CPO/CP Series

Installation, Operation and Maintenance Manual

 Contents

INTRODUCTION 3
PUMP IDENTIFICATION 3
TEMPORARY STORAGE 4
PUMP INSTALLATION 4
PRE-START CHECKS 4
STARTING THE PUMP 4
OPERATING THE PUMP 4
SHUTTING DOWN THE PUMP 4
DISASSEMBY INSTRUCTIONS 5
ASSEMBLY INSTRUCTIONS 7
FRAME SIZES 9
TORQUE VALUES FOR CASING TO STUFFING 9
BOX AND BEARING FRAME TO STUFFING BOX 10 - 11
GENERAL MAINTENANCE 12 - 14
TROUBLESHOOTING 15 - 18

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 their responsibility of using accepted engineering practices in the
installation, operation, and maintenance of this equipment.

Any further questions, contact SAM Engineering (Pty) Ltd +27 (0) 11 823-4250.
 SAMCO Chemical Process Pumps | CPO/CP Series

INTRODUCTION
This manual is furnished to acquaint you with the procedures to install, operate and maintain a $10/$1
pump. Keep it handy for future reference. Additional information can be obtained from your SAM
Engineering Sales Representative.

Equipment cannot operate well without proper care. To keep the unit at top efficiency, correct procedures
for installation and maintenance must be followed. SAM Engineering can assist in the installation of
equipment to ensure that maximum machine life can be attained with minimum downtime.

Your Sales Representative will also help with renewal of parts orders and problems requiring
special attention.

PUMP IDENTIFICATION

PUMP NAMEPLATE

SAMCO PUMPS

MODEL SER. NO.

FLOW (m³/hr) HEAD (m)
MAWP (KPag) @ °C IMP. DIA. (mm)
MOC RPM
SG HYDRO (kPag)

SAM Engineering (Pty) Ltd

Tel: +27 11 823-4250

CUSTOMER:
BEARINGS
O/N
DE: NDE:
TAG NO.

MODEL = Pump Model and Type SER. NO. = Serial Number

FLOW (m³/hr) = Design Flow Rate HEAD (m) = Design Head

MAWP = Maximum Allowable Working Pressure @ Temperature in Deg C

IMP. DIA (mm) = Supplied Impeller Diameter

*MOC – Material of Construction RPM = Operating Revolutions Per Minute

SG = Specific Gravity of Fluid Pumped HYDRO = Hydro Test Pressure (kPa)

Permanent records are kept by SAM Engineering and filed by serial number.

*MOC = Material of Construction of pump shown in abbreviated form and in four parts.
EXAMPLE – CI/SS/CI/EN8 – where casing and stuff box are in Cast Iron, Impeller is in Stainless Steel, frame
is in Cast Iron and shaft is in EN8.

3
 Samco Chemical Process Pumps | Pump Installation

TEMPORARY STORAGE 6. MOTOR DIRECTION

IMPORTANT NOTE: It is very important to check the
If the pump is not to be installed and operated motor direction with the pump disconnected from
soon after arrival, store it in a clean, dry location the motor. Serious damage can result if the pump
where there is slow, moderate changes in ambient is operated with incorrect rotation.
temperature. Rotate the shaft every two weeks to
coat the bearings with lubricant and to retard 7. COUPLING
oxidation, corrosion, and to reduce the possibility Before the coupling is fitted, check that the pump
of false brinelling of the bearings. is turning freely by hand.

