Ruhrpumpen CPP21 User manual

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
End Suction, Single Stage, Overhung
ANSI/ASME B73.1 - 2001
CPP21

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Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001
Installation, Operation, and Maintenance Manual – CPP21
FOREWORD
These units are horizontal process pumps of the overhung power frame configuration and identified by
Ruhrpumpen as CPP21.
It is recommended that the services of a Ruhrpumpen installation technician be employed for the installation
and initial starting of the pump. Such service will help to ensure the user that the equipment is properly
installed, and will provide an excellent opportunity for the plant operator to receive useful tips and guidelines
relative to the unit. The tools and/or equipment referenced in this manual are not supplied by Ruhrpumpen
unless specifically ordered. This pump design can be serviced with standard maintenance tools.
Instructions in this manual are written for trained, experienced technicians who are familiar with the basic
principles and tools involved in the installation, care and service of a pump and who, as part of their trade
education have acquired the ability to interpret and follow the detailed specifications required for such
installation, care, and service. Successful operation of the unit is dependent on careful study of the manual and
a well-planned maintenance program.
A complete reading of this manual by personnel in contact with the pump is essential to safety. Incorrect
installation, operation or maintenance can result in personal injury or death to personnel and damage to the
pump and plant.
Before performing any service function be certain that the unit is separate from its power source or that the
power source is locked out to prevent any form of energy from entering the equipment.
Contact with hot surfaces of the pump can cause severe burns. Care must be taken where such surfaces are
exposed. Care must also be taken to prevent ignition of flammable fluids or other material.
Information in this manual is believed to be reliable, but it is not guaranteed by Ruhrpumpen as to its
completeness or accuracy.
© 2010 Ruhrpumpen
All Rights Reserved.

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Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001
Installation, Operation, and Maintenance Manual – CPP21
CONTENTS
SECTION ONE - PRODUCT DESCRIPTION ....................................................................................................................5
1.1 INTRODUCTION ................................................................................................................................................5
1.2 PUMP CASE, IMPELLER, AND WEAR RINGS......................................................................................................6
1.2.1 Pump Case .................................................................................................................................................6
1.2.2 Impeller and Wear Rings ...........................................................................................................................6
1.3 CASE COVER......................................................................................................................................................6
1.4 BEARING FRAME...............................................................................................................................................6
SECTION TWO - SAFETY ..............................................................................................................................................7
2.1 IDENTIFICATION OF SAFETY INSTRUCTIONS IN THE OPERATING MANUAL.....................................................7
2.2 QUALIFICATION AND TRAINING OF OPERATING PERSONNEL .........................................................................7
2.3 HAZARDS IN THE EVENT OF NON-COMPLIANCE WITH THE SAFETY INSTRUCTIONS .......................................8
2.4 COMPLIANCE WITH REGULATIONS PERTAINING TO SAFETY AT WORK...........................................................8
2.5 SAFETY INSTRUCTIONS RELEVANT FOR OPERATION........................................................................................8
2.6 SAFETY INSTRUCTIONS RELEVANT FOR MAINTENANCE, INSPECTION AND ASSEMBLY WORK .......................8
2.7 UNAUTHORIZED ALTERATIONS AND SPARE PARTS..........................................................................................9
2.8 UNAUTHORIZED MODES OF OPERATION.........................................................................................................9
SECTION THREE - TRANSPORT & STORAGE ............................................................................................................. 10
3.1 SHIPPING ARRANGEMENTS........................................................................................................................... 10
3.2 UNLOADING AND CHECKING EQUIPMENT.................................................................................................... 10
3.3 TRANSPORT ................................................................................................................................................... 10
3.4 STORING ........................................................................................................................................................ 11
3.5 CONSERVATION ............................................................................................................................................. 13
SECTION FOUR - INSTALLATION .............................................................................................................................. 15
4.1 CONCRETE FOUNDATION PREPARATION ...................................................................................................... 15
4.2 LEVELING BASEPLATE .................................................................................................................................... 16
4.3 GROUTING ..................................................................................................................................................... 18
4.3.1 Equipment/Material Required ............................................................................................................... 18
4.3.2 Grouting Precautions.............................................................................................................................. 18
4.3.3 Grouting Procedure ................................................................................................................................ 18
SECTION FIVE - PIPING AND ALIGNMENT................................................................................................................ 21

