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Ruhrpumpen CPP21 Installation, Operation And Maintenance Manual

End suction, single stage, overhung ansi/asme b73.1
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INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
CPP21
End Suction, Single Stage, Overhung
ANSI/ASME B73.1 - 2001

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Summary of Contents for Ruhrpumpen CPP21

  • Page 1 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL CPP21 End Suction, Single Stage, Overhung ANSI/ASME B73.1 - 2001...
  • Page 2 Contact with hot surfaces of the pump can cause severe burns. Care must be taken where such surfaces are exposed. Care must also be taken to prevent ignition of flammable fluids or other material. Information in this manual is believed to be reliable, but it is not guaranteed by Ruhrpumpen as to its completeness or accuracy.

  • Page 3: Table Of Contents

    3 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 CONTENTS SECTION ONE - PRODUCT DESCRIPTION ........................5 1.1 INTRODUCTION ..............................5 1.2 PUMP CASE, IMPELLER, AND WEAR RINGS ......................6 1.2.1 Pump Case ..............................6 1.2.2 Impeller and Wear Rings ...........................6...
  • Page 4 4 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 5.1 PIPING THE SYSTEM ............................22 5.2 ALIGNMENT* ..............................24 SECTION SIX - LUBRICATION ............................ 33 6.1 OIL LUBRICATION ............................33 6.1.1 Recommended Lubricant ........................

  • Page 5: Section One - Product Description

    The CPP21 is a single stage, end suction pump. For these pumps, rotation is clockwise as viewed from the driver (coupling) end. A spacer coupling is provided for accessibility of service and maintenance. The spacer permits back pull-out, that is, complete removal of the rotating element without disturbing the piping or driver.

  • Page 6: Pump Case, Impeller, And Wear Rings

    6 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 1.2 PUMP CASE, IMPELLER, AND WEAR RINGS 1.2.1 Pump Case The pump case is foot mounted. 1.2.2 Impeller and Wear Rings The impeller is dynamically balanced.

  • Page 7: Section Two - Safety

    The responsibilities and supervision of the personnel must be exactly defined by the plant operator. If the staff does not have the necessary knowledge, they must be trained and instructed. Training may be performed by a Ruhrpumpen representative on behalf of the plant operator. Moreover, the plant operator is to make sure that...

  • Page 8: Hazards In The Event Of Non-Compliance With The Safety Instructions

    8 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 the contents of the operating manual are fully understood by the personnel. 2.3 HAZARDS IN THE EVENT OF NON-COMPLIANCE WITH THE SAFETY INSTRUCTIONS Non-compliance with the safety instructions may produce a risk to the personnel as well as to the environment and the unit and results in loss of any right to claim damages.

  • Page 9: Unauthorized Alterations And Spare Parts

    Modifications may be made to the machine only after consultation with a Ruhrpumpen representative. Using spare parts and accessories authorized by Ruhrpumpen is in the interest of safety. The use of parts not authorized by the dealer exempt the manufacturer from any liability, voiding the warranty.

  • Page 10: Section Three - Transport & Storage

    1. Remove unit only by properly supporting the wooden shipping skid. 2. After unloading, inspect the pump, check the shipment against the packing list, and report damages or shortages immediately to freight carrier and to the designated Ruhrpumpen representative. •...

  • Page 11: Storing

    11 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 3.1 – Correct Position of the lifting ropes or chains. 3.4 STORING If the pump is not installed immediately (within one month after shipping date), it should be safely stored prior to installation in a dry location free of dirt and grit.
  • Page 12 13. When the pump is to be installed, remove all the protective coatings and desiccant or drain all oils. One month before installation, a Ruhrpumpen representative should be employed to conduct a final inspection. To properly store the motor (driver) for periods longer than one month, follow these steps: 1.

  • Page 13: Conservation

    13 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 • Always drain the oil before moving the pump, to avoid any damages, and refill the motor on its new location.
  • Page 14 14 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 place. If stored under unfavorable climatic conditions, this protective period may be considerably reduced. Should the anticorrosive layer become damaged, it can be repaired by repainting or respraying.