PUMP INSTALLATION STARTING THE PUMP

1. BASE PLATE SETTING (Before Piping) 1. START
By adding or removing shims under the base, level Start the pump.
and plumb with the pump shaft and flanges. The
base plate does not have to be level. Sufficient 2. DISCHARGE VALVE
shims must be placed under the base so that when When the pump is operating at full speed, open the
the anchor bolts are tightened, the base plate is discharge valve slowly.
not twisted in any way, making male alignment
difficult or impossible. OPERATING THE PUMP
2. SUCTION AND DISCHARGE PIPING 1. NOISES
Piping should always be run to the pump. Both the
Listen for any strange noises coming from the
suction and discharge piping should be inde-
pump. If such noises are identified, stop the pump
pendently supported near the pump and properly
and investigate.
aligned so that no strain is transmitted to the
pump when the flange bolts are tightened.
2. VIBRATION
3. SHAFT ALIGNMENT Feel the pump while it is running for any excessive
Although the pump has been factory aligned before vibration.
shipment, it is important to re-do the shaft align-
ment after the pump has been installed. The align- 3. BEARING TEMPERATURES
ment should be within the coupling supplier’s On oil filled pumps, the bearing temperatures
tolerances. Should this not be available, align to should not exceed 90°C.
within 0.1mm radially and axially, or contact SAM On grease filled pumps, the bearing temperatures
Engineering for further assistance. should not exceed 110°C.

PRE-START CHECKS 4. ADJUSTMENTS

Make all pump output adjustments with the
1. LUBRICATION discharge valve. Do not throttle the suction line to
Before starting the pump, ensure that the oil level adjust the pump output. Adjust gland packing to
is in the centre of the sight glass. Grease lubricat- drip continuously.
ed pumps are factory lubricated before delivery
and don’t need lubrication.
SHUTTING DOWN THE PUMP
2. VALVES
Ensure that all valves in the suction line are fully 1. DISCHARGE VALVE
open. If there are external feed lines to the stuffing Close discharge valve slowly.
box or mechanical seal, ensure that the valves are
open. Keep discharge valve closed. 2. DRIVER
Shut down driver.
3. PRIMING
Prime the pump properly. 3. VALVES
Close valves as required.
4. LOCKING PLATES
Remove locking plates from mechanical seal. 4. DRAIN
Open drain valves as required.
5. STUFFING BOX
Turn on seal water to stuffing box.
4
 Samco Chemical Process Pumps | Disassemby Instructions

DISASSEMBY INSTRUCTIONS 3.2 Mechanical Seal Stuffing Box

Loosen and remove the four nuts holding the
1. REMOVAL OF ROTATING ELEMENT FROM mechanical seal gland plate to the stuffing box.
CASING Pull back the gland plate. Remove the screws
securing the stuffing box to the frame. Pull the
1.1 Lock off all electrical power to motor. Discon- stuffing box cover from the frame, being careful not
nect all piping to the stuffing box and other special to damage the mechanical seal in any way. The
piping. The casing may be left in process line seal rotating element and sleeve may be removed
assembled to the suction and discharge piping if as an assembly. To remove the mechanical seal
repair or replacement is not required. Drain all from the sleeve, loosen the set screw in the locking
liquid from the casing if collar with an Allen wrench. Remove the seal gland
necessary. plate then remove stationary seat from gland. Use
care not to damage seal faces.
1.2 Remove the spacer portion of coupling. If
V-Belt driven, remove belts. 3.3 Cartridge Mechanical Seal Stuffing Box
As there are various arrangements available from
1.3 Loosen and remove the nuts securing the mechanical seal suppliers, obtain more informa-
frame to the casing. Swing the complete rotating tion on disassembly from the mechanical seal
element out and away from the casing using the supplier.
lifting handle provided on frame. The casing gasket
may then be removed followed by the complete
rotating element to shop for further maintenance if 3.4 Dynamic Seal Arrangement
required. Loosen and remove the screw securing the stuffing
box cover to the frame and pull the stuffing box off
2. IMPELLER REMOVAL (Note: Impeller is thread- the frame. Subsequently remove the sleeves,
ed to shaft) O-rings and expeller/s from the shaft. It is advis-
able to mark these parts in the way they are
2.1 To remove the impeller, hold the shaft station- removed to simplify
ary at the drive end by suitable means. Turn the re-assembly.
impeller in a counter clockwise direction, using a
wrench on the hex provided on the impeller. If the 4. BEARING FRAME DISASSEMBLY
impeller is tight, it can be tapped with a mallet or
copper hammer on the vane tips to loosen it. Once 4.1 Oil
loosened, the impeller should turn easily by hand. Remove bottom drain plug to remove oil from the
At no point in time should any heat be applied to frame.
loosen the impeller as this may cause an explo-
sion. 4.2 Deflectors
Loosen the grub screws and remove deflectors at
3. STUFFING BOX REMOVAL the drive and non-drive ends.

