HM, HMR, HMX Pumps

Installation, Operation and Maintenance Manual

 Contents

INTRODUCTION 3
PUMP IDENTIFICATION 3
INSTALLATION 4
TEMPORARY STORAGE 4
SUCTION AND DISCHARGE PIPING 5
OPERATION 5
PRE-START CHECKS 5
PRIMING 6
STARTING 6
OPERATING CHECKS 6
HM SERIES CUT AWAYS 7
TROUBLESHOOTING 8-10
LUBRICATION 11
OIL LUBRICATION 11
GREASE LUBRICATION 12
BEARING LUBRICATION 12
MAINTENANCE 13
GENERAL 13
PERIODIC INSPECTION 13
MAINTENANCE AFTER FLOODED CONDITION 14
DISASSEMBLY 14-15
CLEANING 16
INSPECTION 16
REPAIR AND REPLACEMENT 17
REASSEMBLY 17
STUFFING BOX 18
IMPELLER ADJUSTMENT 19
REPLACEMENT PARTS 19

NOTE:
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 the responsibility of using accepted engineering practices in the
installation, operation and maintenance of this equipment.
 Introduction | Pump Identification

INTRODUCTION d. The dynamic seal, style C-022, is used when

This manual is furnished to acquaint you with the seal water dilution of the product cannot be
easiest and most practical way to install, operate, permitted. This design employs a
and maintain this pump. Keep it handy for future combination static seal and second impeller
reference. Additional information can be obtained to eliminate the conventional stuffing box. Seal
from the nearest SAM Engineering. The Standards water in the amount of 1/4-1/2 GPM is all that
of the Hydraulic Institute are an excellent source is required.
for more detailed advice on the subject of
installation, operation and maintenance. The HM and CWR Pumps are designated by Model
Numbers, Serial Numbers, Size, and Style. This
Equipment cannot operate well without proper information is stamped on an identification plate
care. To keep the unit at top efficiency, correct and affixed to the pump casing. A second plate,
procedures for installing and maintenance must be attached to the pump frame, contains the inboard
followed. SAM Engineering can help install this and outboard bearing part numbers.
equipment correctly, so that maximum machine
life can be attained with a minimum of downtime. a. Permanent records for this pump are kept
by the serial number; therefore, the serial
SAM Engineering Servicemen are experienced, number must be used with all correspondence
factory trained assembly superintendents, and and spare-parts orders.
offer prompt, efficient service at reasonable rates.
Costly errors such as poor grouting, incorrect b. Maintenance instructions in this manual are
alignment, pipe stresses transmitted to the based upon the Model F6 frame.
casings, and improperly cleaned piping are
frequently found and corrected by these
servicemen, thus saving costly repair and
additional delays. The serviceman can be obtained
through the nearest SAM Engineering Sales Office.
This office will also help with spare parts orders
and problems requiring special attention.

PUMP IDENTIFICATION
a. The new HM Pump Standard is designated
style C-011. It combines the best features of
both the HM-ll & HM-12 designs.

b. The C-011 Pump has internal pressure relief

vanes cast integral in the impeller to reduce
stuffing box pressure. Flush water is piped to
the centre of the stuffing box. A split seal cage
delivers the water, sealing the packing from
entrance of abrasive particles. Lower stuffing
box pressure results in longer shaft sleeve and
packing life.

c. The new CWR pump standard designation is

style C-011. It is the same design as the HM
except the impeller is radially ribbed on both
the front and back shroud wall. This is
recommended for highly abrasive slurries. The
impeller ribs cut down on recirculation of
slurry through the wear plate clearance,
reducing wear.

3
 Pump Nameplate | Temporary Storage | Pump Installation

TEMPORARY STORAGE

SAMCO PUMPS If the pump is not to be installed and operated

soon after arrival, store it in a clean, dry place
having slow, moderate change in ambient tempera-
MODEL (1.) SER. NO. (2.)
ture. Rotate the shaft periodically to coat the
FLOW (m³/hr) (3.) HEAD (m) (4.)
bearings with lubricant and to retard oxidation and
MAX.DES.PRS (kPa) (5.) IMP. DIA. (mm) (6.) corrosion.
MOC (7.) RPM (8.)
PUMP INSTALLATION
SUCTION AND DISCHARGE PIPING
Made in RSA by SAM Engineering (Pty) Ltd
Tel: +27 11 823-4250 General: When installing the pump piping, be sure
to observe the following precautions:

These pumps are designated by serial number, a. Both the suction and discharge piping should
model, size, and M.O.C. This information is be independently supported near the pump
stamped on an identification plate and affixed to and properly aligned so that no strain is
the pump frame or casing. transmitted to the pump when the flange bolts
are tightened. Use pipe hangers or other
Permanent records are kept by the factory and supports at necessary intervals to provide
filed by serial number. supports.

