1

PREFACE
This training manual on pumps is intended to be used for basic
skill training for Scientific Assistant trainees. This manual is prepared
with a view of imparting training effectively on Function, Construction,
Material of parts, and maintenance aspects of the pumps. This training
manual will also be used for Tradesman trainees. It has been prepared in
view the important aspect of the subject and bring the competency in the
new entrants so that they can do right maintenance at the first attempt.
I express my sincere thanks to Shri Prashant Puri, STO for
giving his valuable suggestions during preparation of this manual and to
Shri C.M.Mishra, ENC(MT) for his guidance and encouragement to
complete this task. I owe my sincere gratitude to Shri N.Nagaich,
Training Superintendent, RAPS-1 to 4 for his kind cooperation and
motivation in preparation of this manual.

R P Saini
SO/E
Nuclear Training Center

CONTENTS
S. NO.
Chapter-1
1.0
1.1.
Chapter-2
2.0
2.1.
2.2.
Chapter-3
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
3.10.
3.11.
Chapter-4
4.1.
4.2.
4.3.
Chapter-5
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
5.8.
5.9.
5.10.
5.11.
5.12.
Chapter-6
6.0
6.1.
6.2.
6.3.
6.4.

DESCRIPTION
Pumps
Introduction
Classification of Pumps
Centrifugal Pumps
Working Principal
Main Parts of a Centrifugal Pump
Single and Multi Stage Design:
Terms and Characteristics of Centrifugal Pumps
Suction Head and Suction Lift
System Head
Pump Characteristic
System Head Curves
Evaluation of Pump Characteristics
Centrifugal Pump Characteristic Relations
Specific Speed
Net Positive Suction Head
Cavitation
Parallel Operation of Pumps
Series Operation of Pumps
Thrusts and its Balancing in Centrifugal Pumps
Radial Thrust in Centrifugal Pump
Axial Thrust in Centrifugal Pump
Axial Thrust in Multistage Pumps
Operations of Centrifugal Pumps
Initial Start
Pipe Cleanliness
Alignment
Rotation
Pump Bearings
Pump Drive
Priming
Position of The Valves
Pump Warm Up
Starting the Pump
Operating Checks
Pump Shutdown
Maintenance of Centrifugal Pumps
General
Rotating Parts
Stationary Parts
Maintenance Records
Maintenance Intervals
3

PAGE
NO.
3
3
4
4
12
14
14
17
19
20
21
21
22
23
24
25
26
28
36
39
39
40
40
40
41
41
41
41
42
43
43
44
44
51
52
52

Chapter-7
7.1.
7.2.
7.3.
7.4.
7.5.
Chapter-8
8.1.
8.2.
8.3.
8.4.
8.5.
Chapter-9
9.1.
9.2.
9.3.
9.4.
9.5.
Chapter-10
Chapter-11
Chapter-12
12.1
12.2
12.3
12.4
12.5

Rotary Pump
General
Gear Type Pump
Screw Pump
Sliding Vane Type Pump
Lobe Pumps
Rotary Pump Maintenance
General
External- Gear Pumps
Internal - Gear Pumps
Screw Pumps
Sliding Vane Pump
Reciprocating Pump
Introduction
Working of a Reciprocating Pump
Main Parts of a Reciprocating Pump
Classification of Reciprocating Pumps
Air Vessels or Accumulators
Centrifugal Pumps- Trouble Shooting
Positive Displacement Pumps- Trouble Shooting
Maintenance Procedures
Centrifugal Pump
Gear type Rotary Pump
Screw type Rotary Pump
Sliding Vane Pump
Reciprocating Pump

55
55
57
57
58
59
59
60
64
65
67
67
68
71
72
74
78
82
85
87
89
91

CHAPTER - 1

PUMPS
1.1

INTRODUCTION

The hydraulic machines, which convert the mechanical energy into

hydraulic energy, are called pumps. The hydraulic energy is in the form of
pressure energy. Most process in industries involves the transportation of
liquids, or their transfer from one level of pressure or static energy to
another. The pump is the mechanical means for achieving this transport or
transfer, and thus becomes an essential part of all processes.
1.2

CLASSIFICATION OF PUMPS
Pumps may be classified on the basis of application they serve, the material
from which they are constructed, the liquid they handle, and even their
orientation in the space. All such classification, however, are limited in scope
and tend to substantially overlap each other. A basic system of classification is
by which energy is added to the fluid. Following tree diagram gives pumps
classification.
PUMPS

Positive
Displacement Pump

Reciprocating
Pump

Plunger

Piston

Rotary
Pump

Centrifugal

Diaphragm

Gear
pump

External

Rotodynamic
Pump

Screw
pump

Axial or
propeller
pump
Vane
pump

Radial piston
pump

Internal

Radial

Mixed
flow
pump

CHAPTER - 2

CENTRIFUGAL PUMPS
The mechanical energy is converted into pressure energy by means of
centrifugal force acting on the fluid, the hydraulic machine is called
centrifugal pump.
2.0

WORKING PRINCIPAL
The centrifugal pump works on the principle of forced vortex flow, which
means that when a certain mass of liquid is rotated by an external torque, the
rise in pressure head of the rotating liquid takes place. It consists of a rotating
element including impeller & a shaft and a stationary element made up of a
casing, stuffing box. Vanes of impeller impart energy to the fluid through
centrifugal force. The fluid is forced into impeller due to differential pressure
between pressure at water surface in suction tank and the pressure at suction
eye of impeller. Fluid is discharged through impeller outlet at higher pressure
& velocity. The velocity is converted into pressure by means of volute or set
of stationary diffuser vanes surrounding impeller.

Fig. 2.1
2.1.

MAIN PARTS OF A CENTRIFUGAL PUMP

The following are the main parts of a centrifugal pump:
1.
3.
5.
6.

Shaft
Casing.
Stuffing box
Suction pipe with a foot valve and a strainer.

2.
4.
6.
7.

Impeller.
Bearings
Wearing rings
Delivery pipe.

