Pumps are the ‘Hearts’ of any process industry – Hydro Power Station being one
of them. Performance of pumps is directly linked with the efficiency, reliability
and availability of a Hydro Power Station. One of the ways to ensure good
performance of pumps is to maintain them in a planned manner which, in turn,
generates a need for trained people.
Definition of Pumps:
Pump is the machine that lifts liquids, moves them from place to place, and
pressurizes them from a number of useful tasks.
Pumps are mechanical devices used to motivate liquids and gases, for carrying
and conveying through pipes from point ‘A’ to any other given point.
Classification of Pumps:
Basically pumps are of three types:
• Reciprocating.
• Rotary, and
• Centrifugal.
Reciprocating Pump: In this type energy is added to the liquid by the to and fro
movement of piston, plunger, diaphragm etc.
Rotary Pumps:
Here the pumping action is caused by relative movement of roting and stationary
elements of the pump. The can be subdivided into following categories:
• Gear Pump
• Screw Pump
• Vane Pump
• Lobe Pump
Most of the pumps installed the Power Stations are of centrifugal type.
Centrifugal Pump:
This type of pump have an impeller housed in a suitable shaped casing so that
when the impeller rotates momentum is applied to liquid in the pump casing
transporting it from the inlet to the outlet side by changing velocity into pressure
energy.
Centrifugal pumps can be put in different categories:
a) Horizontal.
b) Vertical.
c) Multistage.
d) End suction.
e) Split casing.
Pumps are commonly rated by horsepower, flow rate, outlet pressure in feet (or
meters) of head, inlet suction in suction feet (or meters) of head. The head can be
simplified as the number of feet or meters the pump can raise or lower a column
of water at atmospheric pressure.
From an initial design point of view, engineers often use a quantity termed the
specific speed to identify the most suitable pump type for a particular combination
of flow rate and head.
• Casing.
• Impeller - Single eye or Double eye.
• Shaft or spindle.
Stationary parts consist of casing, bearing and stuffing box and rotating parts
consist of the impeller and the shaft.
a) Casing: Casing or Housing is the main casting which is firstly used to restrain the
water into an approximately circular or spiral path and secondly to collect the
water, as it is delivered from the periphery of the impeller. It is provided with the
inlet ‘Suction’, the outlet ‘Discharge’ and with a stuffing box to permit the
projection of the spindle or a shaft.
b) Impeller: It can be described as a wheel having equally spaced blades or vanes,
arranged around the shaft. At one side is the inlet or eye. From the eye, the blades
run in a curved path to the outer edge of the wheel.
d) Shaft Sleeves: Pump shafts are usually protected from erosion, corrosion and wear
at stuffing box, leakage joints, and internal bearings and in the water ways by
renewable sleeves. The most common function of the shaft sleeves is that of
protecting the shaft from wear at stuffing box.
e) Bearings: Bearings are used to reduce frictional force and to keep the shaft
in correct alignment with the stationary parts under the action of radial and
transverse loads.
f) Pump Sealing: Pump seals are provided to prevent any leakage at the point
where the pump shaft passes out through the casing. The pump seals also prevent air
leakage into the pump, if the pump pressure is less than atmospheric and if the
pressure is above atmosphere the function is to prevent the liquid leaking out of the
pump.
i) Stuffing box.
ii) Mechanical seal.
g) Stuffing Box: stuffing box consists of a number of rings of packing around the
pump shaft housed inside a cylindrical cage between the pump casing and the
pump shaft.
Pump Maintenance: The usual intervals for preventive maintenance are monthly,
quarterly, half yearly and annually.
i) Bearing housing.
ii) Bearing replacement.
iii) Neck ring clearance.
iv) Impeller condition.
v) Changing gland packing.
vi) Check shaft for straightness.
vii) Keyways & keep.
viii) Shaft sleeves tolerance.
ix) Condition of nuts and bolts.
Ensure Control Room Engineer is informed about readiness of pump for trial run.
Ensure that enough water (or any fluid which the pump will handle) is available.
Some basics points to be checked before starting of pumps in day to day use /
application:-
i) Ensure power supply on control panel. Circuit healthy indication
should be available on control panel.
ii) Ensure water at suction or in the sump tank.
iii) Check the coupling.
iv) Check the discharge valve.
v) Check leakage from stuffing box.
vi) Switch off the motor heater or heating lamps.