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5.1 PIPING THE SYSTEM....................................................................................................................................... 22
5.2 ALIGNMENT* ................................................................................................................................................. 24
SECTION SIX - LUBRICATION.................................................................................................................................... 33
6.1 OIL LUBRICATION........................................................................................................................................... 33
6.1.1 Recommended Lubricant ....................................................................................................................... 33
6.1.2. Method of Application........................................................................................................................... 33
6.1.3 Quantity.................................................................................................................................................. 33
6.1.4 Maintenance........................................................................................................................................... 34
6.2 OIL CHANGE................................................................................................................................................... 34
SECTION SEVEN - OPERATION ................................................................................................................................. 36
7.1 PRIMING ........................................................................................................................................................ 36
7.2 STARTUP ........................................................................................................................................................ 36
7.3 OPERATING CHECK ........................................................................................................................................ 37
7.4 DOWELING (OPTIONAL)................................................................................................................................. 39
7.5 STOPPING ...................................................................................................................................................... 39
7.6 SHORT-TERM SHUTDOWN ............................................................................................................................ 40
7.7 LONG-TERM SHUTDOWN .............................................................................................................................. 40
SECTION EIGHT – MAINTENANCE............................................................................................................................ 41
8.1 DISASSEMBLY................................................................................................................................................. 41
8.2 INSPECTION AND CLEANING ......................................................................................................................... 42
8.3 REASSEMBLY.................................................................................................................................................. 43
8.3.1 Coupling Guard Assembly....................................................................................................................... 60
SECTION NINE - SPARE PARTS ................................................................................................................................. 64
SECTION TEN - PARTS INFORMATION ..................................................................................................................... 66
SECTION ELEVEN - TROUBLESHOOTING CHART...................................................................................................... 69

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Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001
Installation, Operation, and Maintenance Manual – CPP21
SECTION ONE - PRODUCT DESCRIPTION
These operating instructions contain important information about the installation, operation and service of the
unit. It is therefore imperative that the installing engineer and the responsible specialist/operating personnel
read and understand these operating instructions before installation and commencement of operation.
This manual must always be available in the operational area of the machine/plant.
Please contact a Ruhrpumpen representative should problems arise. The pump may only be opened by a
Ruhrpumpen approved technician during the guarantee period.
In case of queries, please have your project number and type designation of the pump available. You can find
both of these on the first page of these operating instructions or on the rating plate fixed to the pump.
When ordering spare parts we would further request that you give the description of the required parts,
together with their part numbers and identity numbers. You can find these on the sectional drawing and spare
part list enclosed.
1.1 INTRODUCTION
Ruhrpumpen pumps of type CPP21 are centrifugal pumps of the horizontal, vertically (radially) split case, foot
mounted heavy-duty construction with an overhung impeller, and are designed to meet the requirements of
ANSI/ASME B73.1 - 2001. These pumps are designed for continuous duty pumping of various fluids with
combinations of metallurgical, mechanical, and installation features for application in water, chemical and
industrial service.
The CPP21 is a single stage, end suction pump. For these pumps, rotation is clockwise as viewed from the driver
(coupling) end.
A spacer coupling is provided for accessibility of service and maintenance. The spacer permits back pull-out, that
is, complete removal of the rotating element without disturbing the piping or driver.
The following information is included in the nameplate of your pump unit:
•Serial number
•RPM
•Head
•Capacity
Please provide the pump Serial number when ordering parts; the information in the nameplate is relevant in
some sections of this manual to ensure safety operation of this pump.

