Pumps

05/04/2012

Classification of Pumps

Continuous energy addition Conversion of added energy to increase in kinetic energy (increase in velocity) Conversion increased velocity to increase in pressure

Periodic energy addition Added energy forces displacement of fluid in an enclosed volume Fluid displacement results in direct increase in pressure

API 610 Centrifugal Pump Classification

Centrifugal Pump

Overhung

Between Bearing

Vertically Suspended

Submersible Motor

Flexible Coupling

Overhung Pumps Flexibly Coupled

Horizontal
Foot Mounted Centerline Mounted
Flexible Coupling Thrust Bearings

Vertical
In-Line Bearing Frame

Overhung Pumps Rigidly Coupled Vertical

Rigid Coupling No thrust bearings!

In-Line

Overhung Pumps Close Coupled Horizontal Vertical In-Line High Speed Integral Gear

Overhung Pumps Seal less

Magnetic Drive

Canned Motor

Between Bearing Pumps 1 & 2 Stage Multistage (more than 2 stages)

10

Between Bearing Pumps 1 & 2 Stage Axially Split Radially Split

11

Between Bearing Pumps Multistage

Radially Split
Single Casing Double Casing

Axially Split

12

Vertically Suspended Pumps Single Casing Double Casing

13

Vertically Suspended Pumps Single Casing Discharge Through Column Diffuser Volute Tubular Casing (Axial / Mixed Flow) Seperate Discharge Line Shaft Cantilever

14

V ertically S uspended P ps um D ouble C asing D se iffu r V olute

15

Working of a Centrifugal Pump

Main Parts are Impeller Volute casing

16

Working of a Centrifugal Pump

Impeller rotates exerting centrifugal force on the liquid Kinetic energy is created Centrifugal force throws the liquid out

Creating low pressure at the suction eye

This forces new liquid into the impeller inlet Liquid thrown out of the impeller is met with resistance to flow
17

Working of a Centrifugal Pump

The first resistance is created by the volute As the liquid moves in the volute towards the outlet it slows down due to increasing cross sectional area

As the liquid slows down its velocity (kinetic energy) is converted into pressure

18

Relation between Head and Velocity

Head = pressure in terms of height of liquid

v2 Head (m) = 2xg

v = velocity at periphery of impeller (m/s) g = Gravitational acceleration (m/s2) NxD v (m/s) = 2.748
N = Impeller RPM D = Impeller diameter (mm)
19

Working of a Centrifugal Pump

The impeller is offset in the volute to create a close clearance between the impeller and the volute at the cut water The kinetic energy given to the liquid is proportional to the velocity at the edge of the impeller vane tip. Faster the impeller rotates or bigger the impeller is, higher will be the liquid velocity at the vane tip.

A centrifugal pump neither creates pressure nor does it suck, it only provides flow. Pressure is just an indication of the amount of resistance to flow!
20

Why Head is used to measure the energy of a centrifugal pump?

30 m

2.4 kg/cm2 30 m

3 kg/cm2

30 m

3.6 kg/cm2

Kerosene Sp.gr. 0.8

Water Sp.gr. 1.0

Brine Sp.gr. 1.2

21

Why Head is used to measure the energy of a centrifugal pump?

Pressure at any point in a liquid is caused by a vertical column of liquid due to its weight. Height of this column is called Static head and is expressed in meters of liquid. Head is a measurement of the height of a liquid column that the pump could create from the kinetic energy imparted to the liquid. Pressure is dependent on the specific gravity of a liquid but head is not.

A given pump with a given impeller diameter and speed will raise a liquid to a certain height regardless of the weight of the liquid!
22

Pressure Head conversion

Head (m) =

Pressure (kg/cm2) x 10 Specific Gravity

23

Various Heads
Static Suction Head (hs) Static Discharge Head (hd) Friction Head (hf) Vapour Pressure Head (hvp) Pressure Head (hp) Velocity Head (hv) Total Suction Head (Hs) Total Discharge Head (Hd) Total Differential Head (HT) Net Positive Suction Head Required (NPSHr) Net Positive Suction Head Available (NPSHa)

Exit Various Heads & Continue

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Static Suction Head (hs): Vertical distance between the pump centerline and the liquid surface in the suction tank.

Pd
Vd hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Next Back

25

Static Suction Head (hs): Vertical distance between the pump centerline and the liquid surface in the suction tank. Suction Lift (-hs): Liquid level is below pump center line.

Pd
Vd hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Next Back

26

Static Suction Head (hs): Vertical distance between the pump centerline and the liquid surface in the suction tank.
Suction Head (+hs): Liquid level is above pump center line.

Ps Pd Vs hd hs
Datum Level Pump Center Line

Pvp

Vd

Back

27

Static Discharge Head (hd): Vertical distance between the pump centerline and the point of free discharge or liquid surface in the discharge tank.

Pd
Vd hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Next
28

Static Discharge Head (hd) and Static Suction Head (hs) change as the liquid flows.

Back

29

Friction Head (hf): Head required to overcome resistance to flow in the pipe and fittings.
hf depends upon the size, condition and type of pipe & fittings, flow rate and nature of liquid.

Pd
Vd hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Back
30

Vapour Pressure Head (hvp): is the vapour pressure converted into head. hvp increases with increase in temperature hvp acts opposite to the surrounding pressure acting on the liquid (atmospheric pressure)

Pd
Vd hd
Datum Level Pump Center Line

Ps Pvp Vs

hs

Back

31

Pressure Head (hp): is the absolute pressure (Ps or Pd) acting on the liquid in the suction or discharge tanks.
If tank is open to atmosphere, hp = atmospheric pressure head.

Pd
Vd hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Back
32

Velocity Head (hv): refers to the energy of the liquid as a result of its motion at some velocity. It is the equivalent head in meters through which the liquid would have to fall to acquire the same velocity. hv is relatively small in high head systems and relatively large in low head systems

Pd
Vd

hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Back
33

Total Suction Head (Hs) = Pressure head in suction reservoir (hps) + static suction head (hs) + velocity head at the pump suction flange (hvs) friction head in the suction line (hfs). Hs = reading of the gauge on the suction flange converted to meters of liquid.

Pd
Vd

hd

Hs
Datum Level Pump Center Line

Ps

hs

Pvp Vs Back
34

Total Discharge Head (Hd) = Pressure head in discharge reservoir (hpd) + static discharge head (hd) + velocity head at the pump discharge flange (hvd) + friction head in the discharge line (hfd). Hd = reading of the gauge on the discharge flange converted to meters of liquid.