All the main parts of the centrifugal pump are shown in Fig. 2.2 of a single
stage, end suction centrifugal pump as given below.

Fig. 2.2
2.1.1. SHAFTS: Pump shaft depending upon the type of motor used, the pump shaft
may be a part of the motor rotor, or may be independent and coupled to the
motor shaft. Pumps shafts are normally made of stainless steel or other
corrosion-resistant material. Corrosion resistant materials are used because of
the expense involved when replacing shafts. It is more economical to install a
high quality shaft despite high initial cost.
The shaft may be independently bearing supported, or may be supported by
the motor bearings. The method used will depend upon the design of the
pump.
2.1.2. IMPELLER: The rotating part of a centrifugal pump is called Impeller. It
consists of a series of vanes. Impeller vanes direct the flow of fluid within the
pump. The impeller is mounted on a shaft, which is connected to the shaft of
an electric motor. This applies high energy force to the fluid to give it velocity
and momentum. The open area in the centre of the impeller is called the
impeller eye and partially determines the pump capacity.
The pump impeller is the most critical part of a pump because the size, shape,
and speed determine the pump capacity under all head conditions.
Impeller shrouds enclose the blades of the impeller and contain the flow of
fluid in the impeller area. Suction point, where fluids enter the pump, is
7

normally located near the centre of the casing. The diameter of the passage at
this point partially determines the rate at which the unit can pump.
The solid center portions of the impeller mounts on the shaft and is called the
impeller hub. Depending upon the design and size of the impeller, the hub can
be quite large or small. If the impeller is of the double suction type, the hub
usually is open in the center and two separate hubs will be mounted on the
shaft.
Types of Impellers:
Based on flow:
Radial flow
Mixed flow
Axial flow

:
:
:

Used for high head and low flow.

Used for medium head & flow.
Used for high flow and low head.

Based on construction:
Open type
:
Semi-open type:
Close type
:

Used for fluids having debris.

Used for clean fluids. Single shroud provides strength.
Used for clean fluid.

Based on type of vanes:

Forward vane:

Not normally used due to high consumption, less

efficiency and drooping characteristics.
Not normally suggested due to improper guiding of

Radial vane :
fluid.
Backward vane :
Generally
characteristic)

used

(reason

discussed

under

pump

Impellers are further classified as:

1.
2.

Single-suction with a single inlet on one side.

Double-suction with water flowing to the impeller symmetrically from
both sides, which benefits axial balancing.
Several types of impellers are shown in Fig 2.3:.

Fig. 2.3
The pump impellers can be made of cast iron, cast steel, fabricated steel,
bronze, brass, molded rubber, fiberglass or any other material that will be
compatible with the material being.
2.1.3.

CASING
The casing of a centrifugal pump is an air-tight passage surrounding the
impeller and is designed in such a way that the kinetic energy water
discharged at the outlet of the impeller is converted into pressure energy
before the water leaves the casing and enters the delivery pipe. The casing
encloses the pump impeller, shaft and packing gland. Usually casings are of
the volute or increasing diameter type.
The following three types of the casings are commonly adopted:
a. Volute casing.
b. Diffuser vane casing
c. Regenerative Casing
a. Volute Casing:
Fig 2.4 shows the volute casing, which surrounds the impeller. It is of spiral
type in which area of flow increase gradually. The increase in area of flow
decreases the velocity of flow. The decrease in velocity increases the pressure
of the water flowing through the casing. It has been observed that in case of
volute casing, the efficiency of the pump increases slightly as a large casing,
large amount of energy is lost due to the formation of eddies in this type of
casing.
Converts kinetic energy of fluid into pressure energy.
Designed such as to produce an equal liquid velocity around circumference of
impeller. When operating at other than its peak efficiency, unbalanced forces
occurred around circumference of impeller. This results in radial thrust.
To overcome above problem of radial thrust double volute casing is used.
Double volute casing is similar to two vane diffuser casing.

Fig. 2.4
b. Diffuser Vane Casing
If a circular chamber is introduced between the casing and the impeller as
shown in Fig 2.5, the casing is known as Vortex casing. By introducing the
circular chamber, the loss of energy due to the formation of eddied is reduced
to a considerable extent. Thus the efficiency of the pump is more than the
efficiency when only volute casing is provided.
Compared to volute it is more efficient in converting kinetic energy into
pressure energy, because of better guidance of fluid.
Less efficient when operating at other than peak efficiency.
Hydraulically balance the radial loading of motor.
Less changes in impeller size is permissible in the given casing compared to
volute casing.

Fig. 2.5
c. Regenerative Casing
This casing is shown in fig in which the impeller is surrounded by a series of
guide blades mounted on a ring, which is known as diffuser. The guide vanes
are designed in such a way that the water from the impeller enters the guide
vanes without shock. Also the area of the guide vanes increases, thus reducing
the velocity of flow through guide vanes and consequently increasing the
pressure of water. The water from the guide vanes then passes through the
surrounding casing, which is in most of the cases concentric with the impeller
as shown in fig 2.6.

10

Fig. 2.6
Types of Casing based on Construction:
1. Horizontally split casing e.g. BFP#1,2 & 3; process water booster pump
etc.
2. Vertically split casing e.g. primary coolant pump. Moderator pump, &
BFP#7 etc.
The Horizontal or Axial split is made on the centre line of the shaft and
allows the upper half of the casing to be removed completely, giving access to
the pump shaft, impellers and bearings. The term horizontal Does Not refer to
the horizontal Position of the pump of the split casing. If the pump was
mounted in a vertical position, it could still have a horizontal split casing-the
name indicates the method of the split rather than the position.
Pump casings are also split Radial. Originally, this was called a vertical split,
meaning perpendicular to the centre line of the shaft and not directional.
However, the term was confusing, and it is now more commonly referred to as
a radial split.
When manufactured with a radial split, the casing can be made up in segments
(especially for multistage pumps) and bolted together to form one pump. This
eliminates costly construction and casting that would otherwise be involved in
making a multistage pump.
The pump casings are made of many different materials, such as cast iron,
steel or bronze, as well as many non-corrosive and abrasion-resistant alloys.
2.1.4. WEARING RINGS:
There is a small clearance between impeller hub & casing to reduce inter-stage
leakage. This leakage point allows small amounts of water to recirculate in the
pump. The leakage joint is generally provided with renewable wearing rings,
which avoids costly build up of worn parts by welding. These are designed to
be adjustable so the proper clearance between the impeller and the casing can
be maintained. Wearing rings can be put either on impeller hub or on the
casing or on both. Generally when clearance double, the wearing ring are to be
11

renewed. Fig. 2.7 explains different types of wearing ring & their mounting
procedure.

