Sam AD Series Instruction Manual

1
OPERATION AND MAINTANACE MANUAL
AD, A B & TU SPLIT CASING PUMPS
SAM TURBO INDUSTRY PVT LIMITED
NEELAMBUR, COIMBATORE-641062, INDIA
PHONE: [phone],
E-MAIL: [e-mail]

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WARRANTY
We warranty that the pump supplied by us is free defective
material and faulty workmanship. This warranty holds good
for a period of 12 months from the date of commissioning of
the equipment or 18 months from the date of dispatch from
our factory, whichever is earlier.
Our liability in respect of any complaint is limited to replacing
part/parts free of charge ex-works or repairs of the defective
part/parts only to the extent 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.

3
SL.NO
CONTENTS
PAGE NO
1
GENERAL & FORWARD AND GUARANTY
2
STORAGE & PRESERVATION OF
PUMPS
3
DESCRIPTION OF PUMP
4
ERECTING THE PUMP
5
LAYING AND CONNECTING PIPES
6
LUBRICATION
7
STARTING AND STOPPING
8
SUPERVISION AND MAINTENANCE
STUFFING, BEARING
9
DISMANTLING AND ASSEMBLING
10
BILL OF MATERIAL
11
SECTIONAL DRAWING
12
TROUBLE –CAUSE - REMEDY

4
GENERAL
“AD, A B ” pumps are centrifugal single stag & double stage and “TU”
pumps are double stage single suction radial impeller . The complete
range of “ A B, AD & TU ” pumps are covered by 6 Power Series, thereby,
reducing inventory and achieving maximum interchangeability of parts.
Pumps when properly installed and given proper care-in operation and
maintenance should operate satisfactorily for a long period.
If equipment is to be stored for long periods of time (six months or more),
the following precautions should be taken to insure that the equipment
remains in good condition.
FORWARD AND GUARANTEE:
This erection and operating manual should in all cases be read by your
fitters before erection and start-up. We are not liable for damage incurred
through failure to observe the instructions for erection and operation. In
this connection we refer to our General Terms of delivery for centrifugal
pumps.
During the period of guarantee, repair work, and modification shall be
carried out by our fitters only, or following our approval in writing, it may be
done by you. If contrary to our 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.

5
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 every 12 months. They should be disassembled, cleaned and the
whole preservation process described below should be repeated
All inlet connections in the pump should be closed.
Suction and discharge flanges should be covered to prevent the
entry any kind of foreign environment
The surfaces to be preserved should be covered with the
preservatives suitable for storing environment.
Mechanical seals should be cleaned by compressed air. No other
liquid of material should be applied to the min order to prevent
damage to the secondary sealings and too-ring/gaskets.
Pumps waiting for the installation or start-up should be turned manually
every 15 days. If it is difficult to move the shaft by hand, use a suitable
spanner, by protecting the surfaces of the shaft at the point of operation

6
DESCRIPTION OF PUMP:
4. Pump Nameplate / Ordering Spare Parts / Spare Parts List
Every 'SAM' pump has a name plate giving following details:
Pump type
Serial Number / Year
Duty conditions (Head, Capacity)
Motor details ( KW & RPM ).
While you correspond with us for your requirements of spare parts or for
any technical information, please always quote the above details in your
letter.
Constructional Details:
SAM’s AD, AB are single volute & TU is double volute casing in axial split.
Split casing pumps have been developed for the most exacting conditions
and can be used for multitude operations such as Fan pump, stock feed,
stock circulation, centri-cleaner application in pulp & paper mills Storm
water, irrigation and Industries transfer works The wide passages in the
Suction Zone of the impeller with less number of vanes and non-clogging
design helps to handle stocks easily. Casing is split along the horizontal
centre line of the pump shaft, suction & delivery nozzles are being located
in the lower half. With this arrangement, it is not necessary to disconnect
suction or discharge piping to make repairs to, or replace the rotating
element. Upper and lower half casings are bolted together and doweled to
maintain a smooth volute contour inside the pump. water before it reaches
the shaft, in case drain Bearing brackets form a drip pocket for collecting
stuffing box leakage and are provided with drilled and tapped connections
for draining. The brackets also contain an overflow hole to release the
piping should become clogged. Suction and discharge flanges are drilled
and tapped for gauge connections. Pump suction and discharge nozzles
are drilled and tapped on the underneath side for complete pump drain.
Supporting feet are integrally cast in the lower half casing and are drilled
for bolting and doweling to base plate. Wear rings are provided to
minimize internal bypassing of the liquid being pumped, and to better
efficiency, as well as to reduce the replacement of major components (such
as casing and impeller). Bearings are grease lubricated.

