible with packing materials, an outside supply of seal liquid should be furnished. In general, external-injection liquid (from an outside source) is required when the following conditions prevail: 1.
  • Page 17 More pressure is required, however, for slurries than for clear liquids. Examination of the leakage will indicate whether to increase or decrease external pressure. If slurry is present in the leakage, increase the pressure until only clear liquid drips from the box. If the drippage is corrosive or harmful to personnel, it should be collected and piped away.
  • Page 18 Flow rate through the seal chamber should be approximately 1 l /min. The correct pressure is most impor- tant. The purpose of the manual valve in the exit line is to create the necessary backpressure so that proper stuffing box pressure can be maintained. It is important that the exit line be attached at the top of the stuffing box so air is vented out.

  • Page 19: Operation

    Cartridge seals: Follow the appropriate lubrications directions (single seal or double seal) given in this section. Use the cartridge seal gland flushing taps for your seal water connections. Most cartridge seals provide flushing connections on their glands. The quench taps on the glands (if present) can be used when necessary. Con- sult seal manufacturer's literature for more detailed information.

  • Page 20: Starting

    Filling: Vents should be located at the highest point so entrained gases and air can escape. However, if the gases are flammable, toxic, or corrosive they should be vented to an appropriate place to prevent harm to personnel or other parts of the system. Pipe hangers and anchors should be checked to make sure they are properly set to take the additional weight of the pumpage.

  • Page 21: Shutdown

    Check and record both suction and discharge pressure gauge readings for future reference. Also record voltage, amperage per phase, and kilowatts if an indicating wattmeter is available. 6. Temperature: Check and record bearing temperatures using a thermometer. Temperature should not exceed 82° C.
  • Page 22 NOTE: Complete procedure for testing pumps is given in the Hydraulic Institute Test Standards and ISO standards in terms of S.A.M.’s quality listing. Gauge datum: The datum for all gauge readings is taken at the centerline of the pump shaft. Head measurement: The unit for measuring head should be in metres;...

  • Page 23: Maintenance

    1. The standard cubic metre contains 1000 litres. 2. The specific weight of water at a temperature of 16° C shall be taken as 1 kg per litre. Kilowatt: 1. The formula for kilowatt required at the pump shaft is: Kw = Total head x m³/hr x sg 3.67 x Eff % 2.

  • Page 24: Lubrication

    1. Bearings: Bearing lubrication - oil: Oil lubrication on CP7 pumps is considered standard. Oil lubricated pumps have a slinger which picks up the oil and creates a shower of fine droplets over the entire interior of the bearing cavity.
  • Page 25 attention before starting, provided the pump has been stored in a clean, dry place prior to its first operation. The bearings should be watched the first hour or so after the pump has been started to see that they are operating properly. In greasing anti-friction bearings the use of high pressure equipment is not only unnecessary, but is actually undesirable unless used with great care.

  • Page 26: Couplings

    OVERHEATING OF THE BEARINGS. Remove vent plugs for the first 24 hours of operation after regreasing. Bearing temperature: Normally the maximum desirable operating temperature for ball bearings is 82°C as measured on the bearing housing. Should the temperature of the bearing frame rise above the limit, the pump should be shut down to determine the cause.

  • Page 27: Mechanical Seals

    before new packing is installed. Also check the condition of the shaft or sleeve for possible scoring or eccentricity, make replacements where necessary. New packing should be placed carefully into the stuffing box. If molded rings are used, the rings should be opened sideways and the joints pushed into the stuffing box first.