3.1 Packed Stuffing Box 4.3 Bearing House Removal

Loosen and remove the screws securing the stuff- Loosen the Allen cap screws and remove them
ing box cover to the frame and pull the stuffing box from the bearing housing. Loosen lock nuts on F15
off the frame. and F35 bearing housings. Insert jacking screws of
sufficient length to jack bearing housing complete
with shaft out of the frame. On F45 and F65
frames, remove the shims.

5
 Samco Chemical Process Pumps | Disassemby Instructions

4.4 Bearing Removal

On F15 and F35 frames, remove the circlip that
holds the bearing inside the bearing housing. On
F45 and F65 frames, remove the retaining ring
screws and retaining ring. The bearing housing can
now be pulled off the bearings.

On F15 and F35 frames, remove the circlip that

holds the bearing to the shaft. On F45 and F65
frames, loosen the lock nut and remove the washer
and lock nut from the shaft. The bearings can now
be removed from the shaft with a standard bearing
puller.

4.5 Oil Slingers

On F15 and F35 shafts, remove the oil slinger by
pushing the two spring ends together and then
slide the slinger off the shaft. On F45 and F65
shafts, loosen the two grub screws on the cast
slinger and slide the slinger off the shaft. Make a
note of the slinger to ensure that it goes back to
the same position on re-assembly.

4.6 Lip Seals

Remove lip seals inside the bearing housing and
frame with a suitable tool.

5. PARTS INSPECTION

5.1 Casing and Stuffing Box

All machined parts should be cleaned and inspect-
ed for excessive wear or corrosion.

5.2 Impeller
Check impeller vanes for signs of wear, breakage
or corrosion.

5.3 Shaft Sleeve

Inspect shaft sleeve for excessive wear or grooves.

5.4 Shaft, Bearing Housing and Frame

Inspect for signs of wear or evidence that bearing
races have turned on the shaft or inside the bear-
ing housing and frame.

5.5 Worn Parts

Replace all parts mentioned above deemed not fit
for service.

5.6 Bearings, Lip Seals, Gaskets and O-rings

Replace all.

6
 Samco Chemical Process Pumps | Assemby Instructions

ASSEMBLY INSTRUCTIONS 2.2 Mechanical Seal Stuffing Box

Fit the stationary seat to the clamp plate with an
1. BEARING FRAME ASSEMBLY O-ring. Fit a shaft sleeve to the shaft and slide the
clamp plate over the shaft sleeve. Subsequently fit
1.1 Oil Slingers the mechanical seal to the sleeve as per the seal
Assemble oil slinger on the shaft in same position supplier’s instructions. Tighten the grub screws
prior to removal. On F45 and F65 frames, tighten supplied with the retaining ring. Then fit the stuff-
the grub screws. ing box to the frame and tighten the screws hold-
ing the stuffing box to the frame. Tighten the
1.2 Bearings clamp plate to the stuffing box. For cartridge-type
Use a suitable bearing heater and fit new bearings seals, refer to the seal supplier’s installation
to shaft. On F15 and F35 frames, fit circlip onto instructions.
shaft. On F45 and F65 frames, lock the washer and
nut to the shaft. After tightening the nut, bend one 2.3 Dynamic Seals
of the lock washer tabs into the nut. For dynamic seal assembly, see drawings for one,
two and three stage seals for the sequence. The
1.3 Lip Seals stuffing box will always be the last item to be fitted
Fit new lip seals to the bearing housing and frame to the frame.
with the lips facing outwards.
3. IMPELLER ASSEMBLY
1.4 Bearing Housing
Tap the bearing housing over the drive end bear- 3.1 Fit Impeller
ings and fit a circlip or retaining ring. Fit a new Fit the impeller to the shaft with a new O-ring.
O-ring to the bearing housing. Tighten the impeller to ensure it is seated against
the shaft sleeve. Jack the bearing housing so that
1.5 Frame there is a very small gap between the back of the
Slide the complete bearing housing with shaft into impeller and the stuffing box. To do this, first jack
the bearing frame and pull it in with the Allen cap the impeller up against the stuffing box until it
screws. stops turning, then jack the impeller slowly away
from the stuffing box to the point where the impel-
1.6 Deflectors ler just starts turning freely. Subsequently lock the
Fit deflectors on both sides. impeller in that position with two Allen cap screws
and two jacking screws.

