INSTRUCTION ON

INSTALLATION AND OPERATION

OF TYPE SAP PUMP

Hunan XEMC Changsha Pump Works Co., Ltd

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 CONTENT

Chapter 1 General
1. Construction
Chapter II Installation
1. Goods check
2. Storage
3. Handling
4. Pump cleaning
5. Installation position
6. Foundation
7. Base plate adjustment
8. Calibration
9. On-the-spot motor installation
10.Pipeline
11.Discharge pipe
12.Suction filter gauze
ChapterIII Check before start-up
1. Stuffing
2. Motor preparation and lubrication
3. Bearing
Chapter IV Operation
1. Pump start-up
2. Shut-down
3. Operation check
Chapter V Maintenance
1. Stuffing change
2. Pump disassembling procedure
3. Parts inspection
4. Split casing inspection
5. Pump reassembling
6. Possible troubles and remedies

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Chapter 1 General

Type SAP belongs to single-stage double suction split centrifugal kind. It is used to transmit
clear water without solid particles or other liquids similar to clear water physically and
chemically with the temperature of 0oc-80oc and suitable for drainage project and feed pump
in factory, city, mine, waterworks, field irrigation and water conservancy.
Description of pump symbol figures: (for example)
10SAP-6JA
10 --- The number, obtained from the inlet diameter divided by 25
SAP --- Single-stage double-suction split centrifugal pump
6 --- The number, obtained from the specific speed divided by 10.

J－The pump rotation speed change

A－The pump impeller diameter change

1. Construction
1. The main parts of this pump casing are the upper casing, lower casing and wearing ring etc..
It is to be assembled horizontally. Pump casing is separated by the shaft centerline into upper
casing and lower casing. Both the inlet and the outlet of the pump are on the pump casing
which is vertical to the axis. There is no need to disturb inlet pipe and discharge pipe when
overhauled. After opening the upper casing and taking out the rotor, you can easily overhaul
and replace relative parts.
2. The main parts of the rotor are shaft, impeller, shaft sleeve, lock nut, interstage sleeve and
water deflector ect.. All the parts on the shaft are locked by round nut and protect the whole
main shaft to improve the life of shaft. The axial power on the rotor is balanced by impeller
itself. The rest axial power is supported by the angular contact roller bearing.
3. Bearing is rolling bearing with spread-oil ring and lubricated by mechanical oil sealing.
The bearing is mounted on the bearing bush so that it is easier to replace the parts on the shaft.
The sealing of bearing end cover is mazily sealing. The bearing is cooled by cooling water
and is equipped with bearing thermometer and auto-oil-delivery meter.
4. Shaft sealing has two types for the customer’s choice. They are soft stuffing sealing and
mechanical sealing. Stuffing sealing comprises stuffing sleeve, stuffing ring, stuffing and
stuffing gland. The cooling and lubrication of the stuffing parts is finished by water sealing

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pipe drawing the water from pump itself. Mechanical sealing comprises parts of non-
balancing mechanical sealing and gland. The water for cleaning mechanical sealing parts and
cooling water are drawn from internal pump by water sealing pipe. It can also be finished by
the external water.
5. Water sealing pipe is comprised of water sealing pipe, elbow and sluice valve.
6. This serial pump has flexible pin coupling and is driven directly by the electric motor.
7. Rotating direction of pump: the rotation direction is counter clockwise looking from motor
end, Pump’s inlet is on the leftside and outlet is on the rightside. At the customer’s request,
the motor end can be moved to the other end. At this circumstance, the rotating direction is
clockwise. Pump’s inlet is on the rightside and outlet is on the leftside.

Chapter II . Installation
Note
The pipeline system, foundation and other parts of the equipment are not designed by our
works, so they don’t fall into our responsibilities. Anyhow we’d like to offer you some
materials and suggestions. But we are not responsible for the design and operation.
We suggest that customer should seek advice from designing specialist and design institutions
who are good at foundation, pipeline installation, oil groove and relative devices to
supplement and explain the material offered by pump works and ensures the success of
installation.
1. Arrival check
Check on equipment should be taken immediately before acceptance. When find any defects
due to shipment, please inform the carrier as soon as possible. Please be careful when unwrap
the package (see handling clause). Instruction of pump, instruction of other parts(such as
electric motor) and packing list should be included in package. All these documents should be
put in a safe and convenient place for reference at any time. Please master the whole manual
before installation. The spare parts of pumps can be put under separated package. Please
check the pieces before pick up goods.
2. Storage
Pump should always be kept from corrosion during storage and installation period. If the
pump need to be laid aside for a period of time before installation, please put it in a both dry
and clean place with smooth storage position and avoidance of squeeze. Please do not open
the upper casing. If the storage period is too long, the rust preventing action should be taken.
Put the pump in non-corrosive place.

