Sam ZM 375/00, Operation & Maintenance Manual

Page 1: ...ZM SPLIT CASING PUMPS OPERATION MAINTENANCE MANUAL SAM TURBO INDUSTRY PVT LIMITED NEELAMBUR COIMBATORE 641062 INDIA PHONE 914226193555 E MAIL service sampumps com ...

Page 2: ... that such replacement repairs are attributable to or arise solely from faulty workmanship or defective material We warranty the materials for the chemical composition and mechanical properties of the relevant standard only and not for corrosion and erosion The warranty holds good only for the products manufactured by us SL NO CONTENTS PAGE NO 1 GENERAL 2 FORWARD AND GUARANTY 3 DESCRIPTION OF PUMP...

Page 3: ... Acknowledgement of Order you wish to use the pump for a different service please ask for our acceptance Otherwise the guarantee given for this pump will not be valid STORAGE PRESERVATION OF PUMPS Protect the equipment up to 6 months in an indoor environment The pump must be protected against damage dust or any aggressive environment Pumps stored for period exceeding one year should be serviced ev...

Page 4: ...lf With this arrangement it is not necessary to disconnect suction or discharge piping to make repairs or replace the rotating element Upper and lower half casings are bolted together and doweled to maintain a smooth volute contour inside the pump Supporting feet are integrally cast in the lower half casing and are drilled for bolting and doweling to base plate Bearing brackets form a drip pocket ...

Page 5: ...lts should be tightened evenly but not too firmly Grout the unit as follows 1 Build a strong form around the base plate to contain the grout 2 Soak the foundation top thoroughly and then remove surface water 3 Pour grout Tamp liberally while pouring in order to fill all cavities and prevent air pockets The space between the foundation and base plate should be completely filled with grout In order ...

Page 6: ...urned through an angle Maximum permissible tolerance is 0 05mm At every check take care that the axial float of the rotor is taken into account i e when measuring the rotor and the driver shaft must always be brought to bear in the same direction LAYING CONNECTING PIPES The suction and discharge piping should be installed with the shortest and most direct runs Elbows should preferably be of the lo...

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Page 8: ...e disturbance in the flow caused by the sharp bend so near the pump inlet may result in noisy operation loss in efficiency and capacity and heavy end thrust A long sweep or long radius elbow placed as far away from the pump as practicable should be used if a bend is necessary in the suction line If separate suction lines cannot be used for each pump then a tapering header with Y branches should be...

Page 9: ...fter 100 hours of operation for the first time and thereafter at intervals of 6 12 months Add oil when necessary TO INSTALL A CONSTANT LEVEL OILER AS BELOW 1 Unscrew upper screw sub assembly from lower sub assembly Refer Fig 1 2 Fix lower sub assembly elbow type on pump Please note Pump has two tapings One tapping is for CLO and other is a drain which is at a lower height FIRM Lubricating oil for ...

Page 10: ...r sub assembly Do not over tighten Some bubbling will take place this is O K bubbling will stop once oil has reached its level I i e Ref Fig 6 7 Once bubbling has stopped the pump should be started CLO will automatically maintained oil level in pump Refill oil whenever oil level in doom goes below level Y ref step 1 5 6 Note 1 In case of pump is already full of oil before installing CLO it is reco...

Page 11: ...r ejector operated by air steam water etc to evacuate air from the pump case and suction line by connecting the ejector to the priming connection on top of the pump case 8 Open valves in stuffing box seal lines if fitted Start driver Open discharge valve slowly when the pump is up to speed 9 Overheating and or loss of prime will result if the pump is operated against a closed valve for more than a...

Page 12: ...p shaft Pumps are equipped with packing limited leakage or mechanical seals no leakage Normally the pumped liquid is used to lubricate the stuffing box seal If the liquid is dirty gritty or contains material that would gum or jam the seal use a sealing liquid from an external source If suction pressure is above atmospheric pressure seal piping may not be required For pumps equipped with packing th...