2. STUFFING BOX ASSEMBLY 4. CASING ASSEMBLY

2.1 Packed Stuffing Box 4.1 Casing Gaskets

Push packing base ring into the bottom of stuffing Fit the casing gasket/s with a non-retaining sealant
box. At this stage, do not fit a PTFE lantern ring into the casing. Just fit one casing gasket at first.
into the stuffing box. Fit a shaft sleeve to the shaft
and fit a gland onto the shaft sleeve before fitting 4.2 Rotating Element
the stuffing box to the frame. Subsequently fit the Fit the rotating element into the casing and tighten
stuffing box to the frame and tighten the screws it loosely with 4 nuts. Should the shaft not turn,
that keep the stuffing box to the frame. The stuff- keep on fitting casing gaskets until the shaft
ing box can then be packed with three rings first, rotates freely, then fit all nuts and tighten them.
then slide the lantern ring over the shaft and insert
another two packing rings. Packing joints must be
staggered. Fit the gland follower and tighten the
nuts by hand.

7
 Samco Chemical Process Pumps | Assemby Instructions

4.3 Impeller Clearance 7. GREASE LUBRICATION

After all the nuts have been tightened, place a
clock gauge on the back of the shaft and check the Pumps are factory lubricated before delivery and
total float of the impeller inside the casing by need only be lubricated after 8000 hours of opera-
jacking the bearing housing backwards and tion with ±30 grams of grease each side.
forwards in the frame. The total float should be a
minimum of 0.5mm for pumps operating at a Recommended grease: Total ALTIS EM2 or any
maximum of 200°C. If not, open the casing and fit equivalent polyurea grease. If a polyurea grease is
another casing gasket. not available, the bearings can be packed with a
good lithium based grease.
Once the total float is correct, you can adjust the
working clearance of the impeller. Jack the NB: Do not mix greases.
impeller against the casing until it stops turning,
then jack the impeller slowly away from the casing Operating temperatures should not exceed 110°C.
until it begins turning freely. Adjust the clock
gauge to zero and then jack the impeller a further IMPORTANT NOTE: Do not over-grease bearings as
0.25-0.30mm away from the casing and lock the this will cause a rapid rise in operating
bearing housing in that position with the grub temperature and lead to premature failure of the
screws and Allen cap screws. If there are lock nuts, bearings.
tighten them against the bearing housing. For the
F45 and F65 frames, fit the appropriate amount of
shims and then measure the clearance between
the impeller and the casing with a feeler gauge.
Ensure that the pump turns freely by hand after
adjusting the clearance.

For pumps operating above 200°C, the total float

must be 0.8mm and the impeller clearance
0.4mm.

5. DEFLECTORS

Deflector Adjustment
Push the deflectors into position until they start
rubbing, then pull them away between 1 and 2mm
and lock them in that position with the grub screws
supplied. Once again, make sure the pump is
turning freely and listen for any catching noises.

6. OIL FILL

Fill the pump with correct grade oil until the oil
level is in the centre of the sight glass.

6.1 Oil Lubrication

Recommended oil grade is SAE 10. Temperatures
should not exceed 90°C. Although SAE 10 is
preferred, if it is not available, an SAE 20 or SAE
30 can be used. For pumps pumping liquid at
temperatures above 200°C, use a synthetic oil
type. Change the oil after 4000 hours of operation
or once a year, whichever comes first.
Keep oil level in centre of sight glass.