The pump nameplate contains the following b. It is usually advisable to increase the size of
information: both suction and discharge pipes at the pump
connections to decrease the loss of head from
1. SERIAL NUMBER – Composed of certain friction.
groups of numbers. All groups are necessary for
identification. TYPICAL EXAMPLE: P 2081 / 98 c. Install piping as straight as possible, avoiding
unnecessary bends. Where necessary, use long
2. MODEL - HM, followed by SIZE – Composed of radius or 90° fittings to decrease friction
three (3) groups of numbers. losses.
EXAMPLE: 4 x 3 x 11 – First number (4) is the ASA
suction flange size in inches, second number (3) is d. Make sure that all piping joints are airtight.
the ASA discharge flange size in inches, the third
number (11) is the nominal maximum impeller e. Where flanged joints are used, assure that
diameter in inches. inside diameters match properly.

3. IMPELLER DIAMETER – This number is the f. Remove burrs and sharp edges when making
impeller diameter in millimetres as supplied by the up joints.
factory. EXAMPLE: 265
g. Do not "spring" piping when making any
4. FLOW – Design flow rate in cubic metres per connections.
hour.
h. Provide for pipe expansion when hot fluids are
5. HEAD – Design head in metres. to be pumped. The use of expansion joints is
not recommended.
6. MAX. DESIGN PRESSURE – This refers to
factory standard hydrostatic test pressure for CAUTION: Bolt torque must not exceed 12S ft. Ibs.
hydraulic end of pump. on flanges. Hard iron is brittle and an over-torque
could crack casing.
7. M.O.C. – Material of construction of pump
shown in abbreviated form and in four parts.
EXAMPLE: CI/SS/CI/EN8 – where casing, stuff box
and wear plate (if fitted) are in Cast Iron / 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.
4
 Suction and Discharge Piping | Operation | Pre-start Checks

SUCTION PIPING The gate valve is used in priming and starting, and
when shutting the pump down.
When installing the suction piping, observe the
following precautions: PRESSURE GAUGES
a. The sizing and installation of the suction Properly sized pressure gauges can be installed in
piping is extremely important. It must be both the suction and discharge pipe sections
selected and installed so that pressure losses adjacent to the pump. The gauges will enable the
are minimised and sufficient liquid will flow operator to easily observe the operation of the
into the pump when started and operated. pump, and also determine if the pump is operat-
Many NPSH (Net Positive Suction Head) ing in conformance with the performance curve.
problems can be directly attributed to For slurry service gauges should be of the protect-
improper suction piping systems. ed type. If cavitation, vapour binding or other
unstable operation should occur, widely fluctuating
b. Suction piping should be short in length, as discharge pressure will be noted.
direct as possible, and never smaller in
diameter than the pump suction opening. If NOTE: The standard pump has no drain or vent
the suction pipe is short, the pipe diameter taps.
can be the same size as the suction opening. If
longer suction pipe is required, pipes should OPERATION
be one or two sizes larger than the opening
depending on piping length. PRE-START CHECKS

c. The suction pipe should slope upward to the Before initial start of the pump, make the following
pump nozzle. A horizontal suction line must inspections:
have a gradual rise to the pump. Any high point
in the pipe will become filled with air and thus a. Check alignment between pump and motor.
prevent proper operation of the pump. When
reducing the piping to the suction opening b. Check Rotation. Be sure that the pump
diameter use an eccentric reducer with the operates in the direction indicated by the
eccentric side down to avoid air pockets. arrow on the pump casing, as serious damage
can result if the pump is operated with
NOTE: Never use a straight taper reducer in a incorrect rotation. Check rotation each time
horizontal suction line, as it tends to form an air the motor leads have been disconnected.
pocket in the top of the reducer and the pipe.

DISCHARGE PIPING NOTE: If motor cannot be carefully "bumped" it is

suggested that couplings be disconnected for
For plain liquid service, if the discharge piping is rotation check.
short, the pipe diameter can be the same as the
discharge opening. If the piping is long, pipe c. Check all connections to motor and starting
diameter should be one or two sizes larger than device with wiring diagram. Check voltage,
the discharge opening. On long horizontal runs it is phase and frequency on motor nameplate with
desirable to maintain as even a grade as possible. line circuit.
Avoid high spots, such as loops, which will
collect air and throttle the system or lead to erratic d. Check suction and discharge piping and
pumping. For slurries, it is suggested to consult pressure gages for proper operation.
technical advice on correct pipe sizing. Each
application may require consideration to provide e. Turn rotating element by hand to assure that it
proper line velocity to prevent settling out. rotates freely.
Selection of size of discharge line is important in
order to keep velocities up to prevent slurries from f. Check impeller adjustment.
settling out.
g. Check stuffing box adjustment, lubrication and
VALVES IN DISCHARGE PIPING piping.