Fig. 2.7
Most manufacturers make the wearing rings of bronze or brass. They can be
installed either in the casing or on the impeller, or both, as shown above.. The
type of wearing ring and the method of installing it are determined by the
pump manufacturers.
It should be remembered, however, that wearing rings are subjected to wear
from gritty or abrasive materials and eventually have to be replaced. This
replacement may be necessary in six months, a year, or longer depending upon
the application and the material being pumped.
Wearing rings are not always included in the design of a pump. However,
when they are included, the wearing rings are usually replaceable. Their main
function is to allow some fluid leakage between the impeller and the casing.
By allowing a small amount of leakage between the impeller and the casing in
the suction area, a hydraulic seal is set up, helping the pump to operate more
efficiently. In addition, a small amount of liquid is recirculated from the
discharge to the suction side of the pump.

12

Fig. 2.8

2.1.5. STUFFING BOX:

Stuffing boxes have the primary function of protecting the pump against
leakage at the point where the shaft passes out through the pump casing.
Function of the stuffing box varies depending on whether the pump handles
suction lift or suction pressure. If the pump handles a suction lift and the
pressure at the 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 prevent liquid leakage out of the pump.
Normally gland packing is used. If When the pressure at interior of stuffing
box is negative, packing are used with lantern ring and water injection to
prevent ingress of air into pump through stuffing box. Following are the
various cases, when lantern ring & sealing liquid are used:
1.
2.
3.
4.
5.

A suction in excess of 5meters.

A discharge pressure under 7 meters.
Hot water (over 1200 C) being handled without adequate cooling.
Muddy, sandy, or gritty water being handled.
The liquid being handled is other than water such as acid, juice or
sticky liquids.

A packing gland seals the fluid flow in the pump. The packing gland may use
either a loose or a braided type packing that is replaceable and adjustable or
the mechanical seal.
2.1.6. BEARINGS:
13

The function of bearings in pumps is to keep the shaft or rotor in correct

alignment with stationary parts under the action of radial and transverse loads.
Shaft bearings can be of sleeve, single or double row ball bearing, or roller
bearing types. In addition, some pumps use special thrust bearings to eliminate
development of high end thrust. Thrust bearings are normally used on
multistage pumps, which have high pressures and capacities. On small
horsepower pumps, the impeller and shafts frequently overhang the motor
bearings. In this case, all radial and axial thrust must be taken up by the motor
bearings.
2.1.7. SUCTION PIPE WITH A FOOT VALVE AND A STRAINER:
A pipe whose one end is connected to the inlet of the pump and other end dips
into water in a sump is known as suction pipe. A foot valve, which is a nonreturn valve or one way type of wave is fitted at the lower end of the suction
pipe. The foot valve opens only in the upward direction. A strainer is also
fitted at the lower end of the suction pipe.
2.1.8. DELIVERY PIPE:
A pipe whose one end is connected to the outlet of the pump and other end
delivers the water at a required height is known as delivery pipe.
Single stage, single suction type pumps have served for simple illustrations of
pump parts. Centrifugal pumps are also made in double suction and multistage
designs. The type of pump used will be determined by the amount of fluid to
be pumped and the pressure required.
Multistage Pumps are available in either single or double suction. When
multistage pumps are used, water is discharged from one stage to the next
through internal passages in the pump casing. Each stage builds up the
velocity of the fluid until the desired head is reached.
Impellers discussed so far have been only for single impeller pumps. In
multistage pumps, impeller design must be worked out carefully to avoid
increasing radial and thrust loads at each stage. To offset this, impellers are
frequently mounted back-to-back even though they are several inches apart.
Some pump impellers are equipped with small vanes on the back of the shroud
to pump any water, which gets behind the impeller. This action also helps
counteract the thrust from the normal impeller loading.
Many centrifugal pumps are made with end suction and have a vertical or
horizontal discharge point. Because smaller pumps are usually cast with a
supporting base, the direction of flow is pre-determined by the pump design.
When the pump casing is mounted independent of the supporting framework,
the discharge point could be positioned in several different ways. The
direction or location of the discharge point around the circle depends on the
number of bolts that hold it in position on the frame.
14

On double suction pumps the intake and discharge are normally on the same
horizontal plane, below the pump centerline, and on opposite sides of the
pump. Some double suction pumps, as shown in Fig., are available with
bottom suction and a side discharge port. Most of the double suction pumps
have horizontal split casings.
As was pointed out previously, the sealing mechanism may be either the
mechanical seal or the packing gland type. Selection depends on pump
construction and the material being handled, as well as the manufacturer's
preference.
On pumps handling hot fluids the packing gland is frequently provided with
some type of cooling. This can be cool water, gas, or other liquid, depending
on the material being pumped. In some applications, the pump casing and any
supporting bearings may also need to be cooled.
2.2.

