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Rotating Equipment
CHAPTER 3
PUMPS
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Rotating Equipment
CHAPTER 3
PUMPS
Objectives:
At the end of this chapter the trainee will be able to:
Understand pump types, components, application, performance,
auxiliaries, operation and maintenance.
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CHAPTER 3
PUMPS
CONTENTS
Page Number
SECTION 3.1
The Function of the Pumps
SECTION 3.2
Classification of Pumps
3.2.1 Positive displacement pumps
3.2.1.1 Reciprocating positive displacement pump ..
3.2.1.2 Rotary positive displacement pumps
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10
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15
SECTION 3.3
Centrifugal Pump Components
3.3.1 Centrifugal pump components ..
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SECTION 3.4
Classification of Centrifugal Pumps
SECTION 3.5
Pump Performance Curves, Pump Power and Efficiency
3.5.1 Factors affecting pump performance .
3.5.2 Effects of specific gravity .
3.5.3 Effect of viscosity .
3.5.4 Specific speed
3.5.5 Typical characteristic curves for a centrifugal pump
3.5.6 Pump power ..
3.5.6.1 Definition ..
3.5.6.2 Pump power .
3.5.6.3 Pump power and efficiency ..
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SECTION 3.6
Pump Operation
3.6.1 Safety
3.6.2 Priming .
3.6.3 Starting .
3.6.4 Running
3.6.5 Stopping ..
3.6.6 Operation against closed discharge .
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SECTION 3.7
Operating Difficulties
3.7.1 General ..
52
SECTION 3.8
Cavitations
3.8.1 What is the cavitation?
3.8.2 The main reasons of cavitation ..
3.8.3 What is the effect of cavitation on the pump .
3.8.4 Symptoms of cavitation .
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SECTION 3.9
Pump Auxiliaries
3.9.1 Pump drive
3.9.2 Couplings .
3.9.3 Strainers
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SECTION 3.10
Pump Maintenance
3.10.1 Safety ..
3.10.2 Lubrication .
3.10.3 Gland packing .
3.10.4 Mechanical seal ..
3.10.5 Coupling .
3.10.6 Overhauling overhung pump shaft .
3.10.6.1 General instructions .
3.10.6.2 Dismantling .
3.10.6.3 Inspection of components
3.10.6.4 Assembly .
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SECTION 3.11
Reciprocating Pumps
3.11.1 How it works
3.11.2 Reasons for using reciprocating pumps ..
3.11.3 Disadvantages of reciprocating pumps
3.11.4 Pump classification ..
3.11.5 Liquid end components
3.11.5.1 The liquid cylinder .
3.11.5.2 Pumping element ..
3.11.5.3 Stuffing boxes
3.11.5.4 Valves
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SECTION 3.12
Pulsation Dampeners
3.12.1 The function of pressure pulsation dampener
3.12.2 Installation .
3.12.2.1 Mounting .
3.12.2.2 Precharging .
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SECTION 3.13
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SECTION 3.1
FUNCTION OF PUMPS
A wide variety of pumps are used in petroleum industry. A pump is used to
increase the total energy content of a liquid in the form of pressure increase.
Pumps transfer liquids, for example, between vessels. They are the fluid movers
of liquids.
The pumps are used to perform one of the following jobs:
1- Move liquids from low level to high level (figure 3.1)
2- Move liquids from low pressure location to high pressure location
(figure 3.2)
3- To increase the flow rate of a liquid (figure 3.3)
Figure 3.1
Figure 3.2
Move liquid from low level to high level Move liquid from low pressure
location to high pressure location
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Figure 3.3
To increase the flow rate of liquid
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SECTION 3.2
CLASSIFICATION OF PUMPS
The most common classification of pumps is based on the way energy is added
to the liquid and pump geometry. They are classified into two main categories:
Positive Displacement Pumps
Dynamic Pumps
Reciprocating Pumps
Reciprocating
Piston Pump
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Reciprocating
Plunger Pump
Rotary Pumps
Diaphragm
Pump
1- Gear pump
2- Lobe pump
3- Screw pump
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Centrifugal Pumps
Special Pumps
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3. Liquid enters the pump casing when it leaves the outer edge of the
impeller.
When the liquid enters the casing, speed decreases, as the speed of the
liquid decreases, its pressure increases.
4. As centrifugal force moves the liquid away from the impeller eye, a lowpressure area (zone) is formed in the suction eye. This low pressure area
in the suction eye causes liquid to flow into the suction eye.
A typical centrifugal pumps is show in figure 3.15.
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SECTION 3.3
CENTRIFUGAL PUMP COMPONENTS
3.3.1 Centrifugal Pump Components
Pump consist of rotating components (rotor) and stationary components.
Figure 3.16 show centrifugal pump components.