Page 13: ...re provided with constant level oilers Bottles should be kept filled at all times so that there is a visible supply of oil All lubricants have a tendency to deteriorate in the course of time therefore sooner or later it will be necessary to replace the old lubricant with new Bearings which are dismantled are of course much more easily cleaned than bearings which stay in assembled equipment Oil Re ...

Page 14: ...g bolts and the bearing housing fixing bolts from the lower casing 5 Drain oil from the bearing housing Part no 350 oil lubricated ball bearing units only 6 Remove the outboard oil reservoir with bolting 7 Screw jackscrews down to separate upper and lower case PUMP TYPE OIL SEAL BEARINGS PACKING DE DE NDE DE NDE ZM II 375 00 ID45XOD65X8 ID48XOD72X8 2 6309 6309 ID65XOD90X12 5 10 ZM II 440 00 ID55XO...

Page 15: ...water inlet For repair and removal of mechanical seals 10 Loosen setscrews in sleeve nut Part no 921 and unscrew the nut from the shaft Part no 211 11 Remove o ring Part no 412 with shaft sleeves Part no 524 12 Remove casing wear rings Part no 502 On most pumps casing rings may be removed before disassembling rotating element 13 Impeller Part no 234 with impeller rings can now be removed from eith...

Page 16: ... bottom casing 3 Insert the thrower and inner bearing covers along with oil seals to both the shaft ends 4 Fix the bearing spacer and bearings on the NDE side shaft in back to back arrangement bearing nut to be tightened on the bearing locked with the shaft 5 Fix the bearing on the DE side shaft and oil sleeve to be tightened with shaft set screw available in sleeve 6 Fix the casing wear rings in ...

Page 17: ...rawing Sealing Cover First of all the sealing covers are completely pre assembled This includes the installation of the cover neck bushes the o rings and the correct mounting of the stationary seal ring When mounting the stationary seal rings pay attention to pins in the seal cover If pins are incorporated the stationary rings with their grooves and bores must be pushed carefully over these pins W...

Page 18: ...are cut to size after the pump casing upper half has been screwed on to ensure that leakages are prevented on the gaskets of the mechanical seal covers Generally compressed asbestos fiber gasket of 1 0 mm thickness will be provided as gasket plate Recommended Spare Parts Spare parts should already be in stock at the client s for the initial startup In order to minimize down time we recommend to ob...

Page 19: ...ING 360 02 BEARING COVER INNER 652 OIL SLEEVE 361 BEARING END COVER 673 BREATHER 400 01 GASKET CASING 105 01 105 02 902 STUD GLAND 400 02 FLAT GASKET 361 350 920 HEX NUT GLAND STUD 400 03 FLAT GASKET 360 01 350 921 SLEEVE NUT 400 04 FLAT GASKET 360 02 350 923 BEARING NUT 412 O RING SLEEVE 940 01 KEY IMPELLER 452 GLAND 940 02 KEY COUPLING 458 LANTERN RING 71 72 COOLING CONNECTION ASSY 461 GLAND PAC...

Page 20: ...20 ZM II 630 03 ...

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

Page 22: ...of liquid different from specified value 17 Actual viscosity differs from specified value 18 Operation at too low capacity 19 Pumps are unsuitable for parallel operation 20 Strainer blocked 21 Actual temperature of fluid differs from specified value 22 Too fast temperature changes b Mechanical reasons 23 Foreign bodies in the impeller 24 Incorrect alignment 25 Foundation block too weak 26 Bent sha...

Page 23: ...fluids 40 Excessive thrust 41 Excessive oil in bearing housing blocking oil passages 42 Defective lubrication 43 Bearings incorrectly installed or damaged during installation 44 Dirt in bearings or lubrication system 45 Access of water into the bearings 46 Difficulties arising from the pump driver 47 Sealing rings of mechanical seal damaged 48 Incorrectly adjusted mechanical seal wrong spring tens...