A check valve and gate valve should be installed in h. Assure that bearings are properly lubricated.
the discharge. The check valve, placed between
pump and gate valve, protects the pump from i. Assure that pump is full of liquid.
excessive pressure, and prevents liquid from
running back through the pump in case of power
failure.
5
 Priming | Operating Checks

PRIMING CAUTION: The gate valve in the discharge line

should always be closed when the pump is started.
a. If the pump is installed with a positive head on The excessive current required by the motor to
the suction, it can be primed by opening the start under full load will in time cause motor
suction valve and allowing the liquid to enter trouble. A centrifugal pump, primed and operated
the casing. at full speed with the discharge gate valve closed,
usually requires much less power than when it is
b. If the pump is installed with a suction lift, operating at its rated capacity and head with the
priming must be done by other methods such discharge gate valve open.
as foot valves, ejectors, or by manually filling
the casing and suction line. OPERATING CHECKS

a. Check the pump and piping to assure that

CAUTION: Under either condition, the pump must there are no leaks.
be completely filled with liquid before starting. The
pump must not be run dry in the hope it will prime b. Check and record pressure gauge readings for
itself. Serious damage to the pump may result if it future reference.
is started dry.
c. Check and record voltage, amperage per
STARTING phase, and kW if an indicating wattmeter is
available.
a. Close valve in discharge line and drain valves.
d. Check bearings for lubrication and
b. Fully open all valves in the suction line. temperature.

c. Turn on external flushing water to the stuffing e. Check and adjust stuffing box for correct
box and adjust pressure if necessary. (If operation. Check sealing water lines and
pumped liquid is dirty or if leakage of air is to valves.
be prevented, these lines should always be left
on.) CAUTION: If heat is used to keep the pump from
freezing, do not let the temperature rise above
d. Prime the pump. 37.8°C – 65.6°C.

NOTE: If the pump does not prime properly, or SHUTDOWN

loses prime during start-up, it should be shut down
and the condition corrected before the procedure The following steps of procedure will take care of
is repeated.
most normal shutdowns of the pump. Make any
e. (Pumps moving high temperature liquids.) further adjustments of process piping, valves, etc.,
Open the warm-up valve to circulate liquid for as required. If the pump is to be removed from
preheating. Close the valve after the pump is service for an extended period of time, consult
warmed up. storing procedures, and protection from freezing.

f. Start the pump driver (turbines and engines a. Close the discharge valve slowly.
require warming up, consult the manufacturer's
instructions). NOTE: When stopping pump, always close
discharge valve first.
g. When pump is operating at full speed, open the
discharge valve slowly. (Note: Pump should not
operate against a closed discharge for any b. Shut down the driver (consult manufacturer's
length of time. In some cases this should not instructions for special operations).
be more than a few minutes.)
c. Close seal liquid valves. (If pumped liquid is
h. Adjust the liquid seal valves to proper dirty or if in-leakage is to be prevented, these
pressure according to instructions. lines should always be left open.)

d. Open drain valves as required.

6



 Troubleshooting

Between regular maintenance inspections, be alert for signs of motor or pump trouble. Common symptoms are listed
below. Correct any trouble immediately to AVOID COSTLY REPAIR AND SHUTDOWN.
No liquid delivered
CAUSES CURES

1. Lack of prime Fill pump and suction pipe completely with liquid.

2. Loss of prime Check for leaks in suction pipe joints and fittings; vent
casing to remove accumulated air.

3. Suction lift too high If no obstruction at inlet, check for pipe friction losses.
However, static lift may be too great. Measure with
mercury column or vacuum gauge while pump operates.
If static lift is too high, liquid to be pumped must be
raised or pump lowered.

4. Discharge system head too high Check pipe friction losses. Larger discharge piping
may correct condition. Check that valves are wide open.

5. Speed too low Check whether motor is directly across-the-line and

receiving full voltage. Alternatively, frequency may be
too low; motor may have an open phase.

6. Wrong direction of rotation Check motor rotation with directional arrow on pump
casing. Wrong rotation will cause pump damage.

7. Impeller completely plugged Dismantle pump or use piping hand hole to clean impeller.

Not enough liquid delivered

8. Air leaks in suction piping If liquid pumped is water or other non-explosive material,
and explosive gas or dust is not present, test flanges for
leakage with a flame or match. For such liquids as
gasoline, suction line can be tested by shutting off or
plugging inlet and putting line under pressure. A gauge
will indicate a leak with a drop of pressure.

9. Air leaks in stuffing box Increase seal lubricant pressure to above atmosphere.

10. Speed too low See item 5.

11. Discharge system head too high See item 4.

12. Suction lift too high See item 3.

13. Impeller partially plugged See item 7.

14. Cavitation; insufficient NPSH a. Increase positive suction head on pump by lowering pump
(depending on installation) or increasing suction pipe size or raising fluid level.
b. Sub-cool suction piping at inlet to lower entering liquid
temperature.
c. Pressurise suction vessel.

15. Defective impeller Inspect impeller. Replace if damaged or vane sections

badly eroded.

16. Defective packing Replace packing and sleeves if badly worn.

8
 Troubleshooting

Not enough liquid delivered

CAUSES CURES

17. Foot valve too small or partially Area through ports of valve should be at least as large as area
obstructed of suction pipe, preferably 1½ times. If strainer is used, net
clear area should be 3 to 4 times area of suction pipe.

18. Suction inlet not immersed deep If inlet cannot be lowered, or if eddies through which air is
enough sucked persist when it is lowered, chain a board to suction
pipe. It will be drawn into eddies, smothering the vortex.

19. Wrong direction of rotation Compare rotation of motor with directional arrow on
pump casing. Wrong rotation will cause pump damage.