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The following table shows the correct name for each item.
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2- Shaft
The impeller is firmly attached to the shaft and rotates with it. The shaft
performs two jobs:
Carry the impeller (s) and all other rotating parts and keep them in their
correct position with respect to the pump casing.
Transmit the required driving power to rotate the impeller (s)
3- Shaft Sleeve
To protect the shaft from wear in stuffing box area.
As spacer between different impellers in multi-stage pump.
4- Coupling
Transmits the required power to drive the pump shaft and all other rotating
parts.
5- Wear Rings
One wear ring is fixed to the impeller and rotate with it (impeller wear ring).
One wear ring is fixed to the pump casing and does not rotates (case wear ring).
These two wear rings together work to minimize the internal leakage inside the
pump.
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6- Pump Casing
It contains all rotating parts (shaft, impeller, impeller wear ring) etc.
Pump casing directs the liquid which leaves the impeller to the discharge nozzle
(pump discharge).
7- Stuffing Box
It is a cylindrical cavity where the shaft passes into the casing. The packing
material presses around the shaft in this cylindrical cavity to minimize the
leakage of liquid to outside the pump.
A mechanical seal may be used instead of packing.
8- Bearings
Its function is to carry the pump rotor and keep it in its correct position with
respect to the casing.
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As the impeller vanes rotate, they transmit motion to the incoming product,
which then leaves the impeller, collects in the pump casing, and leaves the
pump under the pressure through the pump discharge. Discharge pressure will
force some product down behind the impeller to the drive shaft, where it
attempts to escape along the rotating shaft. Pump manufacturers use various
design techniques to reduce the pressure of the product trying to escape. Such
techniques include:
1. The addition of balance holes through the impeller to permit most of the
pressure which acting behind the impeller to escape into the suction side
of the impeller. (figure 3.19)
2. The addition of small pumping vanes on the back side of the impeller.
(figure 3.20).
However, as there is no way to eliminate this pressure completely, sealing
devices are necessary to limit the escape of the product to the atmosphere. Such
sealing devices are typically either compression packing or mechanical seal.
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If the pump handles a suction lift and the pressure interior stuffing box end is
below atmospheric, the stuffing box function is to prevent air leakage into the
pump.
If this pressure is above atmospheric, the function is to minimize liquid leakage
out the pump.
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The lantern ring (figure 3.23) is a device made from a rigid material such as
bronze, stainless steel, nylon or TFE, and is of open construction to allow free
passage of sealing liquid ( or lubricant). Normally, the sealing liquid (or
lubricant) enters the outside of the ring, and flows to fill the space between the
packing rings and the shaft ( or shaft sleeve). The lantern ring usually has
packing rings on either side (figure 3.24)
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b. Pollution.
Maintenance cost: Most of the time, the shaft ( or shaft sleeve) should be
changed due to damage. The rubbing between the packing rings and the
shaft will cause score marks and rough surface on the shaft in the stuffing
box area. That means extra maintenance cost and more downtime. Beside
this, most bearing failure is caused by contamination rather than
overloading. The easiest way to contaminate a bearing is from the
leakage coming through the packing.
Speed limits: Packing have limited speed, if you try to use it in speeds
higher than its limits, the failure will happen.
The argument for packing usually centers around four statements:
1.
2.
3.
4.
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Statement 1:
You do have to take the pump apart to change sleeves and bearings. Shaft
sleeve replacement is a normal part of repacking a pump. The fact of the matter
is that you will have to dismantle a packed pump more than a sealed pump.
Statement 2:
If you need reliability, use a mechanical seal with an auxiliary packing gland.
Statements 3:
Packing is cheaper if you consider the packing alone. Bicycles are also cheaper
than automobiles.
Statement 4:
Packing is less complicated only to an inexperienced man. If you have ever tried
to teach an apprentice how to inspect a stuffing box and shaft, cut packing,
install it so as to align the lantern ring, tamp it in place, and adjust it properly so
as to keep leakage to a minimum and not generate excessive heat (you have to
do it by feel), then you know just how complicated packing really is.
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3. Spring (s).
4. Mechanical seal hardware including seal flange (gland ring), shaft sleeve,
etc.
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3. Improperly positioned seals could allow a wide gap between the faces,
causing a leak path. The faces could also be squeezed so tightly together
that no lubrication is present, causing rapid seal failure.
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Figure 3.27
Packing (figure 3-27) forced into a stuffing box around the shaft. It seals by
throttling the fluid trying to leak between the packing and shaft. Packing wears
the shaft and increases the power needed to rotate the shaft.
2. Shaft Run-Out
Shaft run-out is one costly enemy of conventional packing. It beats out packing,
making sealing problem tough. If the shaft run-out is over 0.003 inch, it's
impossible to seal properly, especially at high speeds.
