CPS Pumps

Installation, Operation and Maintenance Manual

 Contents

INTRODUCTION 3
PUMP IDENTIFICATION 3
TEMPORARY STORAGE 4
PUMP INSTALLATION 4
PRE START CHECKS 4
STARTING PUMP 4
OPERATING PUMP 4
SHUTDOWN 5
DISASSEMBLY 5
PARTS INSPECTION 7
ASSEMBLY 8
WET END 10
ADJUSTMENTS 11
DESCRIPTION OF CPS FRONT WEAR-PLATE ADJUSTING STUD 12
MAINTENANCE 13
SEAL MAINTENANCE 15
CLEANING WITHOUT DISMANTLING PUMP 16

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.
 Introduction | Pump Identification

INTRODUCTION
This manual is furnished to acquaint you with the easiest and most practical way to install, operate and
maintain a $14 pump. Additional information can be obtained from your nearest SAM Engineering
Sales Representative.

Equipment cannot operate well without proper care. To keep your unit operating at top efficiency, correct
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
 Temporary Storage | Pump Installation | Pre-start Checks

TEMPORARY STORAGE 4. REMOVE LOCKING PLATES FROM

MECHANICAL SEAL
The pump should be stored in a clean, dry place if
it is not installed and operated soon after arrival. 5. TURN ON SEAL WATER TO STUFFING
You should rotate the shaft every two weeks to coat BOX
the bearings with lubricant and to retard oxidation,
corrosion, and to reduce the possibility of false
6. MOTOR DIRECTION
brinelling of the bearings.
It is very important to check the motor direction
with the pump disconnected from the motor.
PUMP INSTALLATION Serious damage can result if the pump is operated
with incorrect rotation.
1. BASE PLATE SETTING (Before Piping)
Level and plumb the pump shaft and flanges by 7. COUPLING
adding or removing shims under the base. The Before the coupling is fitted, check that the pump
base plate does not have to be perfectly level. is turning freely by hand.
Sufficient shims must be placed under the base so
that when the anchor bolts are tightened, the base STARTING PUMP
plate is not twisted in any way as that would make
alignment difficult or impossible.
1. START
Start the pump.
2. SUCTION AND DISCHARGE PIPING
Piping should always be run in the direction of the 2. DISCHARGE VALVE
pump. Both the suction and discharge piping When the pump is operating at full speed, open the
should be independently supported near the pump discharge valve slowly.
and properly aligned so that no strain is transmit-
ted to the pump when the flange bolts are tight-
OPERATING PUMP
ened.
1. NOISES
3. SHAFT ALIGNMENT Listen for any strange noises coming from the
Although the pump has been factory aligned before pump and if so, stop the pump and investigate.
shipment it is important to re-do the shaft align-
ment after the pump has been installed. The align-
2. VIBRATION
ment should be within the coupling supplier’s
Feel the pump while it’s running for any excessive
tolerances. Should this not be available, align to
vibration.
within 0.1mm radially and axially or contact SAM
Engineering for assistance.
3. BEARING TEMPERATURES
On oil-filled pumps, the bearing temperatures
PRE-START CHECKS
should not exceed 90°C.
On grease-filled pumps, the bearing temperatures
1. LUBRICATION should not exceed 110°C.
Before starting the pump, ensure that the oil level
is in the centre of the sight glass. Grease-lubricat-
4. ADJUSTMENTS
ed pumps are factory lubricated before delivery
Make all pump output adjustments with the
and need no lubrication.
discharge valve. Do not throttle the suction line to
adjust the pump output. Adjust the gland packing
2. VALVES to drip continuously.
Ensure that all valves in the suction line are fully
open. If there are external feed lines to the stuff-
ing box or mechanical seal, ensure that the valves
are open. Keep the discharge valve closed.