  • Page 28: Maintenance Timetable

    E. MAINTENANCE TIME TABLE: EVERY MONTH Check bearing temperature with a thermometer, not by hand. If bearings are running hot (over 82°C), it may be the result of too much lubricant. If changing the lubricant does not correct the condition, disassemble and inspect the bearings.
  • Page 29 symptoms are listed below. Correct any trouble immediately and AVOID COSTLY REPAIR AND SHUTDOWN. No liquid delivered CAUSES CURES 1. Lack of prime. Fill pump and suction pipe completely with liquid. Check for leaks in suction pipe joints and fittings; vent casing to 2.
  • Page 30 14.Cavitation; insufficient a. Increase positive suction head on pump by lowering pump or NPSH (depending on increasing suction pipe size or raising fluid level. installation). b. Sub-cool suction piping at inlet to lower entering liquid temperature. c. Pressurise suction vessel. 15.
  • Page 31 Pump Operates For Short Time, Then Stops 28. Incomplete priming. Free pump, piping and valves of all air. If high points in suction line prevent this, they need correcting. See page 5. 29. Suction lift too high. See item 3. 30.
  • Page 32 Pump Takes Too Much Power CAUSES CURES 33. Head lower than rating; Machine impeller’s O.D. to size advised by factory. See appendix thereby pumping too much “D” Page 33. liquid. 34. Cavitation. See Item 14. 35. Mechanical defects. See items15, 16 and 17 36.

  • Page 33: Servicing

    SECTION VII. SERVICING (Refer to parts list and assembly sections, pages 33 through 45 for catalog numbers contained in procedures. Packing Mech. Seal (Oversize (Std. Stuff. (Std. Stuff. Cylindrical Dynamic Frame Box Only) Box) Stuff. Box) Seal Size Page No. Page No.

  • Page 34: Frame Disassembly

    036- 3) to the frame adaptor (5-193-0). Remove stuffing box. Pull packing (6-924-0), seal cage (6-013-0) and packing base ring (6-152-0) from the stuffing box. Remove the shaft sleeve (6-009- Mechanical Seal Stuffing Box: (Standard Stuff Box or Oversize Seal Chamber. (Single inside mechanical seals are depicted in cross sectional drawings.)) k.

  • Page 35: Part Inspection

    and use cap screws (5-904-4) already removed as jacking screws. e. Next, pull out the complete shaft assembly, including shaft (5-007 -0), bearing housing (5-025-4), bearings (5-026-3 & 5-026-4), and oil slinger (5-485-0). Outboard bearing (5-026-4) for F4Gl & F4Jl frames is double-row angular contact ball bearing and is held in housing by snap ring (5-915- 4).

  • Page 36: Assembly

    0.05mm TIR. 10. BEARINGS Clean bearings using an approved bearing cleaning solvent, or other non-flammable industrial solvent. Inspect the bearings, replacing them if they are noisy or rough when rotated, or if there are signs of wear or pitting in the bearing raceways. WARNING: Under no condition should a combustible solvent such as gasoline be used to clean bearings or any other part of the pump.

  • Page 37: Wet End

    must be positioned with the lip facing outward. The bearing seal is positioned in this fashion to exclude contaminants. NOTE: Lip seal must be square to housing and lip should be pre-lubricated with oil. Slide the outboard bearing housing over the shaft and outboard bearing. Assemble retaining ring to the bearing housing on F4Hl frame using lock washers (5-917-4) and screws (5904-9).
  • Page 38 inside face of the housing and not cocked. For double seal arrangement, pack area between lip seals with grease. For frame F4J 1 attach the seal disk (6-380-9) to the Dynamic Seal housing (6-391-0) using the retaining ring (6-385-0) and four screws. Place the "0" ring (1-914-0) in the seal collar (6-437-0) and assemble onto the outer sleeve (6-657-0).
  • Page 39 PUMP DIMENSIONS FOR MECHANICAL SEAL SETTING Note: setting dim. “G” = dim. “A” – operating length of mech. Seal. DIMENSION FRAME INCH F4-G1 3.228 82.0 F4-H1 3.727 94.7 F4-J1 3.873 98.4 Standard stuff box with flush gland (single seal) DIMENSION FRAME INCH F4-G1...
  • Page 40 PUMP DIMENSIONS FOR MECHANICAL SEAL SETTING Note: setting dim. “G” = dim. “A” – operating length of mech. seal. FRAME DIMENSION INCH F4-G1 3.093 78.6 F4-H1 3.227 82.0 F4-J1 3.889 98.8 Oversize stuff box with flush gland (single seal) DIMENSION FRAME INCH F4-G1...

