Running & servicing pumps

General instructions:
Check the pump immediately after receipt. In case of damages or defects -
complain immediately. All pumps should be marked with indication of type and
number, stamped into the plate as well as into the pump itself - as for centrifugal
pumps, usually in the suction flange - as for other pumps, at an easily visible
place. If the pump is not mounted immediately after receipt it should be
protected during storage.

Mounting instructions:

When calculating the piping system, special regard should be paid to minimizing
pressure losses in the suction line (short pipe lengths, large diameter, few
bendings, no valves). If valves are necessary, then use valves with min. pressure
losses, e.g. slide valves, butterfly valves, flap non-return valves etc. Static
suction lift + total pressure losses in suction line + NPSH value of the pump +
steam pressure of the liquid must not exceed 10 m WC at sea level (and 760 mm
Hg).

For pumps delivered without motor

Mounting of coupling parts:

Before mounting, shaft and coupling parts must be carefully cleaned. Grease
shaft ends and check that key fits. Heat coupling parts to 70'C and push them on
to the shaft ends by hand or by a light pressure. By dismounting a puller will
have to be applied.

Alignment of couplings:

Flexible couplings will absorb small deviating in the relative positions of the shaft
ends to be connected, however, a careful and accurate alignment will prolong
the life of the coupling flexibles. When aligning the coupling halves the parallel
and angular accuracy should be as great as possible. Alignment must be carried
out in two axial planes at right angles (see sketch).
 A perfect alignment can be achieved by means of a straight-edge (axial
parallelism) and a feeler gauge (squareness) or by means of an indicator, as
shown in figures above. The coupling clearance must be within 2-6 mm
according to the size of the coupling.

Installation of the pump:

The entire piping must be pressure and leakage tested and flushed clean before
it is connected to the suction and discharge side of the pump. If the pressure
test takes place with the pump installed the testing pressure must not exceed
the testing pressure of the pump, which is stamped into the pump, usually in the
suction flange. Otherwise, the pump's packing or flanges for the mechanical
shaft seal might be damaged. Connection of the pipes to the pump must take
place without using force as this might interfere with the alignment of the pump.
Precautions must be taken to ensure that the pipe connections to the pump are
supported in a way that prevents tensions from being transmitted to the pump,
e.g. owing to thermal expansion. Check that all other connections to the pump
are in working order, such as lubrication, priming, heating, cooling medium
outlet, etc., and that the various measuring equipment has been correctly
connected. Take care that no parts obstruct access to the pump for inspection or
replacement of important parts. For pumps with axially split casing there should
be sufficient space for dismounting the top part of the pump casing.

Motor wiring:

Electric motors should be connected by means of sufficiently long cables to

permit the motor to be moved a little without dismantling the connections. A
control unit (emergency stop) should be installed close to the pump.

Engine driven pumps (diesel):

When using pumps driven by internal combustion engines vibrations may occur
in the system. It is recommendable to mount the unit on vibration dampers and
to install compensators between pump and pipelines. The calculation of vibration
dampers should be left to specialized companies.

Starting of the pump:

When the preceding preparations and installations have been completed the
pump can be started. Centrifugal pumps must be provided with a bypass if it is
operated for long periods with closed valve on the discharge side as, otherwise,
a too strong heating and expansion of the pump medium will occur. When
starting positive pumps (e.g. piston pumps, gear pumps and others), the valve
on the discharge side must be open as, otherwise, the pump may burst, in spite
of the fact that a bypass valve to the suction side is incorporated in these
pumps.

Pumps provided with mechanical priming pump should be checked for supply /
contents of liquid before starting. - for further information see the OEM's
operation instructions for priming pumps.

Pumps with mechanical shaft seal must be protected against impurities and dry
running. Supply of liquid or oil to the mechanical shaft seal is imperative. Please
note that clogged filters will cause considerable friction losses, which may
decisively affect the suction capacity and output of the pump.