Pd
Vd

hd

Hd
hs
Datum Level Pump Center Line

Ps

Pvp Vs Back
35

Total Differential Head (HT) = Total Discharge Head (Hd) Total Suction Head (Hs)

Pd
Vd Hs hd

Hd
hs
Datum Level Pump Center Line

Ps

Pvp Vs Back
36

Net Positive Suction Head

Before we jump to the term NPSH, we shall understand

Parts of a Pump
Flow through Pump Inlet Cavitation

37

Parts of a Centrifugal Pump

Discharge Flange (outlet) Pump Casing Bearing Bracket Vent Plug Bearing Cover Suction Flange (Inlet) Shaft Bearing Bracket Support Mechanical Seal / Gland Packing
38

Pump Feet (support)

Parts of a Centrifugal Pump

Heating/ Cooling Jacket Outlet(Discharge) Discharge Flange Seal Flushing Pipe

Bearing Bracket Lantern Bearing Bracket

Pump Casing Radial Bearing Casing Wear Ring

Thrust Bearing
Bearing Cover

Impeller Inlet (Suction)

Suction Flange
Impeller nut Casing Cover Bottom Feet Casing Drain Connection Key Shaft Splash Ring Mechanical Seal Shaft Protection Sleeve

Oil Seal Oil Chamber Bearing Bracket Support

39

Impeller Nomenclature
Front Shroud Back Shroud Vane

Outer Hub

Vane Suction Edge Impeller Eye

Shaft

Suction Eye Diameter

Inner Hub Back Vane Vane Discharge Edge

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Flow Through Pump Inlet

Liquid moves through decreasing cross-section area (as in a Venturi). Liquid velocity increases as its pressure decreases not only due to Venturi effect but also frictional loss. At the point of minimum cross-section (impeller eye) velocity is max and pressure is min. Pressure drops down further due to shock & turbulence as the liquid strikes the edges of impeller vanes. Results in creation of low pressure around the impeller eye and beginning of impeller vanes.

41

If the pressure drops below the vapour pressure of the liquid at the operating temperature, the liquid will vaporize.

42

43

Formation of Bubbles inside the liquid New bubbles continue to form and older ones grow in size Bubbles get carried by liquid at high velocity from impeller eye towards impeller exit

Bubbles eventually reach the regions of high pressure within the impeller
The pressure outside of the bubble exceeds that inside of the bubble Hundreds of bubbles collapse by bursting inwards (implosion, not explosion!) When bubbles collapse surrounding liquid rushes to fill the void forming a liquid microjet Creates highly localised hammering effect, pitting the impeller An audible shock wave emanates outward from the point of collapse Bubble Collapse pressures greater than 1GPa (10,000 bar) have been reported! Life cycle of a bubble has been estimated to be in the order of 0.003 seconds!
44

This dynamic process of formation of bubbles inside the liquid, their growth and subsequent collapse is called CAVITATION.
Cavitation can be of two types Vaporous: due to vaporisation of the liquid Gaseous: due to formation of gas bubbles in a liquid containing dissolved gas Cavitation - Heart Attack of the Pump Obstruction to flow Impair performance reduce capacity and head Abnormal noise and vibrations Damage impeller and other sensitive components A Centrifugal pump can handle air in the range of 1/2 % by volume. Cavitation begins if this value is increased to 6%. 45

Impeller Cavitation Regions

46

Cavitation Pitting

47

NPSH
Pumps can only pump liquid, not vapours
1 cu. ft. of water at room temperature becomes 1700 cu. ft. of vapour at the same temperature ! Hence, to pump a liquid effectively, it must be kept always in liquid form

Rise in temperature and fall in pressure induces vaporisation

The pump always needs to have a sufficient amount of suction head present to prevent vaporisation at the lowest pressure point in the pump

NPSH as a measure to prevent vaporisation

The NET POSITIVE SUCTION HEAD is the total head at the suction flange of the pump less the vapour pressure converted to fluid column height of the liquid
48

NPSH
NPSHr - Net Positive Suction Head Required
NPSHr is a function of the pump design
NPSHr is determined based on actual pump test by pump manufacturer. NPSHr is the positive head in meters absolute required at the pump suction to overcome the pressure drop in the pump and maintain the majority of the liquid above its vapour pressure. Net refers to the actual pressure head at the pump suction flange and not the static suction head. NPSHr increases as capacity increases NPSHr is independent of liquid specific gravity
49

NPSH
NPSHa - Net Positive Suction Head Available
NPSHa is a function of the system design
NPSHa is calculated based on the system or process conditions NPSHa is the total suction head corrected to the centerline of the first stage impeller less the vapour pressure head. Net refers to the actual pressure head at the pump suction flange and not the static suction head. NPSHa is independent of liquid specific gravity

50

NPSHa = Pressure head in suction reservoir (hpi) + static suction head (hs) + velocity head at the pump suction flange (hvi) friction head in the suction line (hfi) vapour pressure head at the max. pumping temperature (hvp)

Pd
Vd hd
Datum Level Pump Center Line

Ps

hs

Pvp Vs Back
51

Capacity
Flow rate with which liquid is moved by the pump Measured in m3/hr or GPM or LPM Capacity depends on Liquid characteristics density, viscosity Pump size, inlet & outlet sections Impeller size Impeller rotational speed RPM Size & shape of cavities between vanes Pump suction & discharge temperature and pressure conditions
52

Power and Efficiency

Brake Kilo Watt (BKW) Mechanical power delivered to the pump shaft

Q H Specific Gravity BKW 367

Hydraulic Kilo Watt (WKW)

Q = Capacity, m3/hr
H = Total Differential Head, m h = Efficiency, %

Liquid power delivered by the pump

WKW

Q H Specific Gravity 367

Q = Capacity, m3/hr H = Total Differential Head, m

Pump Efficiency (h)

W KW BKW

BKW = WKW + Mechanical Losses + Hydraulic Losses

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Pump Performance Curve

Shutoff Head Point

Best Efficiency Point

70 60

14
Run Out Point

12 10 8 6 4 2 0 0 10 20 30 40 50

50 40 30 20 10 0

Capacity (m3/hr)

Pump Input (BKW) / NPSHr (m)

Head (m) / Efficiency (%)

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Radial Thrust

Radial Force acting on Impeller = Flow (=constant) x Area (=varying)

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Radial Thrust
The exact points at which the forces will be generated is determined by the Specific Speed (shape) of the impeller. Francis vane impellers (the most popular shape) deflect at approximately 60 and 240 degrees measured from the cutwater, in the direction of shaft rotation. Radial vane impellers deflect at close to 90 and 270 degrees. Axial flow impellers deflect close to 180 and zero degrees from the cut water