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1.2 PUMP CASE, IMPELLER, AND WEAR RINGS
1.2.1 Pump Case
The pump case is foot mounted.
1.2.2 Impeller and Wear Rings
The impeller is dynamically balanced. The balancing is either single or two-plane, to meet the requirements of
ISO 1940 Grade 6.3. The impeller is threaded to the shaft.
1.3 CASE COVER
The case cover is designed to accept a wide variety of single or double mechanical seals and to comply with
ASME B73.1-2001 dimensional requirements.
1.4 BEARING FRAME
The bearing frame, which also serves as a large reservoir for oil lubrication, encloses the two ball type angular
contact thrust and deep groove ball radial bearings. The bearing frame, closed at each end by a cover and lip
seal or labyrinth seal, is cast with fins for air cooling but optional water cooling is available.
Frame Radial (Deep groove ball bearing,
single row)
Thrust (Angular contact ball
bearing, double row)
10 6208 5307 E
30A 6310 5310 E
30B 6311 5310 E
50 6314 5314 E
When purge or pure oil mist is specified, appropriate connections will be identified on the bearing frame. See
SECTION SIX - LUBRICATION for more details.
When water cooling is specified, a cooling coil is used.

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SECTION TWO - SAFETY
This operation manual gives basic instructions that should be observed during installation, operation and
maintenance of the pump. It is therefore imperative that this manual be read by the responsible
personnel/operator prior to assembly and commissioning. It must always be kept available at the installation
site. Not only are the general safety instructions contained under this SECTION TWO - SAFETY that must be
observed but also the specific information provided in other sections.
2.1 IDENTIFICATION OF SAFETY INSTRUCTIONS IN THE OPERATING MANUAL
Safety instructions given in this manual whose non-compliance would affect personal and equipment safety are
identified by the following symbol.
Where electrical safety is involved, the following symbol is shown.
The symbol is inserted in safety instructions whenever non-compliance might endanger the
machine or its function.
It is imperative that signs affixed to the machine are observed and kept legible, for example:
•arrow indicating the direction of rotation
•symbols indicating fluid connections
2.2 QUALIFICATION AND TRAINING OF OPERATING PERSONNEL
The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified.
The responsibilities and supervision of the personnel must be exactly defined by the plant operator. If the staff
does not have the necessary knowledge, they must be trained and instructed. Training may be performed by a
Ruhrpumpen representative on behalf of the plant operator. Moreover, the plant operator is to make sure that

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the contents of the operating manual are fully understood by the personnel.
2.3 HAZARDS IN THE EVENT OF NON-COMPLIANCE WITH THE SAFETY INSTRUCTIONS
Non-compliance with the safety instructions may produce a risk to the personnel as well as to the environment
and the unit and results in loss of any right to claim damages.
Non-compliance may involve the following hazards:
•Risk of injury or death.
•Failure of important functions of the machine/plant
•Exposure of people to electrical, mechanical, chemical, and thermal hazards
•Endangering or damaging the environment due to hazardous substances being released.
2.4 COMPLIANCE WITH REGULATIONS PERTAINING TO SAFETY AT WORK
When operating the pump, the safety instructions contained in this manual, the relevant national accident
prevention regulations, local and federal health and safety regulations, quality system requirements, and any
other service and safety instructions issued by the plant operator must be observed.
2.5 SAFETY INSTRUCTIONS RELEVANT FOR OPERATION
•If hot or cold machine components involve hazards, they must be guarded
against accidental contact (attach warning signs).
•Guards for moving parts (e.g. coupling) must not be removed from the machine
while in operation (mounting must be possible only with tools).
•Any leakage of hazardous fluids must be drained away to prevent any risk to
persons or the environment. Statutory regulations are to be complied with.
•Hazards resulting from electricity must be prevented.
2.6 SAFETY INSTRUCTIONS RELEVANT FOR MAINTENANCE, INSPECTION AND ASSEMBLY WORK
It is the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is

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Installation, Operation, and Maintenance Manual – CPP21
performed by authorized and qualified personnel who have adequately familiarized themselves with the subject
in matter by studying this manual in detail.
Any work on the machine shall only be performed when it is at a standstill. To shut off the machine it is
imperative to follow the procedure for shutting down the machine as described in SECTION 7.5-STOPPING.
Pumps and pump units that convey hazardous materials must be decontaminated before any maintenance work
is performed.
On completion of work all safety and protective facilities must be re-installed and made operative again.
Prior to restarting the machine, follow the instructions listed under SECTION 7.2-STARTUP.
2.7 UNAUTHORIZED ALTERATIONS AND SPARE PARTS
Modifications may be made to the machine only after consultation with a Ruhrpumpen representative.
Using spare parts and accessories authorized by Ruhrpumpen is in the interest of safety. The use of parts not
authorized by the dealer exempt the manufacturer from any liability, voiding the warranty.
2.8 UNAUTHORIZED MODES OF OPERATION
The reliability of the machine is guaranteed if and only if it is used in the intended manner, in accordance with
the statutes of this manual. The limit values specified in the data sheet must never be exceeded under any
circumstance.

