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OPERATION AND MAINTANACE MANUAL
AD, A B & TU SPLIT CASING PUMPS

SAM TURBO INDUSTRY PVT LIMITED

NEELAMBUR, COIMBATORE-641062, INDIA

PHONE: +914226193555,
E-MAIL:

Содержание 10 AD 11.5

Страница 1: ...1 OPERATION AND MAINTANACE MANUAL AD A B TU SPLIT CASING PUMPS SAM TURBO INDUSTRY PVT LIMITED NEELAMBUR COIMBATORE 641062 INDIA PHONE 914226193555 E MAIL service sampumps com ...

Страница 2: ...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 warranty the materials for the chemical composition and mechanical properties of the relevant standard only and not for corros...

Страница 3: ...ESERVATION OF PUMPS 3 DESCRIPTION OF PUMP 4 ERECTING THE PUMP 5 LAYING AND CONNECTING PIPES 6 LUBRICATION 7 STARTING AND STOPPING 8 SUPERVISION AND MAINTENANCE STUFFING BEARING 9 DISMANTLING AND ASSEMBLING 10 BILL OF MATERIAL 11 SECTIONAL DRAWING 12 TROUBLE CAUSE REMEDY ...

Страница 4: ...insure that the equipment remains in good condition FORWARD AND GUARANTEE This erection and operating manual should in all cases be read by your fitters before erection and start up We are not liable for damage incurred through failure to observe the instructions for erection and operation In this connection we refer to our General Terms of delivery for centrifugal pumps During the period of guara...

Страница 5: ... Suction and discharge flanges should be covered to prevent the entry any kind of foreign environment The surfaces to be preserved should be covered with the preservatives suitable for storing environment Mechanical seals should be cleaned by compressed air No other liquid of material should be applied to the min order to prevent damage to the secondary sealings and too ring gaskets Pumps waiting ...

Страница 6: ...pump shaft suction delivery nozzles are being located in the lower half With this arrangement it is not necessary to disconnect suction or discharge piping to make repairs to or replace the rotating element Upper and lower half casings are bolted together and doweled to maintain a smooth volute contour inside the pump water before it reaches the shaft in case drain Bearing brackets form a drip poc...

Страница 7: ...mmon base plate is done in our works the whole set will be carefully mounted and aligned It is necessary to check once more the alignment of the coupling before putting the pump into operation The eye bolts which may be fitted to the driver must never be used to lift the complete set as they are meant to carry the weight of the driver only 2 3 4 5 ...

Страница 8: ...water 3 Pour grout Tamp liberally while pouring in order to fill all cavities and prevent air pockets The space between the foundation and base plate should be completely filled with grout In order to prevent the base plate from shifting fill under the base plate at least four inches in from all four edges Wedges may be left in place 4 After the grout has hardened usually about 48 hours thoroughly...

Страница 9: ...points should remain same when both couplings are turned through an angle Maximum permissible tolerance is 0 05mm The permissible tolerance being 0 05mm provided that the type of coupling is such as to allow this check figure 1 a Otherwise a coupling aligner must be used permissible tolerance 0 05 mm figure 1 b At every check take care that the axial float of the rotor is taken into account i e wh...

Страница 10: ...e A baffle placed in front of A stream of liquid falling into the sump near the intake pipe will churn air into the liquid The supply line should extend down into the sump Liquid supply entering a well perpendicular to the intake line tends to rotate the liquid which interferes with short the supply pipe will remedy for this situation A elbow should never to bolted directly to the pumps suction no...

Страница 11: ... valve and gate valve with the check valve being between the pump and the gate valve The check valve prevents reverse flow and protects the pump from excessive backpressure The gate valve is used to isolate the pump for maintenance priming and starting ...

Страница 12: ...12 ...

Страница 13: ... shipment For bearings the following greases are recommended which are available in the market firm name 1450rpm 2900 rpm INDIAN OIL SERVOGEM 3 SERVOGEM 2 CALTEX STARFAK 3 STARFAK 2 HIND PETROLEUM NATRA3 LITHON3 NATRA2 LITHON 2 GREASING FREQUENCY SERVICE GREASE PERIOD Normal 8 hour day operation Room free of dust and damaging atmosphere 6 Months Severe 24 hour day operation Room with moderate dust...