56

Pump Performance Curve & Radial Thrust

Shutoff Head Point

Best Efficiency Point

70 60 50 40 30 20 10 0

14 12 10 8 6 4 2 0
Preferred operating range Run Out Point

Head (m) / Efficiency (%)

10

20

30

40

50
57

Min. Continuous Stable Flow

Capacity (m3/hr)

Radial Thrust
Allowable operating range

Single Volute Vs Double Volute

58

Effect of Impeller Diameter

70 60 50
Head (m)

70 60 50 40 30 20 10 0 0 10 20 30 40 50
59

40 30 20 10 0 Capacity (m3/hr)

Efficiency (%)

Pump Performance Curve

60

Typical H-Q with Iso-Efficiency Curves

Iso-Efficiency Curves

Head

Capacity

61

System Resistance Curve

Total System Head = = Static System Head + Dynamic System Head
( Discharge Velocity Head - Suction Velocity Head + Discharge Friction Head + Suction Friction Head ) ( hvd - hvs ) + ( hfd + hfs ) ( Vd2 Vs2 ) + ( hfd + hfs ) 2xg Pd Vd hd
Datum Level Pump Center Line

( Discharge Static Head - + Suction Static Head) + (Discharge Pressure Head Suction Pressure Head ) ( hd hs ) + ( hps hpd ) + ( hd hs ) + ( Pd Ps ) rxg

= =
hs = -ve, if suction lift hs = +ve, if suction head suffix s = suction suffix d = discharge r = density, kg/m3 g = gravitational constant, m/s2 hf = z x V2 2xg , (zloss coeff. )

Ps Pvp Vs

hs

62

System Resistance Curve

70 60 50

Head (m)

40 30 20 10 0 0 10 20 30 40 50

Dynamic System Head

Static System Head

Capacity (m3/hr)

63

Operating Point
Best Efficiency Point

70
Operating Point

60

Head (m) / Efficiency (%)

50 40 30 20 10 0 0 10 20 30 40 50
64

Dynamic System Head

Static System Head

Capacity (m3/hr)

Specific speed (Ns) is a non-dimensional design index Ns, is the speed in RPM at which a geometrically similar impeller would operate if it were of such a size as to deliver 1 m3/hr against 1 m head. Ns, is primarily used to describe the geometry (shape) of a pump impeller N Q Ns 3 Ns, is used as an4index to predict certain pump characteristics

Specific Speed (Ns)

N = The speed of the pump in revolutions per minute (rpm.) Q = Capacity in LPM at the best efficiency point H = The total head per stage in meters at the best efficiency point

65

Specific Speed (Ns)

As the specific speed increases, the ratio of the impeller outlet diameter, D2, to the inlet or eye diameter, Di, decreases. This ratio becomes 1.0 for a true axial flow impeller Values of Specific Speed, Ns

66

Impeller Types Based on Flow

Radial Flow Impeller

Mixed Flow Impeller

Axial Flow Impeller

67

Impeller Types Based on Flow

Head Develoved by Flow Vs Head Nature of H-Q Curve Power Input Specific Speed Centrifugal Force Axial Force

Low Flow High Head

Lesser Steep (More Flatter) Increases with flow Lower Specific Speed

High Flow Low Head

More Steep Decreases with Flow Higher Specific Speed

Radial Flow Impeller

Axial Flow Impeller

Mixed Flow Impeller

68

Typical Performance of a Radial Impeller

69

Typical Performance of a Mixed Impeller

70

Typical Performance of a Axial Impeller

71

Affinity Laws
Effect of Speed on Pump Performance
System Resistance Curve

Keeping Impeller diameter D constant

B1

H1 H2 B3

B2

N1 N2 N3

Q2 =

N2 N1

x Q1

H3

H2 =

Head H

N2 2 x H1 N1 N2 3 x P1 N1

N - Speed B - Operating Point

P2 =

Capacity Q

Q3

Q2 Q1
72

Affinity Laws
Effect of Impeller Diameter on Pump Performance
System Resistance Curve

Keeping Speed N constant

B1

H1 H2 B3

B2

D1 D2 D3

Q2 =

D2 D1

x Q1

H3

H2 =

Head H

D2 2 x H1 D1 D2 3 x P1 D1

N Speed (constant) B - Operating Point

P2 =

Capacity Q

Q3

Q2 Q1
73

Effect of Viscosity on Pump Performance

HW HZ BW BZ

Q Z = fQ x QW HZ = fH x QH hZ = fh x Q W
D1 D2 D3 fQ Capacity Correction Factor fQ Head Correction Factor fh Efficiency Correction Factor

Efficiency

Power P

Head H

Capacity Q

QZ

QW

B Operating Point W Water Z Viscous Liquid

74

Viscosity Correction Chart

- use for viscosity greater than or equal to 4.0 cst - not to use for gels, slurries, paper stock (non Newtonian liquids) - use for pumps with conventional hydraulic design, in normal operating range, open or closed impellers - not to use for axial, mixed flow or special hydraulic design - do not extrapolate

75

Effect of Valve Closing on the Operating Point

System Resistance Curve

B4

B3

Q-H Curve B2 B1

Head H
B - Operating Point

Capacity Q
76

Characteristics of Performance Curve

Drooping Curve (unstable)

DH

Flat Curve

Head H

DQ

DQ

Steep Curve

Capacity Q

B - Operating Point
77

Parallel Operation
Two or more pumps operating in parallel Common method for meeting variable capacity requirement Pumps with unstable characteristics may be troublesome unless operation only on the steep portion No pump should be operated at flows less than pump minimum flow

78

Parallel Operation
50 45 40
H1= H2 35 System Head Curve

Head H

30
Combined

25 20 15 10 5 0 0 10 20 30
Q2 Q1 Q1+ Q2

Pump 1 Pump 2

40

50

60

70
79

Capacity Q

Series Operation

Two or more pumps operating in series

Common method for meeting variable head requirement

80

Series Operation
90 80 70 60
Head H

System Head Curve

50
Pump 1

Combined

40 30 20 10 0 0 10 20 30 40 50
81

Pump 2 H2 H1

Capacity Q

H1 + H2

Types of Impellers

Closed Radial Flow Impeller

Closed Mixed Flow Double Entry Impeller

Closed Mixed Flow Impeller

Open Mixed Flow Impeller

Open Mixed Flow Impeller

Axial Flow Entry Impeller

82

Types of Impellers (Non-Clog)

Closed One Vane Impeller

Closed Two Vane Impeller

Closed Three Vane Impeller

Open One Vane Impeller

Open Two Vane Impeller

Open Three Vane Impeller

Used for liquids containing solids More free passage

83

Types of Impellers (Special)

Free Flow Impeller

84

Types of Impellers (based on the no. of inlets)