3. PRIMING
Prime the pump properly.
4
 Shutdown | Disassembly

SHUTDOWN 7. Support the rotating element with a hook and

sling under the adaptor top web and coupling
1. DISCHARGE VALVE end of the shaft.
Close discharge valve slowly.
8. Remove the 16 cap screws that secure the
rotating element to the casing. Separate the
2. DRIVER
rotating element from the casing with jacking
Shut down driver.
screws. Remove the casing gasket.
3. VALVES
Front Wear-plate Removal:
Close valves as required.
1. Remove the 3 adjusting studs and locknuts by
4. DRAIN holding the adjusting stud stationary with a
Open drain valves as required. wrench and rotating the locknut counter
clockwise. Support the front wearplate and
jack it out of the casing fit as far as possible by
DISASSEMBLY rotating the studs counter clockwise. Rotate
each stud one turn and repeat until the studs
WARNING: The CPS may handle hazardous disengage from the wear-plate. Push the
and/or toxic fluids. Precautions must be taken to wear-plate the rest of the way out of the
prevent injury or environmental contamination. casing fit by screwing the studs back into the
Failure to follow these instructions could result in wear-plate and tapping the ends of the studs
serious personal injury or death, and/or property while supporting the wearplate.
damage.
Impeller Removal:
Rotating Element Removal:
1. To remove the impeller, hold the shaft
1. Close the discharge and suction valves. stationary, and turn the impeller counter
clockwise when looking into the impeller eye. If
2. Lock out power to the driver. the impeller does not loosen readily, use one of
the following procedures:
3. Disconnect the power source from the driver,
following proper safety precautions. a) Holding the shaft stationary with a wrench,
place a block of hardwood against the outer
4. Turn off seal water supply and disconnect periphery of an impeller vane and carefully tap
piping from the seal parts. the wood with a mallet in the counter clockwise
direction to loosen the impeller.
5. Drain casing. The casing may be left in the
pipeline attached to the suction and discharge b) Use an impeller removal wrench. Firmly
piping when repair or replacement is not support the impeller stuff box frame assembly.
required. Place the wrench on the pump shaft using the
shaft key. The handle should extend to the left
6. Remove spacer portion of coupling. If the when viewed from the impeller end. Loosen
pump is to be completely dismantled, remove the packing or mechanical seal to allow the
the pump half coupling, key, and the spacer shaft to turn freely and to prevent damage to
portion. (See coupling manufacturer's the mechanical seal. Wear heavy gloves to
instructions.) The motor half coupling may be prevent hand injuries. Viewing from the
left assembled. If the pump is V-Belt driven, impeller end, lift the long arm of the wrench
remove driven sheave and belt. up to the 11:00 O'clock position by rotating the
impeller clockwise. Then turn the impeller hard
counter clockwise, causing the end of the
wrench to strike a hard surface. The impact of
the wrench

5
 Disassembly

generates enough force to loosen the impeller. 3. Remove expeller, expeller O-ring and gasket.
Several strikes may be necessary. A firm hard
striking surface must be used, or the impact of 4. For two-stage dynamic seal, remove the
the wrench will be cushioned, preventing it intermediate plate, intermediate plate gasket,
from loosening the impeller. second stage expeller and expeller O-ring.

WARNING: Never apply heat to the impeller to aid 5. Remove the dynamic seal and static seal parts
in removal. Heating may cause an explosion. as follows. Remove sleeve with rotating collar.
Failure to follow these instructions could result in Loosen the 2 set screws and slide rotating
serious personal injury or death, and/or property collar from the shaft sleeve. Remove an O-ring.
damage. Remove 4 cap screws in order to remove the
retaining ring and 2 disk seals.
CRADLE THE LOOSENED IMPELLER IN A SLING
AND REMOVE IT BY ROTATING THE SHAFT Frame Disassembly
COUNTER CLOCKWISE (FROM THE COUPLING
END). 1. Remove the bottom drain plug to drain all oil
from the frame.
An O-ring can be removed from the impeller hub.
2. For frames with lip seals, remove the inboard
Stuffing Box Removal and outboard synthetic rubber deflectors from
the ends of the frame. Each may be easily
Packed Stuffing Box (Standard Stuffing Box Only): pulled from the shaft. For frames with labyrinth
or magnetic seals, remove the rotors from the
1. Remove the 2 nuts, securing the gland and ends of the shaft.
remove it from the stuffing box. Remove 3 cap
screws, securing the stuffing box to the frame 3. Remove the 4 cap screws securing the
adaptor. Remove the stuffing box. Pull bearing cap to frame. Use 2 of the cap screws
packing, seal cage and packing base ring from already removed as jacking screws in the
the stuffing box. Remove the shaft sleeve. bearing cap to pull it out of the frame bore.

Mechanical Seal with Standard Stuffing Box or

Seal Chamber 4. Next, pull the complete shaft assembly all the
way out of the frame, including shaft, bearings,
1. Remove the 4 nuts holding the mechanical seal oil slingers, and inboard bearing inner race. Be
gland to the stuffing box. Pull back the gland. careful not to damage the oil slingers or the
Remove 3 cap screws, securing the stuffing box inboard bearing inner race.
to the frame adaptor. Pull the stuffing box
from the frame adaptor, being careful not to 5. The inboard bearing outer raceroller assembly
damage the mechanical seal. The seal rotating should not be removed from the frame unless
element and sleeve may be removed from the the bearing is going to be replaced. To remove,
shaft as an assembly. To remove mechanical unscrew the 4 cap screws on the outside of the
seal from the sleeve, loosen the screws in the frame which hold the inboard bearing split
locking collar with an Allen wrench. Remove the retainer ring in place. Lift the 2 retainer ring
gland. Then remove the stationary seat from halves out of the frame. Set the frame on the
the gland. Use care not to damage the seal outboard end and tap the inboard bearing out
faces. with a mallet and a block of wood.

Dynamic Seal
6. The outboard oil seal which is pressed into
1. Remove the 3 cap screws that secure the bearing cap can now be removed, if desired.
dynamic seal (casing) cover to the frame The inboard oil seal can also be removed from
adaptor. Remove the 9 cap screws that secure the end of the frame, if desired.
the dynamic seal parts to the dynamic seal
cover.
6
 Disasembly | Parts Inspection

7. To remove the outboard bearing from the shaft, PARTS INSPECTION

bend the tubes up on the lockwasher. Remove
locknut and lockwasher by turning the nut When the pump is dismantled for any reason, it is
counter clockwise. A standard bearing puller recommended that all parts be inspected for wear
can then be used to remove the bearings from or damage. Check the following, and replace parts
both ends of the shaft. where necessary.