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Direction of Rotation: Clockwise and Anti-Clockwise pump viewed
from driven end.
ERECTING THE PUMP: The assembly of the pump with the driver on a
common base plate is done in our works, the whole set will be carefully
mounted and aligned. It is necessary to check once more the alignment of
the coupling before putting the pump into operation. The eye bolts which
may be fitted to the driver must never be used to lift the complete set as
they are meant to carry the weight of the driver only.
2.
3.
4.
5.

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6. Grouting
7. Grout compensates for unevenness in the foundation and distributes the
weight of the unit uniformly on the foundation. It also prevents lateral
shifting of the base plate and reduces vibration. Use a non shrinking grout.
Foundation bolts 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 to prevent the base plate
from shifting, fill under the base plate at least four inches in from all four
edges. Wedges may be left in place.
4. After the grout has hardened (usually about 48 hours), thoroughly
tighten foundation bolts and check alignment.
5. Approximately 14 days after the grout has been poured or when it is
thoroughly dry, apply an oil base paint to exposed edges of the grout to
prevent air and moisture form coming in contact with the grout.

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Leveling the Base plate & aligning the Coupling:
Level accurately the base plate which carries the complete set with the aid
of a spirit level. Place metallic packing between the base plate and
foundation close to the foundation bolt holes. To prevent sagging of the
base plate, place metallic packing if required - also between the
foundation bolt holes. After leveling' the base plate fill up the foundation
bolt holes-with the bolts inserted .with a quick setting cement compound.
After leveling the pump set, measure the axial clearance between the two
coupling halves. Axial clearance between two corresponding points should
remain same when both couplings are turned through an angle. Maximum
permissible tolerance is 0.05mm. The permissible tolerance being 0.05mm
provided that the type of coupling is such as to allow this check figure 1
(a). Otherwise a coupling aligner must be used, permissible tolerance 0.05
mm figure 1 (b). 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 long radius type.
Pipes must line up naturally. The piping must never be pulled into position
by the flange bolts. Such action may draw the pump out of alignment.

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Pipes should be support independently of the pump so as not to put any
strain on the pump casing. Suction piping, if not properly installed, is a
potential source of faulty operation. Suction lines should be free of air
leaks, and arranged so there are no loops or high spots in which air can
be trapped. Generally, the suction line is larger than the pump suction
nozzle, and eccentric reducers should be used. Eccentric reducers are not
necessary for bottom suction pumps. If the liquid supply is located below
the pump centre line, the reducer should be installed with the straight side
up. Most often air enters the suction pipe entrained in the liquid.
Installations with a static suction lift preferably should have the inlet of the
vertical suction piping submerged in the liquid to four times the piping
diameter.
A large suction pipe will usually prevent the formation of vortexes or
whirlpools, especially if the entrance is flared. A floating vortex breaker
(raft) around the suction piping may be provided if a tendency appears for
a vortex to form at the liquid surface. A baffle placed in front of A stream
of liquid falling into the sump near the intake pipe will churn air into the
liquid. The supply line should extend down into the sump. Liquid supply
entering a well perpendicular to the intake line tends to rotate the liquid,
which interferes with short the supply pipe will remedy for this situation. A
elbow should never to bolted directly to the pumps suction nozzle.
The 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 used.
A straight branch header should never be used. Prior to installing the
pump, suction piping and pump should be inspected internally, cleaned
and flushed. If a strainer is installed in the suction line, the openings in the
screen must be checked and cleaned periodically. The opening must be
smaller than the sphere size allowed by the impeller.
The flow velocity in the suction piping should be 1.5 to 2.5 mts
/sec., for normal cases, but should not exceed 3 mts /sec

11
Discharge piping should be installed with check valve and gate valve, with
the check valve being between the pump and the gate valve. The check
valve prevents reverse flow and protects the pump from excessive
backpressure. The gate valve is used to isolate the pump for
maintenance, priming and starting.