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Mechanical Seal
1. How Does it Work?
Figure 3.28
Mechanical seal (figure 3-28) has two seal faces at right angles to the shaft. One
seal face is fastened to the shaft and revolves with it, while the other is
stationary and is held against the machine casing. The wearing faces that seal
have a small area compared to the area conventional packing seals against.
Because of this small area, and the preloaded spring(s) forcing the two faces
together, there's less friction at the seal faces. And of course there is no wear on
the shaft because seal faces take it all, they can relapped or replaced when
needed.
2. Shaft Run-Out
Mechanical seals can take more shaft run-out without leaking. Reason is that
sealing faces are at right angles to shaft. The elastomeric gaskets and the
spring(s) allow for some misalignment between the seal faces which could
happen due to shaft run-out.
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End play (shaft axial play) is common with most shafts especially when starting
up or shutting down. Such shaft movement does not affect the packing if shaft
has no grooves in packing area. But usually shafts or sleeves do groove after a
short while. Then shaft end play disturbs packing, open it up and causes
leakage.
Figure 3.31 The effect of shaft axial play on the mechanical seal
Shaft end play (shaft axial play) does not affect the mechanical seal if this end
play within certain limits (about 0.003" for rolling element bearings as a thrust
bearing and about 0.015" for slide surface bearing as a thrust bearing). The
spring (s) will keep the seal faces close.
4. Power Consumption
It is relatively high in case of packing (about three times the power consumption
in mechanical seal for the same shaft size and speed).
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In case of Packing:
Can be packed in place. It needs adjusting several times after start up
until it reach the normal running conditions.
Mechanical Seal:
Installed over shaft end. It needs more time for installation. It does not
need any additional adjustment after the installation.
6. Pollution
Is relatively high in case of packing because the packing must leak for cooling
and lubrication.
In case of mechanical seal in normal running conditions, less leakage i.e. less
pollution. Double seals are able to stop product leakage 100%.
7. Cost of Product
In case of packing, the cost of product is high- due to high leakage rates.
In case of mechanical seal, the cost of product is low- due to very small
leakage rates.
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SECTION 3.4
CLASSIFICATION OF CENTRIFUGAL PUMPS
Centrifugal pumps can be classified with respect to the following parameters:
1- With respect to the impeller design.
2- With respect to the flow of liquid after it leave the impeller.
3- With respect to the pump case design.
4- With respect to the split of the casing.
5- With respect to the number of stages.
6- With respect to the shaft position.
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Axial flow
Mixed flow
Radial flow
Figure 3.35
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Figure 3.41
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5- Number of Stages
The pump could be single stage (one impeller) figure 3-16 or multi stage
(figure 3-41).
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SECTION 3.5
PUMP PERFORMANCE CURVES
The centrifugal pump is now the most widely used type of pumps in the
petroleum industry. It must be correctly sized, fitted, and installed to operate
satisfactorily. This section is a guide to the selection, application, and
limitations of centrifugal pumps.
Running speed.
Impeller size (diameter).
Liquid specific gravity.
Liquid viscosity.
NPSH (net positive suction head)
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Centrifugal pump can push a heavy liquid and a light liquid to the same height,
even if water is piped to the pump instead of lighter oil, it continues to raise the
liquid to the same elevation. The pressure on the discharge line would increase
as a result of the higher specific gravity of water. The pump would have to
exert more force and would automatically require more horsepower.
NS =
NQ
H
1
2
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Figure 3.43
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Figure 3.44
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Figure 3.45
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3.5.6.1 Definitions
Capacity: The pump capacity Q is the volume of liquid per unit time delivered
by the pump.
In English measure it is usually expressed in gallons per minute (GPM) and for
large pumps, in cubic feet per second (ft3/sec).
In metric measure the units are liters per second (L / Sec.) and cubic meters per
second (M3 / Sec)
Head: The pump head (H) represents the net work done on a unit weight of
liquid in passing from the inlet or suction flange (S) to the discharge flange (d).
Power: There are liquid horsepower and mechanical horse power.
Liquid horsepower = Lhp =
QSH
3,960
Q in GPM
S specific gravity
H in feet
B.H.P. =
T.S M - RE (Rev. 3) May 2004
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SECTION 3.6
PUMP OPERATION
3.6.1 Safety
Ensure that all protective guarding is in position and securely fixed.
3.6.2 Priming
The pump must not be run dray at any time. The pump casing and inlet line
must be completely filled with liquid before the pump will operate.
3.6.3 Starting
In general, the following procedure should followed:
1- When fitted ensure that flushing and / or cooling liquid supplies are
turned on.
2- Close the outlet valve (on the discharge line of the pump).
3- Be sure that the suction valve (on the suction line of the pump) is open.