Single Suction

Double Suction
85

Axial Thrust
(Single Suction Impeller)
Discharge Pressure Discharge Pressure

Suction Pressure

Discharge Pressure

Discharge Pressure

86

Axial Thrust
(Double Suction Impeller)
Discharge Pressure Suction Pressure Discharge Pressure Suction Pressure

Suction Pressure Discharge Pressure

Suction Pressure Discharge Pressure

87

Axial Thrust
Discharge Pressure Balanced Forces Un-Balanced Forces Un-Balanced Forces Balanced Forces

Discharge Pressure

The Unbalanced Axial Thrust on an impeller is counterbalanced by Thrust Bearings 88

Axial Thrust
Methods to Reduce Unbalanced Axial Thrust

Back Vane

89

Axial Thrust
Methods to Reduce Unbalanced Axial Thrust

Balancing Hole

Back Wearing Ring Balancing Hole

90

Axial Thrust
Methods to Reduce Unbalanced Axial Thrust
Counter Balancing Disc

Balancing Disc

Balancing Disc

91

Axial Thrust
Methods to Reduce Unbalanced Axial Thrust
Expansion chamber Balancing water line to the suction casing of the pump or to the feedwater tank

Oil-lubricated thrust bearing

Balancing Drum (Single Piston)

Balancing Piston
92

Axial Thrust
Methods to Reduce Unbalanced Axial Thrust
Expansion chamber Balancing water line to the suction casing of the pump or to the feedwater tank

Oil-lubricated thrust bearing

Balancing Drum (Double Piston)

Balancing Double Piston

93

Internal Recirculation
Recirculation is a flow reversal at the suction and or discharge tips of impeller vanes Recirculation depends on impeller design Every impeller has a critical flow at which recirculation occurs Recirculation can cause noise, vibration & cavitation Pumps with Low NPSHR is more susceptible to cavitation when operating in the regions of recirculation flows Suction Specific Speed (NSS) is a guide to predict how close the pump is to be operated to the BEP to avoid recirculation and thus cavitation

Suction Recirculation

Discharge Recirculation 94

Suction Specific Speed (NSS)

Nss, is used as a non-dimensional index to predict cavitation due to suction recirculation flow

Nss

N Q at BEP 3 4 NPSH at BEP

N = The speed of the pump in revolutions per minute (rpm.) Q = Capacity in GPM (m3/s) at the best efficiency point of top impeller NPSH = The NPSH in feet (meters) at the best efficiency of top impeller Higher the NSS, the closer will be the beginning of recirculation to the capacity at best efficiency Guideline: NSS should not exceed 12,000 USGPM, ft, rpm (or 232 m3/s, m, rpm). Lower the NSS safer the pump against cavitation. If the available NPSH is low enough to require a pump with NSS of 18,000 US units(348 metric units) then it is better to use an axial flow impeller ahead of the centrifugal impeller.
95

Initial recirculation

*Typical h1/D2 ratios are as follows Double suction 0.35-0.50 Multistage 0.50-0.70

1. For water pumps rated at 2500 gpm & 150 feet total head or less the min. operating flows can be reduced to 50% of the suction recirculation values shown for continuous operation & 25% for intermittent operation
2. For hydrocarbons the min. operating flows can be reduced to 60% of the suction recirculation values shown for continuous operation & 25% for intermittent operation.

96

Diffuser
Impeller Impeller Diffuser

Volute Casing without Diffuser

Volute Casing with Diffuser

97

Diffuser

Comparison of Radial Forces acting on an impeller inside a volute casing and inside a diffuser casing
98

Diffuser
A diffuser consists of a number of vanes set around the impeller Flow from a diffuser is collected in a volute or circular casing and discharged through the outlet pipe A diffuser does the same function as the volute casing in energy conversion A diffuser converts vortex flow at the exit of an impeller into a vortex-free flow with minimum loss A diffuser reduces the unbalanced radial forces acting on an impeller Diffuser is used in high pressure multistage pumps, in vertical turbine (axial flow) pumps and seldom applied to a single stage radial flow pump.
99

Common Suction & Discharge Configurations

End Suction / Top Discharge

Top Suction / Top Discharge

Side Suction / Side Discharge

100

Axially Split Casing Pump

Single Stage, Double Suction, Between Bearing, Side Suction / Side Discharge

Multistage Stage, Single Suction, Between Bearing, Side Suction / Side Discharge

101

Radially Split Casing Pump

Single Stage, Single Suction, Overhung, End Suction / Top Discharge

Multi Stage, Ring Section, Single Suction, Between Bearing, Top Suction / Top Discharge
102

Barrel Casing & Ring Section

Multi Stage, Ring Section, Single Suction, Between Bearing, Top Suction / Top Discharge Barrel Casing

Multi Stage, Double Casing, Single Suction, Between Bearing, Top Suction / Top Discharge

103

Vertical (Can) Barrel Casing Pump

Thrust Bearing

Column Pipe Guide Bearing Line Shaft

Bowl Casing Impeller Pump Shaft Barrel Casing

104

End-Suction, Back Pull-out Arrangement with Spacer Coupling

Discharge Pipe

Suction Pipe

Coupling with Spacer

105

End-Suction, Back Pull-out Arrangement with Spacer Coupling

Remove Spacer

106

End-Suction, Back Pull-out Arrangement with Spacer Coupling

Pump Suction & Discharge nozzles remain connected to piping!

107

End-Suction, Back Pull-out Arrangement with Spacer Coupling

Back Pull-out assembly lifted!

108

End-Suction, Back Pull-out Arrangement with Spacer Coupling

109

Advantage of a Double (Barrel) Casing Pump

Discharge Pipe
Cartridge Barrel Casing Suction Pipe

Cartridge Removal Tools

110

Pump Priming

Earths atmosphere is approx. 80,000 m above the earth, resting on the earth with a weight equivalent to a layer of water 10 m deep at sea level The weight of water is approx. 8000 times that of air
111

Pump Priming
Centrifugal pumps can pump air at their rated capacity, but only at a pressure equivalent to the rated head of the pump. Centrifugal pump can produce only 1/8000 of its rated water pressure when handling air In other words, for every 1m water that has to be raised to fill the pump, the pump must produce a discharge head of approx. 8000 m, which is impossible! Hence, it is necessary to fill the waterways in a pump with liquid before starting it. A centrifugal pump is said to be PRIMED when the waterways of the pump is completely filled with liquid to be pumped.