Страница 14: ... 3AD 12 4AD 8 4AD 9 5 4AD 11 4AD 14 6AD 8 5 6AD 11 Gr IV V 84 4 AD 11 5 4 AD 18 5 6 AD 9 5 6 AD 11 5 6 AD 14 6 AD 16 5 8 AD 11 Gr VI 112 8 AD 13 5 8 AD 17 10 AD 11 5 10AD 13 5 GRAMS MODEL 84 3TU 13 112 4TU 14 130 5TU 15 150 6TU 16 175 8TU 17 GRAMS MODEL 84 6A 19B 112 8A 20 B 10A 16B 130 10A 20 B 14A 20B 150 12A 19 B 14A 22B ...

Страница 15: ...allowed to escape through the vent valve while filling 7 If the pump operates on a suction lift and no foot valve is provided use a vacuum pump or ejector operated by air steam water etc to evacuate air from the pump case and suction line by connecting the ejector to the priming connection on top of the pump case 8 Open valves in stuffing box seal lines if fitted Start driver Open discharge valve ...

Страница 16: ... buildup in the pump because of absorption of the input power into the pumped fluid Other less understood reasons for restrictions are 1 Increased radial reaction at low flows in single volute casings 2 Increased NPSHR at low flows 3 Noisy rough operation and possible physical damage due to internal recirculation 4 Increased suction and discharge pulsation levels 5 The size of the pump the energy ...

Страница 17: ...ing must be positioned such that the water seal connection is opposite lantern ring 5 Clean out the stuffing box 6 Inspect shaft sleeve if it is scored or grooved it should be replaced 7 Make sure the st box bushing if furnished is set at the bottom of the box 8 Insert rings of packing and tap lightly to seat against bushing Be sure rings are of the proper size an length and installed with cuts st...

Страница 18: ...p specifications When these clearances are doubled or the capacity of the pump is reduced by 5 to 10 the rings should be renewed The purpose of these rings is to keep internal bypassing of the liquid being pumped to a minimum Clearances should be checked periodically and whenever the pump casing is opened Check with feeler gauge or by direct measurement Measure ID of case ring and OD of impeller r...

Страница 19: ... the vanes The impeller must be installed with the vanes in the same direction Remove Impeller Rings It is not necessary to remove the impeller from the shaft to replace the impeller rings First remove the rotating element Remove the locking set screws from the rings Inspection Visually inspect parts for damage affecting serviceability Check o rings and gaskets for cracks nicks or tears packing ri...

Страница 20: ...n DE side to bearing housing 8 The complete set of rotating assembly to be placed with bottom casing bearing housings should be carefully placed on locating pin Tight the bearing housing casing joint bolts 9 Check the casing wear ring positions there is a locating pin available in the casing wear ring 10 Check the impeller position if its touch with casing then to adjust the impeller with help of ...

Страница 21: ...tructural unit will be inserted into the pump casing lower half part no 1B taking care that the half collar of the neck bushes part no 63 is inserted in such a way that it is not towering the gasket and that the fitting locking pin part no32 are inserted in the grooves in the pump casing lower part Furthermore the half collars of the neck bushes and the wear rings have to be pushed to the casing l...

Страница 22: ... are for reference only and are subjected to change without prior notice NOTE Clearance are for standard bronze or cast iron fitted pumps For materials with a tendency to gall such as stainless steel increase clearance approximately 0 25mm for worn case ring maximum allowable diametrical clearance add 0 76 to the higher to tolerance limit Clearance in mm 0 38 to 0 53 0 40 to 0 55 0 43 to 0 58 0 45...

Страница 23: ...NG 1 NO A35 ID2 835 XOD3 490X1 32 BRG COVER 2 NOS ID6 25 XOD8 X0 8 ST BOX 2 NOS ID8 XOD11 X1 ADOPTER 2 NOS 14 4 AD 11 5 6209 3209 ID2 18 X0 375 10 SQ ID1 94 XØ 0 103 SLEEVE 2 NOS ID7 25 XØ 0 139 ST BOX 2 NOS 750X750X1 CASING 1 NO A45 15 4 AD18 5 ID6 25 XOD8 X0 8 ST BOX 2 NOS 16 6 AD 9 5 ID3 35 XOD4 245 X1 32 BRG COVER 2 NOS 17 6 AD 11 5 ID8 XOD11 X1 ADOPTER 2 NOS 18 6 AD 14 19 6 AD 16 5 20 21 8 AD...

