process pumps (india) pvt ltd

VERTICAL CANTILEVER SHAFT SUMP PUMP (PPCS)_

NON 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: [email protected]

VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

© 2005-2006. Process Pumps (I) Pvt. Ltd.

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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: 27.09.2010



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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.



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1. Introduction The PPCS plastic 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 plastic Pump is concentric

non metallic volute.

b) Impeller: The impeller with the PPCS plastic 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 through

threads.

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



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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.



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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 IF THE PUMP IS NOT LEVELED WITH IN THIS TOLERANCE, DO NOT IF THE PUMP IS NOT LEVELED WITH IN THIS TOLERANCE, DO NOT IF THE PUMP IS NOT LEVELED WITH IN THIS TOLERANCE, DO NOT

PROCEED UNTIL THIS CONDITION IS RESOLVEDPROCEED UNTIL THIS CONDITION IS RESOLVEDPROCEED UNTIL THIS CONDITION IS RESOLVEDPROCEED 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.



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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.



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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.



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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.



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12. Dismantling Procedure

Total Assembly of the Pump is shown in Figure 12.1

Figure 12.1



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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



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Step 2: Lift the Pump along with Mounting Plate keep it horizontally on the table

Figure 12.3

Step 3: Disconnect the delivery pipe and loosen the nuts of tie rods .Separate

the lantern ring coil and remove the Impeller Casing.

Figure 12.4



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Step 4: Hold the shaft tightly at the coupling end and unthread the impeller by

rotating in anticlockwise direction. Separate the impeller by shaft.

Figure 12.5



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Step 5: Pullout Back plate and Gasket.

Figure 12.6

Step 6:

a) Unscrew the bolts holding the Mounting plate,column pipe, intermediate

plate and intermediate support..

b) Unscrew the bolts holding the intermediate plate and Gland housing.

c) Unscrew the bolts holding the Intermediate support and Housing

support.

d) Unscrew the bolts holding the Intermediate support and Bearing

housing.

e) Unscrew the bolts holding the Bearing housing and housing support.

f) Unscrew the bolts holding the Housing support and coupling chamber.



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Figure 12.7

Step 7:

a) Separate the Mounting plate from column pipe.

b) Separate the column pipe from Intermediate plate.

c) Separate the Intermediate support from Housing support.

d) Separate the Housing support from coupling chamber.



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Figure 12.8

Step 8: Pull out the shaft along with the bearing housing

Figure 12.9



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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 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



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Step 10:

a) Separate the far end oil seal 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



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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.



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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

Pump

� Check power supply.

� Dismantle and

overhaul as necessary.

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

insufficient capacity

� Low speed. � Check the speed.

5. Excessive

Motor vibration.

� Foreign material

trapped in the pump

cavity.

� Incorrectly supported

pipeline.

� Remove the foreign

material.

� Check the pipeline.



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6.Bearing over heating � Insufficient

lubrication.

� Bearing defect

� Misalignment

� Check the bearing

lubrication.

� Renew the bearing.

� Check the alignment.

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)

process pumps (india) pvt ltd

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