Torishima Pump CAL User manual

PT. TORISHIMA GUNA INDONESIA
CAL
END SUCTION

CAL Standard Design
SAFETY PRECAUTIONS
Before using this machine, be sure to read this “SAFTY PRECAUTIONS” and the
appended “INSTRUCTION MANUAL” carefully for proper operation.
After reading through this paper, be sure to keep it in the place exposed to view at all time
for operators.
Concerning the safety precautions, this paper describes the contents of WARNING by the use
of the following symbols and signs.
Indicating the contents where a possibility of leading to serious results such as
danger of injuries which persons may undergo in cases of mishandling due to
neglect of this display is conceivable.
Besides the above, the following WARNING label is affixed to the safety cover (coupling guard) of body coupling unit
or its vicinity.
The contents given below should always be following since any of them covers important note
on safety.
WARNING
1. General
1) Never allow any persons other than service engineers to engage in disassembly or repair, or remodeling work.
2) Never work alone and be sure to put on helmet, safety goggles, ear plugs, safety shoes, etc. in conformity with the
Labor Safety and Health Law, etc.
3) Prior to carrying out any sparking work such as welding, etc., make sure that there are no dangers of fire and
explosion hazards.
4) Check the place where emission of toxic gas and deficiency of oxygen are conceivable, such as pit, manhole, etc.
before starting on works and make sure of safety.
5) When carrying out the work for centering check, disassembly, etc., be sure to turn OFF the motor switch and affix a
tag indicating “NO POWER ON” or the like to the switch so that the switch will not be turned ON by mistake.
6) Before starting on work, be sure to conduct checking of singing outfits such as crane, wire-rope. etc. unfailingly.
7) Install safety fences around the working area and secure an emergency passageway.
8) Since any splits oil on the floor, passageway, etc. may lead to a cause of slippage etc., wipe it off forthwith.

CAL Standard Design
WARNING
9) Shaft seal parts will not function to stop the pumped liquid completely. When handling such a liquid which may
cause serious troubles to the human body, therefore, do not touch the splashing liquid from shaft seal parts.
10) Keep away from the casing of the pump that is handling such a hot liquid as may lead to a danger of scalds if
coming in contact with the human body.
11) Do not gain access to rotating parts recklessly since there is possibility of scattering caused by breakage of rotating
parts.
12) If you lean against, or step on the guard, it causes damage to the pump, and may result in scattering.
13) Do not open the terminal cover of electric equipment (motor, etc.) in live status. Otherwise, you may get electric
shock.
2. Handling
1) Where both pump and motor are assembled on the common bed, never hang a wire-rope on the eyebolt of the
motor. Furthermore, do not gain access to the underside of the suspended pump.
3. Direct-coupling
1) Fasten the coupling guard securely at the specified position with mounting bolts.
4. Maintenance
1) When carrying out the work for replacement of gland packing or mechanical seal, be sure to turn OFF the motor
switch and affix a tag indicating “NO POWER ON” or the like to the switch so that the switch will not be turned
ON by mistake.
5. Disassembly and Reassembly
1) Before carrying out the disassembly work, be sure to turn OFF the motor switch and affix a tag indicating “NO
POWER ON” or the like to the switch so that the switch will not be turned ON by mistake.
2) To drain liquid from inside of the pump, close the suction valve and the discharge valve completely. If the liquid is
at a high temperature, drain the liquid through the drain valve after the liquid cools down almost to a room
temperature.
3) When the pumped liquid is a chemical solution, it may cause injury (inflammation, etc.) if it touches the human
body. To prevent this, make sure that the liquid in the casing is completely drained.
4) When removing parts and partly-assembled components, hang wire-ropes to the positions as shown in the
Instruction Manual and use a chain block, etc.
5) When handling hot components such ball bearing, coupling, etc., be sure to put on protective gloves.