20. Too small impeller diameter Check with factory to see if a larger impeller can be used;
(probable cause if none of the otherwise, cut pipe losses or increase speed, or both, as
above) needed. Be careful not to seriously overload drive.

Not enough pressure

21. Speed too low See item 5.

22. Air leaks in suction piping See item 8.

23. Mechanical defects See items 15, 16, and 17.

24. Obstruction in liquid passages Dismantle pump and inspect passages of impeller and
casing. Remove obstruction.

25. Air or gases in liquid (Test in May be possible to overrate pump to the point where it will
laboratory, reducing pressure on provide adequate pressure despite condition. It is better to
liquid to pressure in suction line. provide gas separation chamber on suction line near pump,
Watch for bubble formation.) and periodically exhaust accumulated gas. See item 14.

26. Excessive impeller clearance Adjust impeller clearance.

27. Too small impeller diameter See item 20.

(probable cause if none of
the above.)

Pump operates for a 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.

29. Suction lift too high See item 3.

30. Air leaks in suction piping See item 8.

31. Air leaks in stuffing box See item 9.

32. Air or gases in liquid See item 25.

9
 Troubleshooting

Pump takes too much power

CAUSES CURES

33. Head lower than rating; thereby Machine impeller's OD to size advised by factory.
pumping too much liquid

34. Cavitation See item 14.

35. Mechanical defects See items 15, 16, and 17.

36. Suction inlet not immersed See item 18.

enough

37. Liquid heavier (in either viscosity Use larger driver. Consult factory for recommended size.
or specific gravity) than allowed Test liquid for viscosity and specific gravity. See item 6.
for

38. Wrong direction of rotation Release gland pressure. Tighten reasonably. If sealing
liquid does not flow while pump operates, replace
packing. If packing is wearing too quickly, replace scored
shaft sleeves and keep liquid seeping for lubrication.

39. Stuffing box too tight (Packing) Check alignment. Examine pump for friction between
impeller and casing. Replace damaged parts.
Check for pipe strain.

40. Casing distorted by excessive Check alignment. Examine pump for friction between
strains from suction or discharge impeller and casing. Replace damaged parts. Check for
piping pipe strain.

41. Shaft bent due to damage - Dismantle pump and inspect shaft.
through shipment, operation, or
overhaul

42. Mechanical failure of critical Check bearings and impeller for damage.
pump parts Any irregularities in these parts will cause a drag on the shaft.

43. Misalignment Realign pump and driver.

44. Speed may be too high (brake hp Check voltage on motor.

of pump varies as the cube of the
speed; therefore any increase in
speed means considerable
increase in power demand)

45. Electrical defects The voltage and frequency of the electrical current may
be lower than that for which the motor was built: or there
may be defects in the motor. The motor may not be
ventilated properly due to a poor location.

46. Mechanical defects in turbine, If trouble cannot be located, consult factory.

engine, or other type of drive
exclusive of motor

NOTE: If unable to correct troubles with cures outlined above, or if other difficulties develop, contact nearest SAM
Engineering representative. Describe completely the operating conditions of pump at time of failure along with other
pertinent data.

10
 Lubrication | Oil Lubrication

LUBRICATION e. In installations with moderate temperature

changes, humidity, and dirt, the oil should be
Proper lubrication of the pump bearings is changed after approximately 160 hours of
essential in obtaining maximum trouble-free operation. The oil should be inspected this
operation. The quantity of lubricant used is as time to determine the operating period before
important as the right type. The lubricant for the next oil change. Oil change periods may be
anti-friction bearings protects the bearing parts increased up to 2000-4000 hours based on an
from corrosion, and helps dissipate heat that is 8000 hour year. Check the oil frequently for
generated by use. moisture, dirt or signs of "breakdown."

Oil Lubrication CAUTION: DO NOT OVER OIL: this causes the

bearings to run hot. The maximum desirable
a. The oil-lubricated pumps have splash oiling in operating temperature for ball bearings is 82.2°C.
which the oil is picked up from the reservoir Should the temperature of the bearing frame
by a rotating slinger arid deposited as fine exceed 82.2°C (measured by thermometer) shut
droplets on the shaft bearings and entire down pump to determine the cause.
interior of the bearing housing.
Oil Reservoir
b. After the pump has been installed, flush the
bearing housing to remove dirt, grit and other The capacity of the oil reservoir is as follows:
impurities that may have entered the bearing
housing during shipment or assembly. Then FRAME SIZE QUANTITY PINTS
refill the bearing housing with proper lubricant. F6 Frame
The oil level to be maintained is shown by a I 3/4
line in the sight glass or oil level indicator. II 1
III 2
c. Experience shows that oils meeting the
following specifications will provide satisfactory
lubrication. These oils can be furnished by all
major oil companies. It is the responsibility of
the oil vendor to supply a suitable lubricant.

1 Saybolt viscosity at 100°F 150 - 200 SSU

2. Saybolt viscosity at 210°F 43 SSU
3. Viscosity index, minimum 95
4. API gravity 28-33
5. Pour point, maximum -30°C
6. Flash point, minimum 200°C
7. Additives Rust and
Oxidation
Inhibitors

d. The oil should be well-refined, good grade,

straight cut, filtered mineral oil. It must be free
from water, sediment, resin, soaps, acid and
fillers of any kind, and should also be
non-foaming.

