WEL-TECH CP Series User manual

An ISO 9001:2015
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [email protected]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 1 of 25
CP Series
Centrifugal pump
USER MANUAL
‘CP’ Series
W E L - T E C H E Q U I P M E N T S
Plot No. 57/9, Ph I, G.I.D.C. Vatwa,
Ahmedabad, Gujarat, India, 382 445
Ph. No. (079) 403258489925040029
E-mail:
[email protected]
[email protected]
Web : www.weltechpumps.com

An ISO 9001:2015
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Em [email protected]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 2 of 25
CP Series
Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General information and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Service and support
Inspection of delivered items
Lifting
Storage
General
Pump description
Application
Installation
Safety
Flushing
Environment
Mounting
Installation of the set
Assembly
Alignment of the coupling
Tolerances for aligning coupling
Piping
Mounting accessories
Commissioning
Precautions before commissioning
Preparation of lubrication
Preparing the unit for commissioning
Checking the sense of rotation
Starting the pump
Adjustment of shaft sealing
Stuffing box packing
Mechanical seal
Control
Installation guidelines for pump piping
Maintenance
Daily maintenance
Shaft sealing
Gland packing
Mechanical seal
Lubrication of the bearings
Grease lubricated bearings (L1,L2)
Oil-bath lubricated bearings (L3,L4)
Environmental influences

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 3 of 25
CP Series
Faults
Cause of failure
Trouble shooting
Fault finding chart
Possible causes
Technical data
Lubrication
Oil
Oil contents
Grease
Interchangeability chart for ‘CP’ series
Pump parts
Cross sectional drawing ‘CP’ series
‘CP’ pump part list
Cross sectional drawing ‘CP-A’ series
‘CP-A’ pump part list
Pump Disassembly

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 4 of 25
CP Series
Introduction
Preface
This manual provides the information for proper functioning and maintenance
of the pump and contains instructions to prevent possible accidents and damages
and to ensure the safe and smooth functioning of the pump.
Before commissioning of the pump, read the manual carefully and strictly follow the
instructions.
General information and safety instruction
The product supplied by WELTECH has been designed with safety in mind.
Pump installation area must be kept clean and free of obstructions that may
restrict safe access to the controls and maintenance access point
The pump nameplate is fitted to each unit must not be removed. Loss of it
could make identification impossible which in turn could cause difficulty in
obtaining spare parts. If accidental loss occurs, contact WTE immediately.
Access to the equipment should be restricted to the personnel responsible for
installation, operation and maintenance and they must be trained adequately
qualified and supplied with appropriate tools for their respective tasks.
All personnel that are responsible for installation-operation-maintenance of
the pump must study the product instruction manual before any work is done
and that they will comply with all local and industry based safety instructions
and regulations.
Safety glasses or goggles should be worn where working with pressurized
systems and hazardous substances. Other personal protection equipments
must be worn where local rules apply.

Do not wear loose clothing or jewelry which could catch on the controls or
become trapped in the equipments.
Read the instruction manual prior to installation and confirm that the manual is
relevant copy by comparing pump type on the nameplate and with that on the
manual.
Note the ‘limits of product application and permissible use’ specified in the
manual. Operation of the equipment beyond those limits will increase the risk
from hazardous and may lead to premature hazardous pump failure.
Clear and easy access to all controls, gauges, and dials etc. must be
maintained at all the times.
Hazardous or flammable material must not be stored in pump rooms unless
safe area or racking and suitable containers have been provided.