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3. Handling
Please be careful when remove the pump. It may cause pump’s damage and permanent
maladjustment when wrongly handled. Be careful not to damage and deform the water pipe
when lift up the pump.
Enough lifting capacity is necessary for the equipment, which are used to lift up pump or
other component part.
4. Pump cleaning
Pump cavity should be cleaned with clean water before operation. Be sure to get rid of rust
and sundries accumulated during transportation, storage and installation. The pump has to be
disassembled, cleaned and checked before operation if it has been laid aside for more than six
months.
5. Installation position
The proper installation position of pump should be as close as possible to the source of liquid
pumped. Please ensure proper room for operation, maintenance, disassemble and check.
Take main pump house into careful consideration and make sure that the pump house has
equipment and auxiliary equipment with sufficient lifting capacity. When the pump is driven
by electric motor, the influence to the equipment by environment should be taken into
consideration. The house is required to be ventilated and avoidance of over-heat or over-
moisture.
6. Foundation
The foundation should be strong enough to absorb pumps vibration and to support the whole
unite permanently. We generally use reinforced concrete to make foundation which has to
support the weights 1.5 times as that of the wholes unite(including electric motor). The foot
bolts are suggested to be fixed in concrete. For fear of rotation, please weld a big gasket with
protrusion on the foot of the blot and casing pipe. The foundation plane of the first time
pouring-cement-mortar should be 20-40mm lower than the lower plane of the base plate, for
the convenience of the second time pouring-cement-mortar.
7. Base plate adjustment
Put the equipment on the foundation. Then use spacer to level up the base plate and use the
level to check the horizontal degree. After fastening the foot bolt, recheck the horizontal
degree of base plate with level. Adjustment is required if necessary.
8. Calibration
The concentricity of pump and electric motor is very important. Although pump and electric
motor are assembled together in works, the pump may not be concentric with the electric

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motor for the deform of base plate during shipment period and deform of pipeline. So it is
necessary to recheck the concentricity before operation.
After fixing the pump casing with base plate, take out the coupling bolt and check the angular
deviation with micrometer. Generally speaking the clearance between the pump and electric
motor coupling is 3~5mm. Check the distances between two couplings every 900 and check
the radial shift very 900 across two couplings with ruler. The error value of shift is measured
by plug gauge.
9. On-the-spot electric motor installation
Key: Check the eccentricity of electric motor. The eccentricity of rotors should be checked
when the pump and motor are installed in works. The eccentricity of motor coupling should
be checked during the adjustment of installation of pump and electric motor. It was common
that the shaft was damaged when the on-the-spot motor installation is devoid of check of shaft
eccentricity.
10. Pipeline
After installing equipment, please connect the suction pipeline with discharge pipeline. It is
not allowed to use the pump as pipeline support. All the pipelines can’t be supported by pump.
Keep pump from any pressure when install accessories. More straight pipes or less elbows are
better when connecting pipeline. The straight pipe before and behind inlet and outlet should
be 5~10 times as long as the pipe diameter when using elbow, after which please recheck the
adjustment of equipment according to the requirements mentioned above.
11. Discharge pipe
Discharge pipe should be one size larger than discharge opening. It is generally better to
install a sluice valve and check valve on the discharge pipe, for check valve can avoid damage
to pump by return-flow when shut down and the sluice valve can help to draw water and help
pump with start-up. For the convenience of check, check valve should be fixed between sluice
valve and pump. Our works is not responsible for the damage caused by non-installation of
check valve.
The exception: large capacity and low head such as:
condensate circulating pumps and pumps for irrigation can be devoid of check valve.
12. Suction filter gauze
It is critically important to prevent rotors from being damaged by sundries in the new pipeline.
To get rid of sundries, install a filter gauze whose valid area should be larger than sectional
area of suction pipe as close as possible to the pump suction on the suction pipe. To measure
the resistance of filter gauze, fix manometer which should be carefully observed when

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equipment start-up on both sides of the filter gauze. The abnormal increase of differences
between two pressures shows that the filter gauze has been blocked up by dirt and scale. At
this time the pump should be shut down; sundries should be got rid of and filter gauze should
be replaced. Take out the filter gauze when dirt in pipeline has been got rid of.