12

13
Cleaning the piping and Suction Pit; after the piping has been
installed, it should be cleaned and emptied of welding waste, welding rod
ends and other foreign material. Likewise, the suction pit should be
thoroughly cleaned of all loose rubbish. AD, AB & TU pumps are Grease
lubricated design The grease-lubricated bearings have been lubricated
before shipment. For bearings the following greases are recommended
which are available in the market.
firm name 1450rpm 2900 rpm
INDIAN OIL SERVOGEM 3 SERVOGEM 2
CALTEX STARFAK 3 STARFAK 2
HIND PETROLEUM NATRA3/LITHON3 NATRA2/LITHON 2
GREASING FREQUENCY
SERVICE
GREASE
PERIOD
Normal, 8-hour day operation. Room free of dust and damaging
atmosphere.
6 Months
Severe, 24-hour day operation. Room with moderate dust and /
or damaging atmosphere, or outdoor service.
1 Month
Light, approximately 10-hour week. Room relatively free of dust
and damaging atmosphere.
1 Year

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AMOUNT OF GREASE FOR BALL BEARINGS
FRAME
GRAMS
MODEL
Gr-I
28
2AD 8, 2AD 11, 2.5 AD 13, 3AD 8, 3AD 10
Gr-II & III
39.2
3AD 15.5, 3AD 12, 4AD 8, 4AD 9.5, 4AD 11,
4AD 14, 6AD 8.5, 6AD 11
Gr-IV & V
84
4 AD 11.5, 4 AD 18.5, 6 AD 9.5, 6 AD 11.5, 6
AD 14, 6 AD 16.5, 8 AD 11
Gr-VI
112
8 AD 13.5, 8 AD 17, 10 AD 11.5, 10AD 13.5
GRAMS
MODEL
84
3TU 13
112
4TU 14
130
5TU 15
150
6TU 16
175
8TU 17
GRAMS
MODEL
84
6A 19B
112
8A 20 B, 10A 16B
130
10A 20 B, 14A 20B
150
12A 19 B, 14A 22B

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STARTING AND STOPPING
After coupling alignment and before bolting the coupling halves, check the
pump direction of rotation. Pump rotation is indicated by an arrow
attached to the casing assembly
STARTING:
1. pump shaft should rotate freely by hand.
2. Check the bearing lubricant
3. Open the valve in the pump suction line.
4. Close discharge valve
5. Prime the pump, If the pump operates under positive head, open vent
valve on top of the pump casing till all entrained air has escaped, close the
vent valves. Rotate the shaft, if possible, to allow any air trapped in the
impeller passages to escape.
6. If the pump operates on a suction lift and a foot valve is included in the
system, fill the pump and the suction line with liquid from an outside
source. Trapped air should be allowed to escape through the vent valve
while filling.
7. If the pump operates on a suction lift and no foot valve is provided, use
a vacuum pump or 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 few minutes.
10. The coupling guard should be in place when the unit is started. Stay
clear of any exposed rotating parts while the pump is operating. Contact
with rotating parts may result in injury to personnel.
11. Adjust the gland packing, until there is a slight leakage from the
stuffing box. Mechanical seals need no adjustment there should be no
leakage. pumps have limitations as high as 40-50% of the best efficiency
point.

16
STOPPING
The pump may be stopped with the discharge valve open without causing
damage. However, in order to
prevent water hammer effects, the discharge valve should be closed first.
1. Close discharge valve.
2. Stop driver.
3. Close water seal valves.
4. Close valve in the pump suction line. If danger of freezing exists, drain
the pump completely.
Minimum operating Flow;
All centrifugal pumps have limitations on the minimum flow at which they
should be operated. The most common limitation is to avoid excessive
temperature buildup in the pump because of absorption of the input
power into the pumped fluid. Other less understood reasons for
restrictions are:
1. Increased radial reaction at low flows in single volute casings.
2. Increased NPSHR at low flows.
3. Noisy, rough operation and possible physical damage due to internal
recirculation.
4. Increased suction and discharge pulsation levels.
5. The size of the pump, the energy absorbed, and the liquid pumped are
among the considerations in determining these minimum flow limitations.
For example, most small pumps such as domestic home circulators,
service water pumps and chemical pumps have no limitations, except for
temperature buildup considerations while many large, high horsepower
capacity.