4- Prime the pump
5- Start the motor and immediately check outlet pressure.
If the gauge does not register positive pressure, stop the motor and check
for air leakage or any other possible cause.
6- If the pressure is satisfactory, slowly open outlet valve. Do not operate
the pump with valve closed for more than a few minutes.
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3.6.4 Running
1- Packed gland should leak, and leakage should take place soon after the
stuffing box is pressurized. Until steady leakage takes place, the pump
may overheat. If this happens, the pump should be stopped and allowed
to cool and when re-started, leakage should take place.
In general, gland nuts should not be slackened but when hot liquids are
being pumped, this may become necessary. After the pump has been
running for ten minutes with steady leakage, tighten the gland nuts.
Continue to tighten gland nuts until leakage is reduced to an acceptable
level. When adjustment is completed there should be drip leakage from
the gland, ensuring that overheating does not take place.
2- With a mechanical seal, no adjustment is necessary and any slight initial
leakage will disappear when the seal is run in.
3.6.5 Stopping
Close outlet valve and switch off motor.
1
the rated power because of friction of parts
2
and the churning of the enclosed liquid. This condition requires that precaution
be taken.
No centrifugal pump should be operated against a closed discharge valve. It
may be necessary to hold the valve closed or nearly closed for few second when
starting the unit. Power absorbed in rapidly churning the liquid results in a
dangerous temperature increase. This condition is usually provided for by
means of a small by pass with a check valve around the discharge valve.
Another protective measure is the installation of by pass with valve to the
pump sump or the suction side of the pump.
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SECTION 3.7
OPERATING DIFFICULTIES
3.7.1 General
This section gives information on fault diagnosis and possible remedies to
operating difficulties. The matrix in next page details a list of ten possible
symptoms to which the possible cause or causes can be ascertained by reading
off composite the black rectangles.
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SECTION 3.8
CAVITATION
3.8.1 What is the Cavitation?
The formation and subsequent collapse of vapor-filled cavities in a liquid due to
dynamic action are called cavitation. The cavities may be bubbles, vapor-filled
pockets, or a combination of both. Cavitation happens if the local pressure
becomes equal to or below the vapor pressure of the liquid at this temperature,
and the cavities must encounter a region of pressure higher than a vapor
pressure in order to collapse.
Dissolved gases are often liberated shortly before vaporization begins.This may
be an indication of impending cavitation, but true cavitation requires
vaporization of the liquid. Bubbles which collapse on a solid boundary may
cause severe mechanical damage. All known materials can be damaged by
exposure to bubble collapse for a sufficiently long time. This is properly called
cavitation erosion or pitting.
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SECTION 3.9
PUMP AUXILIARIES
3.9.1 Pump Drive
Electrical Motors
Motors are the major drivers to supply energy to rotating pumps. The motor
power should be greater than the pump input power in order to allow for friction
and other types of losses.
Steam Turbines
The availability of steam may suggest a turbine drive. A steam turbine drive is
usually chosen where exhaust or high-pressure steam is available.
Gas Turbines
A gas turbine drive may be used to power a rotating pump. Gas turbines are
usually available in the large size power.
Gas Engines
A gas engine drive may be used when gas is available at a low cost. Gas engines
are used to provide power to drive reciprocating or centrifugal pumps.
Diesel engine
This drive is similar to the gas engine drive. The difference is the fuel used. The
compression ratio of a diesel engine is greater than that of a gas engine.
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3.9.2 Couplings
On most centrifugal pumps, couplings (Figure 3.48) join the shafts of the
drivers and pumps. Alignment of shafts is very important for good and smooth
operation of the pump. Misalignment will cause the shaft and other pump parts
to vibrate. Serious vibration can generate enough stresses to break the shaft and
coupling. Also, vibration can cause bearings to wear, internal parts to rub so
they become unbalanced, etc. All of these conditions require maintenance and
result in equipment downtime.
3.9.3 Strainers
The primary function of a strainer is to protect the equipment. Normally
strainers are placed in the line at the inlet to pumps, control valves or any other
equipment that should be protected against damage. The strainer is selected for
the design capacity of the system at the point where it is to be inserted in the
line.
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SECTION 3.10
MAINTENANCE
3.10.1 Safety
The following safety precautions should be observed before commencement of
maintenance.
1. Do not attempt any maintenance on the pump whilst it is in operation.
2. Before carrying out dismantling or maintenance, isolate the power supply
to the pump driving unit and/or automatic starting devices.
3. Ensure inlet and outlet isolating valves are closed and holding.
4. Drain pump casing to a safe area. Wear the correct protective clothing to
suit the pumped liquid when removing drain plug.