SINGLE and MULTI STAGE DESIGN:

A pump in which the head is developed by a single stage is called single stage
pump. Often the total head to be developed requires the use of two or more
impellers operating in series, each taking its suction from the discharge of the
preceding impeller. For this purpose two or more single stage pumps may be
connected in series or all impellers may be interposed in a single casing. The
unit is then called a multistage pump. If an electric motor operating at about
3450 rpm is supposed to deliver 600ft of head at a capacity of 200gpm, for
such pump specific speed will be around 400, indicating use of extreme type
of radial type of impeller. Such impeller will be difficult to design. If two
stages are used, head per stage will be 300ft, and specific speed is 600, which
represents much less difficult design. For such reasons multi stage centrifugal
pump are used.
The water from suction pipe enters the 1st impeller at inlet and is discharged at
outlet with increased pressure. The water with increased pressure from the
outlet of the 1 st impeller is taken to the inlet of the 2nd impeller with the help of
a connecting pipe as shown in fig 2.8. At the outlet of the 2nd impeller, the
pressure of water will be more than the pressure of water at the outlet of the 1st
impeller. Thus if more impellers are mounted on the same shaft, the pressure
at the outlet will be increased further.
Let

n = Number of identical impellers mounted on the same shaft,

H = Head developed by each impeller.

Then total head developed

=nxH
The discharge passing through each impeller is same.
15

16

Chapter-3
TERMS AND CHARACTERISTICS OF CENTRIFUGAL PUMP

3.1

Suction head and Suction lift

Suction head is the term used to describe a pump condition where the level of
the source of supply is located above the centre line of the pump. Suction lift is
the term used to describe a situation where the level of the source of supply is
located below the centre line of the pump.

3.2

System head
In strict terms, a pump can only operate within a system. To deliver a given
volume of liquid through that system, a pump must impart energy to the
liquid, made up of the following components, which applies to all types of
pumps:

Static head.
Friction head.
Entrance and exit losses.

3.1.1. Static head

The static head refers to a difference in elevation. Thus, the total static head
of a system is the difference in elevation between the liquid levels at the
discharge and the suction points of the pump (Fig.3.1). The static discharge
head is the difference in elevation between the discharge liquid level and the
pump centerline. The static suction head is the difference in elevation
between the suction liquid level and the pump centerline. If the static suction
head has a negative value because the suction liquid level is below the pump
center line, it is usually spoken of as a "static suction lift". If either the suction
or discharge liquid level is under a pressure other than atmospheric, this
pressure can be considered either as part of the static head or separately as an
addition to the static head.

17

Fig- 3.1

Fig 3.1 c
3.1.2. Friction head
The friction head is the head (expressed in feet of the liquid being pumped)
that is necessary to overcome the friction losses caused by flow of liquid
through piping, valves, fittings and any other elements such as heat
exchangers. These losses very approximately as the square of the flow through
the system. They also very with the size, type and surface condition of the
piping and fittings and with the character of the liquid pumped. The resulting
curve is called " system friction curve" as shown in Fig. 3.2.

Fig. 3.2
18

In calculating friction losses, we must consider that they will increase as the
piping deteriorates with age. It is usual to base the losses on data established
for average piping that is 10 or 15 years old.

3.1.3. Entrance and exit losses:

If the supply of a sump originates in a reservoir, tank or in take chamber,
losses occur at the point of connection of the suction piping to the source of
supply. The magnitude of these losses depends on the design of the pipe
entrance. A well-designed bell mouth provides the lowest possible loss.
Similarly, on the discharge side of the system where the discharge line
terminates at some body of liquid, the velocity head of the liquid is entirely
lost and must be considered as part of the total friction losses of the system.
3.2.

System Friction and System Head Curves

As mentioned earlier, friction, entrance and exit losses vary approximately as
the square of the flow through a system. For solving pumping problems, it is
convenient to show the relationship, between capacity and friction head losses
graphically. These losses are therefore calculated at some predetermined flow,
either expected or design, and then calculated for all other flows, using the
square of the flow relationship. The resulting curve is called the system
friction curve as shown above.
When we combine the static heads, pressure differences and friction head
losses of any system and plot them against the capacity, the resulting curve
(Fig 3.3) is called the system head curve. Superimposing a pump head
capacity curve at constant speed on this system head curve (Fig3.4) will
permit us to determine the capacity at the point where the two curves interact.
This is the capacity that will be delivered into the system by that pump at that
particular speed.

19

Fig. 3.3

Fig. 3.4

For systems having varying static heads or pressure differences, it is possible

to construct curves corresponding to the minimum and maximum conditions,
as shown in fig 3.5. The corresponding intersections with the pumps head
capacity curve will then determine the minimum and maximum flows that the
pump will deliver into the system.
3.3.

PUMP CHARACTERISTIC:
Characteristic curves of centrifugal pumps are defined those curves which are
plotted from the results of a number of tests on the centrifugal pump. These
curves are necessary to predict the behavior and performance of the pump
when the pump is working under different flow rate, head and speed. The
followings are the important characteristic curves for pumps:
1. Main characteristic curves.
2. Operating characteristic curves

3.3.1. MAIN CHARACTERISTIC CURVES:

The main characteristic curve of a centrifugal pump consists of variation of
head (manometric head, Hm), power and discharge with respect to speed. For
plotting curves of manometric head versus speed, discharge is kept constant.
For plotting curves of discharge versus speed, manometric head (H4 ) is kept
constant. And for plotting curves of power versus speed the manometric head
and discharge are kept constant. Fig 3.5 shows main characteristic curves of a
pump.

20

Fig. 3.5

3.3.2. OPERATING CHARACTERISTIC CURVES:

If the speed is kept constant, the variation of manometric head, power and
efficiency with respect to discharge gives the operating characteristics of the
pump. Fig 3.6 show the operating characteristic curves of a pump.

Fig.3.6
A centrifugal pump operating at certain speed can deliver any capacity from
zero to a maximum depending on pump size, design & suction condition. The
interrelations of capacity, head, power & efficiency are called the pump
characteristics, Fig. shows ideal characteristic of various types of pumps.

Actual characteristic is different because of following losses:

Circulatory flow.
Friction loss.
Turbulence.