Check also that the pump shaft can be turned by hand. Check also when starting
the pump that the direction of rotation is correct (usually shown with an arrow
on the pump), and open slowly the valve on the discharge side of the pump. At
normal discharge head the pump should run smoothly without abnormal noises
and vibrations after about one minute of operation.
Pumps with priming device:

The valve on the discharge side of the pump must be closed

during priming. The operating instructions for the priming
system should be strictly followed, see instructions for the
system in question (mechanical system with pump or ejector
system driven by compressed air). After priming of the
pump, open the valve on the discharge side slowly and
adjust it in such a way that permissible vacuum is not
exceeded.
Self-priming pumps:

All pumps:

It is an absolute requirement that pumps are not operating unnecessarily long

without liquid, normally max. 5 min. During the first hours of operation bearings,
packings and mechanical shaft (seal(s) should be checked for heating and
leakage. Normal bearing temperature is 40-75'C. Max. temperature for normal
ball and roller bearings is up to 105'C.

Maintenance of pumps:
Lubrication:

To pumps directly coupled on motor shaft it applies that only the bearings of the
motor require lubrication.

Pumps designed with bearing bracket and grease lubricated bearings should be
lubricated every 3rd month with ball bearing grease (lithium soap grease -
MOBILUX EP2 or similar quality). Check that not too much grease is pressed into
the bearings as this will cause generation of heat. All bearings are provided with
sealing rings in order to prevent humidity and impurities from entering. The
grease must not be pressed through these sealing rings. For bearings which are
exposed to higher pressures or humidity a heat resisting and water-repelling
grease will apply (MOLYPAN LT-1 or similar quality).

For pumps designed with oil lubrication, lubricating oil (MOBILGEAR 682 or
similar quality) can be used for normally loaded bearings. For more heavily
loaded bearings DTE26 or similar quality should be used. In case of oil sump
lubrication the oil level should be checked by means of screw-plug, oil-level
glass, oil indicator or other control equipment. see instructions for the pump in
question.
3 months' check:

Check the pump for false noises, vibrations and leakage. Pumps with mechanical
shaft seal must not leak, neither during standstill with inlet pressure on the
pump, nor during operation. The bypass pipe to the mechanical shaft seal must
be intact, and permit free flow. Likewise, the piping system and filter of the
priming device must be intact and permit free flow. In case of defects they must
be corrected immediately as they may greatly influence the operation and life of
the pump.

12 months' check:

Disassemble the pump (see instructions). Check the components of the rotary
element and perform all necessary repairs. Normal clearance between impeller
and sealing rings is 0,2-0,3 mm, and max. clearance is 0,5-0,8 mm, according to
size and capacity. Clean the pump casing inside and paint it if necessary (e.g.
with APEXIOR No. 3 or with more corrosion-resistant products, e.g. HEMPADUR
No. 1513 "Hempel Marine Paints").

Disassembling instructions:

Before starting the disassembly of the pump the sectional drawings of the
various pump parts should be studied closely. Most pumps are designed for easy
disassembly, and no special tools should be required. The pumps consist of
standard components, which means a large number of the components are used
in various pump sizes, for which reason it is necessary to keep a small stock of
spares for various sizes of the same pump type.

Pumps with split casing, can be disassembled without dismantling motor and
pipe connections. After dismounting of coupling bolts (tripartite coupling),
bearing housing top part and pump casing top part, the rotating element
consisting of shaft with impellers(s), bearings, casing wear rings, mechanical
seal(s) and coupling half can be lifted out for inspection, repair or replacement.

Assembling instructions:

When assembling the pump the mechanical seal must be treated with the
greatest care. Take care that the various parts are placed correctly. The rubber
bellows is mounted on the shaft by means of grease, which gives approx. two
hours respite before the bellows jams on the shaft. This means that within this
period it can be displaced when the packing flange is clamped by means of two
or four nuts. Otherwise, the mechanical seal might be damaged. Before
mounting the 0-rings (if any) they must be cleaned and provided with a thin
layer of grease. For further information see instructions for mechanical seal.

Bearing packing which was removed, must be reinstalled. In such places where
liquid packing has once been used this type of packing must be used again when
remounting the pump, as other types of packing would produce wrong spaces.