3.10.2 Lubrication
1- Pump and Motor Bearings Grease Lubrication
Machines are supplied with bearings pre-packed with grease and ready to put
into service. For re-lubrication, a lithium based grease such as Shell Alvania R3
is recommended. As a guide to quantity of grease, the actual bearing should be
filled and then one third of the housing.
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When a pump has been initially operated with a particular grade of oil, the
bearing temperature should be checked. You must use the oil which is specified
by the manufacturer.
The oil should be changed every six months when the pump is operating for 8
hours per day. When conditions are more severe, such as hot service, damp or
corrosive atmosphere or continuous service, the oil should be changed more
frequently.
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2- stuffing boxes are equipped with a lantern ring (Figure 3.49) which can
be used to feed water or a compatible fluid to the packing. This is useful,
when the inlet pressure is less than atmospheric, as air leakage into the
pump is prevented. Also, when an independent fluid source is used, it is
possible to flush the packing of any grit or solids handled by the pump.
3- The gland should be inspected at frequent intervals to check that
operation is correct.
3.10.5 Coupling
The coupling should be examined at frequent intervals to ensure that correct
alignment is maintained and that the driving elements are not worn.
3.10.6 Overhaul
3.10.6.1 General Instructions
1- The frequency of a complete overhaul depends upon the hours of
operation of the pump, the severity of service and the care the pump
receives during operation. DO NOT open the pump for inspection unless
there is evidence of trouble inside the pump or in the bearings.
2- Should dismantling prove necessary, great care must be taken. For ease of
re-assembly, lay out all parts in the order in which they are removed.
3- Protect all machined faces against metal to metal contact and corrosion.
Do not remove the bearings unless they are to be replaced.
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3.10.6.2 Dismantling
The sequence of steps to strip down the pump depends mainly on the type of the
pump. The pump could be overhang pump or in between bearings pump. For
this reason this section divided into two parts. Each one covers one of these
two designes.
One important thing should taken into consideration:
The manufacturers instructions should be followed when dismantling and
assembling the pump.
For this pump (overhang) please check figure 3-50 and spare parts list on the
next two pages.
1- The pump is of the "back pull-out" type which enables the pump casing
to remain secured to the baseplate and pipework when dismantled. The
spacer coupling enables the motor to remain secured to the baseplate and
consequently no further alignment should be necessary after re-assembly.
Care must be exercised during dismantling, to prevent damage to internal
components.
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Figure 3.50
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Remove the nuts securing the seal plate (seal flange) to the casing and slide
the seal flange away.
Unscrew the stuffing box cover/bearing adapter bolts (where fitted) and
remove the stuffing box cover. The inboard seat on a double seal will come
away in the stuffing box cover.
Mark the position of the seal drive collar to the shaft. Loosen the drive
screws in the seal drive collar and remove the rotating element of the seals,
from the shaft sleeve. For double seals, smooth any marks on the sleeve made
by inboard seal before removing outboard seal.
Remove stationary seat, from the seal plate. This should only be done if the
stationary face or its seating ring are being replaced.
Remove shaft sleeve.
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1. Shaft
Examine the shaft carefully. Its condition should be checked where the impeller,
shaft sleeve and bearings fit. The shaft may become damaged by corrosion or
pitting, caused by leakage along the shaft at the impeller end of the shaft sleeve.
Check the shaft keyway for distortion. Excessive thermal stresses or
corrosion may loosen the impeller on the shaft and subject the keyway to
excessive shock. Replace a shaft that is bent or.
Check the shaft for possible runout.
2. Bearings
Extreme care is to be taken when removing the bearings as they may be
damaged to such an extent that they are no longer usable.
Always check the bearings immediately after removal for any
imperfections, or for any play between the races.
It is recommended that new bearings are installed, because very often
damage caused by removal cannot detected until the pump is put back
into service.
3. Impeller
After removal, the impeller should be checked for corrosion, blocked waterways
and worn spots. Impellers should be statically balanced after any machining
work is carried out.
4. Joints
It is recommended that new joints (gaskets, O-rings) are installed after the pump
has been dismantled. The joints should be of the same material and thickness as
the original joint, so that they will compress to the same thickness.
5. Stuffing Box
The packing rings should be replaced by new set with the same size, same
material.
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3.10.6.4 Assembly
General
1. To assemble the pump, reverse the dismantling procedure previously
described. Consult the exploded-view illustrations and take note of the
following procedures which detail special considerations of assembly
which must be observed.
2. Ensure all gaskets are assembled correctly. Clean the inside of the
integral frame/bearing housing and adapter and the bores for the
bearings.
3. The inner races of the bearings are an interference fit on the shaft. These
should be fitted by either heating or by using hydraulic press.
NOTE
The method described in the previous paragraph is preferred. Heat the bearings
in an oil bath or electric oven to uniform temperature and mount it quickly on
the shaft.