ChapterIII. Check before start-up

1. Stuffing seal
First you have to make sure whether the pump had stuffing. If the stuffing is fixed in works,
they can be used directly.

The detailed installation of stuffing is as follows:

First disassemble the stuffing gland, next take out the water seal ring and clear away the dirt
on shaft and in stuffing box, after that pack in two annular stuffing whose cuts are 1800
alternated to each other, then install the water seal ring which should be along the lubrication
water hole in stuffing box, later on feed the stuffing, finally cover the stuffing gland.
Uniformly screw gland nut then loose it. Then screw again with hands until your fingers feel
tight. In this way you can ensure the proper amount of leakage to lubricate the stuffing.
Note
Do not screw the stuffing gland too tight, which will cause the stop of leakage. A few
leakage can lubricate the stuffing. Stuffing and shaft sleeve will be damaged for lack of
leakage.

2. Electric motor preparation and lubrication

Please make full preparation for electric motor operation according to instructions from
Electric Motor Works. After connecting wire, you have to confirm before connecting
coupling that the rotating direction should be identical to the direction drawn with arrow
marks on pump.
Note
Before connecting coupling, check the rotating direction of electric motor. Incorrective
rotating direction of the equipment will damage the equipment and hurt people.
When drive the motor, please keep the voltage frequency indicated on the electric motor name
title identical to wireline. Check all the wiring head and operate in the light of wireline
drawing.

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The lubrication of electric motor is to be conducted with reference to the instructions from
Electric Motor Works.

3. Bearing
The rolling bearing is lubricated with grease, which preferably occupy 40% of the bearing
box when poured into bearing.

Chapter IV. Operation

After finishing all the check before start-up, please pay attention to the following operation
procedures for preparation for start-up.
1. Start-up
(1). Turn round the rotor for at least one circuit with hands to observe whether all the part
components can rotate smoothly. For the incorrect management during the installation and
transportation, the deform of the pipeline will cause the rotors bite each other.
(2). There are all together three ways to draw water to pump. One is to draw water of fluid
source. Another is to draw water of other sources. The other is to draw water by exhaust
vacuum.
(3). Inspect the system arrangement. Reasonable arrangement of pipeline can make pump
transmit pumped fluid effectively. Everytime when pump start-up, please shut off the outlet
sluice valve when there is no pressure on discharge pipe.
(4). If the stuffing box is external water sealing, the sufficient pressure of external water
source is required to create proper capacity. If the stuffing box use the pressure water, please
use the water sealing pipe component.
(5). When start up the driving motor, accelerate the pump and have the interior parts
lubricated.
(6). When pump arrive at the rated rotating speed, please open the discharge valve gradually
in order to avoid sudden change in speed and fluctuation of pressure in suction pipe. Not to
operate for a long time in closed state at any time, otherwise the temperature of liquid in
pump would rise up and even up to vaporization which will abrade the pump or make the
pump out of suction ability for flow failure.
(7). Adjust valve to control sealing water in stuffing box to ensure proper leakage which will
sufficiently lubricate stuffing. It is very important to keep the gland as loose as possible with
proper leakage. If the gland is too tight, it will cause the abrasion of bearing and stuffing, and
simultaneously increase the mechanical loss.

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(8). After operating for a short time, check whether all the bolts are loose or tight and at the
same time check whether the coupling is coaxial and whether the rotor is flexible.
2. Shut-down
(1). When shutting down the pump, slowly close the discharge valve and vacuum cock to let
the remaining water run out of the pump for preventing crack due to freezing.
(2). If the pump is to be idled for a long time, it should be taken apart, dried, oiled with
pickling oil on the polished surfaces, and preserved judiciously.
3. Operation check
(1). Care to keep the temperature of the bearing not higher than that in surrounding and the
highest temperature not is over 750c.
(2). A little leakage is needed to lubricate and cool the stuffing. Please adjust the gland
according to the ways mentioned above.
(3). Inspect the elastic coupling periodically.
(4). In the operation period, the pump should be examined periodically. If the clearance
between the impeller and the wearing ring is too large, the former or the latter should be
replaced.