CAL Optional Design
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Instruction Manual
Contents
Contents.......................................................................................... 1
0. General .................................................................................. 1
0.1. Quality Control Plan .................................................... 1
0.2. Nameplate .................................................................... 1
0.3. Transportation .............................................................. 2
0.4. Construction................................................................. 2
1. Installation............................................................................. 4
1.1. Installation of base plate............................................... 4
1.2. Direct coupling............................................................. 5
1.3. Piping........................................................................... 5
2. Operation............................................................................... 6
2.1. Starting......................................................................... 6
2.2. Stopping ....................................................................... 7
2.3. Start/stop frequency ..................................................... 7
3. Maintenance Control ............................................................. 7
3.1. General......................................................................... 7
3.2. Shaft seal...................................................................... 7
3.3. Meters and gauge ......................................................... 8
3.4. Bearings ....................................................................... 8
3.5. Sliding Clearance ....................................................... 10
3.6. When the pump is left unused for a long period......... 10
4. Disassembling and Reassembling ........................................11
4.1. General........................................................................11
4.2. Disassembling ............................................................ 12
4.3. Reassembling ............................................................. 12
4.4. Spare parts.................................................................. 12
5. Mechanical seal................................................................... 13
5.1. General....................................................................... 13
5.2. Outline of Construction Parts..................................... 13
5.3. Causes leakage from mechanical seal ........................ 18
5.4. Disassembling ............................................................ 18
5.5. Inspection and maintenance of disassembled parts .... 19
5.6. Reassembling ............................................................. 19
6. Gland packing ..................................................................... 21
7. Troubleshooting................................................................... 22
7.1. Pump cannot be filled with liquid. ............................. 22
7.2. Pump cannot start....................................................... 22
7.3. Insufficient discharge or incapable of pumping ......... 22
7.4. Motor overload........................................................... 22
0. General
Carefully read this Manual before operating the CAL pump.
Also, keep this Manual at an easily accessible place.
All the pump components are manufactured under the strict quality
control system to assure of their specific performance. However,
our compensation shall be out of application to trouble or damage
caused by the following.
(1) Operation of the pump under liquid quality, density and
temperature, and running conditions which are deviated
from those specified in the pump specifications.
(2) Pump damage which is caused by improper handling and
operation, incorrect installation, use of improper materials,
improper piping, etc. -- that is – by noncompliance with the
descriptive instruction given in this Manual
(3) Pump damages caused by natural disaster.
The long-term satisfactory running of any pump will be ensured by
proper installation, handling and operation.
When repair is required, it is recommended to repair the pump by
our skilled serviceman as far as possible or to return it to our
factory.
In this Manual, each part name is followed with parenthesized part
number, when deemed as necessary, to easily identify the
components and parts.
0.1. Quality Control Plan
All inspection and test for material, dimension, performance, etc.
are performed in the manufacturing process in accordance with
quality control plan (QCP) submitted to the purchaser when the
pump was ordered. Only pumps that have fully satisfied the
specified performance values upon inspection and test are allowed
for shipment.
0.2. Nameplate
Each pump is provided with nameplate.
When ordering spare parts or replacement parts, let us have the
following information stamped on the nameplate.
(1) Pump type & size, Product No.(expressed with AP******,
etc.), date of production, etc.
(2) Parts name, material and quantity included in the Sectional
Drawing and Spare Parts List.

CAL Optional Design
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0.3. Transportation
When transporting the pump directly coupled to a motor, apply a
wire rope to the pump and motor, as illustrated in Fig 0.3-1. (Do
not apply absolutely a rope to the eye-bolt of the motor.)
Fig 0.3-1
0.4. Construction
The CAL pumps provide single-stage, axial single-suction structure
for vertical (upward) discharge. The pump casing is of back
pull-out type with integral-casted axial suction nozzle and top
discharge nozzle and support foot. The pump can be disassembled
and internally inspected without removing the casing (1020) from
the piping.
Refer to Table 0-1 for a representative Pump Sectional Drawing.
Table 0-1 Pump structure
Pump structure Reference
figure
Mechanical seal (type of CA)
Oil lubrication (round oil gauge) Fig 0.4-1
Gland packing
Grease lubrication Fig 0.4-2
Mechanical seal
Oil lubrication (constant level oiler) Fig 0.4-3
Note1. The above figure is one structural example.
Note2. In the case of a mechanical seal of the option type, refer to Fig 0.4-3 .
Fig 0.4-1 Sectional Drawing (mechanical seal type is “CA”, oil lubrication with round oil gauge)