If the alternate method (using of hydraulic press) is used, apply the force using
an arbor press (hydraulic press), in forcing the bearing onto the shaft, ensure
that the race is never misaligned. The inner race should be checked with a
feeler gauge to ensure it is right up against the shaft shoulder.
Heat the bearing to expand it so that it can easily be placed in position
and allowed to shrink to grip the shaft. To avoid damage to bearing shield
and grease, care is to be taken that the temperature is not raised above
100 deg C.
Force the bearing onto the shaft using equipment that can provide a
steady, even load. Care is to be taken to avoid damage to the bearing and
the shaft.
4. On grease lubricated pumps, pack the bearings with grease and pack the
bearing cover cavity approximately one third full with grease.
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5. When fitting labyrinth thrower deflector the groove in the pump end
bearing cover should be filled with grease and the labyrinth thrower
positioned to give a clearance of 0.5 to 0.65 mm in front of the bearing
cover. Screws for the drive end bearing cover should be tightened
uniformly.
6. When refitting the shaft sleeve, ensure the joint or "0"-ring is correctly
fitted.
7. The stuffing box should be packed with good quality packing, suitable
for the liquid being handled.
It is important to fit the lantern ring and the packing" seating ring in their
correct positions to ensure that the lantern ring is situated in line with the
gland seal connections. The packing scarf joints should be staggered by
90-180 degrees from the previous ring.
8. When replacing a mechanical seal, extreme cleanliness is required. The
two sealing faces of the seal and the surface of the sleeve must be free
from scratches and other damage.
9. Carefully press the stationary seat into the seal flange ensuring that the
seat sealing ring is not deformed, that where an anti rotation pin is fitted
correct engagement with slot is achieved, and that the face is square to
housing.
10. The rotating element (rotating face) should be carefully mounted onto the
shaft sleeve ensuring that the sealing ring is not damaged.
11. Position the seal into the same position, remembering to check setting
dimension that it originally occupied and tighten the drive screws in the
seal drive collar.
When refitting the seal plate (seal flange), check that the seal is
compressed by the action of moving the seal plate into position. It should
not be over compressed and locked up solid.
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11.Lift out the rotor of the pump including shaft, impeller (s), mechanical
seals and ball thrust bearing.
12.Procedure from this point depends almost entirely on the nature of the
trouble and the extent of repairs or replacements.
3.10.7.2 Inspection
Washing and cleaning is essential before start inspection of the parts.
Remove the old gaskets (between upper and lower halves of the pump
casing) and use oil stone for cleaning these surfaces and to make it flat.
1- Rotor Inspection
Check the straightness of the shaft on lathe machine check any signs of
corrosion or wear shaft sleeves: Corrosion or wear due to rubbing.
Impellers: Any sings of corrosion,
3- Thrust Bearings
4- Throat Bushings
5- Case Wear Rings
Any signs of corrosion, wear due to rubbing check the grooves of wearing rings,
throat bushing.
6- Pump Casing
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All gaskets and O rings must be replaced, use the same thicknesses
and materials.
2-
For mechanical seals (if it is used), the seal faces must be re-lapped and
all gaskets should be replaced. Assemble the mechanical seal on the
pump shaft.
3-
4-
5-
Lower the rotor in the lower half of the pump, wear rings must fit
correct in its position wear ring lock pins should fit correctly in its
positions.
6-
Added some oil between the shaft and the bearings and rotate the shaft
slowly. Check if there is any rubbing between the rotor and stationary
parts. Make the required corrections.
7-
Put the gasket between lower and upper halves of the pump casing.
8-
Lower the top half of the pump casing. Be sure that it fit properly in its
places. Use guide pins. Before seating the top half completely, insert
the duel pins. Tight all nuts hand tight. Apply the required fighting
torque as sequence given by the manufacture.
9-
Rotate the shaft slowly to check any rubbing could happen. Check
the shaft axial play. Make the required correction if it is needed.
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10- Added the lubricating oil in the bearing housing. Connect all piping
either for pump venting or mechanical seal system.
11- Check the shaft alignment between the motor and the pump. Make the
required corrections.
12- Re-assemble the coupling. Check the rotation of the system.
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SECTION 3.11
RECIPROCATING PUMPS
3.11.1 How it Works
A reciprocating pump is a positive displacement machine, i.e, it traps a fixed
amount (fixed volume) of liquid at near suction conditions, compresses it to
discharge pressure, and pushes it to discharge nozzle.
In a reciprocating pump, this is accomplished by the reciprocating motion of a
piston, plunger or diaphragm.
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Number of cylinders
Term
1
2
3
4
5
6
7
8
Simplex
Duplex
Triplex
Quadruplex
Quintuplex
Sextuplex
Septuplex
Nonuplex
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Figure 3-54 shows two examples of power reciprocating pumps use an electric
motor for the drive.