Pumps head-capacity curves can be classified as follows:

21

1. Steady rising head characteristic- Rising head- capacity characteristic,

meaning a curve in which the head rises continuously as the capacity is
decreased. (Fig 3.7a )
2. Steep rising head characteristic-A rising head-capacity characteristic in
which there is a large increase in head between that developed at design
capacity and that developed at shutoff. (Fig 3.7b )
3. Drooping head characteristic- Drooping head characteristic, indicating
cases in which the head-capacity developed at shutoff is less than that
developed at some other capacities. This is also known as a drooping
curve. (Fig 3.7c )
4. Flat head characteristic. A head capacity characteristic in which the head
varies only slightly with capacity from shutoff to design capacity. The
characteristic might also be either drooping or rising. All drooping curve
have a portion where the head developed is approximately constant for a
range in capacity, called the flat portion of the curve. (Fig 3.7d )

Fig. 3.

Fig. 3.

Fig. 3.7a

Fig. 3.7b

22

Fig. 3.7c

3.4

Fig. 3.7d

SYSTEM HEAD CURVES:

To see the best suitability of pump it is necessary to identify system head
capacity curve. This is done most frequently for centrifugal pump. Fig 3.8
shows system head curve which constitute friction head & total static head
components for a given capacity. Friction head is the friction losses in the pipe
line, valves etc. friction head curve will change on variation in system
resistance e.g. throttling of valves etc.

Fig. 3.8
3.5

EVALUATION OF PUMP CHARACTERISTICS

Some process operations such as those requiring precise flow controls need a
head that varies markedly with a change in capacity. Pumps with rising head
characteristic best fill these services. Other process, such as cooling water
supply system, need a head that remains relatively constant for a wide
variation in capacity should have pumps with flat head characteristic. There is
no clear-cut distinction between flat head & rising head characteristics.
However as a rule of thumb, curves that shows a 150% increase in head from
the capacities of peak efficiency & shut off are called steep rising curve;
those showing a 10 to 25% rise are called steady rising curves & those with no
more than 10% increase are called flat.

23

Pumps with drooping characteristic give two flows at certain head leading to
unsuitability in regulation. Hence such pumps should not be operated in unsafe
region.
On comparison of actual H-Q and power curves of forward, radial and
backward vane impellers. We can see following advantages of backward vane
impeller:
* Stable H-Q characteristic.
* Limiting Power Characteristic.

Fig.3. 9 indicates characteristics of radial flow, mixed flow and axial flow
pumps.

Fig. 3.9
3.6.

CENTRIFUGAL PUMP CHARACTERISTIC RELATIONS

Certain relations exist that allow the performance of a centrifugal pump to be
predicted for a speed other than that for which the pump characteristic is
known. Similarly prediction of performance of a pump is possible for reduced
diameter of the impellers from the characteristics obtained at the large
diameters
Q N
H N2
P N3

Q D
H D2
P D3
24

Where N is speed in RPM and D is diameter.

3.7.

SPECIFIC SPEED
The principle of dynamic similarity expresses the fact that two pumps
geometrically similar to each other have similar performance characteristics. In
order to have some basic comparison among various types of centrifugal
machines it became necessary to evolve a concept, which linked three main
factors of performance characteristic- capacity, head, & speed into single term.
The term specific speed is such a concept. Specific speed is the speed of a
geometrically similarly pump, which delivers one unit capacity against one unit
of total head. In its basic form, the specific speed is an index number, expressed
as:

Here
N
Q
H

N Q
--------H3/4

NS

=
=
=

rpm of pump.
flow at optimum efficiency in gpm.
head in ft. (head per stage for a multistage pump)

Specific speed for various pumps:

Radial flow pump
Mixed flow pump
Axial flow pump

:
:
:

below 4000
4000 to 9000
above 9000

Specific speed is a useful tool in determining the NPSH required by a given

impeller. Those that produce high total dynamic head have lower specific
speed and reverse is also true. At a particular head & capacity, a pump of
lower specific speed will operate safely at lower NPSH than one with a higher
specific speed.

3.8.

NET POSITIVE SUCTION HEAD

Adequate NPSH is essential for working with any pump whether centrifugal,
rotary or reciprocating pump, to prevent cavitation. Cavitation occurs, when
absolute pressure of liquid reaches equal to its vapour pressure- this causes
formation of vapour bubbles in the fluid system, which are carried along until
pressure increases again. When these vapour bubbles collapse, void informed
demand immediate replacement of fluid. This result formation of pressure
wave causing damage to impeller. Cavitation occurs at point such as the pump
impeller entrance, trailing edge of valve gates other loss pressure points.
25

Cavitation can remove considerable amount of metal form impeller surface or

other affected surfaces. Cavitation does not mean immediate failure of he
pump. But is should not be tolerated.
Net positive suction head can be expressed as follows:
NPSH, ft.= Ha Hv + Hs Hf
Where:
Ha
Hv
Hs

:
:
:

Hf

Pressure on fluid in suction tank, ft.

Vapour pressure of fluid at pumping temperature ft.
Static head or lift from fluid level to pump centre line for
suction head this term will be positive for suction lift this term
will be negative.
Friction loss for the designed flow rate at the pump suction, ft.

NPSH for existing installation can be measured as follows:

NPSH, ft = Pa + Ps + (Vs2/2g) Hv

Where :
Pa
Ps

:
:

V2/2g
Hv

:
:

Atmosphere pressure, ft.

Gage pressure measured at pump suction flange
corrected to datum, ft.,
velocity head, ft.
Vapour pressure of fluid, ft.

All pumps require certain NPSH to permit the liquid flow in the pump casing.
This is determined by pump designer, and influenced by speed of rotation, the
inlet area, or eye area of impeller in a centrifugal pump, the type and number
of vanes in impeller, etc. on reciprocating pumps it largely function of speed
and valve design. Available NPSH must be greater than required NPSH; effect
of cavitation on centrifugal pump characteristic is shown in fig.3.10

26

Fig. 3.10
3.9.

