VERTICAL CANTILEVER SHAFT SUMP PUMP (PPCS)_

METALLIC

INSTALLATION,
OPERATION AND MAINTENANCE
MANUAL

PROCESS PUMPS (INDIA) PVT LTD

Plot No.86, III Phase, Peenya Industrial Area, Bangalore – 560058
Phone: 91-80-28395327/28
Fax: 91-80-28395807
WEBSITE: www.process-pumps.com
E-mail: contact@process-pumps.com
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

CONTENTS

1.0 INTRODUCTION
2.0 SCOPE OF SUPPLY
3.0 HANDLING
4.0 STORAGE
5.0 INSTALLATION
5.1. ERECTION
5.2. FOUNDATION
6.0 PIPE WORK INSTALLATION
7.0 STARTING THE PUMP
7.1. PRE START CHECK UP
8.0 OPERATION OF THE PUMP
9.0 CORROSION
10.0 STOPPING THE PUMP
11.0 DIRECTION OF ROTATION
12.0 DISMANTLING PROCEDURE
13.0 REASSEMBLING
14.0 ROUTINE MAINTENANCE SCHEDULE
14.1 WEEKLY MAINTENANCE
14.2 BIANNUAL MAINTENANCE
15.0 TROUBLE SHOOTING
16.0 RECOMMENDED SPARE FOR TROUBLE FREE OPERATION

Date: 12.12.2010

2
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

SAFETY PRECAUTIONS

Please follow all safety norms as required for assembly of heavy

mechanical rotating equipment. Ensure that electric power is not connected to
the pump until all preliminary checks have been completed.

Before starting the pump ensure that the suction line is clean and
completely free of any blockage.

3
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

1. Introduction

The PPCS Pump is a single stage, vertical end suction Centrifugal

Cantilever shaft Pump fitted with either a closed or semi open impeller. For
handling clear liquids, a closed impeller is used where as for handling liquids
containing solids a semi- open type impeller is preferred. The pumps are
designed to ISO and API standards. The drive from the electric motor is
transmitted to the pump through a spacer type flexible coupling.
1.1 Construction Details

a) Impeller Casing: The casing of the PPCS Pump is concentric metallic

volute.
b) Impeller: The impeller with the PPCS Pump is either full open or closed
depending up on the fluid used. The impeller has integral curves vanes
and the rear hub of the impeller is attached to the shaft by key way.
c) Motor End: This consists of a motor, coupling, motor mount, thrust
bearing, Shaft and it is also attached to the mounting plate.
d) Bearings: The pump consists of a Double row angular contact ball
bearing to take the thrust loads and some of the radial loads.
e) Discharge pipe: The discharge pipe is terminated in a circular flange
with bolt holes for connection to the customer’s equipment.

2. Scope of Supply

The pump is supplied with the following accessories as a standard practice

a) Gland Packing
b) Coupling
c) Mounting Plate
d) Discharge Pipe

4
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

3. Handling
On receipt of consignment please check and ensure the following:
a) That the Tally plate details are in accordance with your order.
b) All the accessories are as per the packing list.
c) All the components have been received in a good condition.
d) The shaft can be turned by hand easily. If heavy resistance is felt or the
pump doesn’t rotate this means that the equipment is damaged in
transportation.
e) Discrepancies if any must be immediately reported.
f) Packages should not be dropped or rough handled to prevent damage to
the pump and motor.

4. Storage
The place of storage should be well ventilated and protected from dust,
heat, moisture and rain etc.
In case the pump is not installed with in a period of three months then please
follow the following precautions:
a) Check that the bearings are properly lubricated.
b) The external surfaces are free from rust peeling of paint etc.
c) Rotate the shaft at least once every two weeks to make sure that the shaft
and bearings are free.

For maintenance of motor please refer to the motor manufacturer’s manual for
their recommendations and instructions.

5
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

5. Installation

5.1 Erection
All external parts of the pump and motor must be thoroughly cleaned
before erection begins.
5.2 Foundation

The pump should be installed on a tank flange or a concrete foundation

properly fitted with grouted foundation bolts. The foundation must be designed
to absorb all the loads forces and vibrations and provide a proper support to the
Mounting plate of the pump. This is important in maintaining the alignment of
the unit with respect to the pump shaft position, piping and the driver shaft.
The Mounting plate of the pump must be leveled using a spirit level by
taking readings at 0°, 90°, 180° and 270° such that the shaft centre line is with
in one are minute of the mounting plate. The level can be adjusted by inserting
shims between the bed and mounting plate accompanied by a gentle tightening
of the foundation bolts.

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

PROCEED UNTIL THIS CONDITION IS RESOLVED”

Twelve numbers of φ17 holes are provided on the mounting plate for fastening
to the bed with M16X50 bolts and nuts.

6
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

6. Pipe work installation

The discharge pipe must be supported independently near the pump to

avoid undue loads on the discharge pipe. Care must be taken to ensure that no
piping strains are transmitted to the pump as this may cause misalignment.

It is preferable to use the suction piping of one size lager diameter than
the pump suction size. Don’t use a discharge pipe diameter lower than the
actual pump discharge pipe diameter.

7. Starting the Pump

7.1 Prestart Check up

Rotate the coupling by hand. The shaft should rotate freely, with no
resistance in any position. The pump should always be run in the direction
indicated by the arrow provided on the bearing housing.
The pump has to rotate in the clockwise direction when viewed from the
top. If the pump runs in the reverse direction, the lock nut unscrews and which
in turn damage the impeller and shaft. Phase sequence motor has to be used to
get desired direction of rotation.
If motor is operated through Star-Delta starter, then run for a moment in
star position to check the direction. Wiring to the motor terminals and starter
should be checked. Direction of rotation of incorrect must be corrected by
reversing two of the starter leads.
Delivery valve should be closed before starting the pump. On acid or
organic liquid service the pump should not be run with the delivery valve
closed for more than few seconds because the increase in temperature of the
liquid may be harmful. The pressure indicated in the delivery gauge should go
up steadily.