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The size of a power pump is normally designated by listing first the diameter of
the plunger (or the piston), and second the length of the stroke. For example a
pump designated as 2 x 3 has a plunger diameter 2 inches and a stroke length of
3 inches.
For a direct acting pump, the same convention is followed, except that the
diameter of the drive piston precedes the liquid end element diameter.
For example, a pump designated 6 x 4 x 6 has a drive piston diameter of 6
inches, a liquid piston diameter of 4 inches and a stroke length of 6 inches.
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The number of piston rings and its dimensions, configuration and materials
depends on the working conditions (fluid, pressure and temperature) and the
cylinder size.
The piston rings must be able to move freely in the piston ring grooves and the
piston head assembly (piston head and the piston rings) must be able to move
inside the cylinder with enough tighting pressure against the cylinder wall.
The function of the piston rings is to stop the leakage between the piston head
and the cylinder wall (or cylinder liner) during the pumping stroke (discharge
stroke)
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A plunger (figure 3-57) is a smooth rod and, in its normal configuration, can
only be single acting.
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Application
For cool water and fluids with comparable lubricity.
Total packing length must be less than plunger stroke length to properly
wet the last ring of packing with pumpage.
2- Standard lubricated stuffing box
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Application
High friction causes excess heat.
Short life of packing and plungers.
Poor application improper use of standard box.
5- Modified gland follower to allow bleed off
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Application
Minimal leakage.
Normally limited to intermittent duty.
Self adjusting.
7- Lubricated spring loaded V-ring packing
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Application
Lubrication is optional
3.11.5.4 Valves
The valves in a reciprocating pump are spring loaded non return valves. It
opened by the liquid differential pressure, and allow flow in only one direction.
When the flow stoped the valve will close immediately.
They have variety of shapes:
1- Stem guided disk valve
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4- The flow velocity for a simplex (single cylinder) double acting, direct
acting pump is shown in figure 3-73.
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The resultant flow velocity for a duplex (two cylinders) double acting,
direct acting pump is almost constant, as shown in figure 3-73 b.
One cylinder starts before the other stops, and the resulting overlap (with
properly set valves) results in a relatively smooth flow in both suction
and discharge lines.
5- With a power pump, the velocity of the pumping element (piston, plunger
or diaphragm) varies approximately as the sine of the angle of the crank
throw.
Since the velocity of liquid in the piping is proportional to plunger
velocity, it can be plotted as a percent of average, as shown in figure
3-74.
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Liquid end
1234-
Valves.
Packing & stuffing box.
Plunger and piston rod (in case of piston pumps).
Cylinder (or cylinder liner) in piston pumps.
Drive end
12345-
Crosshead.
Connecting rod.
Crank shaft.
Bearings.
Power Frame.
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Errosion in the disk or the seat due to high flow speed. This could be
due to wrong selection of materials or changed working conditions.
Presence of solid particles which will cause damage in both disk and
the seat.
2- Broken spring (s) due to corrosion, or spring stiffness may change.
3- Plockaged spring due to presence of foreign materials in the liquid being
pumped.
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Crosshead
Connecting rod
Crankshaft
Bearings
Power fram
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SECTION 3.12
PULSATION DAMPENERS
3.12.1 The Function of Pulsation Dampeners
Multi-cylinders arrangement is used with plunger pump and piston pumps to
minimize the pressure pulsation. Pressure pulsation dampeners are used beside
multi cylinder arrangement to smooth out the pressure pulsation.
It is installed on the discharge line of these pumps.
3.12.2 Installation
3.12.2.1 Mounting
Pulsation dampeners (see figure 3.77) are mounted on standard ANSI and API
flanges which can met with ring joint or raised-face connections.
Caution: Do not attempt to precharge the dampener prior to mounting the unit
onto the piping system.
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3.12.2.2 Pecharging
The correct precharge is vital for maximising the efficiency of the pulsation
dampener. Generally, precharge pressure is based on the average operating
pressure of the system. Other system parameters can affect the precharge
pressure.
Suction Dampeners
All units are shipped with zero psig nitrogen precharge. Generally, unless the
suction system is being pressurised by a precharge pump, no additional
precharging of a suction dampener is required.
When using a precharge pump, set the precharge to approximately, but no more
than, 50 percent of the available suction pressure.
Precharge Procedure
Precharging pulsation dampener requires standard hand tools, a charging hose
assembly and a torque tool capable of applying 120-150 lb-in torque.
1. Unscrew the lifting eye counter clockwise in order to expose the charging
valve.
2. Connect the nitrogen source to the charging valve.
3. Open the charging valve by turning the top hex nut 3 to 4 full turns
counter clockwise (see 3.78).