SUPERVISION AND MAINTENANCE
Stuffing Box:
The purpose of a stuffing box is to limit or eliminate leakage of the pump fluid and
to prevent air from entering the suction spaces along the pump 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, there must
always be leakage of 100 drops/minute aproxi, but we recommend a steady
dripping of liquid through the gland. Stuffing box glands should be adjusted after
the pump is started. When leakage is excessive, tighten gland bolts evenly a little
at a time. Allow an interval for packing to adjust to new position. Never tighten
gland to be leak proof, as this will cause overheating and undue wear on shaft
sleeves. Replace stuffing box packing as follows:
1. Shutdown the pump.
2. Take precautions to prevent the driver from being inadvertently started.
3. Remove the gland bolt nuts and gland.
4. Remove and discard old packing rings –note location of lantern ring. When
repacking stuffing box, lantern ring must be positioned such that the water seal
connection is opposite lantern ring.
5. Clean out the stuffing box.
6. Inspect shaft sleeve, if it is scored or grooved, it should be replaced.
7. Make sure the st. box bushing (if furnished) is set at the bottom of the box.
8. Insert rings of packing and tap lightly to seat against bushing. Be sure rings are
of the proper size an length and installed with cuts staggered. Lantern ring must
be installed opposite sealing water connection.
9. Install gland and finger tight. While the pump running, adjust gland. Care
should be taken during the first hour of operation to take up on the packing
gradually just enough to maintain the required amount of leakage. If the pump is
operated continuously the packing should be renewed about every two to three
months before it gets hard and scores the shaft sleeves. Mechanical seals should
be removed, assembled, and/or adjusted according to the seal manufacturer's
instructions. There should be no leakage from the gland if mechanical seals are
used, except for a brief run in period.
Bearings:
Frequency of lubrication depends upon operating conditions and environment,
therefore, lubrication intervals must be determined by experience. Lubricants
need replacing only because of
contamination by dirt or dust, metal particles, moisture or high temperature
breakdown.
A small amount of grease may be added about every 400 hours of operation. The
bearing housing should be about 1/3 full of grease. 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. Solvents may be used more freely and effectively.
For cleaning bearings without dismounting, hot light oil at 180- 200F may be
flushed through the housing while the shaft is slowly rotated. Light transformer
oils, spindle oils, or automotive flushing oils are suitable for cleaning bearings, but
anything heavier than light motor oil (SAE 10) is not recommended. The use of
chlorinated solvents of any kind is not recommended in bearing cleaning.
Grease lubrication pumps are shipped with grease in bearing housings.
1. Thoroughly clean grease fitting and outside of bearing housing.
2. Remove drain plug.
3. Inject clean, new grease forcing out the old.
4. Start and run the pump for a short time to eject any excess grease.
5. Wipe off all excess grease and replace drain plug.
Wear Ring Clearance:
Running fits between wear rings is given under the pump specifications. When
these clearances are doubled, or the capacity of the pump is reduced by 5 to
10%, the rings should be renewed. The purpose of these rings is to keep internal
bypassing of the liquid being pumped to a minimum. Clearances should be
checked periodically and whenever the pump casing is opened. Check with feeler
gauge or by direct measurement. Measure ID of case ring and OD of impeller
ring, then compute clearance (ID minus OD).
DISMANTLING PROCEDURE
1. Remove the coupling guard and disconnect coupling halves.
2. Disconnect any piping from the upper half casing that will interfere with
its removal.
3. Remove the glands (Part no.17)and the gland bolts ( Part no.17B)
4. Remove the steady pin from casing.
5. Remove casing fixing bolts and the bearing housing fixing bolts from the
lower casing.
6. Drain oil from the bearing housing (Part no. 350) (oil lubricated ball
bearing units only).
7. Remove the outboard oil reservoir with bolting.
8. Screw jackscrews down to separate upper and lower case.
9. Lift upper casing ( Part no. 1A)straight up until clear of the impeller.
10. Place slings around the shaft near the bearing housings and lift rotating
element from lower casing
11. Place rotating element in a clean, dry work area for necessary
disassembly. Case wear Rings will be loose on assembly.