8
 Samco Chemical Process Pumps | Frame Sizes

FRAME SIZES

PUMP SIZE $10 PUMP SIZE CP FRAME SIZE

CPO 1x¾x6
CPO 1.5x1x6 CP 30-150
CPO 3x1.5x6 CP 40-150
CPO 3x2x6 CP 50-150 F15
CPO 1.5x1x8 CP 30-200

CPO 3x1.5x8.5 CP 40-216

CPO 3x2x8.5 CP 50-216
CPO 4x3x8.5 CP 80-216
CPO 6x4x8.5 CP100-216
CPO 2x1x10 CP 30-250
CPO 6x4x10 CP 100-250
CPO 3x1.5x11 CP 40-280 F35
CPO 3x2x11 CP 50-280
CPO 4x3x11 CP 80-280
CPO 3x1.5x13 CP 40-330
CPO 3x2x13 CP 50-330
CPO 4x3x13 CP 80-330
CPO 6x4x13 CP 100-330

CPO 8x6x13 CP 150-330 F45

CPO 8x6x15 F65

CPO 10x8x15

TORQUE VALUES FOR CASING TO STUFFING BOX AND BEARING

SIZE N.m

M8 30
M10 60
M12 100
M16 240
M20 470

9
 Samco Chemical Process Pumps | General Maintenance

GENERAL MAINTENANCE Couplings should be dismantled and thoroughly

cleaned. Lubricate the coupling with one of the
Operating conditions vary so widely that to coupling manufacturer’s recommended lubricants
recommend one schedule of preventative where required.
maintenance for all centrifugal pumps is not possi-
ble. However, it is imperative that some sort of Any pump that is properly sealed at all joints and
regular inspection is planned and followed. We connected to both the suction and discharge
suggest a permanent record be kept of the should exclude outside liquid. Therefore, it should
periodic inspections and maintenance performed not be necessary to go beyond the bearings,
on your pump. This recognition of maintenance stuffing box and coupling when servicing the
procedure will keep your pump in good working pump.
condition, and prevent costly breakdowns.
BEARING LUBRICATION — GREASE
One of the best rules to follow in the proper
maintenance of your centrifugal pump is to keep a Grease lubricated ball bearings are packed with
record of actual operating hours. Then, after a grease at the factory and ordinarily will require no
predetermined period of operation has elapsed, attention before starting, provided the pump has
the pump should be given a thorough inspection. been stored in a clean, dry place prior to its first
The length of this operating period will vary with operation. The bearings should be observed in the
different applications, and can only be determined first hour or so after the pump has been started to
from experience. New equipment, however, should see that they are operating properly.
be examined after a relatively short period of
operation. The next inspection period can be The importance of proper lubrication cannot be
lengthened somewhat. This system can be followed over emphasised. It is difficult to say how often a
until a maximum period of operation is reached bearing should be greased, since this depends on
which should be considered the operating schedule the conditions of operation. It is recommended
between inspections. that one ounce of grease is added at regular
intervals, however, it is equally important to avoid
MAINTENANCE OF PUMP DUE TO FLOOD adding too much grease. For average operating
DAMAGE conditions, it is recommended that one ounce of
grease be added at intervals of three to six
months, using only clean grease. It is advised that
The servicing of centrifugal pumps after a flooded
the unit is stopped while grease is added to avoid
condition is a comparatively simple matter under
overloading.
normal conditions.
NOTE: Excess grease is the most common cause of
Bearings are a primary concern on pumping units.
overheating.
First, dismantle the bearings; clean and inspect
them for any rusted or badly worn surfaces. If
The bearing frame should be kept clean, since any
bearings are free from rust and wear, re-assemble
contamination of foreign matter which gets into
and re-lubricate them with one of the recommend-
the housing will destroy bearings in a short time.
ed pump lubricants. Depending on the length of
When cleaning bearings, use a bearing cleaning
time the pump has remained in the flooded area, it
solvent or an industrial cleaning solvent. Do not
is unlikely that bearing replacement is necessary;
use gasoline. Use lint free cloths. Do not use waste
however, in the event that rust or worn surfaces
rags.
appear, it may be necessary to replace the bear-
ings.
A regular ball bearing grease should be used, but a
standard commercial vaseline can be substituted
Next, inspect the stuffing box, and clean out any
if necessary.
foreign matter that might clog the box. Packing
that appears to be worn, or no longer regulates
Do not use graphite. A no. 1 or 2 grease is
leakage properly should be replaced. Mechanical
generally satisfactory for operation at ordinary
seals should be cleaned and thoroughly flushed.
temperatures – the lighter grease for operation at
high speed or low room temperature.
10
 Samco Chemical Process Pumps | General Maintenance