Mounting of motors on direct-coupled pumps:

If the pump is delivered without motor a distance ring is mounted between the
packing flange and the shaft. This ring must not be removed until the motor has
been mounted and the pump shaft screwed together with the motor shaft. Do
not forget to remove the ring before starting the pump!

Pumps with split casing:

When mounting the rotating element in the pump, take

care that the tongue of the wear rings fits correctly in the
groove of the pump casing. The bolts of the pump casing
must be tightened with a factor of 6,0 kg/m, the bolts of
the bearing housings with a factor of 3,0 kg/m.
When reassembling pumps, take care that impellers, as regards the vanes, have
the same direction of rotation as before the disassembling.

Maintenance (Storage instructions):

General instructions:
All pumps which are taken out of operation for some time should be protected
against corrosion and frost by being kept in a dry place. Additionally, the
following directions should be observed:

Preservation of bearings:

Both ball / roller bearings and slide bearings should be lubricated all over with
their normal lubricant.

Preservation of interior parts of the pumps: The interior parts of the pumps
should be protected against aggressive pumping media, for instance by using a
water-repelling solvent containing at the same time corrosion inhibiting nitrides.
We recommend MOBIL OIL - ARMA 245 or similar quality.

Preservation of gear wheel pumps and gearboxes: Gear wheel pumps do not
need any protection if they have been operating with oil products. If not, they
should be lubricated all over with a neutral oil. Gearboxes should be completely
filled with the oil specified. If the standstill lasts longer than 12 months the oil
should be emptied and replaced by MOBILARMA25 or similar quality and the
gearbox should be flushed with this oil.

Preservation procedure:

Flush the pump with pure, hot water (does not apply to screw pumps and gear
pumps) and let it airdry. Close the valves on both sides of the pump and flush
the pump with MOBIL ARMA 25 or similar quality. Flushing can take place
through the manometer connections.

Restarting of the pumps:

When restarting pumps it is advisable to fill the pump with hot water through the
manometer connections (does not apply to screw pumps and gear wheel pumps)
and to turn the pump shaft by hand before starting the pump. Watch the
operation of the pump for about 10 minutes and open the valve in the normal
way. Bearings, gearboxes etc. should be lubricated with normal oil or grease if a
change of oil has taken place.

Trouble shooting
Before starting any particular troubleshooting, you should check these basic
items.

• Check direction of rotation (marked with an arrow).

• Check that there is liquid in the pump (might have been emptied by
standstill).
• Check that the pump is able to turn by hand.
• Check that the pump has been lubricated with grease.
• Check the pump for noises and vibrations immediately after starting.
• Check priming pump (if any). See special instructions.

Possible problems...

A. Pump and motor cannot be actuated

B. Motor running but no pumping effect
C. Insufficient capacity
D. Pump pressure too high
E. Capacity too large
F. Discharge head too low
G. Power consumption too large
H. Pump output decreases or stops
I. Irregular running
K. Increasing noise level
L. Leaks
M. Bearing temperature too high
N. Pump wears out quickly
O. Stark vibrations

A. Pump and motor cannot be actuated:

1. Impeller or shaft blocked.

2. Motor fault.

B. Motor running but no pumping effect:

1. Motor rotation is not transmitted through coupling.

2. Discharge valve closed.
3. Non-return valve or other valves are closed.
4. Suction line closed or filter clogged.
5. Air in pump casing.
6. Suction line leaking.
7. Shaft seal leaking.
8. Bottom valve defective.
9. Suction lift too high.
10. Priming pump defective.

C. Insufficient capacity:

1. Wrong direction of rotation.

2. Number of revolutions too low.
3. Counter-pressure too high.
4. Suction line or impeller partly clogged.
5. Air in pump casing.
6. Air in pumping medium.
7. Suction lift too high (inlet pressure too low).
8. Capitation.
9. Suction line leaking.
10. Shaft seal leaking.
11. Pump worn out.