7
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

8. Operation of the Pump

The desired capacity is to be set by throttling the discharge valve.

Operating the pump at the point other than the specified duty point have an
adverse effect on the performance of the pump.
The running of the pump can be checked by observing the Voltage (by
volt meter), Pressure (by Pressure Gauge), Current (by Ammeter) and Speed
(by Tachometer). Before stopping the pump discharge valve must be closed.
Then motor is switched off.

9. Corrosion

The material of construction of the pump has been selected after

careful study of the liquid to be handled, its composition, its corrosiveness,
specific gravity, pH, temp, solid content, particle size, viscosity, etc. A slight
variation in any of the above factor can cause severe corrosion of the wetted
parts.
Therefore it is necessary that ample care be taken to ensure with
every fresh batch of liquid that its properties are the same for which
the pump originally is meant.
When number of pumps with different materials of construction have
been supplied for different duty conditions great care must be taken to ensure
that the right pump is put to in service.
Operating the pump at the point other than the specified duty point
might also have an adverse effect as far as the corrosion is concerned. Spare
parts of the same original material are to be used while parts are replaced to
avoid the formation of galvanic cell, which initiates corrosion.

8
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

10. Stopping the Pump

Before stopping the pump the discharge valve must be closed. The
motor is switched off.

11. Direction of Rotation

The pump should always be run in the direction indicated by the

arrow provided on the bearing housing. The pump has to rotate in the
clockwise direction when viewed from the motor fan side.

9
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

12. Dismantling Procedure

Total Assembly of the Pump is shown in Figure 12.1

Figure 12.1

10
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Step 1:
a) Remove the coupling between the pump shaft and motor
b) Remove the Motor as shown in Figure 12.2 below

Figure 12.2

Step 2: Lift the Pump along with Mounting Plate keep it horizontally on the table
11
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Figure 12.3
Step 3: Disconnect the delivery pipe and remove the Impeller Casing by
loosening the bolts.

Figure 12.4

12
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Step 4: Hold the shaft tightly at the coupling end and loosen the Impeller Nut
by rotating in anticlockwise direction.

Figure 12.5
Step 5: Pullout the Impeller and Backplate.

13
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Figure 12.6
Step 6:
a) Unscrew the bolts holding the Mounting plate and column pipe.
b) Unscrew the bolts holding the column pipe and Intermediate support.
c) Unscrew the bolts holding the column pipe and Gland housing.
d) Unscrew the bolts holding the Intermediate support and Housing
support.
e) Unscrew the bolts holding the Intermediate support and Bearing
housing.
f) Unscrew the bolts holding the Bearing housing and housing support.
g) Unscrew the bolts holding the Housing support and coupling chamber.

14
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Figure 12.7

Step 7:
a) Separate the Mounting plate from column pipe.
b) Separate the column pipe from Intermediate support.
c) Separate the Intermediate support from Housing support.
d) Separate the Housing support from coupling chamber.

15
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Figure 12.8
Step 8: Pull out the shaft along with the bearing housing

Figure 12.9

16
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Step 9:
a) Unscrew the align bolts of gland housing cover & gland housing.
b) Remove the gland cover and remove the gland packing.
c) Separate the drive end oil seal and bearing cover from drive end
bearing housing.
d) Unscrew the bearing lock nut and push the bearing housing down.
This will expose the Bearing.

Figure 12.10

17
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

Step 10:
a) Separate the far end oil seal and bearing cover from far end
bearing housing.
b) Separate bearing housing from the far end bearing.

Figure 12.11
Step 11:
a) Separate the bearing housing
b) Separate the bearing from the shaft

18
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

13. Reassembling:

For reassembly we have to do the reverse of the above procedure.

14. Routine Maintenance Schedule

14.1 Weekly Maintenance

• The pump has to be checked weekly for bearing temperature,
discharge, pressure, undue noise or vibration.

14.2 Biannual Maintenance

• For every Two years the pump has to be dismantled and the following
checks should be carried out to avoid any extensive damage or
replacements or total breakdown at a later stage.
• Pumps are supplied with the grease-lubricated bearings. Proper grade
of grease should be provided at intervals.

19
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

15. Trouble Shooting

In the event of failure of any component or assembly, the primary cause

of failure should be established before renewing the defective parts.

Symptoms Possible cause Remedy

1. Pump fails to start.
No supply to motor or
Check power supply.
power failure.
Dismantle and

Seizure of motor or overhaul as necessary.
Pump
2. Pump fails to lift
Clogging of the
Clean the suction
liquid. suction strainer or strainer or discharge
discharge line line.
3. Pump fails to
Pump running at low
Check the speed.
maintain speed.
discharge
Suction strainer
Clean the suction
Pressure. choaked. strainer.
4. Pump delivers
Low speed.
Check the speed.
insufficient capacity
5. Excessive
Foreign material
Remove the foreign
Motor vibration. trapped in the pump material.
cavity.
Check the pipeline.

Incorrectly supported
pipeline.
6.Bearing over heating
Insufficient
Check the bearing
lubrication. lubrication.

Bearing defect
Renew the bearing.

Misalignment
Check the alignment.

20
 VERTICAL CANTILEVER SHAFT PUMP ( PPCS )

16. Recommended Spare for Trouble Free Operation

1) Impeller Casing (Part No 1)
2) Impeller (Part No 2)
3) Shaft Coupling Unit (Part No 25)
4) Gasket (Part No 15)
5) Oil seal (Part No 18, 20, 21 and 24)

21