Страница 24: ...D70XØ3 6 SLEEVE 2 NOS ID5 5 32 XOD7 3 8 X0 06 BRG COVER 2 NOS 1000X1000X1 CASING 1 NO ID68 07XOD92 07X1 SUC SLEEVE 1 NO 4 12 A 19 B 6316 7316 2 ID109 47X OD142X 16 Sq 10 NOS ID38XDIA3 SLEEVE 2 NOS 1000X1000X1 CASING 1 NO ID96 52XOD120 65X1 SLEEVE 2 NOS ID170XOD260 4X0 8 BRG COVER 2 NOS 5 14 A 20 B 6314 7314 2 ID3 1 2 X OD4 3 4 x 5 8 SQ 10 NOS ID76 2XDIA3 SLEEVE 2 NOS 1200X1000X1 CASING TO SUIT PRO...

Страница 25: ......

Страница 26: ...asing upper half in accordance with figure see Instructions the flange screws Recommended Spare Parts Spare parts should already be in stock at the client s for the initial startup In order to minimize down time we recommend to obtain one complete set of spare parts Complete rotor assembly Set of wear rings Set of bearings Sets of complete mech seals resp Stuffing box packings For normal operation...

Страница 27: ... lock washer 1 14 Shaft sleeve 2 71 Adopter 2 16 Inboard bearing 1 73 1 Gasket casing 1 17 Gland 2 73 2 Adopter Gasket 2 17B Gland bolt 4 73 3 Stuffing box gasket 2 18 Outboard bearing 1 73 4 Bearing cover gasket 2 20 Sleeve nut RH 1 83 Stuffing box 2 20A Sleeve nut LH 1 123 Brg housing plug 1 22 Bearing lock nut 1 127 Water seal pipe 2 29 Lantern ring 2 130 1 O Ring sleeve 2 31 Inboard brg housin...

Страница 28: ......

Страница 29: ...r 2 8 Impeller wear ring 2 41 Bearing cap 2 13 Gland packing 6 6 46 Coupling key 1 14 Shaft sleeve 2 63 Stuffing box bushing 2 16 Ball bearing 1 68 Shaft collar 2 17 Gland 2 69A Brg lock washer 1 18 Outboard bearing 2 73 Gasket s sleeve 2 20 Sleeve nut 2 73 1 Gasket casing 1 22 Bearing lock nut 1 73 2 Gasket brg housing 2 29 Lantern ring 2 127 Seal piping 2 31 Inboard brg housing 1 130 O Ring s sl...

Страница 30: ......

Страница 31: ...earing cap 2 13 Gland Packing 2 Set 48 Coupling key 1 14 Shaft sleeve 2 58 Interstage sleeve 1 16 Bearing DE 1 63 Stuffing box bush 2 17 Gland 2 68 Shaft collar 2 17B Bolt Gland Cas 4 69A Brg lock washer 1 18 Bearing NDE 2 73A Casing gasket 1 22 Bearing lock nut 1 73B Bearing cover gasket 2 29 Lantern ring 2 113 Interstage bush 1 31 Inboard brg housing 1 127 Seal piping 2 32 Impeller key 2 130 O R...

Страница 32: ......

Страница 33: ...king or mechanical seal 9 10 24 26 28 32 33 34 35 36 37 38 39 48 Excessive noise or vibration of Pump 2 3 4 5 6 7 15 18 23 24 25 26 27 28 31 35 36 40 42 43 44 46 49 Overheating or excessive wear of bearings 12 14 15 16 17 18 24 25 26 27 28 30 36 38 40 41 42 43 44 45 49 50 51 Overheating and seizing of pump 1 4 18 19 21 22 24 25 27 28 35 36 40 41 49 Possible Reasons for Operating Troubles Hydraulic...

Страница 34: ...k 4 Bent shaft 5 Rubbing of rotating parts on fixed parts 6 Worn bearings 7 Worn wear rings distance sleeves and throat bushes 8 Wrong design of suction line leading to asymmetrical flow or vortexing 9 Impeller damaged 10 Shaft sleeve worn 11 Incorrectly installed packing 12 Incorrect packing type installed 13 Non concentric running of rotor due to bearing wear or incorrect alignment 14 Rotor not ...

Страница 35: ...f mechanical seal damaged 26 Incorrectly adjusted mechanical seal wrong spring tension 27 Incorrectly installed rotor shaft nuts loose 28 Unsuitable lubricant 29 Oil level too low 30 Inner leaking due to damaged sealing ...

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