112

Methods of Pump Priming

Foot Valve

113

Methods of Pump Priming

Priming Chamber

114

Methods of Pump Priming

To Vacuum Pump

115

Methods of Pump Priming

Self Priming Pump

116

Inducer
Inducer is an axial flow impeller fitted ahead of the centrifugal impeller to reduce the NPSH of the pump or to permit the pump to operate at higher speeds. Impeller

Inducer

Inducer
117

Inducer
Inducer is mounted on the same shaft as that of the centrifugal impeller and rotates at the same speed Inducer increases the suction pressure of a conventional impeller Although the efficiency of the inducer is low, it will not reduce the pump overall efficiency significantly

Inducers have typically 2 but not more than 4 vanes

NPSHr

NPSH without Inducer NPSH with Inducer

Capacity Q

118

Methods of Reducing Pump NPSH

Double Suction Arrangement

119

Methods of Reducing Pump NPSH

Impeller

Inducer

Inducer Arrangement
120

Methods of Reducing Pump NPSH

Increase Impeller Eye Area

121

TYPICAL MATERIAL OF CONSTRUCTION

122

TYPICAL MATERIAL OF CONSTRUCTION

123

Torque Speed Characteristics

124

Bearing Bracket
Radial Bearing
Shaft Deflector Oil Seal Oil Seal Thrust Bearings

125

REQUIREMENTS OF API 610 Scope API 610 is a standard that covers the minimum requirements for centrifugal pumps for use in petroleum, heavy duty chemical and gas industry services. It includes pumps running in reverse as hydraulic power recovery turbines. Why is API 610 Published? API 610 has been written to ensure a minimum standard for: Safety Reliability Maintainability

Pump Types Covered 126 API 610 covers all types of centrifugal pumps,

 Long Reliable Life

FEATURES OF API 610

API pumps must be designed and constructed for a minimum service life of 20 years and at least 3 years of uninterrupted operation (clause 2.1.1). In practice there are many API 610 pumps in industry that have been operating for in excess of 40 years and many oil refineries are now reporting MTBF figures in excess of 7 years.

Casing Design
The pump pressure casings must be designed using the stresses, welding and inspection practices given in the pressure vessel code (2.2.1). Overhung pumps, between bearings radially split pumps, multi-stage pumps and vertical double case pumps are to be designed with a pressure rating equal to the lesser of 4,000 kPa-g or an ANSI 300#127 flange rating (2.2.2).

FEATURES OF Moments External Nozzle Forces andAPI 610

API 610 lists the maximum forces and moments, which the pump nozzles must be able to take, and still give satisfactory performance. Case distortion and shaft misalignment are considered when assessing satisfactory performance (2.4.1). The pump must meet these requirements without any bearing housing support (3.3.6).

Rotors
Default impeller design is closed and constructed as a one piece casting. Except on vertical suspended pumps, impellers must be keyed to the shaft and secured by a cap screw or cap nut, which in turn must have a positive mechanical locking method (2.5.1, 2.5.2, 2.5.3) Shaft runout is limited to 0.001 inch (2.5.6). 128 Shaft stiffness must limit the deflection at the

 Mechanical Seals

FEATURES OF API 610

Vibration

There is now an API standard for mechanical seals, API 682 (2.7). Both API 610 and API 682 specify seal chamber dimensions. These dimensions help ensure an ideal environment for the mechanical seal. External Nozzle Forces and Moments API 610 specifies maximum allowable vibration levels nominally 3.0 mm/s RMS unfiltered, at the bearing housing (2.8.3).

Balancing

Bearings

Single stage and two stage pumps: impellers dynamic balanced to Grade G1.0 (2.8.4.1). Multi-stage pumps: impellers and major components balanced to grade G1.0, rotors balanced to G2.5 (5.2.4.2)
Minimum L10 design bearing life is 25,000 hours, at rated conditions (table 2.7). In practice most API 610 pumps will have an L10 bearing design life far in excess of this figure. Bearing housings must have constant level oilers fitted. Default impeller design is closed and constructed as a one piece casting. Except on vertical suspended pumps, impellers must129 be keyed to the shaft and secured by a cap screw or cap nut, which in turn must have a positive mechanical locking method (2.5.1, 2.5.2,

Rotors

 Drivers

Baseplates

Driver power ratings must be at least equal to the following (table 3.1): Motor kW Percentage of Rated Pump Power <22 125% 22-55 115% >55 110% Strict guidelines are given for baseplate design. These design criteria ensure minimal misalignment of pump and driver shafts (3.3.5). Baseplates must be single piece drain rim or drain pan design, to ensure that any leakage is contained within the baseplate (3.3.1, 3.3.2). Pump and drive train components must have mounting pads, fully machined flat and parallel. Values are specified for measuring compliance (3.3.3). The manufacturer must keep quality records for at least 20 years (4.2.1.1). The purchaser should specify which parts are to be subjected to surface and subsurface examination, and the type of examination required (i.e. magnetic particle, liquid penetrant, radiographic or ultrasonic) (4.2.1.3). 130 The standard lists the appropriate procedure and acceptance

FEATURES OF API 610

Inspections

Material Inspections

 SUMMARY

FEATURES OF API 610

Heavy duty casing design Centerline supports Low shaft stiffness ratio Low shaft deflection at the seal faces Long design bearing life Low vibration levels High allowable forces and moments on nozzles Stringent testing requirements

131

Need to Seal a Pump

132

Stuffing Box / Seal Chamber

Shaft Protection Sleeve

Impeller

Shaft

133

Need to Seal a Pump

Pump Wall
Shaft Process Fluid Leakage Environment

134

Seal Types

Gland Packing

Mechanical Seal

135

Gland Packing
Stuffing Box Gland

Shaft Lantern Ring (Seal cage)

Shaft Sleeve

Packing

136

Mechanical Seal
Secondary Sealing Element
Stuffing Box (Seal Chamber)

Mating Ring Shaft Primary Ring Secondary Sealing Element

137

Mechanical Seal
Principle Components
1. A rotating face (primary ring)

2. A stationary seat, (mating ring)

3. A secondary sealing element 4. A mechanical loading device to press face and seat together, and 5. Auxiliary components

138

Mechanical Seal
Primary Ring Snap Ring O-Ring Disk Springs O-Ring Mating Ring

Mating Ring Assembly (Stationary)

Retainer Set Screw

Seal Head (Rotating)

Shaft
139

Mechanical Seal
Process Fluid Acts as Lubricant Between Faces
Pump Housing Gland Process Fluid

Primary Ring

Mating Ring

Invisible Leakage: 140 Fluid Evaporates Upon Reaching Atmosphere

Mechanical Seal
Without Lubrication, Faces Run Dry And Overheat
Pump Housing
Gland No Fluid Or Dry Running

Primary Ring

Mating Ring

141

Mechanical Seal
Heat Transfer

Conduction Convection

142

Mechanical Seal
Flushing

Removes Heat Replenishes Cool Clean Lubricating Liquid Removes any solids Injection

143

Mechanical Seal
Single Seal Flushing By - Pass from Discharge (API Plan 11)
Discharge By- pass Line from Pump Discharge to Seal Gland

Flow

Suction
144

Mechanical Seal
Balance Ratio

Balance ratio is used to control the face load. Closing Force Opening Force

145

Mechanical Seal
Balance Ratio

Balance ratio is the ratio of the closing area to the opening area.