CAVITATION
Cavitation is defined as the phenomenon of formation of vapour bubbles of a
flowing liquid in a region where the pressure of the liquid falls below its
vapour pressure and the sudden collapsing of these vapour bubbles in a region
of higher pressure. When the vapour bubbles collapse, a very high pressure is
created. The metallic surfaces, above which the liquid is flowing is subjected
to these high pressures, which cause pitting action on the surface. Thus
cavities are formed on the metallic surface and also considerable noise and
vibrations are produced.
Cavitation includes formation of vapour bubbles of the flowing liquid and
collapsing of the vapour bubbles. Formations of vapour bubbles of the flowing
liquid take place only whenever the pressure in any region falls below vapour
pressure. When the pressure of the flowing liquid is less than its vapour
pressure, the liquid starts boiling and vapour bubbles are formed. These
vapour bubbles are carried along with the flowing liquid to higher pressure
zones where these vapours condense and bubble collapse. Due to sudden
collapsing of the bubbles on the metallic surface, high pressure is produced
and metallic surfaces are subjected to high local stresses. Thus the surfaces are
damaged.
PRECAUTION AGAINST CAVITATION:
The following precautions should be taken against cavitation:
i.)

ii.)

The pressure of the flowing liquid in any part of the hydraulic system
should not be allowed to fall below its vapour pressure. If the flowing
liquid is water, then the absolute pressure head should not be below 2.5m
of water.
The special materials or coatings such as aluminum bronze and stainless
steel, which are cavitation resistant materials, should be used.

EFFECTS OF CAVITATION:
The following are the effects of cavitation:
i.)
The metallic surfaces are damaged and cavities are formed on the
surfaces.
ii.)
Due to sudden collapse of vapour bubble, considerable noise and
vibrations are produced.
27

3.10

PARALLEL OPERATION OF PUMPS

Adding flow of each pump at common head can draw combined characteristic.
If the individual pump characteristic is identical, capacity shared by each
pump will be equal at any load. But if the pumps have different characteristic
capacity sharing will be unequal and at certain capacity the pump with lower
shut off head may go out of line. Operating point is indicated at the location
where system characteristics is cut to combined pump characteristics. For
smooth operation pumps should not have unstable characteristic. (Refer
fig.3.11)

Fig. 3.11

3.11

SERIES OPERATION OF PUMPS

For higher head requirement series operation of pump may be opted.
Combined characteristic can be draw by adding head of each pump at common
flow. (Refer fig.3.12) Operating point is indicated at the location where system
characteristics is cut to combined pump characteristics.

28

Fig.3.12

29

Chapter-4

THRUSTS AND ITS BALANCING IN CENTRIFUGAL PUMPS

4.1

Radial Thrust In Centrifugal Pump

The internal water action in volute type casings tends to set up unbalanced
radial forces as shown in fig.4.1. To reduce this unbalanced force, some
pumps use a double volute casing as shown in Fig.4.2a & 4.2b. This double
volute adds another guiding vane to the water. It also splits and balances the
internal radial forces of the liquid on the pump impeller shaft and bearings.

Fig. 4.1

Fig. 4.2a

Fig. 4.2b
30

The double volute guide vanes also help to strengthen the casings internally,
reducing some of the stress load on the casing walls. The double volute guide
vanes can be supplied for both solid and split type casings without much
danger of improper matching because of the casting and pouring techniques
developed in recent years. Double volute guide vanes are also used on
multistage pumps to balance the discharge head and guide the fluid to the
suction side of the next stage.
In a single-volute pump casing design, uniform or near uniform pressures act
on the impeller when the pump is operated at design capacity (which coincides
with the best efficiency) fig. 4.3. At other capacities, the pressures around the
impeller are not uniform, and there is a resultant radial reaction (F). A
graphical representation of the typical change in this force with pump capacity
is shown in Fig.4.4 note that the force is greatest at shut-off head.

Fig. 4.3

Fig. 4.4

For any percentage of capacity, radial reaction is a function of total head, and
of the width and diameter of the impeller. Thus, a high-head pump with a
large-diameter impeller will have a much greater radial reaction force at
partial capacities than a low-head pump with a small-diameter impeller. A
zero radial reaction is not often realized; the minimum reaction occurs at
design capacity. In a diffuser-type pump, which has the same tendency for
over capacity unbalance as a single-volute pump, the reaction is limited to a
small arc repeated all around the impeller, with the individual forces canceling
each other.
The application of the double-volute design principle to neutralize reaction
forces at reduced capacity is illustrated in Fig.. Basically, this design consists
of two 180-deg volutes; a passage external to the second joins the two into a
common discharge. Although a pressure unbalance exists at partial capacity
31

through each 180. deg arc, forces F 1 and F 2 are approximately equal and
opposite, thereby producing little, if any, radial force on the shaft and
bearings. Although the double-volute casing design principle has been known
for some time, it was once a serious manufacturing problem, especially with
horizontal-discharge axially split double-suction pumps. This was because the
division wall spanned the split (Fig. 4.5).

Fig. 4.5
The double-volute design has many "hidden" advantages. For example, in
large- capacity medium- and high-head single- stage vertical pump
applications, the rib forming the second volute and separating it from the
discharge waterway of the first volute strengthens the casing .
4.2

Axial Thrust In Centrifugal Pump:

The pressures generated by a centrifugal pump exert forces on both its
stationary and rotating parts. The design of these parts balances some of these
forces, but separate means may be required to counterbalance others.
Axial hydraulic thrust is the summation of unbalanced impeller forces acting
in the axial direction. As reliable large-capacity thrust bearings are now
readily available, axial thrust in single-stage pumps remains a problem only in
larger units.
Asymmetric pressure distribution on suction side & back shroud in single
suction impeller causes axial thrust. Fig. 4.6 depicts pressure distribution.

32

Fig.4.6
Methods of axial thrust balancing:
1.
2.
3.
4.
5.

Use of double suction impeller.