8. To remove the inboard bearing inner race, use 1. Casing

the two 1.0" long square keys of the same Clean all machined surfaces. The main casing
cross section size as the coupling key. Place joint and wear-plate bores should be free of
the keys in the removal slots provided in the rust, burrs or raised surfaces. Check for
shaft with one end against the race. Use a evidence of extreme wear or corrosion.
standard bearing puller on the free ends of the
keys to pull the race off the shaft. 2. Impeller
Check the impeller vanes for signs of wear,
9. Remove the oil slinger assemblies from the breakage or corrosion. Check threads for burrs.
shaft to prevent their damage while handling
the shaft. There are 2 set screws, one on top 3. Front wear-plate
the other, in each hole in the collar. Remove the Clean all machined surfaces. The locating turns
set screws and slide each assembly off the should be free of rust, burrs or raised surfaces.
shaft. Check for evidence of extreme wear or
corrosion. Clean and check adjusting stud
10. If required, the adaptor can be removed from threads.
the frame by removing 4 cap screws and using
2 of them in the jackscrew holes in the adaptor 4. Adjusting studs
flange to push the adaptor off the frame. Clean the machined surfaces. Check
threaded portion and flange for burrs or
FIGURE 1 damage.

To disassemble and assemble pump, use 5. Stuffing box cover

conventional tools. Clean the machined surfaces and gasket joint.
Make sure that stuffing box cavity is clean.
The sketch below shows a shaft wrench that fits Check the surface that is next to the impeller
all sizes of $14 Pumps. It is suggested for for indications of wear.
impeller removal.
6. Adaptor
Clean all machined surfaces. Check the
machined faces, bores, and turns for burrs and
raised surfaces.

7. Shaft
Check all rotating close-clearance surfaces for
wear. Check to see if the shaft is straight within
0.002" TIR. Make sure the threads are clean
and free of nicks and burrs.

8. Shaft sleeve
The shaft sleeve must be smooth. If grooved, it
should be replaced.

7
 Parts Inspection | Assembly

9. Bearings ASSEMBLY
Clean bearings using an approved bearing
cleaning solvent, or any other non-flammable Pump and frame parts are reassembled in the
industrial solvent. Inspect the bearings, reverse order of dismantling, with special notes as
replacing them if they are noisy or rough when outlined below. Follow all installation precautions
rotated, or if there are signs of wear or pitting covered in this manual.
in the bearing raceways.
Frame assembly
WARNING: Under no circumstance should a com-
bustible solvent such as gasoline be used to clean It is recommended that the frame be reassembled
bearings or any other part of the pump. The use of in the vertical position.
such solvents could lead to fire or explosion.
Failure to follow these instructions could result in 1. Install the inboard bearing inner race on the
serious injury or death, and/or property damage. inboard end of the shaft. The inner race may
be pressed on, or heated to 200°F maximum
10. Shaft seals and slipped on the shaft. Heat the inner race
Replace the lip seals. If equipped with optional using a bearing induction heater, a clean oil
labyrinth seals, replace O-rings. If equipped bath, or a dry oven. Be sure the race is firmly
with optional magnetic seals, replace O-rings seated against the shaft shoulder.
and inspect seats, replace if required.
CAUTION: Use insulated gloves when handling hot
11. Frame bearings. Failure to follow these instructions could
Clean all machined surfaces and check the result in personal injury, and/or property damage.
machined faces, bores, and turns for burrs and
raised surfaces. Check the bearing bores for 2. Insert 2 oil slingers through the slots in the
wear. Clean the interior of the oil reservoir. collar. Slip this oil slinger assembly over the
Replace oil sight glass if damaged or centre portion of shaft. Locate this assembly
discoloured. Make sure the inboard and 2.00" from the inboard bearing shoulder.
outboard oil return grooves are clean. Tighten the first set screw in each hole against
the shaft, and the second (locking) set screw
12. Outboard bearing cap against the first. Repeat for the second slinger
Clean the machined surfaces. The frame turn assembly, locating it 2.00" from the outboard
and bearing face should be free of burrs and bearing shoulder. Handle the shaft carefully
raised surfaces. from this point on to avoid damaging the oil
slingers and inboard bearing inner race.
13. Mechanical seal
Check the sealing faces and gaskets. Sealing 3. Install the outboard bearings on the outboard
faces must show no evidence of wear. Any end of the shaft. The outboard bearings
cracked or chipped seal face should be consist of two angular contact ball bearings.
replaced. Refer to the specific seal These bearings must be installed
manufacturer's instructions. "back-to-back" (wide shoulders of outer race
contacting as shown in the Assembly Section.)

14. Dynamic seal parts Remove the preservative from the outside
Clean the machined surfaces and gasket joints. diameter and faces of the bearings. Heat both
Make sure that expeller cavities are clean. bearings to 200°F at the same time. Place the
Check expeller bores and faces for burrs and first bearing on the shaft. Very quickly place
raised surfaces. the second bearing on the shaft. When
installing the second bearing, push against the
15.Gaskets and O-rings and adjusting stud seals inner race to remove all clearance between the
Replace all gaskets, O-rings and adjusting stud inner races of the two bearings, and between
seals. the inner race of the first bearing and the shaft
shoulder.