A c

Closing Area Balance Ratio = Opening Area

146

Mechanical Seal
Balance Ratio An Unbalanced Seal
Fc = p x Ac P = Fc / Ao

= (p x Ac) / Ao

Fc

A o

147

Mechanical Seal
Balance Ratio A Balanced Seal

Ac

Ao

148

Mechanical Seal
Secondary Sealing Element Pusher Seal

O-ring must move axially

149

Mechanical Seal
Secondary Sealing Element Non Pusher Seal

Static O-ring
150

Mechanical Seal
Secondary Sealing Element
Elastomeric Bellows Half Convolution Teflon Bellows Welded Metal Bellows

V Rings

U Cup

Wedge

Encapsulated O Ring

O Ring

151

Mechanical Seal
Pusher vs. Non-Pusher

O-ring secondary seal must slide along shaft as seal face wears

Bellows secondary seal expands to accommodate face wear. Bellows tail is stationary against shaft

152

Mechanical Seal
Multiple Seal Arrangements
Classical Tandem

Process seal

Backup seal

Classical Double

Process seal

Barrier fluid seal

153

Mechanical Seal
Un-Pressurised Arrangement
Unpressurised (Tandem)

Pressure

Process

Buffer

Atmosphere

154

Mechanical Seal
Pressurised Seal Arrangement

PRESSURISED (double)

Pressure

Barrier Process

Atmosphere
155

Mechanical Seal
Categories of Mechanical Seal
Pusher / Bellows Cartridge / Conventional Wet Seals / Gas seals Split / Whole Single / Double

156

Mechanical Seal
Merits of Pusher & Non-Pusher Seals
PUSHER SEALS (NON BELLOWS) O ring seals Wedge seals NON PUSHER SEALS (BELLOWS) Metal Bellows Rubber Bellows PTFE Bellows No hang up Better abrasive handling More tolerant to misalignments

More material options Higher Pressures Easier to manufacture

157

Mechanical Seal
Cartridge Seal

O-Ring

Metal Bellows

Elastomer Bellows

158

Mechanical Seal
Merits of Cartridge Seals & Conventional Seals
CARTRIDGE SEALS CONVENTIONAL (COMPONENT)
Less expensive Adaptable

Easier to fit - reliable Factory set reliable Less downtime in replacement

159

Mechanical Seal
Need for Flushing Plans & Sealing Systems
Pumped Liquid may be Too hot

Too cold
Too viscous Prone to solidify or crystallise Abrasive Close to boiling point Contains dissolved gases The liquid can not get to the seals Dangerous liquid Sensitive liquid
160

Such a liquid if used for seal flushing may damage the seal and cause seal failure. Hence, the need to condition the liquid before being used as a seal flushing liquid for satisfactory seal operation

API PLANS
Seals generate heat and require lubrication while face sealing. These systems are used to dissipate this generated heat and cool the seal faces thus extending the seal life

161

Flushing Liquid
Fluid which is introduced into the seal chamber on the process fluid side in close proximity to the seal faces typically used for cooling & lubricating the seal faces

FLUSHING
REMOVES HEAT GENERATED BETWEEN RUBBING FACES. PROVIDES LUBRICATION. INCREASES MARGIN BETWEEN VAPOUR PRESSURE AND STUFFING BOX PRESSURE. KEEPS LIQUID INSIDE STUFFING BOX IN CONSTANT CIRCULATION. IN CASE OF EXTERNAL FLUID FLUSHING - FLUSHING DOES NOT ALLOW ABRASIVES TO REACH SEAL FACES.

Plan 01

Plan 01
Integral (internal) re circulation is from discharge to seal. A connection is made from an area behind the impeller, near discharge to seal chamber. Recommended for clean fluids. Plan 01 (if possible to provide in the stuffing box) is superior to Plan11 for the liquids, which may become viscous or freeze at lower temperature. This minimizes the risk of freezing of the fluids in the piping.

Disadvantage - No control on the flush flow rate.

Plan 02

Plan 02
The stuffing box is dead-ended (with no circulation of fluid). This plan is preferred plan for the clean and relatively cool liquids having sufficient (at-least 1 kg/cm2) margin between vapour pressure and stuffing box pressure. Care should be taken to vent the stuffing box properly. One 5 mm diameter hole at the topmost position of the throat should be provided for venting purpose. Depending on the requirement cooling or heating is provided in the stuffing box jacket. For liquids at self ignition temperature API Plan 02 is not recommended.

Plan 11

Plan 11

A line with flow control orifice is connected from the discharge side of the pump into the gland flush connection. It is default seal flush plan.
Orifice must be sized properly.

Minimum orifice size recommended is 3 mm. For larger pressure drop multiple orifice is recommended instead of reducing the size of orifice.

Orifice

Plan 13

Horizontal Pump

Orifice From Seal

Suction

Plan 13
Vertical Pump From Seal
Orifice

Suction

Plan 13
A line is connected from the gland, through a flow control orifice, to the suction piping. It is standard flush plan for vertical pumps where stuffing box pressure is equal to discharge pressure. Whenever stuffing box pressure is more than suction pressure, API PLAN 13 is better than API PLAN 11. In this plan liquid moves away from the seal face instead of impinging on to it ( API Plan 11) and the stuffing box pressure reduces making the seal more comfortable.

Plan 14
MEDIA FROM DISCHARGE TO SEAL CHAMBER THRU ORIFICE.

MEDIA FROM SEAL CHAMBER TO SUCTION THRU ORIFICE.

Plan 14

It is combination of Plan 11 and Plan13. It is mostly used for vertical pumps handling volatile liquids. In Plan 13 because of throat bush, pressure in the seal area may drop and liquid may vaporise. Plan 11 provides cool fluid to the seal area whereas Plan 13 provides complete venting in the seal area.

Plan 21

Plan 21
A line with orifice is connected from the discharge side of the pump through a flow control orifice and cooler into the seal chamber. It provides cool flush to the seal. This plan is the best for liquids at self ignition temperature. In the event of seal leakage, cool liquid will continue to reach seal faces as long as the pump is running ,ensuring that hot liquid does not come out. The disadvantage is that heat loss is more, also cooling water requirement is high.