Balancing hole in impeller.
Pump out vane in impeller.
Hydraulic balancing.
Staggering of stages in multi stage pump

4.2.1. Double Suction Impeller

Theoretically, a double-suction impeller is in hydraulic axial balance with the
pressures on one side equal to and counter- balancing the pressures on the
other (Fig.4.7). In practice, this balance may not be achieved for the following
reasons:
1. The suction passages to the two suction eyes may not provide equal or
uniform flows to the two sides.
2. External conditions, such as an elbow being too close to the pump suction
nozzle, may cause unequal flows to the suction eyes.
3. The two sides of the discharge casing may not be symmetrical, or the
impeller may be located off-center. These conditions will alter the flow
characteristics between the impeller shrouds and casing, causing unequal
pressures on the shrouds.
4. Unequal leakage through the two leakage joints will tend to upset the
balance.
Combined, these factors create definite axial unbalance. To compensate for
this, all centrifugal pumps, even those with double-suction impellers,
incorporate thrust bearings.

33

Fig. 4.7
The ordinary single-suction radial-flow impeller with the shaft passing
through the impeller eye (Fig.4.8), is subjected to axial thrust because a
portion of the front wall is exposed to suction pressure, thus exposing
relatively more back wall surface to discharge pressure. If the discharge
chamber pressure were uniform over the entire impeller surface, the axial
force acting towards the suction would be equal to the product of the net
pressure generated by the impeller and the unbalanced annular area.

Fig. 4.8
Actually, pressure on the two single-suction impeller walls is not uniform. The
liquid trapped between the impeller shrouds and casing walls is in rotation,
and the pressure at the impeller periphery is appreciably higher than at the
impeller hub. Although we need not be concerned with the theoretical
calculations for this pressure variation, Fig. describes it qualitatively.
Generally speaking, axial thrust towards the impeller suction is about 20 to 30
percent less than the product of the net pressure and the unbalanced area.
4.2.2. Balancing Holes
To eliminate the axial thrust of a single suction impeller, a pump can be
provided with both front and back wearing rings. To equalize thrust areas, the
inner diameter of both rings is maintained in a chamber located on the
impeller side of the back-wearing ring by drilling so called balancing holes
through the impeller. Leakage past the back-wearing ring is returned into the
suction area through these holes.

34

Fig. 4.9
However, with large single stage single suction pumps balancing holes are
considered undesirable because leakage back to the impeller suction opposes
the main flow, creating disturbances. In such pumps, a piped connection to the
pump suction replaces the balancing holes.
4.2.3. Pump Out Vanes
Another way to eliminate or reduce axial thrust in single-suction impellers is
by use of pump-out vanes on the back shroud. The effect of these vanes is to
reduce the pressure acting on the back shroud of the impeller (Fig. 4.10). This
design, however, is generally used only in pumps handling gritty liquids,
where it keeps the clearance space between the impeller back shroud and the
casing free of foreign matter.

Fig. 4.10
4.2.4. Balancing Drum
The balancing drum is illustrated in Fig.. The balancing chamber at the back
of the last-stage impeller is separated from the pump interior by a drum that is
either keyed or screwed to the shaft and therefore rotates with the shaft. The
drum is separated by a small radial clearance from the stationary portion of the
balancing device, called the "balancing drum head," that is fixed to the pump
casing.
35

The balancing chamber is connected either to the pump suction or to the vessel
from which the pump takes its suction. Thus, the back pressure in the
balancing chamber is only slightly: higher than the suction pressure, the
difference between the two being equal to the friction losses between this
chamber and the point of return. The leakage between the drum head is, of
course, a function of the differential pressure across the drum and of the
clearance area.
The forces acting on the balancing drum in Fig.4.11 are the following:
1. Towards the discharge end-the discharge pressure multiplied by the front
balancing area (area "B") of the drum.
2. Towards the suction end-the back pressure in the balancing chamber
multiplied by the back balancing area (area "C") of the drum.
The first force is greater than the second, thereby counterbalancing the axial
thrust exerted upon the single-suction impellers.
Actually, the drum diameter can be selected to balance axial thrust completely
or within 90 to 95 percent, depending on the desirability of carrying any thrust
bearing loads.

Fig 4.11
It has been assumed in the preceding simplified description that the pressure
acting on the impeller walls is constant over their entire surface and that the
axial thrust is equal to the product of the total net pressure generated and the
unbalanced area. Actually, this pressure varies somewhat in the radial
direction because of the centrifugal force exerted upon the water by the outer
impeller shroud (see Fig.). Further more, the pressures at two corresponding
points on the opposite impeller faces (D and E) may not be equal because of
36

variation in clearance between the impeller wall and the casing section
separating successive stages. Finally, pressure distribution over the impeller
wall surface may vary with head and capacity operating conditions.
This pressure distribution and design data can be determined by test quite
accurately for anyone fixed operating condition, and an effective balancing
drum could be designed on the basis of the forces resulting from this pressure
distribution. Unfortunately, varying head and capacity conditions change the
pressure distribution, and as the area of the balancing drum is necessarily
fixed, can destroy the equilibrium of the axial forces. The objection to this is
not primarily the amount of the thrust, but rather that the direction of the thrust
cannot be predetermined because of the uncertainty about internal pressures.
Still, it is advisable to predetermine normal thrust direction, as this can
influence external mechanical thrust bearing design. Because 100 per cent
balance is unattainable in practice and the slight but predictable unbalance can
be carried on a thrust bearing, the balancing drum is often designed to balance
only 90 to 95 per cent of total impeller thrust.

Balancing drum modifications

To reduce the balancing drum leakage, a series of steps along the drum with
small relief chambers at each step is sometimes provided. The drum surface is
also frequently serrated.
Experience indicates that the most successful simple balancing drum designs
are of relatively long length. The length reduces the pressure drop per linear
unit and thus decreases the rate of wear. This design, however, suffers from
the fact that it substantially increases the pump shaft span.
Figure 4.12 illustrates a modification of the balancing drum that incorporates a
"labyrinth" construction with concentric pressure-reducing passages. The
example illustrated provides approximately 18 inches of effective drum length
in only 7 1/2 in. of axial length.
The balancing drum satisfactorily balances the axial thrust of single-suction
impellers and reduces pressure on the discharge side stuffing box. It lacks,
however, the virtue of automatic compensation for any changes in axial thrust
caused by varying impeller reaction characteristics. In effect, if the axial thrust
and balancing drum forces become unequal, the rotating element will tend to
move in the direction of the greater force. The thrust bearing must then
prevent excessive movement of the rotating element. The balancing drum
performs no restoring function until such time as the drum force again equals
the axial thrust. This automatic compensation is the major feature that
differentiates the balancing disk from the balancing drum.