8
 Assembly

Use locknut to hold the bearings together 7. Place an O-ring in bearing cap groove. For
against the shaft shoulder while they cool. frames with lip seals, press the outboard lip
First, place the bearing lock washer on the seal into the outboard bearing cap. The
shaft, locking tabs away from the bearing. bearing seal must be positioned with the lip
Install the locknut with the bevelled edge facing facing outward to exclude contaminants. The
the bearing. Tighten it as much as possible lip seal must be square to the housing and the
with a spanner wrench turned by hand. lip should be pre-lubricated with oil. For
frames with optional labyrinth or magnetic
4. After the bearings have been cooled to room seals, press the outboard stator into the
temperature, retighten the locknut as much as bearing cap. The expulsion port on labyrinth
possible with a spanner wrench turned by seals must be down. (The word "top" is cast on
hand. Then use a hammer on the wrench to the top of the bearing cap.)
tighten the locknut an additional eighth to
quarter turn. Make sure a slot on the nut lines 8. Insert the shaft assembly into the frame after
up with a tab on the lock washer. Bend one of the bearings have cooled to room temperature.
the lock washer tabs into a matching slot on Lubricate the inboard bearing inner races and
the bearing locknut. outboard bearing outer races on the shaft.
Reach into the frame and centre inboard
5. Install the inboard bearing’s outer race roller bearing cage and press rollers radially
assembly in frame. Set the frame vertically outward. Insert the shaft assembly. Be careful
with the outboard end up. Place outer race not to damage the oil slinger. Do not change
roller assembly in the inboard bore in frame, the direction of travel of the shaft assembly
ensuring it is not cocked. Tap it lightly and (from inserting to removing) while the slingers
evenly into the bore with a block of wood and a are passing through the frame outboard
mallet until it is against the shoulder in the bearing bore, as this will bend the spring steel
frame. (It will protrude approximately 0.03" slingers. When outboard bearings are about
when properly seated in the bore.) Turn the two-thirds into the outboard bore, the inboard
frame on its side. Place the split retainer ring bearing inner race on the shaft will start to
in the frame against the bearing so that the engage the inboard bearing rollers in the
oil return hole lines up with the oil return frame. Rotate the shaft slightly at this point
groove in the frame. Loosely secure with cap and continue to advance the shaft assembly
screws from outside the frame. into the frame.

NOTE: If the retainer ring bolt pattern is 9. Place the outboard bearing cap over the shaft
non-symmetrical so that the ring cannot be and into the frame. Make sure the word "top" on
installed incorrectly, tighten cap screws uniformly the bearing cap is in the uppermost position.
to pull retainer ring against bearing. Fasten cap to the frame with 4 cap screws. For
frames with lip seals, assemble deflectors at
6. For frames with lip seals, press the inboard lip both ends of the frame. For frames with
seal into the frame so that the seal lip is labyrinth or magnetic seals, assemble rotors at
directed away from the frame. The seal must both ends of the frame.
be positioned in this fashion to exclude
contaminants. The lip seal must be square to 10. Assemble adaptor onto the inboard end of
housing and the lip should be pre-lubricated frame and secure with 4 cap screws. Ensure
with oil. For frames with optional labyrinth or that the top adaptor rib is up by positioning
magnetic seals, press inboard stator into the adaptor with the notch on the outside
bearing cap. The expulsion port on labyrinth diameter of the small frame, flange down.
seals must be down.

9
 Wet End

WET END NOTE: The seal collar must be adjusted later when
the pump is placed in service. It is properly adjust-
Packed Stuffing Box ed when near zero leakage is achieved when the
pump is not running.
1. Place the stuffing box on a table or work bench CAUTION: Excessive heat and eventual leakage will
with the stuffing box opening up. Place the result if the collar is adjusted too tightly against
shaft sleeve with hook end down in the stuffing seal discs. Failure to follow these instructions
box. could result in personal injury and/or property
damage.
2. Assemble the packing base ring in bottom of
the stuff box. Insert 2 rings of packing and 2. Slide the seal-housing assembly over the shaft
seal cage, and 3 rings of packing and gland. sleeve. The lugs on the housing must straddle
Stagger the packing joints to prevent excessive the lugs on the adaptor as shown in Figure 2.
leakage. It is suggested that the split of the
3. Assemble the expeller(s) and intermediate
last packing ring be down. Pull the gland plate as follows:
retaining nuts to finger tightness. Make sure
the seal cage is over the stuff box lube hole. For one-stage units, slide O-ring and first stage
expeller over the shaft.
3. Slide the stuffing box assembly over the shaft
and seat the stuffing box then turn in the For two-stage units, slide an O-ring and second
adaptor bore, being sure that the holes in the stage expeller over the shaft, assemble gasket
stuffing box line up with corresponding holes in on the turn of the housing and slide the
the adaptor. Fasten the stuffing box to the intermediate plate over the turn, then slide an
O-ring and first stage expeller over the shaft.
adaptor with 3 cap screws.
4. Place the gasket on the turn of the housing or
Mechanical Seal with Standard Stuffing Box or Seal intermediate plate and slide the dynamic seal
Chamber (casing) cover over the turn, making sure that
the holes in the adaptor line up with the
1. Refer to the mechanical seal manufacturer's corresponding holes in the cover and that a
instructions. Press stationary seat into gland, housing cap screw lug is in uppermost
being careful not to damage the seal face. position. Insert and tighten 3 adaptor-cover
Slide the gland with its gasket onto the shaft. cap screws. Tighten 9 dynamic seal cap
Position the seal rotating assembly on the screws.
shaft sleeve. Tighten all set screws. Slip sleeve
assembly over the shaft.