D. Pump pressure too high:

1. Number of revolutions too high.

2. Impeller oversized.
3. Too many pressure stages.
4. Specific gravity of pumping medium too high.
5. Viscosity of pumping medium too low.
6. Inlet pressure too high.
7. Manometer defective.

E. Capacity too large:

1. Number of revolutions too high.

2. Impeller diameter too big.
3. Counter-pressure too low.

F. Discharge head too low:

1. Number of revolutions too low.

2. Impeller diameter too small.
3. Too few pressure stages.
4. Specific gravity of pumping medium too low.
5. Viscosity of pumping medium too high.
6. Manometer defective.

G. Power consumption too large:

1. Motor too small.

2. Motor fault.
3. Capacity too large.
4. Counter-pressure too low.
5. Stuffing-box tightened too much.
6. Shaft ends out of alignment.
7. Electricity supply incorrect (voltage, amperage, frequency).

H. Pump output decreases or stops:

1. Suction line leaking.
2. Shaft seal leaking.
3. Increasing suction lift.
4. Filter clogged.
5. Cavitation.

I. Irregular running:
1. Bearings defective.
2. Motor fault.
K. Increasing noise level:
1. Beginning cavitation.
2. Air in pumping medium.
3. Capacity too large.
4. Clamping to base loosened.
5. Base bolts loosened.
6. Influences from pipe connections or base.

L. Leaks:
1. Cracks in pump casing.
2. Faulty assembly of pump.
3. Pipe connections leaking.
4. Shaft seal leaking (in case of soft stuffing-box packing minor leaks are
necessary).

M. Bearing temperature too high:

1. Faulty lubrication or wrong lubricant.
2. Deficient pump alignment.
3. Influences from pipe line.
4. Coupling distance wrong.
5. Shaft bent.
6. Foreign bodies or impurities in bearings.

N. Pump wears out quickly:

1. Wrong materials in relation to pumping medium.
2. Cavitation.
3. Stuffing-box tightened too much.
4. Shaft bent.
5. Deficient alignment.
6. Influences through pipe line.

O. Stark vibrations:
1. Foreign bodies in pump.
2. Motor out of balance.
3. Other influences.
 Types of pumps
Centrifugal

Shown above is a cross section through a vertically mounted centrifugal pump.

Water is led to the suction eye of the rotating impeller. The water gains energy by
the centrifugal action of the pump and is discharged to the volute outlet casing. The
volute is created by increasing the area of the outlet port and is greatest at outlet
from the pump. By this design the kinetic energy of the water is converted to
pressure energy.

Sealing is provided by a mechanical seal (one half of which is shown above and in
more detail below) or by packed gland. For the former cooling water is supplied from
the discharge side of the pump. For the latter cooling is provided by the allowance of
slight leakage, lubrication is by a grease filled manual lubricator.
Mechanical seal

Packed gland seal

The pump unit shown above relies on the driving motor bearings for alignement. For
larger pumps a leaded bronze or brass bush may be fitted positioned just below the
seal.For the largest pumps, especially those fitted with an inducer the shaft may be
extended below the impeller fixing and a second bearing fitted
Impellers

The kinetic energy of the fluid flowing through the impeller is converted to pressure
energy by the shape of the volute casing. For high pressure pumps such as boiler
feed pumps a diffuser ring is fitted in the casing which converts a greater portion of
the pressure energy allowing greater pressures to be generated.

A scroll type inducer may be fitted to the inlet which improves the efficiency of unit
and allows the pump to operate with low suction pressures.

Wear rings

For efficient operation it is important to ensure that leakage from the high to low
pressure side is kept to a minimum. This is achieved by the use of wearing rings.
Traditionally these are fitted to the casing,to increase the longevity of the impeller
wear ring tyres may be fitted.

The clearance given for wear rings is often a source of contention especially
when dealing with on-ship made rings. A clearance of 1/1000 of the diameter of
the bore is often quoted although this may be very difficult to achieve in practice.

Axial force

Without careful design an axial force is created by the action of the impeller. This is
due to the low pressure acting on the suction eye whilst the rest of the impeller is
subjected to discharge pressure.