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Horizontal End Suction Pump for Chemical Process, ASME B73.1-2001
Installation, Operation, and Maintenance Manual – CPP21
SECTION THREE - TRANSPORT & STORAGE
3.1 SHIPPING ARRANGEMENTS
The pump, coupling hub, and driver are generally shipped mounted on the baseplate.
A wooden skid is furnished for support and ease of transportation. Other required items (e.g. coupling,
hardware, spare parts, etc.) are boxed or secured to the skid.
3.2 UNLOADING AND CHECKING EQUIPMENT
The following steps should be completed for all pumps when received.
1. Handle all equipment carefully.
1. Remove unit only by properly supporting the wooden shipping skid.
2. After unloading, inspect the pump, check the shipment against the packing list, and report damages or
shortages immediately to freight carrier and to the designated Ruhrpumpen representative.
•Do not place lifting rig around bearing frame or under baseplate. Do not use the
eyebolt at the top of pump and bearing frame to lift unit.
3.3 TRANSPORT
•To avoid damage, the unit must be transported and handled with care. It should
be gently lowered onto an even surface. Pay attention to and indentify the signs
marking the points of equilibrium and fastening places for ropes, or the
openings for forklift trucks.
•Observe the plant’s safety precautions when lifting heavy components.
•When transporting with a crane, the rope should be slung round the unit as
shown below in Figure 3.1.
•The rope should not be slung around the lugs attached to the motor or around
the lugs attached to the pump.

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Figure 3.1 – Correct Position of the lifting ropes or chains.
3.4 STORING
If the pump is not installed immediately (within one month after shipping date), it should be safely stored prior
to installation in a dry location free of dirt and grit. Furthermore, the pump unit (pump, driver, etc.) should not
be subject to sudden temperature changes or vibrations.
Observe the following steps:
1. Remove pump from shipping crate, but do not damage the crate because the unit is to be reboxed.
2. Remove all instruments and mechanical seal; store them safely.
3. Plug the instrument taps.
4. Thoroughly dry the pump with hot air.
5. Any painted surface damaged in shipment should be repainted or sprayed with oil.
6. Keep the pump moisture-free by the following two means:
a. Spray the pump case, bearing frame with acid-free, moisture-free, protective oil or kerosene.
b. Place desiccant or humidor bags inside the suction and discharge areas of the pump.

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•Attach red tags with a “Remove Moisture Absorbent Material Bags Prior to
Installing” to warn about the presence of this desiccant material.
7. Cover all the openings with plywood or metal covers. Recheck the condition of thes covers every month
and replace as necessary.
8. If the pump’s external parts have protective coatings, periodically inspect and renew the coating as
required.
9. Rotate the shaft 1 ¼ revolutions every week. Lubricate shaft bearings prior to rotation.
•The client must keep a record of the weekly rotation of the shaft. Failure to
document and present these records as evidence will void the warranty.
10. Check the packaging for damage every month.
11. Ensure pump flange covers remain in place.
12. Return the unit to the shipping crate.
13. When the pump is to be installed, remove all the protective coatings and desiccant or drain all oils.
One month before installation, a Ruhrpumpen representative should be employed to conduct a final inspection.
To properly store the motor (driver) for periods longer than one month, follow these steps:
1. Store the motor in a clean, dry area, or cover it with a loose tarp (the tarp must be loose in order to
prevent condensation).
2. Exercise precautions to avoid transit or nesting of rodents, snakes, birds, and insects.
3. Inspect and, if necessary, recoat the rust preventive coating of external machined surfaces.
4. Fill with lubricant the grease-lubricated cavities of the motor, but first remove the drain plug and fill the
cavity until the grease starts to purge.
•Follow the instruction manual of the driver manufacturer to ensure the
lubrication is performed properly.
5. Upon receipt, considering that the oil-lubricated drivers are not shipped oil-filled, fill the reservoir to
maximum level with properly selected oil with rust and corrosion inhibitors.