  • Page 15: Section Four - Installation

    Installation, Operation, and Maintenance Manual – CPP21 SECTION FOUR - INSTALLATION Correct and orderly installation/assembly is necessary for trouble-free operation of the unit. Ruhrpumpen does not assume any liability for damage resulting from inadequate installation/assembly. The chosen location for installation must offer enough space for maintenance activities.

  • Page 16: Leveling Baseplate

    16 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 4.1 – Imaginary lines. 3. It is recommended to build foundation approximately 3 inches (76 mm) larger overall than the pump baseplate to provide ample anchorage for the foundation bolts.
  • Page 17 17 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 The foundation must be kept free of all contamination after it has been prepared for grouting. To continue with the leveling procedure: 1.

  • Page 18: Grouting

    18 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 evenly. • NOTE: The baseplate should be mounted without distortion. 7. When baseplate is level, 'snug' the foundation bolt nuts, but do not tighten completely.
  • Page 19 19 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 • Grout forms should be attached with drilled anchors. Do not power nail. • Apply three coats of paste wax to the inside surfaces of the forms in order to prevent adherence.
  • Page 20 20 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 9. Use a lifting rig to position the pump and driver on their baseplate so that the mounting feet line up with their respective tapped holes.

  • Page 21: Section Five - Piping And Alignment

    21 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SECTION FIVE - PIPING AND ALIGNMENT • These units are furnished for a specific service condition. Any change in the hydraulic system may affect the pump performance adversely.

  • Page 22: Piping The System

    22 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 5.1 PIPING THE SYSTEM 1. Check whether the piping is loosely laid, so that no strain is placed on the pump.
  • Page 23 23 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 12. Proceed in the same way with the discharge pipe. • Make sure that there are isolation block valves at the pump for each type of auxiliary piping.

  • Page 24: Alignment

    24 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 5.2 ALIGNMENT In the following pages, alignment procedures are explained with dial indicators. Laser alignment is also possible. The specific method in laser alignment will depend on the manufacturer’s instructions; however, the basic principles and rotation of the shafts apply, as in the Reverse Indicator Alignment Method.
  • Page 25 25 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 foot should be checked first and eliminated. This can easily be done by mounting a dial indicator on the base plate indicating off the top of foot on the machine to be checked. Each foot in rotation is then checked by loosening only the bolt with the rest of the bolts being tight.
  • Page 26 26 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 5.2 Indicator sag. With the indicator bracket attached to the motor hub reading off the pump hub, rotate unit in 90° increments and take readings.
  • Page 27 27 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 5.3 Motor shaft extension relative to the pump shaft center line. Now with the indicator bracket attached to the pump hub reading off the motor hub, rotate unit again in 90°...
  • Page 28 28 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Drawing a straight line through these two points crossing the plane of the two motor feet. The shim adjustment can now be read directly off the graph. In this example, 0.004 inch (0.102 mm) should be added to the front foot and 0.001 inch (0.025 mm) should be added to the back foot.
  • Page 29 29 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 1. Distance from centerline of one disc pack to the centerline of the other disc pack. In the example, it is 9- 1/2 inches (241.3 mm).
  • Page 30 30 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 5.8 Indicator sag in across the disc pack alignment analysis example. With the indicator bracket attached to the pump hub, reading out the center member a convenient distance, (in this example 8 inches [203.2 mm] was used) rotate the unit in 90°...
  • Page 31 31 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 5.9 Plot of the plus reading in the across the disc pack alignment analysis example. Now with the indicator bracket attached to the motor hub reading out on the center member, rotate the unit in 90°...
  • Page 32 32 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 5.10 Plotting the motor in the across the disc pack alignment analysis example. In this example, the motor should be shimmed up 0.013 inch (0.330 mm) under front feet and shimmed up 0.016 inch (0.406 mm) under back feet.

  • Page 33: Section Six - Lubrication

    • Ruhrpumpen takes every precaution during our assembly process and subsequent final assembly audits to ensure no Bearing Frame oil leaks exist prior to shipment. Oil can leak past the labyrinth seal in an “overfill” condition.