2. Slide the stuffing box assembly over the shaft

and seat stuffing box turn in the adaptor bore,
being sure that the holes in the stuffing box
line up with corresponding holes in the
adaptor. Fasten the stuffing box to the adaptor
with 3 cap screws.

Dynamic Seal

1. Attach the 2 static seal disks to the dynamic

seal housing using the retaining ring and 4 cap
screws. Place an O-ring in the seal collar and Figure 2: View of a dynamic seal housing showing orientation
assemble onto the sleeve. Do not tighten the of the dynamic seal cover. Notice that the 9 housing lugs
collar set screws. Place 9 cap screws through straddle the 3 adaptor lugs.
the holes in the housing.
Impeller Assembly

1. Place an O-ring into the groove of the impeller

hub.
10
 Dissembly | Adjustments

2. Apply a coat of anti-seize compound to the CAUTION: Do not attempt to adjust the front
shaft threads. wear-plate with the pump running. Failure to follow
these instructions could result in personal injury
3. To thread the impeller on the shaft, cradle it in and/or property damage.
a sling and rotate the shaft clockwise from the
coupling end. 1. Loosen the adjusting stud locknuts just enough
so that the studs can be rotated, but not
4. To secure the impeller, hold the shaft in the enough to allow them to move axially. Do this
fixed position and place a block of wood by holding the stud stationary with a 3/8"
against an impeller vane. Carefully tap with a wrench on its flats, and rotating the locknut
mallet to tighten. slightly counter clockwise with a 1-1/16"
wrench.
5. Ensure that the shaft rotates freely. Check the
impeller back clearance, it should be between
2. Move the front wear-plate all the way forward
0.031" and 0.078".
against the impeller by rotating the studs
Casing Assembly counter clockwise. Rotate each stud one turn
and repeat until the front wear-plate makes
1. Apply a light coat of anti-seize compound to contact with the impeller.
the fine threads on the 3 adjusting studs.
Screw these studs into the holes of the front 3. Before setting the running clearance, seat the
wear-plate until the flange seats on the new seal rings around the studs by tightening,
wear-plate. then loosening, the locknuts just enough so the
studs can be turned. Also, before setting the
NOTE: The end of the adjusting stud with the fine running clearance, remove any axial "play" in
thread screws into the wear-plate. Line up the the adjusting stud wear-plate threads by
adjusting studs with the holes in the casing rotating the adjusting studs clockwise by finger
(2-001-0) and assemble the wear-plate into the without moving the wear-plate away from the
casing bore. impeller, then tightening the locknuts finger
tight.
NOTE: The adjusting studs are not equally spaced
on some sizes, so the wear-plate will only go into 4. Set the impeller front running clearance to the
the casing one way. Rotate the wear-plate so that valve shown in the table below. Back the
the adjusting studs do not bind against the sides wear-plate away from the impeller by rotating
of the holes in the casing. each adjusting stud and nut together
clockwise, the number of turns or flats are
2. Place a metal seal cup flange side toward shown in the table. Then check to see that the
casing, Teflon seal ring, metal follower washer,
impeller rotates without rubbing.
and locknut over each stud. Tighten locknuts
finger tight.
IMPELLER FRONT RUNNING CLEARANCE VS.
3. Check that the suction (small) end of the TEMPERATURE
wear-plate is seated against the casing
shoulder. (If the directions in 1. and 2. above TEMP CLEAR. NO. OF NO. OF
are followed, the wear-plate should already be of IN. TURNS* FLATS**
seated.) This can be done visually and by 100 .015-.025 1/4-1/2 1 1/2-3
rotating each stud one turn clockwise and 200 .020-.030 13/-1/2 2-3
repeating until the wear-plate is seated. 300 .030-.040 . 1/2-2/3 3-4
400 .040-.050 2/3-5/6 4-5
ADJUSTMENTS 500 .045-.055 5/6-1 5-6

Impeller clearance adjustment *1 Turn = .056 in.

**1 Flat = 1/6 Turn = .009 in.
The impeller clearance is adjusted by moving the
front wear-plate. See illustrations. 5. Tighten the locknuts by holding the adjusting
stud stationary with a wrench on its flats and
rotating the locknut clockwise.
11
 Description of CPS Front Wear Plate Adjusting Stud

Dynamic seal static collar

Adjust the Dynamic Static Seal collar before filling the pump with fluid. Move the collar toward the static
seal disk until the collar touches the disk. Back off the seal collar approximately 1/64" and tighten the 4
collar set screws (2 in each hole). The seal collar is properly adjusted when near zero leakage is achieved
when the pump is not running.