Plan 23

Plan 23

In this plan process fluid is recirculated with the help of a pumping ring in the seal chamber through a cooler and back in to the seal chamber. A Plan 23 flushing system is most effective way of providing a cool flush to the seal faces. In this arrangement fluid in seal chamber is isolated from that in the impeller area of the pump by a throat bush. Use of an internal circulating device to circulate the fluid through a closed loop cooler allows the cooler to continuously cool a recirculated stream rather than a continuous (hot) stream from discharge to seal (Plan 21). The cooler is required to cool the liquid in the loop. Therefore cooler size reduces drastically as compared to Plan 21 cooler. Also the cooling water requirement is much less than Plan 21.

Coolers for API Plan 21 & 23

Air Fin Coolers

NATURAL

DRAUGHT

Plan 23M

Modified API plan by ESSIL

Plan 23: Process liquid through coil & cooling liquid through shell. Plan 23M: Process liquid through shell & cooling liquid through coil

Plan 23M

It is shell and tube type heat exchanger.

Advantages:
Vapour Lock : Plan 23 is not self venting Friction loss: More in Plan 23 Heat transfer rate: The pot area is sufficient to carry away heat generated by the seal and soaked heat. In majority of the cases if proper thermal barrier is provided at the bottom of the throat bush cooling water coil is not required.

Plan 31
Solid Sp.Gravity should be at least 2 times media Sp. Gravity.

Plan 31
Process liquid is recirculated through a cyclone separator to the seal. Solid particles are centrifuged through cyclone separator and sent back to suction. The Plan is specified for services containing solids with a specific gravity at least twice that of the process fluid. Normally cyclone separators do not remove the solids effectively and cause seal failure. Even if the efficiency of cyclone separator is 92%.about 8% of the finer particles reach to the seal faces. The finer particles can enter between the seal faces and cause damage to the seal.

Cyclone Separator

Plan 32
PRESSURE GAUGE STRAINER

EXTERNAL FLUSH TO SEAL ORIFICE

Plan 32

Flushing product is brought from an external higher pressure source to the seal.. This plan is excellent for liquid containing solids/ abrasives. The flushing fluid mixes with the product. Therefore it must be ensured that the flushing fluid is compatible with the product. A close clearance throat bush restricts the product to come to the seal area and also increases the pressure margin. Flushing fluid dilutes the product. Therefore unnecessarily more liquid should not be circulated .

Plan 41
Solid Sp.Gravity should be at least 2 times media Sp. Gravity.

Plan 41

It is combination of Plan 21 and Plan 31. Process liquid is recirculated through a cyclone separator and cooler to the stuffing box. The plan is recommended for hot liquids containing solids. Specific gravity of the solid particles should be at least twice that of the process fluid. Solid particles are centrifuged through cyclone separator and sent back to suction. If the process liquid is very dirty or is slurry, it may choke the cooler.

Plan 51

In this plan an external reservoir provides a dead ended blanket for the fluid to the quench connection of the gland.

Plan 52

Barrier Fluid Properties

One of the most important properties of a good buffer or barrier fluid is its viscosity. A good buffer or barrier fluid should be a good heat transfer fluid. A good barrier or buffer fluid should not present any potential danger whether equipment is running or stationary. The fluid must be compatible with the metallurgy, elastomers and other materials of the sealing system.

Barrier Fluid Properties

The fluid should also be highly compatible with the process pumpage being sealed.

Foaming risks are to be avoided.

Fluid stability must be ensured for a longer maintenance cycle time.

Plan 52
In this plan external reservoir provides buffer fluid for the outer seal of an un-pressurized dual seal arrangement ( Arrangement 2). During operation an internal pumping ring provides circulation. The reservoir is connected to a vapour recovery system and is maintained at a pressure less than the pressure in the seal chamber. It is normally used for the applications where process fluid leakage to atmosphere must be minimised and contained. Plan 52 works best with clean, nonpolymerising pure products that have vapour pressure more than the buffer system pressure. Leakage of higher vapour pressure process liquid into buffer system will flash in the seal pot and escape into the vent system. Leakage of the process fluid will mix with the buffer fluid and contaminate the buffer fluid over a time. Therefore the buffer fluid must be compatible with the process fluid.

Plan 53

Plan 53

In this plan external pressurised barrier fluid reservoir provides fluid for to the seal chamber. The Plan 53 is for double back to back seal (Arrangement 3). During operation an internal pumping ring provides circulation. It is normally used for the applications where process no fluid leakage to atmosphere is permitted. The barrier fluid must be pressurised to about 1.5 to 2 kg/cm2 above the pump seal chamber pressure. Inner seal leakage (if any) will be barrier fluid into the product and no process fluid will be allowed to leak in to barrier fluid area. Plan 53 is selected over Plan 52 for dirty, abrasive or polymerising products which may either damage the seal faces or cause problem with the buffer fluid system if Plan 52 was used.

Plan 53A

Plan 53B

Pressurised barrier fluid circulation with bladder accumulator. Cooler outside the reservoir.

Plan 53C

Pressurised barrier fluid circulation with piston accumulator. For Dynamic tracking of system pressure

Plan 54

Plan 54

In Plan 54 cool clean product from an external source is supplied. The supply pressure must be at-least 1.5 kg/cm2 greater than the pump seal chamber pressure. Plan 54 is used for the fluids where the process fluid is hot, contaminated with solids or both. In Plan 54 care should be taken of barrier fluid system. A contaminated system may cause seal failure. A properly engineered barrier fluid system is typically complex and expensive. Where these systems are properly engineered they provide most reliable system.

QUENCHING
KEEPS ATMOSPHERE AWAY
TOXIC FLUIDS CRYSTALLIZING PRODUCTS CRYOGENIC APPLICATIONS

HIGH FREEZING POINT FLUIDS

HIGH TEMP. FLUIDS WHICH DECOMPOSE IN CONTACT WITH ATMOSPHERE FLUID HAVING TENDENCY TO BECOME VISCOUS IN CONTACT WITH ATMOSPHERE

ADDITIONAL ADVANTAGES
KEEPS AREA OUTSIDE SEALS CLEAN
PROVIDES HEATING / COOLING TO SEAL FACES.

Plan 61

Tapped and plugged connect for purchasers use.

Plan 62

Plan 62

In Plan 62, a quench stream is brought from an external source on atmospheric side of the seal faces.
The quench fluid can be clean water, steam or low pressure Nitrogen.

Quenching is provided to keep atmosphere away. In following conditions atmosphere must be kept away from the seal face.

Plan 62
1) Toxic fluids 2) Crystallising products. 3) Cryogenic Application. 4) High Freezing point fluids. 5) High temp. Fluids, which decompose in contact with

atmosphere.
6) Fluid having tendency to become viscous in contact with atmosphere.