Mineral greases with a soda soap base are recom- The oil should be well refined, good grade, straight
mended. Grease made from animal or vegetable cut, filtered mineral oil. It must be free from water,
oils are not recommended due to the danger of sediment, resin, soaps, acid and fillers of any kind.
deterioration and forming of acid. Most of the It should also be non-foaming with a viscosity of
leading oil companies have special bearing greases about 150-200 SSU at 38°C. (approximately SAE
which are satisfactory. For specific 20).
recommendations, consult the factory.
In installations with moderate temperature
The maximum desirable operating temperature for changes, humidity and dirt, the oil should be
ball bearings is 82°C. Should the temperature of changed approximately every 160 hours of opera-
the bearing frame rise above 82°C, the pump tion. The oil should be inspected to determine the
should be shut down to determine the cause. operating period before the next oil change. Oil
change periods may be increased up to 2000-4000
Grease lubricated bearings should not be used hours based on an 8000-hour year. Check the oil
where temperature of the pumped liquid exceeds frequently for moisture, dirt or signs of ‘break-
180°C. down’.

NOTE: A bearing frame which feels hot to the touch is CAUTION: DO NOT OVER-OIL; THIS CAUSES THE
not necessarily running hot. Check with an accurate BEARINGS TO RUN HOT. THE MAXIMUM DESIRABLE
temperature measuring device to be sure. OPERATING TEMPERATURE FOR BALL BEARINGS IS
82°C. SHOULD THE TEMPERATURE OF THE BEAR-
BEARING LUBRICATION — OIL ING FRAME EXCEED 82°C (MEASURED BY THER-
MOMETER), SHUT DOWN PUMP TO DETERMINE THE
The oil-lubricated pumps may have an oiling ring, CAUSE.
in which the oil is picked up from the reservoir by a
rotating oil ring and deposited on the shaft and STUFFING BOX
bearings inside the bearing housing; or they may
have an oil slinger, which creates a shower of fine The standard stuffing box consists of rings of
droplets over the entire interior of the bearing packing, (See assembly section for number of
cavity. rings) a seal cage and a gland. A shaft sleeve which
extends through the box and under the gland is
After the pump has been installed, flush the normally provided to protect the shaft.
bearing housing to remove dirt, grit and other
impurities that may have entered the bearing A tapped hole is supplied in the stuffing box
housing during shipment or erection, then refill the directly over the seal cage to introduce a clean,
bearing housing with proper lubricant. The oil level clear sealing medium. The stuffing box must at all
to be maintained is midway in the sight glass. times be supplied with sealing liquid at a high
enough pressure to keep the box free from foreign
Experience shows that oils meeting the s matter, which would quickly destroy the packing
pecifications below will provide satisfactory and score the shaft sleeve.
lubrication. These oils can be furnished by all
major oil companies. It is the responsibility of the Water Lubrication
oil vendor to supply a suitable lubricant.
Only a sufficient volume of sealing liquid is
(1) Saybolt viscosity at 38°C 150-200 SSU required to create a definite direction of flow from
(2) Saybolt viscosity at 99°C 43 SSU the stuffing box inward to the pump casing, but the
(3) Viscosity index, minimum 95 pressure is important. Apply seal water at a rate of
(4) API gravity 28 - 33 2-4l/m, at 35-70kPa above stuffing box operating
(5) Pour point, maximum +93°C pressure.
(6) Flash point, minimum 200°
(7) Additives: Rust and Oxidation inhibitors

NOTE: Oils from different suppliers should not be

mixed.
11
 Samco Chemical Process Pumps | General Maintenance

We recommend that piping supplying sealing liquid Fibre Packing

to the stuffing box be sized to supply a sufficient
volume of water at the required pressure, based on The standard packing is a soft, square asbestos,
the location of the pump (or pumps) with respect impregnated with oil and graphite. A soft well-lubri-
to the liquid source. A small pipe can be utilised cated packing reduces stuffing box resistance and
for the connection to the stuffing box. A valve prevents excessive wear on the shaft or shaft
should be installed to adjust and regulate the sleeve. Many brands of packing on the market have
sealing liquid and a gauge installed to check the desired qualities. For specific recommenda-
pressure to the box. tions, consult the factory.