NOTE: Oils from different suppliers should not be

mixed.

11
 Grease and Bearing Lubrication

Grease Lubrication Bearing Lubrication Notes

a. The lubricating grease should be a mixture of a. Bearings in the pump are anti-friction (ball
highly refined mineral oil and a soap base. The bearings). Since bearings are lubricated to
most commonly used soap bases are sodium, reduce friction, remove heat and prevent
calcium, lithium, barium, aluminium, and corrosion, it is important to add the proper
strontium. amount of the right lubricant at the right time
and to flush as often as necessary.
b. Sodium soap greases can be used at bearing
temperatures up to 121°C. Under ordinary b. Bearings are normally lubricated every 3 to 6
temperatures, this grease is comparatively stiff. months and flushed yearly. When applying
The emulsifying properties of the grease this schedule, take into consideration the
permit absorption of a certain amount of number of hours of operation, starting and
water. The lubricant manufacturer should be stopping cycles, dirt, dust and moisture (from
consulted for recommendations, temperature rain or condensation).
limits, and length of lubricant life. All
recommendations here are based on standard c. The condition of the lubricant - discolouration
greases. A good bearing grease should have and contamination - will determine the proper
the following properties: maintenance schedule. The bearings should be
inspected when the pump is dismantled for
1. Freedom from chemically or mechanically other repairs. If the bearing shows signs of
active ingredients such as free lime, iron galling, it may be suspected that too much
oxide, and similar material or solid grease has been "packed" into the bearings,
substances. thus causing the balls to slide rather than roll.
If the bearing is pitted, the grease or oil is not
2. Be free from possible tendency to change in preventing corrosion; or dirt and dust maybe
composition or consistency such as entering the bearing housing.
thickening, separation of oils, acid
formation or hardening ("milling down"). d. After grease has been added to the pump (for
grease lubricated pump) the drain plug on the
3. A melting point considerably higher than bottom of the bearing housing should be
the operating temperature to assure removed for half an hour while the pump is
adequate film strength. running.

4. Ability to protect metal surfaces from rust. Bearing Seal Lubrication

NOTE: Since lubricant qualities are not assured Inboard and outboard bearings are protected from
solely on these points, it is advisable to secure entrance of moisture and dirt by a grease seal
lubricants from a reputable manufacturer who which is independent from bearing lubrication. The
assumes responsibility for his products. seal consists of a metal backed rubber slinger
which fits over the shaft and is pressed up close to
c. Mineral oil from which grease is compounded the bearing cover. The bearing cover has an annu-
should conform to the following tests: lar labyrinth groove and grease cavity to trap any
foreign material protecting the bearing.
1. Flash Minimum 171°C
2. Fire 193°C Grease fittings are located on the bearing cover.
3. Viscosity at 37.8°C 200 SSU Grease should be applied every three months. A
Minimum relief hole will discharge the excess grease and
4. Cold test (POST) maximum -1.1°C prevent overloading.

NOTE: The grease used in this pump should

conform to NGLI Grade 2 standards.

12
 Maintenance | General | Periodic Inspection

MAINTENANCE

GENERAL

NOTE: A pump properly installed and operated will require minimum maintenance. For the best overall
performance, be sure to adhere to the instruction in this manual.

a. Operating conditions vary so widely that to recommend one schedule of preventive maintenance for all
centrifugal pumps is not possible. It is suggested that a permanent record be kept of the periodic
inspections and maintenance performed on the pump. This recognition of maintenance procedure will
keep the pump in good working condition and prevent costly breakdowns.

b. One of the best rules to follow in proper maintenance is to keep a record of actual operating data and
hours of operation. The length of this operation period will vary with different applications and can only
be determined from experience. The next inspection period can be scheduled based on the condition
of the components at this first inspection. This system can be followed until a maximum period of
operation is reached, which should be considered the operation schedule between inspections.

PERIODIC INSPECTION

The following table is provided as a guide for performing periodic inspections on the pump:

PERIOD INSPECTION

Every Check bearing temperature with a thermometer, not by hand. If bearings are running hot, it may be
month the result of too much lubricant. If changing the lubricant does not correct the condition, disassemble
and inspect the bearings. Adjust impeller clearance to retain operating efficiencies.

Check grease lubricated bearings for saponification. This condition is usually incurred by the infiltra-
Every 3 tion of water or other fluid past the bearing shaft seals, and can be noticed immediately upon inspec-
months tion, since it gives the grease a whitish colour. Wash out the bearings with kerosene and replace the
grease with the proper type as recommended.

Check the packing and replace if necessary. Use the grade recommended. Be sure the seal cages are
centred in the stuffing box at the entrance of the stuffing box piping connection.

Every 6 Check shaft or shaft sleeve for scoring. Scoring accelerates packing wear.
months
Check alignment of pump and motor. Shim up units if necessary. If misalignment recurs frequently,
inspect the entire piping system. Unbolt piping at suction and discharge flanges to see if it springs
away, thereby indicating strain on the casing. Inspect all piping supports for soundness and effective
support of load.

Remove the rotating element.