  • Page 34: Maintenance

    34 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Oil quantity Frame U.S. gallons 0.80 3.00 Always verify and replenish the oil if the level falls below the middle of the oil sight glass.
  • Page 35 35 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 2. Drain the oil out and clean the bearing frame with a suitable cleaning liquid. Flushing the bearing frame with clean lightweight oil is possible.

  • Page 36: Section Seven - Operation

    36 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SECTION SEVEN - OPERATION 7.1 PRIMING Pumps handling hot (>500 °F, >260 °C) fluids must be gradually preheated to operating temperature. The most common method used for warming a pump, or maintaining a standby pump in a warm condition, is the use of a warming line and orifice, thus circulating the hot pumpage through the idle pump.

  • Page 37: Operating Check

    37 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 The startup procedure is as follows: 1. Before starting the pump, check the security of all bolting, piping, and wiring. 2. Check all gauges, valves and instruments for proper working order.
  • Page 38 To monitor flow, pressure, temperature, and lubrication, regular visual inspection and monitoring is advisable and/or necessary during operation. Ruhrpumpen recommends checking the pump constantly at regular intervals in order to detect problems early, in case they arise. The operational check routine must include minimum the following points: •...

  • Page 39: Doweling (Optional)

    39 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 • The pump may only be operated under the minimum operating range for short periods. The minimum pump flow is given in the characteristic line.

  • Page 40: Short-Term Shutdown

    40 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 6. Ensure the drive motor cannot be unintentionally turned on. 7. Ensure the shut-off devices in the suction and pressure pipes cannot be unintentionally opened.

  • Page 41: Section Eight - Maintenance

    Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SECTION EIGHT – MAINTENANCE To perform the maintenance of the CPP21 pump, no special (custom made) tools are needed. • Before initiating maintenance procedures disconnect all power sources to the equipment and discharge any parts which may retain an electric charge.

  • Page 42: Inspection And Cleaning

    8.2 INSPECTION AND CLEANING 1. Thoroughly clean all parts and dry with compressed air or a clean, lint free cloth. 2. Inspect all components for corrosion, erosion, pitting, and scoring. If required, replace with Ruhrpumpen O.E.M. genuine replacement parts. a. Visual check all individual parts for any damage b.

  • Page 43: Reassembly

    43 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 8.3 REASSEMBLY • Observe the plant's safety precautions when lifting heavy components. Request help when moving or positioning them. • Mounting of bearings should be carried out in a dry, dust free area away from metal working or other machines producing shavings and dust to avoid contamination of bearings.
  • Page 44 44 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 3. As soon as the bearing has reached the temperature of 230 °F (110 °C), place the thrust bearing on the shaft (with the serial number visible from the outside).
  • Page 45 45 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.3 Positioning the lock washer. 5. Position the locknut with the taper towards the side of the lock washer at full-stop.
  • Page 46 46 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.5 Heating the radial ball bearing. 7. As soon as the bearing reaches the 230 °F (110 °C) temperature, it is manually positioned in the shaft (with the serial number visible from the outside).
  • Page 47 47 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.7 Positioning the rotor assembly on the power frame (from coupling side). 9. Tighten the bearing lock nut as tight as possible by hand using a spanner wrench. Ensure at the end of the tightening process that one of the lock washer tabs lines up with the slot in the locknut.
  • Page 48 48 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 11. To insert the labyrinth seals into the covers, follow these steps: a. Lubricate the outside ring of the labyrinth seal. Lubricant supplied by isolator manufacturer or P- 80 Rubber Lubricant Emulsion is recommended (grease is NOT recommended).
  • Page 49 49 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 • Do not use a hydraulic press, since the seal can be broken. e. Perform this procedure on both covers. Figure 8.13 Repeating the process for each cover.
  • Page 50 50 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.16 Radial cover assembly. • Inspection point: Check that the bearings enter evenly in the frame; the bearing should rest against the wall of the power frame. After this assembly, the shaft must be able to rotate by hand;...
  • Page 51 51 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.18 Lubricating the internal diameter of the labyrinth seal. 17. Slide cover onto the shaft, ensuring cover is rotated to the correct position (do not use a hammer).
  • Page 52 52 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 • Apply pipe tape sealant only if it is a pass-through thread (except for the vent). • Inspection point: Check visually that all the threads in the power frame have a plug installed (no thread should remain free after this step).
  • Page 53 53 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 a. Each of the wear rings of the impeller (two, one for each side) is inserted into its position (to the limit where it stops) using a press or a rubber mallet.
  • Page 54 54 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.26 Positioning the mechanical seal ring. b. Grease the joint of the mechanical seal head and install it in the internal diameter.
  • Page 55 55 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.29 Positioning the rotary face. e. Install the spring in the shaft. Figure 8.30 Positioning the spring in the shaft.
  • Page 56 56 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 .3125 inch Figure 8.32 Positioning the spacer. h. Tighten the set screws to set the spacer in that position. Figure 8.33 Fixing the spacer in the shaft.
  • Page 57 57 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.35 Paired nuts to tighten the stud. c. Tighten both nuts as shown. Figure 8.36 Tightening the paired nuts. d. Use the spanner to tighten the stud.
  • Page 58 58 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.38 Removing the nuts. Repeat these steps to tighten each of the remaining studs. 24. Install the case cover in the power frame.
  • Page 59 59 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 27. Apply antiseize protection on the shaft thread and position the impeller. With a torque spanner, on the shaft at the coupling side, lock the rotation of the shaft. Rotate the impeller to tighten it to the possible extent.