External sealing liquid should be adjusted to the When a pump with fibre packing is first started, it
point where the packing runs only slightly warm, is advisable to have the packing slightly loose
with a very slow drip from the stuffing box. Excess without causing an air leak. As the pump runs in,
pressure from an external source can be very gradually tighten the gland bolts evenly. The gland
destructive to packing. More pressure is required should never be drawn to the point where packing
for abrasive slurries than for clear liquids. Exam- is compressed too tightly, and no leakage occurs.
ination of the leakage will indicate whether to This will cause the packing to burn, score the shaft
increase or decrease external pressure. If slurry is or shaft sleeve, and prevent liquid from circulating
present in the leakage, increase the pressure until through the stuffing box, cooling the packing. The
only clear liquid drips from the box. If the drip- stuffing box is improperly packed or adjusted if
page is corrosive or harmful to personnel, it should friction in the box prevents turning the rotating
be collected and piped away. element by hand. A properly operated packed
stuffing box should run lukewarm with a slow drip
A common error is to open the external piping of sealing liquid. After the pump has been in
valve wide and then control the drippage by tight- operation for some time and the packing has been
ening the packing gland. In actuality, a combina- completely run-in, drippage from the stuffing box
tion of both adjustments is essential to arrive at should be at least 40 to 60 drops per minute. This
the optimum condition. The life of packing and will indicate proper packing and shaft sleeve
sleeves depends on this careful control more than lubrication and cooling.
any other factor.
NOTE: Eccentric operation of the shaft, or sleeve,
Grease Lubrication through the packing could result in excess leakage
that cannot be compensated for. Correction of this
Pump stuffing boxes are also suitable for grease defect is very important.
lubrication. Several types of grease lubricators are
available. When using a grease lubricator, grease Packing should be checked frequently and replaced
pressure to the stuffing box should be equal to the as indicated by service. Six months might be a
pump discharge pressure. reasonable expected life, depending on operating
conditions. It is impossible to give any exact
Packing predictions. A packing tool may be used to remove
all old packing from the stuffing box. Never reuse
Pumps are not packed before shipment, unless old and lifeless packing or merely add some new
otherwise requested. If packed, packing used is rings. Make sure that the stuffing box is thoroughly
quality branded standard material. Before the cleaned before new packing is installed. Also check
pump is put into operation, check the condition of the condition of the shaft or sleeve for possible
the packing. If the pump is installed within 60 scoring or eccentricity, making replacements where
days after shipment, the packing will be in good necessary.
condition with a sufficient supply of lubrication. If
the pump is stored for a longer period, it may be
necessary to repack the stuffing box. In all cases,
however, we recommend an inspection of the
packing before the pump is started.

12
 Samco Chemical Process Pumps | General Maintenance

New packing should be placed carefully into the sealing faces. Even light scratches on these faces
stuffing box. If moulded rings are used, the rings could result in leaky seals.
should be opened sideways and the joints pushed
into the stuffing box first. The rings are installed 2. Normally, mechanical seals require no adjust-
one at a time, each ring seated firmly, and the ment or maintenance except routine replacement
joints staggered so that they are not in line. The of worn or broken parts.
joints should be kept toward the upper side of the
shaft and should be at about a 90° angle from 3. A mechanical seal which has been used should
each preceding joint. not be put back into service until the sealing faces
have been replaced or re-lapped. (Re-lapping is
If coil packing is used, cut one ring to accurate generally economical only in seals two inches in
size with either a butt or mitered joint. An accu- size and above.)
rately cut butt joint is superior to a poor fitting
mitered joint. Fit the ring over the shaft to assure Four important rules which should always be
proper length, then remove and cut all other rings followed for optimum seal life are:
to the first sample. When the rings are placed
around the shaft, a tight joint should be formed. 1. Keep the seal faces as clean as possible
Place the first ring in the bottom of the stuffing
box, then install each succeeding ring, staggering 2. Keep the seal as cool as possible
the joints as described above and making sure
each ring is firmly seated. Make sure the seal cage 3. Assure that the seal always has proper
is properly located in the stuffing box under the lubrication
sealing water inlet. The function of the seal cage is
to establish a liquid seal around the shaft, prevent 4. If the seal is lubricated with filtered fluid, clean
leakage of air through the stuffing box, and lubri- the filter frequently
cate the packing. If it is not properly located, it
serves no purpose. CLEANING WITHOUT DISMANTLING PUMP