Inspect thoroughly for wear, and order replacement parts if necessary.
Remove any deposit or scaling.
Clean out stuffing box piping.
Every Measure total dynamic suction and discharge head as a test of pipe connection. Record the figures
year and compare them with the figures of the next test. This is important especially where the fluid being
pumped tends to form a deposit on internal surfaces.

Inspect foot valves and check valves, especially the check valve which safeguards against water
hammer when the pump stops. A faulty foot or check valve will also reflect in poor performance of the
pump while in operation.

13
 Maintenance After Flooded Condtion | Disassembly

MAINTENANCE AFTER FLOODED CONDITION DISASSEMBLY

The servicing of centrifugal pumps after a flooded Pump Style C-011

condition is a comparatively simple matter under
normal conditions. Any pump that is properly a. Close suction and discharge valves or
sealed at all joints and connected to both the otherwise isolate pump from liquid system.
suction and discharge should exclude outside
liquid. Therefore, it should not be necessary to go b. Disconnect power source to driver.
beyond the bearings, stuffing box and coupling
when servicing the pump. However, in the event c. Turn off water supply to stuffing box and
that flood liquid or other foreign matter enters the disconnect piping.
pump, it may be necessary to flush the pump, and
inspect and clean wearing surfaces. d. Disconnect drive.

a. Bearings are a primary concern on horizontal 1. Spacer type coupling - Universal type
pumping units. First, dismantle the bearings, Remove four cap screws from flanges of
clean and inspect them for any rusted or badly both the drive and driven ends of the spacer
worn surfaces. If bearings are free from rust coupling. Remove spacer section to permit
and wear, reassemble and re-lubricate them disassembly of rotating element from
with one of the recommended pump pump.
lubricants. Depending on the length of time
the pump has remained in the flooded area, it 2. V -Belt Drive
is unlikely that bearing replacement is Loosen bolts on motor slide base and move
necessary, however, in the event that rust or motor base toward pump to relax tension on
worn surfaces appear, it may be necessary to belts. Remove belts from driven sheave.
replace the bearings.
e. Support frame assembly with a hook and sling
b. Inspect the stuffing box, and clean out any under the top web of the frame. Loosen and
foreign matter that might clog the box. Packing remove cap screws, washers and nuts holding
that appears to be worn, or no longer regulates frame to casing.
leakage properly should be replaced.
f. Using sling, slide frame from casing, out and
c. Couplings should be dismantled and away from pump. Strip off gasket.
thoroughly cleaned. Lubricate the coupling
with one of the coupling manufacturer's NOTE: If desired, the complete rotating element
recommended lubricants where required. may now be removed as a unit and taken to the
shop for further disassembly. The casing is left in
place, bolted to suction and discharge piping.

g. To remove suction wear plate, remove cap

screws and washers holding suction wear plate
to casing. Take suction wear plate out of
casing. Strip off gasket.

14
 Disassembly | Rotating Element | Frame

Rotating Element Frame

a. Remove oil drain cap from nipple on underside NOTE: Study Figure 8 showing recommended
of frame and drain oil from bearing housing. method of handling frame assembly during the
dismantling and assembly operations. Using the
b. Remove sheave or coupling fitting yoke from impeller as a stand, the frame with frame liner
pump shaft. maybe lifted vertically with hooks as shown.

c. Hold drive end of pump shaft with padded a. First remove deflectors from
wrench, or insert rod through hole in shaft and shaft and remove outboard bearing cap.
turn impeller counter clockwise to remove. If
impeller is tight and will not loosen readily, b. Screw impeller onto shaft far enough to
use the following procedure: provide a rigid mounting and stand the
assembly on end.
1. Place a block of hardwood against edge of
impeller vane and strike with mallet to c. Remove screws from inboard bearing cap
loosen. and drop cap from frame liner.

or d. Assemble lifting hooks into upper end of frame

liner and slowly raise frame with liner off of
2. Place large block of hardwood upright on the shaft and bearings assembly.
ground so that when the rotating assembly
is turned 180° with wrench or rod attached e. Unscrew shaft from impeller, remove inboard
to shaft, the end of the wrench strikes the bearing cap and proceed with pressing
block. This method imparts considerable bearings from shaft.
force to loosen the impeller.
f. Remove oil slingers and collar from shaft to
NOTE: Impeller will unscrew counter clockwise prevent its damage while handling the shaft.
(from impeller end), so wrench must strike the
block in this same direction. NOTE: It is suggested that the parts frame linear
and frame, be kept assembled with adjusting screw
3. It is sometimes helpful to apply heat with a unless replacements are needed.
torch to the impeller hub to assist in
loosening the threads.

d. Remove cap screws holding wear plate to

stuffing box. Strip off gasket.

e. Remove two nuts from studs holding stuffing

box cover to frame. Loosen gland bolts and
remove split gland pieces. Pull stuffing box
from frame and remove packing.

f. Remove shaft sleeve from shaft using bearing

puller. Apply heat from torch if necessary. If
this fails it may be necessary to cut the sleeve
by splitting it lengthwise on one side with a
chisel.