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 5 of 25
CP Series
Improper installation, operation or maintenance of this WELTECH product
could result in injury or death.
Warranty
WELTECH warrants the pump supplied by us is free from defective material
and faulty workmanship. This warranty holds good for a period of 12 months from the
date of commissioning of the pump 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 our arise solely
from faulty workmanship or defective material.
Warranty is void for Mech.seal if Brocken or dry run of pump.
This warranty holds good only for the products manufactures by us.
Service and support
This manual is intended for technicians and maintenance staff and for those
who are in charge of ordering spare parts.
This manual contains the spare and replacement parts recommended by
WEL-TECH EQUIPMENTS.
The pump number is stated on the nameplate. Please refer to this number
and the other data mentioned on the nameplate when corresponding or ordering
parts.
Inspection of delivered items
Check the consignment immediately on arrival for damage and conformity with the
advice note.
In case of damage and/or missing parts, have a report drawn up by the carrier at
once.
Lifting
If a pump or a complete pump unit has to be lifted, the slings should be fixed as
shown in figure 1.

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 6 of 25
CP Series
General
Figure 1 Lifting instruction pump set CP
Note: Proper care should be taken to protect pump and prime mover and/or
paint at contact area of sling or rope at the time of lifting.
Storage
In case the pump is not immediately being used, the pump shaft has to be rotated
manually twice a week.
Pump description
“CP” Pump is a range of horizontal non-self-priming centrifugal pumps
according to DIN 24255. Flange dimensions, bolt circle and number of holes comply
with DIN 2533 ND 16 and other standard as per request.
The pump is driven by a standard IEC foot motor. The power is transmitted through a
coupling.
Hydraulic range:
Delivery head up to 100 Mtr.
Capacity of up to 350 m3/hr.
1) THE BOOKLET COVERS INSTRUCTION FOR FOLLOWING MODELS OF “CP”
SERIES PUMP
SHAFT
GROUP
CP SERIES PUMP MODEL IN
CI/BRONZE
CONSTRUCTION
0
25
-
125
0+ 25-160,32-200s.
1 32-125,32-160,32-200,32-250,40-125,40-200,40-250,50-125,50-
160,50
-
200,50
-
200,
65
-
125
,65
-
160,65
-
200,80
-
160
2 65-250,80,200,100-160,100-200,125-250,200-200

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 7 of 25
CP Series
Installation
1. WEL-TECH “CP” Series are of back pull out design which enables to removes the
rotating unit of pump for inspection and repairs without disturbing the pipe
connection and motor by using spacer type coupling.
2. “CP” Series pump covers the range by four shaft group thereby reducing inventory
and achieving interchangeability of parts.
3. When the pump is received, sometime before the actual use of pump, it should be
inspected and located in dry place .the coupling should be rotated one in a month to
prevent pitting of bearing surface.
Application
In general, the “CP” pumps can be used for thin, clean, or slightly polluted liquids.
The liquids should not affect the pump materials. The maximum allowed system pressure
and temperature and the maximum speed depend on the pump type and the pump
construction.
Please do not use the pump for purposes other than for which it is delivered.
Safety

Read this manual carefully before installing and commissioning pump.
Non observance of these instructions may cause serious damage to the pump
and that will not be covered by our guarantee terms. Follow the instructions step
by step.
Make sure the motor cannot be started when work is done to the pump-motor
combination and running parts are insufficiently shielded.
When installing the pump unit, take appropriate protection and warning measures
to prevent contact with hot pump parts.
If danger arises in case of static electricity. The entire pump unit should be earth
properly.
If there is a danger that the pumped liquid might be harmful to men or the
environment, the user should take appropriate measures for safe drainage. Also
possible leakage fluid from the shaft seal should be safely discharged.
Flushing