CAUTION: Excessive heat and eventual leakage will result if the collar is adjusted too tightly against seal
discs. Failure to follow these instructions could result in personal injury and/or property damage.

FIGURE 3

DESCRIPTION OF CPS FRONT WEAR-PLATE ADJUSTING STUD

The CPS front wear-plate adjusting mechanism is similar to a lead screw and traveling nut. Three
"adjusting studs" serve as lead screws. These are assembled through holes in the casing wall with an
integral flange on the inside and a locknut on the outside, so the stud can rotate but not move axially. The
adjusting studs are threaded into the wear-plate which acts as the traveling nut. The wear-plate is held in the
casing so that it can move axially, but not rotate. Just as with a standard bolt and nut, turning the adjusting
stud (bolt) counter clockwise while preventing the front wear-plate (nut) from rotating pushes the front
wear-plate (nut) away from the adjusting stud (bolt).

The adjusting studs are sealed where they penetrate the casing by a miniature stuff box and gland. A steel
cup (stuff box) fits around the stud. A specially machined Teflon seal ring (packing) fits around the stud and
inside the cup. A steel washer (gland) fits over the stud and against the seal ring. Tightening the adjusting
stud locknut (gland nut) compresses the seal ring against the face of the casing and around the stud.

The front wear-plate is adjusted by loosening the adjusting stud locknuts just enough so that the studs can
be rotated. The wear-plate is first moved against the impeller by rotating the studs counter clockwise. With
the locknuts finger tight enough to eliminate axial play in the studs, the wear-plate is pulled away from the
impeller by rotating each stud and locknut together clockwise a third turn (1.5 flats). The wear-plate is then
locked in position by turning the locknuts clockwise while holding the studs stationary with a wrench on
their flats.
12
 Maintenance

GENERAL MAINTENANCE AND PERIODIC Couplings should be dismantled and thoroughly

INSPECTION cleaned. Lubricate the coupling with one of the
coupling manufacturer’s recommended lubricants
Operating conditions vary so widely that to where required.
recommend one schedule of preventative
Any pump that is properly sealed at all joints and
maintenance for all centrifugal pumps is not
connected to both the suction and discharge
possible. However, it is imperative that some sort
should exclude outside liquid. Therefore, it should
of regular inspection is planned and followed. We not be necessary to go beyond the bearings, stuff-
suggest a permanent record be kept of the period- ing box and coupling when servicing the pump.
ic inspections and maintenance performed on your
pump. This recognition of maintenance procedure
will keep your pump in good working condition, BEARING LUBRICATION – OIL
and prevent costly breakdowns.
Oil lubrication on CPS pumps is considered
One of the best rules to follow in the proper main- standard. Oil lubricated pumps have a slinger
tenance of your centrifugal pump is to keep a which picks up the oil and creates a shower of fine
record of actual operating hours. Then, after a droplets over the entire interior of the bearing
predetermined period of operation has elapsed, cavity.
the pump should be given a thorough inspection.
The length of this operating period will vary with After the pump has been installed, flush the
different applications, and can only be determined bearing housing to remove dirt, grit and other
from experience. New equipment, however, should impurities that may have entered the bearing
be examined after a relatively short period of housing during shipment or erection, then refill the
operation. The next inspection period can be bearing housing with proper lubricant. The oil level
lengthened somewhat. This system can be followed to be maintained is midway in the sight glass when
until a maximum period of operation is reached the pump is running.
which should be considered the operating schedule
A Mobil DTE Medium turbine oil, or equal, meeting
between inspections.
the following specification will provide satisfactory
lubrication. The oils can be furnished by all major
MAINTENANCE OF FLOOD DAMAGED PUMPS oil companies. It is the responsibility of the oil
vendor to supply a suitable lubricant.
The servicing of centrifugal pumps after a flooded
condition is a comparatively simple matter under (1) Saybolt vise at l00°F 215 SSU-240 SSU
normal conditions. (2) Saybolt vise at 2l0°F 49 SSU
(3) Viscosity index, minimum 95
Bearings are a primary concern on pumping units. (4) API gravity 30.6
First, dismantle the bearings; clean and inspect (5) Pour point, maximum -6°C
them for any rusted or badly worn surfaces. If (6) Flash point, minimum 200°C
bearings are free from rust and wear, re-assemble (7) Additives Rust & Oxidation inhibitors
and re-lubricate them with one of the recommend- (8) ISO viscosity 46
ed pump lubricants. Depending on the length of
time the pump has remained in the flooded area, it NOTE: Oils from different suppliers should not be
mixed. Engine oils are not recommended.
is unlikely that bearing replacement is necessary;
however, in the event that rust or worn surfaces
The oil should be non-foaming, well refined, good
appear, it may be necessary to replace the grade, straight cut, and filtered mineral oil. It must
bearings. be free from water, sediment, resin, soaps, acid
and fillers of any kind.
Next, inspect the stuffing box, and clean out any
foreign matter that might clog the box. Packing
that appears to be worn, or no longer regulates
leakage properly should be replaced. Mechanical
seals should be cleaned and thoroughly flushed.