15
 Cleaning | Inspection | Figure 8. Front Liner Assembly

CLEANING

Clean all parts in a suitable cleaning solvent. Pay

particular attention to all machined surfaces and
gasket joints. At the frame, check and clean the oil
level indicator. Be sure to clean stuffing box cavity
and sealing liquid inlet.

INSPECTION

Inspect all parts for excessive wear or damage. Pay

particular attention to the following items:

a. Casing. Check for evidence of extreme wear or

corrosion, especially at threaded taps. Examine
casing joint for rust, burrs or raised surfaces.

b. Front Wear Plate. See that wear face fits closely

to impeller. Replace wear plate if wear is
excessive.

c. Impeller. Check impeller vanes for signs of

wear, cracks or corrosion.

d. Stuffing Box Details. Check gland and seal

cage for nicks or burrs. Replace all packing.

e. Shaft Sleeve. Examine shaft surface to see that

it is smooth and free from grooves or scoring.
Check to see that sleeve is round without any
appreciable eccentricity.

f. Shaft. Inspect all rotating, close-clearance

surfaces for wear. Check for straightness by
mounting in a lathe. (If lathe not available, use
suitable Vee blocks.)

g. Bearings. After cleaning, rotate bearings very

slowly under hand pressure to feel for smooth
and even action. Never spin a dry bearing.
Examining carefully for "dull" spots indicating
hollows; for "shiny" spots indicating
concentrated wear; for pitting, "galling," or
other damage to races, ball, or rollers. Check Figure 8. Front Liner Assembly
for cracks, for burrs on outside or inside
diameters, or other structural damage.
Replace the bearing if there is any doubt as to
complete serviceability.

16
 Repair and Replacement | Reassembly

REPAIR AND REPLACEMENT c. Outboard Bearings: Heat bearing in a clean

hot-air oven at 93-107°C. Install heated
a. General Replacement. Replace all parts that bearings on the shaft, against the shaft
are excessively damaged or worn. shoulder and allow to cool in place.

b. Casing. If necessary, use a fine stone to d. Place inboard bearing cap shaft. Screw the
remove rust, burrs, raised surfaces, dirt, paint, shaft into the impeller and stand the assembly
etc. from casing joint. on end.

c. Shaft Sleeve. If shaft sleeve surface is grooved, NOTE: The adjusting screw group and liner consti-
polish to remove grooves. If grooves are too tute a matched, drilled set that should not be
deep to polish, replace shaft sleeve. disassembled. If they were disassembled, be sure
that all parts are from the same set. If liner has
d. Fibre Packing. The standard packing is a soft, been replaced, install a new nut and screw. Drill
square asbestos, impregnated with oil and and pin nut in place with spring. Washer should be
graphite. A soft well-lubricated packing fully compressed to eliminate end play.
reduces stuffing box resistance and prevents
excessive wear on the shaft, or shaft sleeve. e. Inspect slingers to make sure they have not
Many brands of packing have the desired been bent or broken. Since your unit has
qualities. Those listed below should be spherical roller bearings, tap the outer race
regarded as typical rather than specific square to shaft, as it must enter the frame liner
recommendations for replacements: perfectly straight to avoid serious damage.

1. No. 317 Anchor Packing Company f. Lower frame and liner over shaft and bearings
2. Centripack Style C-7 Johns-Manville Co. per Figure 8. Proceed slowly and notice that as
3. Garlock No. 234 Garlock Packing Co. slingers enter the frame liner they must deflect
4. Monarch Style No. 454 Monarch Packing Co. and spring back into place when they reach the
5. No.193 U.S.RubberCo. centre of the bearing cavity. With a spherical
6. Regal No. 49 Quaker Rubber Co. roller bearing, it may be necessary to guide it
7. Semi-Metallic Bausman Packing Co. into the fit in the liner. Note the outer race
8. Ace-O-Pak Packing Engineering Co. from an old bearing serves as an ideal tool if
placed into the liner at this time. You may slide
REASSEMBLY it down in the fit until it contacts the upper
shaft bearing. By tapping lightly on this "tool"
In general, reassemble in the reverse order of you can square up the bearing race and it will
disassembly. Always replace all gaskets, packing, enter to fit easily. Continue to lower frame and
or a-rings at each disassembly of the pump. liner until the liner rests solidly against the
lower bearing outer race.
Frame
g. Remove lifting hooks and allow unit to stand
NOTE: Study Figure 8 showing recommended vertically.
method of handling frame assembly during the
assembly operation. h. Position end caps with gaskets and bolt into
place.
a. Inboard Bearings. Heat bearings in a clean
hot-air oven at 200° - 225°F. Install heated i. Assemble deflectors on both ends.
bearing over threaded half of shaft. Assemble
lock washer and nut. Tighten with a spanner j. Remove impeller and place unit in a horizontal
wrench. Nut should be tight, a few sharp blows position. Adjust liner to set dimensions.
on the spanner wrench will assure this. Meter
bearings cool, tighten nut again and bend lock k. Replace all plugs and special oil fittings that
tab of lock washer into place. may have been removed in cleaning.
b. Slip oil slinger over centre portion of shaft.
Adjust spacing "A" and "B". Tighten slinger
locking screws. Take care in handling the shaft
from this point on as these slingers are
easily bent or broken.
17
13
 Stuffing Box