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•Always drain the oil before moving the pump, to avoid any damages, and refill
the motor on its new location.
6. Rotate the shaft of the motor once a month.
7. Some form of heating must be used to prevent condensation. This heating should maintain the winding
temperature at a minimum of 9 °F (5 °C) above the surrounding ambient temperature. There are three
options:
oIf space heaters are supplied, they should be energized.
oIf none are available, single phase or “trickle” heating may be utilized by energizing one phase of the
motor’s windings with a low voltage, producing heat in the winding conductor.
•Request the required voltage and transformer capacity from the driver
manufacturer.
oA third option is to use an auxiliary heat source and keep the windings warm by either convection or
blowing warm dry air into the motor.
•Be careful not to overheat, since keeping the temperature of the motor frame
9 °F (5 °C) above the surrounding ambient temperature is sufficient.
After the storing period, follow the next steps as start-up preparations:
1. Motor should be thoroughly inspected and cleaned to restore to an “As Shipped” condition.
2. Motors, which have been subjected to vibration, must be disassembled and each bearing inspected for
damage.
3. Oil and/or grease must be completely changed using lubricants and methods recommended on the
motor's lubrication plate, in the “LUBRICATION” section of the driver manufacturer’s manual.
4. If storage has exceeded one year, the motor manufacturer’s Quality Assurance Department must be
contacted prior to equipment start-up for any special recommendations.
3.5 CONSERVATION
All exposed, machined, working surfaces (flanges, seals, surfaces supporting the motor), shaft ends, unpainted
couplings and the like have been cleaned and treated with anticorrosive agents. After being cleaned, all parts
inside the pump housing have been sprayed with anticorrosive agents.
The period of protection offered by these conservation measures is approximately 18 months if stored in a dry

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place. If stored under unfavorable climatic conditions, this protective period may be considerably reduced.
Should the anticorrosive layer become damaged, it can be repaired by repainting or respraying.
•Anticorrosive layers inside the pump housing must be removed with process
neutral solvents before commencing pump operation.
•When removing the protective coating with a neutral solvent, follow the safety
instructions of the solvent manufacturer carefully.
•The anticorrosive layer applied to the exposed parts does not need to be
removed before putting the pump into operation.

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SECTION FOUR - INSTALLATION
Correct and orderly installation/assembly is necessary for trouble-free operation of the unit. Ruhrpumpen does
not assume any liability for damage resulting from inadequate installation/assembly. The chosen location for
installation must offer enough space for maintenance activities.
4.1 CONCRETE FOUNDATION PREPARATION
1. Choose a solid ground location for foundation; check that the bearing capacity of the soil is at least one third
higher than both static and dynamic loads together.
2. The effects of vibrating equipment on the surrounding area should be investigated and the isolation
required for the foundation should be considered. It is important to consider that the driver and the driven
machinery must be supported from a common foundation.
•All foundation materials shall be selected to prevent deterioration due to
exposure to an aggressive environment; the use of a protective coating should
be considered.
•The mass of the concrete foundation should be five (5) to ten (10) times the
mass of the supported equipment.
•Imaginary lines extended downward 30 degrees to either side of a vertical line
through the pump shaft should pass through the bottom of the foundation and
not the sides, as shown in Figure 4.1.

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Figure 4.1 – Imaginary lines.
3. It is recommended to build foundation approximately 3 inches (76 mm) larger overall than the pump
baseplate to provide ample anchorage for the foundation bolts.
3.1. Since water can accidentally flow in the floor, a height for the surface of the foundation of 4 inches (100
mm ) at least above floor level is recommended.
4. Use a template to accurately locate foundation bolts according to the General Arrangement.
4.1. Choose foundation bolts of size specified in drawing (ASTM A36, M 1020 and ASTM A575 are
recommended); they should be long enough to allow a minimum of two threads above the nuts.
5. Provide pipe enclosures for the bolts, which are three or four diameters larger than the bolts.
6. Protect area around the bolts from contact with the concrete.
7. Pour the concrete and provide a chamfer at all corners.
8. Allow concrete to cure completely (at least seven days) before preparing the surface for grout preparation.
4.2 LEVELING BASEPLATE
Before leveling the unit onto the foundation, the following preparations must be made:
1. Chip away all damaged concrete with a hammer and chisel, eliminating about one inch of the
surface of the foundation. After surface chipping is done, the foundation shall be thoroughly cleaned
free of debris. Clean the anchor holes.
2. Check that the placement and dimensions of the foundation and the anchor holes correspond to the
assembly plan.