4. Install nitrogen precharge.
5. After precharge has been installed, close the charging valve and tighten it
using 120-150 lb-in torque.
6. Remove the nitrogen source and install the lift eye.
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3.12.4 Maintenance
3.12.4.1 Precharge
The pulsation dampener is virtually maintenance-free if properly installed and
precharged. However, the vessel should be checked periodically for proper
precharge and also for leaks. Unless conditions indicate otherwise, checking the
unit every six months should be sufficient.
Remember: The precharge is based on the average pressure in the system. If
this pressure changes, adjust the precharge.
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3.12.4.2 Troubleshooting
The fault analysis tree is shown in figure 3.79
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Cut around the metal insert and remove the top portion of the
diaphragm. Remove the remaining portion by folding and pulling
it out.
b.
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9. Install a new gasket and mount the dampener. Secure flange studs and
nuts.
10.Remove, clean and inspect the charging valve and the O-ring seal.
Replace valve if damaged or worn enough to be doubtful of its ability to
seal at either the O-ring or the stem.
11 Clean and inspect the charging valve adapter on the body. Remove all
scale or rust with fine sandpaper if necessary. Install the charging valve
using thread lubricant.
Caution: Do not use Teflon tape!
12 Tighten the lower hex nut on the charging valve using 50 to 60 lb-ft
torque.
13. Precharge the dampener with nitrogen only. Proper precharging is vital
for maximising the efficiency and life of the diaphragm.
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SECTION 3.13
DIAPHRAGM METERING PUMPS
Are Positive Displacement Reciprocating Pumps
3.13.1 How it Works?
1- A diaphragm metering pumps is a reciprocating power pump that displaces a
predetermined amount (volume) of liquid in a specific period. This pump is
also known as a controlled volume, proportioning or chemical injection
pump.
2- The pump is usually driven from an outside source, which may be at a
constant or variable speed.
3- The pump contains a flexible diaphragm, one side of which is in direct
contact with the process liquid (liquid being pumped). The diaphragm can
be driven hydraulically or mechanically (figures 3.82, 3.83).
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In this design the amount of pumpage liquid can be controlled by either the
length of the stroke of the diaphragm push rod or the number of strokes, i.e. the
speed.
Rate of change
Reciprocating
Rotary
Centrifugal
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Linearity is the maximum deviation from the ideal straight line that can be
drawn through plotted calibration test points that describe how flow is varying
with the capacity setting. This deviation is expressed as a perecentage of the
rated capacity. A typical value is 1%.
Steady state accuracy is the flow variation expressed as a percentage of rated
capacity under fixed system conditions. Steady state accuracy applies
throughout the turndown ratios. A typical value is 1%. In some
specifications, this defined as a percentage of the mean delivered flow instead
of rated capacity.
Flow repeatability, expressed as a percent of rated capacity, describes the
reproducibility of a pump flowrate under a given set of conditions when the
capacity setting is varied and then returned to the set point being tested. A
typical value is 1%.
Pump Components
The pump components can be classified into two groups:
Drive end or power end and.
Liquid end.
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Diaphragm (s)
Diaphragms provide isolation and transmit hydraulic motion from one liquid to
another liquid on the other side (liquid being pumped). Diaphragms must
withstand maximum flexing, with stresses below the materials endurance limit
and should be of sufficient thickness and density to prevent permeation.
On both sides of the diaphragm there are dish plates to prevent excessive
flexure. The diaphragm moves within these two dish plates back and forth to
perform pumping.
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Valves
Refer to figure 3.86 the following valves are widely used in this type of pumps.
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3. Pneumatic
Where metering pumps are utilized in continuous processes, it is necessary that
they be controlled automatically. In pneumatic systems the standard 3 to 15 Psi
gage air signal is utilized to actuate air cylinders or diaphragms directly
connected to the stroke adjusting mechanism.
4. Electric
On electric control systems, stroke adjustment is through electric servos
which actuate the mechanical stroke adjusting mechanism. These accept
standard electronic control signals.
5. Variable Speed
This method of adjusting capacity is achieved by driving a reciprocating pump
with a variable speed prime mover. Since it is necessary to reduce stroke rate
to reduce delivery, discharge pulses are widely spaced when the pump is turning
slowly. Surge chambers or holdup tanks are used when this factor is
objectionable.
In control situations involving pH and chlorinization, two variables exist at
once, e.g., flow rate and chemical demand. This is easily handled by a metering
pump driven by a variable speed prime mover. Flow rate can be adjusted by
changing the speed of the pump, and chemical demand by changing its
displacement.
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3.13.6 Installation
Proper installation of metering pumps is very important if reliable pump
operation is to be obtained.
NPSH must be kept as high as possible, and manufacturers recommendations
as to pipe size and length, strainers, relief valves, and bypasses must be
observed.
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