Stuffing Box

a. Place wear plate on the table with bolt holes up and cement gasket in place.

b. Place stuffing box cover on wear plate, line up holes and assemble cap screws but do not tighten until
later. Insert shaft sleeve in centre of stuffing box cavity to act as a guide when installing packing. Insert
packing base ring in bottom of cavity.

c. Assemble studs into flange of cover plate.

d. If moulded fibre packing is used, open packing ring sideways and push joint into stuffing box first.
Install two rings, one at a time, seating each ring firmly. Stagger the ring joints at least 90°. Install seal
cage, being sure that it will line up with the seal liquid inlet in cover when packing is compressed.
Install remaining two or three packing rings. Refer to the Stuffing Box Dimensions below for the
particular pump being assembled for the correct quantity and size of packing to install.

STUFFING BOX DATA HM and CWR (Dimensions in Inches)*

Stuffing Box Size of Packing

Pump Size Frame Shaft Sleeve Seal
Flushing
and Size Diameter in Cage
Max. Imp. Length Bore Box Width Connections Number of Size
to Box Rings (Square)
4x3x F-6D2 3 3-5/16 2-1/4 3/4 1/4 4 1/2
11-1/2
5x4x F-6D2 3 3-5/16 2-1/4 3/4 1/4 4 1/2
11-1/2
5 x 4 x17 F-6E2 3-1/8 4-5/16 3-1/4 11/16 1/2 4 1/2
6 x 5 x17 F-6E2 3-1/8 4-5/16 3-1/4 11/16 1/2 4 1/2
8 x 6 x17 F -6E2 3-1/8 4-5/16 3-1/4 11/16 1/2 4 1/2
10x 8 x17 F -6E2 3-1/8 4-5/16 3-1/4 11/16 1/2 4 1/2
12x10x17 F-6E2 3-1/8 4-5/16 3-1/4 11/16 1/2 4 1/2
8 x 6 x21 F-6F2 6 6-3/4 5-1/4 1-1/4 1/2 5 3/4
10x 8 x21 F-6F2 6 6-3/4 5-1/4 1-1/4 1/2 5 3/4
14x12x21 F-6F2 6 6-3/4 5-1/4 1-1/4 1/2 5 3/4
16x14x21 F-6F2 6 6-3/4 5-1/4 1-1/4 1/2 5 3/4

*Refer to factory for stuffing box data on other styles.

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14
 Impeller Adjustment | Replacement Parts

Rotating Element REPLACEMENT PARTS

a. Remove shaft sleeve from the stuffing box, and a. The pumps covered by this manual have been
slide sleeve onto shaft. designed and built with all wearing parts
replaceable. A recommended inventory of
b. Install stuffing box cover group onto shaft and spare parts is dependent upon the installation
frame group carefully to keep the packing in and the importance of continued operation.
position within stuffing box. Attach cover to
frame with nuts and washers. b. For critical service requiring a minimum of
down time, a complete rotating element is
c. Install packing gland and secure with recommended.
attaching parts. If fibre packing is used,
tighten nuts firmly but not too tight. If metallic c. For normal service, all items in the parts list
packing is used, tighten nuts tightly. Final that are coded with "*" are recommended for
adjusting of nuts will be made during the each pump in service.
pump run-in.
d. Parts should be ordered as far in advance of
d. Tighten cap screws holding wear plate to their use as possible since circumstances
stuffing box cover. If wear plate tends to drop beyond the control of the Company may
and rub on sleeve it may be supported reduce existing stock. Not all parts are
temporarily with a shim against the sleeve. stocked; some must be manufactured for each
order.
e. Apply a thin coat of "white lead" or a similar
anti-seize thread compound to threads of e. When ordering spare parts, always include the
shaft. Install impeller on shaft, and tighten following information:
securely while holding shaft.
1. Pump Serial Number
CAUTION: Torque casing bolts to 125 ft. lbs. 2. Pump Model Number
maximum. 3. Pump Size and Type Number
4. Catalogue Number of part
Pump 5. Name of part
6. Quantity of each part
a. Assemble suction wear plate with new gasket 7. Material desired (if different than original
and secure in casing with attaching parts. material). (Parts will be furnished in original
materials unless specified as a material
b. Before installing rotating element into pump change. All material substitutions should be
casing, the total clearance of impeller in discussed with the factory.)
casing must be established. Proceed as
follows:

IMPELLER ADJUSTMENT

After assembling pump, set impeller clearance

according to the following: Check that the two
clamping screws on side of frame are loose, to
allow liner to move freely. Turn adjusting screw (at
lower frame) clockwise until impeller contacts
suction wear plate. Now turn adjusting screw
counter clockwise just enough to allow impeller to
rotate freely. Normal clearance is
0.38mm-0.64mm. Tighten clamp screws.

20
18
15
 SAM Engineering (Pty) Ltd.
24 Duncan Road, Lilianton, Boksburg, South Africa
Tel: +27 (0) 11 823-4250 | Fax: +27 (0) 11 823-4943
Email: [email protected]
www.sameng.co.za