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 8 of 25
CP Series
Before putting the pump in to operation, drain off any preservative agent and flush
the pump thoroughly with hot water.
Environment
The foundation must be hard, level and flat
The area in which the pump unit is to be placed should be adequately ventilated.
A too high ambient temperature and air humidity, as well as a dusty environment
may have a negative effect on the functioning of the pump.
Around the pump unit there should be enough space to operate and if
necessaries repair the pump.
Behind the cooling air inlet of the motor there should be a free area of at least ¼
of the electric motor diameter, to ensure unobstructed air supply.
Mounting
Installation of the set
Pump and motor shafts of complete sets are adjusted perfectly in line in the
works. In case of permanents arrangements place the base plate on the foundation
with the aid of shims and tighten the nuts on the foundation bolts carefully.
The check the alignment of pump and motor shafts and realign, if necessary
according to the instruction in Figure 1.
Assembly
If the pump and the electric motor still have to assembled, proceed as follows:
1. Mount the two coupling halves on the pumps and motor shaft respectively
2. Place the pump on the foundation slab. Secure the pump with bolts.
3. Place the electric motor on the foundation slab. Between the two coupling halves
there should be a gap of 3 mm.
4. Place some copper shims under the feet of the electric motor. Secure the electric
motor with bolts.
5. Align the coupling according to the following instruction.
Alignments of the coupling
1. Place a ruler (A) on the coupling. The ruler should touch both coupling halves across
the whole width. See figure 3.
2. Do the same check against both sides of the coupling near the axis.
3. For all security the alignment is also checked with a pair of outside calipers (B) at 2
diametrically opposite points of the side surfaces of the coupling halves. See fig.3

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 9 of 25
CP Series
Figure 3 Aligning of the coupling for SM
Tolerances for aligning coupling
The maximum allowable tolerances in the alignment of the coupling halves are
shown in the table below. See figure 4.
Va
Va
Vr
min
max.
Figure4
Aligning tolerances:
Outer diameter
Coupling (mm) Va min. (mm) Va max. (mm) Va max-Va min. (mm) Vr max (mm)
81
-
95
2
5*
4
6*
0.15
0.15
96-110 2 5* 4 6* 0.18 0.18
111-130 2 5* 4 6* 0.21 0.21
131-140 2 5* 4 6* 0.24 0.24
141-160 2 6* 6 7* 0.27 0.27
161-180 2 6* 6 7* 0.30 0.30
181-200 2 6* 6 7* 0.34 0.34
201
-
225
2
6*
6
7*
0.38
0.38
*= for spacer coupling.

An ISO 9001:2008
Certified company
WEL
-
TECH EQUIPMENTS PVT.LTD
MFR.OF INDUSTRIAL CENTRIFUGAL PUMPS
Regd .Office & works : Plot No : 57/9 , Phase-1 , Nr.Kiran Industries ,G.I.D.C ,Vatva , Ahmedabad-382445, Gujarat , India
Phone : [phone] Email : [e-mail] , [e-mail]
Web : www.weltechpumps.com
_________________________________________________________________________________
Page 10 of 25
CP Series
Commissioning
Piping
The piping to the suction and delivery connections must fit exactly and must not be
subject to stress during operation.
The passage of the suction pipe must be amply dimensioned. This pipe should be as
short as possible and run towards the ump in such a way that no air pockets can
arise. If this is not possible, a venting facility should be provided at the highest point
of the pipe.
If the inside diameter of the suction pipe is larger than the suction connection of the
pump, an eccentric reducer should be applied to prevent air pockets and whirls.
If there is a risk that this pressure might be exceeded, for instance because of an
excessive inlet pressure, appropriate measures should be taken by mounting a
safety valve in the piping.
Sudden changes in the rate of flow can lead to high pressure impulses in the pump
and the piping (water shock). Therefore, don’t use quick acting closing devices,
valves etc.
Mounting accessories
Mount any parts that may have been supplied separately.
If the liquid does not flow towards the pump, mount a foot valve at the bottom of
the suction pipe. If necessary, combine this foot valve with a suction strainer to
prevent impurities from being drawn in.
When mounting, place temporarily (for the first 24 operating hours) fine gauze
between suction flange and suction pipe so as to prevent internal parts from
being damaged by foreign matter. If the risk of damage continues to exist, mount
a permanent filter.
In case of a pump with a cooled stuffing box (shaft sealing variant S4), connect
the cooling chamber to the cooling system.
Precaution before commissioning
Pump
Construction with stuffing box: whether the gland nuts have not been over tightened.
If necessary, loosen the gland nuts and retighten them by hand.
Check whether the shaft turns freely. Do this by turning the shaft end at the coupling
a few times by hands.
Motor