One solution is shown above where radial blades are cast into the back (stuffing box
side) of the impeller. These blades are commonly called pump-out vanes, and are
meant to increase the centrifugal force of the fluid trapped behind the impeller. This
causes the fluid to be "thrown" outwards, reducing the pressure behind the impeller
for the same reason that the impeller causes a reduction of pressure at the suction
eye.

Another method which may be found in conjunction with the pump-out vanes are the
balancing holes. These are holes drilled near the center of the impeller, connecting
the space in the back of the impeller with the suction eye. This reliefs the pressure
behind the impeller by allowing the high pressure fluid trapped there to flow to the
low pressure region at the suction eye. In order for this to be effective, there must
be a tight clearance between the impeller and the casing to reduce the flow of fluid
into the back of the impeller.

Alternately dual back to back impellers may be fitted in common with a double
casing

Materials suitable for general service

Shaft Stainless steel
Impeller Aluminium bronze
Casing Bronze or cast iron
Wear ring Aluminium bronze or brass

Positive Displacement
This class of pump differs from the centrifugal class by several important factors

• Generally self priming whereas centrifugal generally require a priming means such as
a belt driven priming pump
• Require the fitting of a safety valve to limit maximum pressure- this pump cannot be
started against a shut discharge valve.
Centrifugal pumps may be started against a shut or partially shut discharge valve. This is
especially true for larger pumps where the shutting of the discharge reduces starting and
running load.
It should be noted that the partially shutting of the suction valve on both types of pumps
leads to damaging cavitation.
• Positive displacement pumps can handle high differential pressures
• More suited to low to medium flow rates
• May operate with higher viscosity fluids then centrifugal types

Gear
The pump shown above is of very common design. It is used for pumping many
types of liquid and gas and is capable of delivering at very high pressures. This
makes it suitable for hydraulic supply.

The tooth profile is similar involute gear teeth for liquid pumps. For gas pumps
special profiling with very fine tolerances is employed.
Scroll

These pumps are seen in many applications and have a higher capacity then double
row type. Fluid enters the pump and is screwed by the idler shafts along the outer
edge to the discharge port. Axial thrust of the idlers is absorbed by the integral
thrust collar of the driven shaft. The axial thrust of the driven shaft is absorbed by
the thrust bearing.
The scroll sit in a replaceable insert which is sealed to the outer casing by o-rings.
Piston

This type of pump is in common use as a bilge pump or tank stripping pump. For
older vessels steam driven varieties served in almost all systems.

The design is simple, robust and reliable. Materials are very much dependent on the
usage but bronze is common for larger parts and stainless steel for piston rods

There are many other forms of positive displacement pump such as rotary vane
(often found in use as cooling water pumps, Scroll or Screw pumps were the fluid
passes axially along the shaft and Diaphragm Pumps (commonly used as portable
salvage pumps)

This air supply valve assembly normally takes the form of a shuttle valve.
 Axial Flow

These tend to fit somewhere between postive displacement and centrifugal. They
tend to be of the very large capacity type and are oftern seen in use for supply of
cooling water for steam ship condensers. This is particularly true where 'scoops' are
employed as the axial flow pump offers very little resistance to flow when idling.
During operation cosiderable end trust occurs and a tilting pad thrust bearing is
employed. Guide vanes smooth flow into and out of the impeller.

Inducers

A type of axial flow pump is sometimes attached to the suction side of a centrifugal
pump. This is called and inducer and is used where the suction heads are very low or
where suction occurs close to the vaporiation pressure of the fluid being pump.
Typical examples are the main condenser extraction pumps on steam ships and
cargo pumps on LNG and LPG carriers

Cavitation

Disturbances in the water flow causes rapid localised pressure variations. This can
lead to instantaneous vaporisation and bubble formation. When these bubbles
collapse there is a rapid in rush of water. When this occurs near to a surface this slug
of water can strike at speeds of up to 500m/s and lead to destructive erosion and
removal of protective oixides thereby increaseing rates of corrosion