Chapter V. Maintenance
The following is the regular maintenance procedure of overhaul.
1. Stuffing change
We suggest changing stuffing when it is so worn and torn that leakage can’t be controlled.
First screw off the nut and take off the gland, next take out the stuffing and water seal ring
with gripper or hook, after that clean the stuffing box thoroughly, later on check shaft sleeve
and replace the worn shaft sleeve, finally install new stuffing. Please refer to <<Detailed
installation of stuffing>> described above.
2. The procedure of disassemble
(1). Cut off the electricity supply plug.
(2). Switch off the coupling.
(3). Shut down pump and other auxiliary system.
(4). Take off all auxiliary pipeline which would possibly disturb disassemble.
.(5). Let the water run out of pump.
(6). Screw off the stuffing gland nut. Take off gland (If it is mechanical seal, it is necessary to
take off the gland bolt).
(7). Screw off bolts on split.

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(8). Disassemble top casing.
(9). Take off pin and bolts of bearing upper cover before take off the bearing upper cover.
(10). Take off rotors and put them under the stand.
(11). Disassemble coupling.
(12). Take off bearing end cover, bearing upper cover, bearing stand, interstage sleeve, water
deflector and shaft sleeve.
(13). Disassemble impeller sleeve, O-ring, water seal ring, stuffing and stuffing internal
sleeve or shaft sleeve with mechanical seal (when using mechanical seal).
(14). Take off casing ring.
(15). Take off impeller and key.

3. Parts inspection
Use standard casing wear ring. Check comprehensively whether the bearing has fatigue trace.
If any, please replace it.

4. Split of upper casing and lower casing check

Because the split seal of upper casing and lower casing use manual seal gum, please clean the
seal gum on split to ensure the sealing effect of reassemble.

1. Pump reassemble
(1). First put on impeller key; secondly install the impeller on the shaft; thirdly install casing
wear ring on the impeller.
(2). Assemble impeller interstage sleeve, shaft sleeve (a), O-ring, shaft sleeve (b), water
sealing ring and stuffing gland.
(3). When install interstage sleeve and water deflector, please fix the bearing stand on the
upper casing with bolts.
(4). Install bearing interior sleeve with bearing on the shaft.
(5). Assemble gasket of end cover, end cover of bearing , and locked round nut on the driven
end of shaft.
(6). Assemble gasket of end cover, end cover of bearing, coupling and locked round nut on
the driving end of shaft.
(7). Install rotors on the casing .
(8). Make sure that the position of casing wear ring and pins are correct.
(9). Screw the bolts on the bearing body.

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(10). Coat the split of upper casing uniformly with seal gum.
(11). Screw the bolts on the upper casing and split symmetrically. Please make sure the axial
clearance of rotor is between 0.15 and 0.2mm, and the rotor is flexible.
(12). Install packing in line with <<Detailed method of stuffing>>.
(13). Put the water deflector 1~6mm away from bearing support.
(14). Install coupling pin and check the coaxiality of motor. If necessary, please make
adjustment.

6. Possible troubles, causes and remedies.

Troubles Causes Remedies
1. Pump doesn’t suck; Water filled into pump is Refill water into pump, block
pointers in manometer and insufficient, air leaks in leak-age.
vacuum gauge pulsate pipelines and meters.
violently.
2. Pump doesn’t suck, Bottom valve is not opened Adjust or replace bottom valve,
vacuum gauge shows high or blocked, resistance in clean or change suction line,
vacuum. suction line too large, lower suction head.
suction head too large.
3. Manometer shows Resistance in discharge line Inspect or shorten pipelines and
pressure, but pump too large, rotation direction inspect motor rotation
delivers no water yet. incorrect, impeller blocked direction, clean impeller,
speeds of rotation not increase speed of rotation of
enough. pump.

4. Capacity lower than that Pump blocked or wear ring Clean pump and pipe lines,
expected. worn too much, speed of replace wear ring, increase
rotation not enough. speed of rotation of pump.
5. Power consumed too Stuffing gland too tight, Loosen stuffing gland or take
much. stuffing box heated, stuffing off to be squared,
impeller worn badly, replace impeller, and adjust
amount of water supply sluice valve to lower capacity.
increased.
6. Pump is noisy and Gate valve opened too Adjust gate valve to lower the

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doesn’t suck. large, resistance in suction capacity, inspect suction line,
line too large, suction head and inspect bottom valve, lower
too large, air infiltrates in suction head, block leaks, and
suction opening, lower temperature of liquid.
temperature of liquid
delivered too high.
7. Pump vibrates. Shaft centerlines of pump Align shaft centerline of pump
and motor not in alignment. with that of motor.

1.Bearing over No oil, shaft centerlines of Add oil, align the shaft

heated. pump and motor not in centerlines, inspect or clean

alignment, oil ring doesn’t bearing box.
run.

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