Quenching fluid keeps area outside seals clean and provides heating / cooling to seal faces

Plan 62 Recommended flow rates: Media: Water Flow: 1 lpm Pressure: 0.5 kg/cm2

Media: Steam
Flow: 1 m3/hr Pressure: 0.5 kg/cm2

Plans for dry containment seals and single seals

Plan 71, 72, 74, 75 and 76 are for the dry containment seal. Plan 71, 72 and 74 are similar to Plan 51,52 and 54. Instead of liquid ,gas is provided between the two seals. Plan 75 and 76 are for single seal as well as for containment seals.The leakage collection. Plan 75 is for non volatile liquids and Plan 76 is for volatile liquids.

Plan 71

This is used in Tandem (Arrangement 2) un pressurized dual seals, which utilize a dry containment seal and where no buffer gas is supplied but the provision to supply a buffer gas is desired. Buffer gas may be needed to sweep inner seal leakage away from the outer seal into a connection system or to dilute the leakage, but it is not specified.

Plan 72

Plan 72

Plan 72 is used Tandem (Arrangement 2) un-pressurized dual seals, which utilize a dry containment seal and where buffer gas is supplied. The buffer gas can be used to sweep inner seal leakage away from the outer seal to a collection system and /or dilute the leakage so the emissions from the containment seal are reduced.

Plan 74

Plan 74

The system is used on dual pressurized seals (Arrangement 3),where the barrier medium is a gas. They are the gas barrier equivalent to the traditional plan 54 liquid barrier system. The most common barrier gas is nitrogen The supply pressure to the to the seal is typically at least 0.17 Mpa (1.7 bar) (25 ps) greater than the seal chamber pressure. This results in small amount of gas leakage into the pump, with most of the gas barrier leakage to atmosphere. This arrangement should never be used where the barrier gas pressure can be less than the sealed pressure If this were to happen the entire barrier gas system could become contaminated with the pump fluid.

Plan 74

Plan 74 systems are typically used in services which are not too hot (within elastomer property limits) but which may contain toxic or hazardous materials whose leakage cannot be tolerated. Because they are pressurized dual seal systems, leakage to the system is eliminated under normal conditions. Plan 74 may also be used to obtain very high reliability, since solids or other materials which may lead to premature seal failure cannot enter the seal faces.

Plan 75

Plan 75

Systems are typically used on Arrangement 2, unpressurised dual seals, which also utilize a dry containment seal and where the leakage from the inner seal may condense. They may be used with a buffer gas (Plan 72) and without a buffer gas (Plan 71) If an unpressurised dual seal is installed, usually it is because leakage of the pumped fluids to the atmosphere must be restricted more than can be done with an arrangement 1 seal. Therefore a mean is needed to collect the leakage and route it to a collection point. The Plan 75 system is intended to perform this collection for pump fluids that may form some liquid (condense) at ambient temperature

Plan 76

Plan 76

System is typically used on arrangement 2, unpressurised dual seals, which also utilize a dry containment seal and where leakage from the inner seal will not condense. They may be used with a buffer gas (plan 72) or without a buffer gas (Plan 71). If an unpressurised dual seal is installed, usually it is because if leakage of the pumped fluid into the atmosphere must be restricted more than can be done with an Arrangement 1 seal. Therefore a means is needed to route the leakage to the collection point. The Plan 76 system is intended for services where no condensation of the inner seal leakage or from the collection system will occur.

PUMP VIBRATIONS

BASIC SOURCES OF VIBRATION

MECHNAICALLY INDUCED SYSTEM INDUCED

OPERATION INDUCED

220

PUMP VIBRATIONS
MECHNAICALLY INDUCED
BAD BEARINGS BENT SHAFT UNBALANCED ROTOR CHECK VALVE INSTALLED BACKWARDS MISALIGNMENT LOOSENESS SOFT FOOT MAXIMUM SIZE IMPELLER

221

PUMP VIBRATIONS
SYSTEM INDICED
PARTIALLY / PLUGEGD STARINER CLOGGED IMPELELR OR SUCTION LINE INSTALLATION

OPERATIONALLY INDICED
CAVITATION FLOW SPEED INSUFFICIENT IMMERSION OF SUCTION PIPE OR BELLMOUTH
222

PUMP VIBRATIONS
ACCEPTABLE LIMITS AS PER API 610

223

PUMP VIBRATIONS
API 610 REQUIREMENTS

224

PUMP VIBRATIONS

225

PUMP VIBRATIONS

226

Trouble shooting
Classification of Failure causes Common Problems in Centrifugal Pumps Specific Failure Cases Troubleshooting Modern methods of Troubleshooting Pump Troubleshooting Software

Classification of Failure Causes

Design Related
The problems related specifically to the design parameters of the pump which are specified by the Process Engineer / Machinery Engineer / Vendors Counterpart in the Pump Mechanical Datasheet. Operation Related The problems related to the operation of the pump at site/shop due to reasons dependent/independent of its design.

Common Failures in Centrifugal pumps

Insufficient Capacity / Insufficient Head Internal recirculation Cavitation Excessive Power Consumption Excessive Noise and Mechanical Vibrations

Insufficient capacity
The problem is in a. The Pump b. The Suction side c. The Discharge side

Insufficient Head
The problem is in a. The Pump b. The Suction side c. The Discharge side

Internal Recircultion
Suction Recirculation - Cause and Effect Discharge Recirculation - Cause and Effect

Cavitation
What is Cavitation? Causes of Cavitation - Vaporization - Air Ingestion - Internal Recirculation - Flow Turbulence - Vane Passing Syndrome

Excessive Power Consumption

Reasons could be due to - use of oversized pump - change in product - increase in bearing loading - starting procedure could be a problem - too much axial thrust

Excessive Noise and Mechanical Vibrations

Unbalance Critical Speed Resonance with natural Frequencies Misalignment Hydraulic Disturbances Cavitation Surging Water Hammer Other Reasons

Troubleshooting
Skill takes time to develop Pump may be a cause of a symptom Regulations may have additional safety precautions Make sure suction and discharge gages are available Verify pump speed Verify motor amps, voltage and power factor Make sure drivers are locked before doing any inspection Information gathering What is different from when it ran fine? When was the last maintenance work done? What was done? How do things look? Get the basics: inlet and discharge pressure, flow, speed, liquid, temperature, viscosity, duty Noise?

Troubleshooting
Rotation Loss of suction Loss of developed head Wear Viscosity Pulsations, vibrations, noise Amps and power Hydraulics, mechanics, electrics

THANK YOU
237