Disassembly of Rotating Element:
1. Remove the pump half coupling.
2. Detach bearing cover ( Part no. 35-inner & outer ) and separate
covers from the bearing housings.
3. Remove bearing housings inboard DE( Part no. 31).
4. remove bearing nut ( Part no.20&20 A) in AD & AB pumps
5. Remove packing ( Part no.13), lantern ring( Part no. 29), and stuffing
box bush (p.no. 63 if applicable) the number of packing rings on either
side of the lantern ring. For repair and removal of mechanical seals.
6. Loosen setscrews in sleeve nut ( Part no.20&20A) and unscrew the nut
from the shaft( Part no.6).
7. Remove o-ring ( Part no.130&130.1) with shaft sleeves( Part no.14)
8. Remove casing wear rings( Part no. 7&7A).
9. Disassembling rotating element.
10. Impeller (Part no.2&2A) with impeller rings can now be removed from
either end of the shaft. When removing the impeller, note the direction of
the vanes. The impeller must be installed with the vanes in the same
direction.
Remove Impeller Rings:
It is not necessary to remove the impeller from the shaft to replace the impeller
rings. First remove the rotating element. Remove the locking set screws from the
rings.
Inspection:
Visually inspect parts for damage affecting serviceability. Check o-rings and
gaskets for cracks, nicks, or tears; packing rings for excessive compression,
fraying or shredding, and embedded particles. Replace if defective in any way.
Mount the shaft between lathe centers and check eccentricity throughout the
entire length. Eccentricity should not exceed .002 inches (0.05mm). Bearing
surfaces should be smooth and shoulders
square and free of nicks. Measure OD of impeller hub or impeller wear rings and
ID of casing wear ring. Compute diametral clearance (ID minus OD) and compare
with clearance given under the
Pump Specifications.
Surfaces must be smooth and concentric. Examine impeller passages for cracks,
dents or embedded material. Examine shaft sleeves for wear.

Assembly of rotor & Pump assembly
Before assembling parts of the rotor, the bearings and the pump casing ascertain
that all surfaces are absolutely clean and without any dust particles. Before
mounting check that shaft run out value of 0.03 mm.
The parts should be as assembled in the following sequence.
1.Check the impeller vanes direction (P. no. 234) & along with wear rings fix on
the shaft( P. no. 211).
2.Fix the sleeves (P. no. 524) with O-ring (P.no. 412) at the both side of impeller.
3.Fix the sleeves nuts with hand tight (to be tightened after positioning the
impeller at the bottom casing).
4.Insert the thrower and inner bearing covers along with oil seals to both the shaft
ends.
5.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.
6.Fix the bearing on the DE side shaft and oil sleeve to be tightened with shaft
(set screw available in sleeve)Fix the casing wear rings in the bottom casing &
Insert the bearing housings on the bearings.
7.Fix the oil rings and insert the inner & outer bearing covers ( oil seal also fitted
in DE side) to bearing housing.
8.The complete set of rotating assembly to be placed with bottom casing ,
bearing housings should be carefully placed on locating pin. Tight the bearing
housing/ casing joint bolts.
9.Check the casing wear ring positions there is a locating pin available in the
casing/wear ring.
10.Check the impeller position if its touch with casing then to adjust the impeller
with help of sleeve lock nuts. After positioning the impeller the sleeve lock nut to
be tightened along with grub screw.
11.Fix the gasket on the bottom casing , mount the top casing , fit the casing
steady pin in that location. Top and bottom casing half’s with help of casing
joining bolts. Check the pump hand free rotation.
12.Fix the gland packings and lantern rings. After that split gland to be fitted with
pump. Connect the auxiliary pipings .
13.If bearing housing positioning bolts is available in the pump the special care to
be taken for adjusting the complete rotor set.
14.Shaft part No 6, Key-Impeller part No . 32, Impeller part No . 2 & With impeller
rings part No.8 in AB model, casing wear ring 7 in AD model and part no. 7&7A in
TU model pump.
15.When mounting the impeller, pay attention to the direction of rotation of the
entry of blade. Shaft Sleeve (part.no)14 with Sleeve nut part(no.20&20A) have
right-hand & left-hand thread