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The foundation must be kept free of all contamination after it has been prepared for grouting.
To continue with the leveling procedure:
1. Remove the pump and driver from the base to facilitate the leveling procedure.
2. Remove baseplate from wooden skid.
3. Attach lifting rig hooks to lifting holes of baseplate as described in
4. Guide baseplate to position above foundation bolts and lower baseplate into position over foundation
bolts; be sure to respect the above-mentioned clearance between concrete and baseplate.
SECTION 3.3-TRANSPORT.
•There should be a minimum annular clearance of 1/8 inch (3 mm) between
anchor bolt holes and the anchor bolts to allow for field alignments.
•Exercise proper caution when working under or around suspended objects.
5. Using a precision level across baseplate pads, adjust jacking bolts as necessary to ensure that baseplate is
level in all directions (See Figure 4.2), within 0.002 in/ft (0.2 mm/m).
Figure 4.2 – Baseplate leveling planes
•The alignment of the base plate is effected only with the help of adjusting
screws. Wedges may not be used for this purpose.
•NOTE: Each jacking bolt should have a mounting pad, to distribute the stresses

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evenly.
•NOTE: The baseplate should be mounted without distortion.
7. When baseplate is level, 'snug' the foundation bolt nuts, but do not tighten completely.
4.3 GROUTING
4.3.1 Equipment/Material Required
•Grout Mix: Non Shrink Type
•Sufficient lumber for foundation template and grout trough.
•Risers or funnels for guiding grout.
•Sufficient oil paint for grout protective covering.
•Dial indicator.
•One bracket, suitably stiff having an arm length of sufficient length to extend from the driver coupling hub
to the pump coupling hub.
4.3.2 Grouting Precautions
During all the grouting process, the involved personnel must follow these safety precautions:
1. Wear goggles or face shields, aprons, and protective gloves at all times.
2. Wear dust masks if in contact with the dry aggregates.
3. Wash hands regularly with soap and water.
•Some epoxy grouts have highly exothermic reactive properties; they should be
handled with care. They may become extremely hot and cause severe burns.
4.3.3 Grouting Procedure
1. Verify that anchored bolt sleeves are clean and dry. Fill them with a nonbonding moldable material to
prevent them from being grouted.
2. The anchor bolt threads should be protected with tape before grouting.
3. Provide a form around the baseplate to contain the grout. The form should be chamfered at all corners.

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•Grout forms should be attached with drilled anchors. Do not power nail.
•Apply three coats of paste wax to the inside surfaces of the forms in order to
prevent adherence. Do not use oil or liquid wax.
•Prevent grout leakage, as leaks will not self-seal.
Apply the grout. The use of push tools to get rid of trapped air is allowed if done in long strokes.
•Do not vibrate or violently ram the grout (it may cause the aggregates to
separate).
•Do not plug any baseplate fill or vent holes until the grout has set to avoid
baseplate distortion.
•Check with the supplier of the grout the preferred thickness for your
installation.
4. Tap baseplate to eliminate air pockets.
•It is imperative to get rid of all trapped air before the grout hardens.
•Check frequently for grout leaks.
•Leaks will not self-seal and may cause voids.
5. Remove jackscrews and grout-forms once the grout has completely hardened (takes around 3 days).
6. Do not use grout to fill the jackscrew’s holes; use a sealant material instead.
7. Tighten the foundation bolts with an appropriate torque value. In case of doubt, please contact your
Ruhrpumpen representative.
8. Apply oil paint to exposed grout to protect from air and moisture.

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9. Use a lifting rig to position the pump and driver on their baseplate so that the mounting feet line up with
their respective tapped holes.
10. Fasten the pump and driver hold down bolts, attach all auxiliary piping and wiring.