  • Page 60: Coupling Guard Assembly

    60 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 b. Lift the assembly of the power frame and position it over the case shoulder. Figure 8.43 Positioning the power frame assembly on the case.
  • Page 61 61 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.44 Coupling already mounted and aligned. 2. Put together the lower pump side cover with the motor side cover. Figure 8.45 Putting together the lower pump and the motor side covers.
  • Page 62 62 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Figure 8.47 Positioning and securing second motor side cover. 5. Position the pump side upper cover and insert the two bolts in the upper frame supports. Install the nuts to secure the coupling guard assembly and tighten by hand.
  • Page 63 63 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 7. Before tightening all bolts and nuts with a spanner, adjust the length of the coupling guard to close the distance between the coupling guard and the motor to approximately ⅛ inch (3.175 mm).

  • Page 64: Section Nine - Spare Parts

    64 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SECTION NINE - SPARE PARTS The recommended quantity of spare parts to meet regular conditions of constant operation over a period of two...
  • Page 65 65 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Material Storage of spare parts • Store the spare parts in their original packaging. • Store in a dry place, preferably at a constant temperature.

  • Page 66: Section Ten - Parts Information

    66 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SECTION TEN - PARTS INFORMATION Bearing Frame: B-10 Case 423-1 Radial Labyrinth Seal Impeller Axial Labyrinth Seal Case Cover Case Gasket...
  • Page 67 67 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Bearing Frame: B-30A / B-30B Case 423-1 Radial Labyrinth Seal Impeller Axial Labyrinth Seal Case Cover Case Gasket Mechanical Seal Head...
  • Page 68 68 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 Bearing Frame: B-50 Case 423-1 Radial Labyrinth Seal Impeller Axial Labyrinth Seal Case Cover Case Gasket Mechanical Seal Head Shaft Bearing Bracket...

  • Page 69: Section Eleven - Troubleshooting Chart

    69 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SECTION ELEVEN - TROUBLESHOOTING CHART TROUBLE PROBABLE CAUSES SUGGESTED SOLUTION a. Insufficient Oil a. Add Oil. b. Contaminated Oil b. Drain and clean reservoir. Refill with clean oil.
  • Page 70 70 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 TROUBLE PROBABLE CAUSES SUGGESTED SOLUTION a. Check suction line for leaks. a. Air leaks into suction b. Speed too low b. Check driver and its power source c.
  • Page 71 71 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 RUHRPUMPEN, Inc. 4501 South 86th East Ave. Tulsa, Oklahoma 74145 USA Phone:+1 (918) 627-8400 GERMANY RUHRPUMPEN GmbH Stockumer Strasse 28 58453 Witten/Germany P.O.
  • Page 72 72 / 72 Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001 Installation, Operation, and Maintenance Manual – CPP21 SEPTEMBER 2010...

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