13
 Maintenance

NOTE: Do not over oil as this causes the bearings Periodic Addition of Grease
to run hot. The maximum desirable bearing hous-
ing operating temperature for ball and roller bear- If you are uncertain about the amount of grease
ings is 80°C. Should the temperature of the bear- that should be in a bearing at re-lubrication
ing frame exceed 80°C (measured by intervals, the safe rule is to add grease slowly, one
thermometer), shut down pump to determine the ounce at a time, as the bearing operates. A ball or
cause. roller bearing in most applications is assured of
adequate lubrication if the level of grease is
BEARING LUBRICATION — GREASE maintained at about 1/2 the capacity of the
bearing and bearing housing space. Any greater
Grease lubrication on CPS pumps is optional. amount will, as a rule, be discharged by the seals
Standard frames are oil lubricated. and be wasted. EXCESS GREASE IS THE MOST
COMMON CAUSE OF OVERHEATING OF THE
Grease lubricated ball and roller bearings are BEARINGS.
packed with grease at the factory and ordinarily
will require no attention before starting, provided Refilling Grease after Cleaning
the pump has been stored in a clean, dry place
prior to its first operation. The bearings should be When cleaning bearings during a major overhaul,
observed in the first hour or so after the pump has use a bearing cleaning solvent, industrial cleaning
been started to see that they are operating solvent, or kerosene. In case of badly oxidized
properly. grease, soak bearings in hot, light oil (93° to
115°C). Do not use gasoline. Use lint-free cloths.
The importance of proper lubrication cannot be Do not use waste rags.
over-emphasised. It is difficult to say how often a
bearing should be greased, since this depends on Hand pack clean bearings (not the housing)
the conditions of operation. It is recommended completely full with fresh grease while the pump is
that one ounce of grease is added at regular disassembled. Add additional grease to the bear-
intervals, however, it is equally important to avoid ing housing. The resulting total level of grease
adding too much grease. For average operating should be about 1/2 the capacity of the bearing
conditions, it is recommended that one ounce of and bearing housing space. Any greater amount
grease be added at intervals of three to six will, as a rule, be discharged by the seals and be
months, using only clean grease. It is advised that wasted. EXCESS GREASE IS THE MOST COMMON
the unit is stopped while grease is added to avoid CAUSE OF OVERHEATING OF THE
overloading. BEARINGS.

A lithium-based NLGI-2 grade grease should be BEARING TEMPERATURE

used for lubricating bearings where the ambient
temperature is above 20°F. Grease lubricated Normally the maximum desirable operating
bearings are packed at the factory with Mobilux EP temperature for ball and roller bearings is 180°F
No.2 grease. Other recommended greases are as measured on the bearing frame. Should the
Texaco Multifak EP-2 and Shell Alvania EP2. Do not temperature of the bearing frame rise above the
use grease with graphite additives. limit, the pump should be shut down to determine
the cause. A bearing frame which feels hot to the
In greasing the anti-friction bearings, the use of touch of the hand is not necessarily running hot.
high pressure equipment is not only unnecessary, Check with an accurate temperature measuring
but is actually undesirable unless used with great device to be sure.
care. High pressure may damage the bearings or
seals, cause unnecessary loss of grease, create a For high temperature service, an optional frame
danger of overheating due to over greasing, and cooling device is available. The cooling device can
produce unsightly conditions around the bearing. be installed without disassembling the frame. It
requires approximately 0.5 GPM of external
cooling water.