  • Page 41: Adjustments

    Impeller Assembly a. For F4G I and F4J1, place "O" ring (4-914-0) into the impeller (4-005-5) "O" ring groove. For F4Hl, place "O" ring over impeller hub. Screw the impeller onto the shaft. b. Hold the coupling end of the shaft and tighten the impeller firmly using the cast hex. NOTE: Be sure impeller tightens on shaft threads before rubbing stuff box cover.
  • Page 42 IMPELLER AXIAL CLEARANCE TO CASING MAX. F4G 1 FRAME F4H1 FRAME F4J1 FRAME FLUID ADJUSTMENT RESULTING ADJUSTMENT RESULTING ADJUSTMENT RESULTING TEMP °C (NOTCHES) CLEARANCE (NOTCHES) CLEARANCE (NOTCHES) CLEARANCE (COLD)inch/mm (COLD) inch/mm. (COLD) inch/mm. .010 / 0.25 .010 / 0.25 .015 / 0.38 .014 / 0.36 .018 / 0.46 .021 / 0.53...

  • Page 43: Appendix "A" Engineering Information

    APPENDIX" A" ENGINEERING INFORMATION A. CASING AND IMPELLER DATA: CASING DESIGN DATA - Dimensions In Inches - mm Flange Bolt ANSI Minimum Pump Frame Std. EE Wall Size Group (Lbs) Thickness inch/mm Size inch/mm 1,5 x 1 x 6 5/16 – 7.9 3/8 / M10 3 x 1.5 x 6 5/16 –...
  • Page 44 MAXIMUM WORKING PRESSURES - VS - TEMPERATURE AND CONSTRUCTION CONSTRUCTION TEMP. WORKING PRESSURE kpa °C MATERIAL 125/150 Cast Iron 1200 1200 1200 1140 1040 ANSI Ductile Iron 1900 1900 1900 1800 1720 1590 1380 1180 Flanges (1) Stainless / Alloys 1900 1900 1900...

  • Page 45: Seal Lubrication Pressure

    B. STUFFING BOX DATA: PACKED STUFFING BOX - DIMENSIONS IN inches / mm (STD. STUFFING BOX ONLY) Bolts Packing Lantern Connection Frame Sleeve ring to lantern group Depth Bore diameter B.c./pcd Size rings Size width ring (BSP) F4Gl 2.250/57.1 2.00/50.8 1.375/34.9 3.500/88.9 .38/M10 .31/8 .50/12.7...

  • Page 46: Shaft And Bearing Data

    C. SHAFT AND BEARING DATA SHAFT AND BEARING DATA - DIMENSIONS IN inches / mm IDENTIFYING FRAME SIZE DATA F4Gl F4Hl F4J1 Shaft Diameters Under Impeller (Nom.) .75-16NF2 THD 1. 00-12NF2 THD 1.75-12NF2 THD Under Shaft Sleeve (D) 1.125 / 28.6 1.875 2.250 At Inboard Brg.

  • Page 47: Pump Weights

    D. PUMP WEIGHTS Bare Pump Pump Size Frame Group (Approx. Weight) lbs / kg 1.5x1x6E 90 / 41 3x1.5x6 100 / 45 3x2x6 F4G1 105 / 48 4x3x6 145 / 66 1.5x1x8 105 / 48 3x1.5x8 115 / 52 3x1.5x8.5E 230 / 105 3x2x8.5E 240 / 109...
  • Page 61 24 Duncan Road P O Box 17788 Lilianton Sunward Park Boksburg 1470 1459 Phone +27 11 823 4250 Gauteng +27 11 823 4943 Republic of South Africa E-mail pumps@sameng.co.za...

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