MECHANICAL SHAFT SEALS We recommend that an increasing suction nozzle,

bolted to the suction flange, be used. (If this is not
General done, a short section of pipe designed so that it
can be readily dropped out of the line can be
A mechanical shaft seal is supplied in place of a installed adjacent to the suction flange.) With this
packed stuffing box where specifically requested. arrangement, any matter clogging the impeller is
On certain applications, mechanical seals are accessible by removing the nozzle (or pipe
preferred over packing because of better sealing section).
qualities and longer serviceability. Leakage is
eliminated when a seal is properly installed, and The suction nozzle should be equipped with a
normally the life of the seal is much greater than handhole with removable cover and a pipe tap for
that of packing on similar applications. injecting high-pressure clean out water into the
pump. This high-pressure water (up to 5.5 bar) can
General instructions for operation of the various be injected to flush out any matter clogging the
mechanical sealing arrangements are included impeller or water passages. The water should be
below. It is not feasible to include detailed instruc- applied only with the suction valve closed.
tions for all mechanical seals in this booklet
because of the almost unlimited number of possi- Other cleaning methods include running an auger
ble combinations and arrangements. Instead, seal into the pump through the clean out hole in the
manufacturer’s instructions will be included as a suction nozzle, or through the casing handhole.
separate supplement to this book where required. This should free any clogging in the impeller eye.

1. Mechanical seals are precision products and If the pump cannot be freed of clogging after the
should be treated with care. Use special care when above methods have been tried, dismantle the unit
handling seals. Clean oil and clean parts are as previously described to locate the trouble.
essential to prevent scratching the finely lapped
13
 Samco Chemical Process Pumps | Maintenance Time Table

MAINTENANCE TIME TABLE

Every Month Check bearing temperature with a thermometer, not by hand. If bearings are running
hot (over 82°C), it may be the result of too much lubricant. If changing the lubricant
does not correct the condition, disassemble and inspect the bearings.

Every 3 Months Check grease lubricated bearings for saponification. This condition is usually incurred
by the infiltration of water or other fluid past the bearing shaft seals and can be
identified immediately upon inspection, since it gives the grease a whitish colour. Wash
out the bearings with a clean industrial solvent and replace the grease with the proper
type as recommended.

Every 6 Months 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.

Check the shaft or shaft sleeve for scoring. Scoring accelerates packing wear.

Check alignment of the 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.

Every Year Remove the rotating element. Inspect thoroughly for wear and order replacement parts
if necessary.

Check wearing clearances.

Remove any deposit or scaling. Clean out stuffing box piping.

Measure total dynamic suction and discharge head as a test of pipe connection. Record
the figures and compare them with the figures of the last 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 reflect
also in poor performance of the pump while in operation.

14
 Samco Chemical Process Pumps | 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 handhole to clean impeller.

15
 Samco Chemical Process Pumps | Troubleshooting

No liquid delivered
CAUSES CURES

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
(depending on installation) pump 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.

17. Foot valve too small or partially Area through ports of valve should be at least as large as
obstructed area 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
enough is 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.

16
 Samco Chemical Process Pumps | Troubleshooting

Not enough pressure

CAUSES CURES

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
laboratory, reducing pressure on will provide adequate pressure despite condition. It is
liquid to pressure in suction line. better to provide gas separation chamber on suction line
Watch for bubble formation.) near pump, 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

CAUSES CURES

28. Incomplete priming Free pump, piping and valves of all air. If high points in
suction line prevent this, they need correcting.
See page 5.

29. Suction lift too high See item 3.

30. 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.

17
 Samco Chemical Process Pumps | Troubleshooting

No liquid delivered
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 dis-charge 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. Any
pump parts
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

18
 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