14
 Seal Maintenance

SEAL MAINTENANCE Packing should be checked frequently and replaced

as service indicates. Six months might be a
Packing maintenance reasonable expected life, depending on operating
conditions. It is impossible to give any exact
Pumps are not packed before shipment, unless predictions. A packing tool may be used to remove
otherwise requested. If packed, packing used is all old packing from the stuffing box. Never reuse
quality branded standard material. Before the old and lifeless packing or merely add some new
pump is put into operation, check the condition of rings. Make sure the stuffing box is thoroughly
the packing. If the pump is installed within 60 cleaned before new packing is installed. Also check
days after shipment, the packing will be in good the condition of the shaft or sleeve for possible
condition with a sufficient supply of lubrication. If scoring or eccentricity, and make replacements
the pump is stored for a longer period, it may be where necessary.
necessary to repack the stuffing box. In all cases,
however, we recommend an inspection of the New packing should be placed carefully into the
packing before the pump is started. stuffing box. If moulded rings are used, the rings
should be opened sideways and the joints pushed
The standard pump packing is made from acrylic into the stuffing box first. The rings are installed
yarn impregnated with petroleum lubricants and one at a time, each ring seated firmly and the
graphite. joints staggered at about 90° angle from the
preceding joint. It is suggested that the split of the
A soft, well-lubricated packing reduces stuffing box last packing ring be down.
resistance and prevents excessive wear on the
shaft and sleeve. Many brands of packing on the If coil packing is used, cut one ring to accurate
market have the desired qualities. For specific size with either a butt or miter joint. An accurately
recommendations, consult your SAM Engineering cut butt joint is superior to a poor fitting miter
Sales Representative. joint. Fit the ring over the sleeve to assure proper
length. Then remove and cut all other rings to the
When a pump with fibre packing is first started, it first sample. When the rings are placed around the
is advisable to have the packing slightly loose shaft, a tight joint should be formed. Place the first
without causing an air leak. As the pump runs in, ring in the bottom of the stuffing box. Then install
gradually tighten the gland bolts evenly. The gland each succeeding ring, staggering the joints as
should never be drawn to the point where packing described above, making sure each ring is firmly
is compressed too tight and no leakage occurs. seated.
This will cause the packing to burn, score the shaft
sleeve arid, and prevent liquid from circulating The standard stuffing box consists of a base ring,
through the stuffing box and cooling the packing. two rings of packing, a seal cage, three rings of
The stuffing box is improperly packed or adjusted packing, and a gland. Make sure the seal cage is
if friction in the box prevents turning the rotating properly located in the stuffing box under the seal
element by hand. A properly operated stuffing box water inlet. The function of the seal cage is to
should run lukewarm with a slow drip of sealing establish a liquid seal around the shaft, prevent
liquid. After the pump has been in operation for leakage of air through the stuffing box and lubri-
some time, and the packing has been completely cate the packing. If it is not properly located it
run-in, drippage from the stuffing box should be at serves no purpose.
least 40 to 60 drops per minute. This will indicate
proper packing, and shaft sleeve lubrication and
cooling.

NOTE: Run-out on the shaft sleeve could result in

excess leakage that cannot be compensated for.
Correction of this defect is very important.

15
 Cleaning Without Dismantling Pump

MECHANICAL SEAL MAINTENANCE

General instructions for operation of the various

mechanical sealing arrangements are included
below. It is not feasible to include detailed
instructions for all mechanical seals in this booklet
because of the almost unlimited number of
possible combinations and arrangements. Instead,
seal manufacturer’s instructions will be included as
a separate supplement to this book where
required.

1. Mechanical seals are precision products and

should be treated with care. Use special care
when handling seals. Clean oil and clean parts
are essential to prevent scratching the finely
lapped sealing faces. Even light scratches on
these faces could result in leaky seals.

2. Normally, mechanical seals require no

adjustment or maintenance except routine
replacement of worn or broken parts.

3. A mechanical seal which has been used should

not be put back into service until the sealing
faces have been replaced or re-lapped.
(Re-lapping is generally economical only in
seals two inches in size and above.)

Four important rules which should always be

followed for optimum seal life are:

1. Keep the seal faces as clean as possible

2. Keep the seal as cool as possible

3. Assure that the seal always has proper

lubrication

4. If the seal is lubricated with filtered fluid, clean

the filter frequently

CLEANING WITHOUT DISMANTLING PUMP

We recommend that an increasing suction nozzle,

bolted to the suction flange, be used. (If this is not
done, a short section of pipe designed so that it
can be readily dropped out of the line can be
installed adjacent to the suction flange.) With this
arrangement, any matter clogging the impeller is
accessible by removing the nozzle (or pipe
section).

16
 Inspection

PERIOD INSPECTION

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

Check the oil on oil lube units for metal particles or water. Replace oil with the recommended type.

Every 3 Check grease lubricated bearings for saponification. This condition is usually incurred by the
months 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.

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

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.

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 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 also reflect in the poor performance of the pump while in operation.

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 the poor performance of
the pump while in operation.

17
 Pulpy Solids & Corrosives Pump

112A
CPS Series
100
112C
PLEASE NOTE:
130 When ordering spare parts,
110 131 indicate model size,
133
material of construction
139
and / or pump serial number.
132

145 Catalog
165 Code Part Name
155
163 100 Casing
160 148
110 Wear Plate
148A 112 Adjsting Stud
140 112A Seal Cup & Ring
112B Seal Washer
144
112C Lock Nut
151 120 Impeller
121 Impeller O-Ring
143
130 Stuffing Box
162 130A Dynamic Seal Cover
121
Wearplate Adjustment 131 Packing Base Ring
164 132 Gland
120 150A 133 Lantern Ring
112B
134 Static Seal
112
135 Dynamic Seal Housing
136 Expeller
137 Static Seal Retaining Ring
138 Static Seal Collar
110 150
138A Static Seal Collar O-Ring
166 139 Packing Ring
140 Frame
167
141 Frame Foot
168 142 Bearing Housing
144 Retaining Ring
147 145 Frame Adapter
143 Bearing Cap
156
148 Breather
138
148A Red. Bush
138A
150 Shaft
137 150A Keyway
136
135
134 151 Slinger
130A 155 Shaft Sleeve
141 156 Spacer Sleeve
160 Pump End Bearing
162 Drive End Bearing
163 Bearing Oil Seal
164 Bearing Oil Seal
Static sealing 165 Deflector
for Dynamic Seal 166 Deflector
167 Bearing Locknut
168 Bearing Lockwasher
 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