37

Fig. 4.12
4.2.5. Balancing Disks:
The operation of the simple balancing disk is illustrated in Fig.4.13. The disk
is fixed to and rotates with the shaft. It is separated from the balancing disk
head installed as a casing part, by a small axial clearance. The leakage through
this clearance flows into the balancing chamber and from there either to the
pump suction to the vessel from which the pump takes its suction. The back of
the balancing disk is subject to the balancing chamber back pressure whereas
the disk face experiences a range of pressures. These vary from discharge
pressure at its smallest diameter to back pressure at its periphery. The inner
and outer disk diameters are chosen so that the difference between the total
force acting on the disk face and that acting on its back will balance the
impeller axial thrust.

Fig. 4.13

38

If the axial thrust of the impellers should exceed the thrust acting on the disk
during operation, the latter is moved towards the disk head, reducing the axial
clearance is reduced so that the friction losses in the leakage return line are
also reduced, lowering the back pressure in the balancing chamber. This
automatically increases the pressure difference acting on the disk and moves it
away from the disk head, increasing the clearance. Now, the pressure builds
up in the balancing chamber, and the disk is again moved towards the disk
head until an equilibrium is reached.
To assure proper balancing disk operation, the change in back pressure in the
balancing chamber must be of an appreciable magnitude. Thus, with the
balancing disk wide open with respect to the disk head, the back pressure must
be substantially higher than the suction pressure to give a resultant force that
restores the normal disk position. This can be accomplished by introducing a
restricting orifice in the leakage return line that increases back pressure when
leakage past the disk increases beyond normal. The disadvantage of this
arrangement is that the pressure on the stuffing box packing is variable a
condition that is injurious to the life of the acting and therefore to be avoided.
The higher pressure that can occur at the packing is also undesirable.
4.2.6. Combination disk and drum:
For the reasons just described, the simple balancing disk is seldom used. The
combination balancing disk and balancing drum (Fig. 4.14) was developed to
obviate the shortcomings of the disk while retaining the advantage of
automatic compensation for axial thrust changes.
The rotating portion of this balancing, device consists of a long cylindrical
body (that turns within a drum portion of the disk head. This rotating part
incorporates a disk similar to the one previously described. In this design,
radial clearance remains constant regardless of disk position, where as the
axial clearance varies with the pump rotor position. The following forces act
on this device:
1. Towards the discharge end-the sum of the discharge pressure multiplied by
area A, plus the average intermediate pressure multiplied by area B.
2. Towards the suction end-the back pressure multiplied by area C.
Whereas the "position-restoring" feature of the simple balancing disk required
an undesirably wide variation of the back pressure, it is now possible to
depend upon a variation of the intermediate pressure to achieve the same
effect. Here is how it works. When the pump rotor moves to- wards the
suction end (to the left, in Fig. ) because of increased axial thrust, the axial
clearance is reduced, and pressure builds up in the intermediate relief
chamber, increasing the average value of the intermediate pressure acting on
area B. In other words, with reduced leakage, the pressure drop across the
radial clearance de- creases, increasing the pressure drop across the axial
clearance.
39

Fig. 4.14
The increase in inter- mediate pressure forces the balancing disk towards the
discharge end until equilibrium is reached. Movement of the pump rotor
towards the discharge end would have the opposite effect of increasing the
axial clearance and the leakage and decreasing the intermediate pressure
acting on area B.
Figure 4.15 illustrates the pressure distribution in a combination balancing
disk and drum. No attempt is made to describe the exact manner in which the
pressure decreases between any two points, although this curve is not
necessarily a straight line. Also, this illustration is not quantitatively correct. It
only serves to show that changes in the balancing device position vary the
internal pressure distribution without altering the back pressure. The only
possible variation may be caused by pressure changes at the point where the
balancing device leakage is returned to the system. An orifice may still be
located in the return line. Its function now, however, is not that of changing
back pressure but rather of gagging the volume of leakage flow. This flow
should not be throttled outside the balancing device; the orifice pressure drop
is negligible, ranging from about 2 to 20 psi.

40

Fig.4.15

4.3

Axial thrust in multistage pumps:

It might seem that the advantages of balanced axial thrust and greater available
suction area in a double-suction impeller would warrant applying such
impellers to multistage pumps. But, there are definite shortcomings to this
practice. The average multistage pump has relatively low capacity when
compared to the entire range covered by modern centrifugal pumps. It is
seldom necessary, therefore, to use double- suction impellers just to reduce the
net positive suction head required for a given capacity. Even if a double
suction impeller is desirable for the first stage of a large capacity multistage
pump, it is hardly necessary for the remaining stages. As to the advantage of
the axial balance it provides, it must be considered that a certain amount of
axial thrust is actually present in all centrifugal pumps and the necessity of a
thrust bearing is therefore, not eliminated.
Most important, the use of double suction impellers in a multistage pump adds
needless length to the pump shaft span. Additional space is required for the
extra passage leading to the second inlet of each successive stage. In a pump
with four or more stages (Fig.4.16), this increase becomes quite appreciable
and causes additional casting difficulties. If shaft diameter is in- creased to
compensate for the longer span so as to maintain reasonable shaft deflection,
the impeller inlet areas are correspondingly reduced. The result is that the
advantage of superior suction conditions usually offered by double-suction
impellers is considerably reduced. Finally, as it is impractical to arrange the
various double suction impellers in any but the ascending order of the stages,
the impeller at one end of the casing becomes the last stage impeller and the
pressure acting on the adjacent stuffing box becomes the discharge pressure of
the next-to-last stage. To reduce this pressure, a pressure-reducing bushing
must be interposed between the last-stage impeller and the stuffing box, and
this bushing further increases the over-all length. The result of all these
considerations is that most multistage pumps are built with single-suction
impellers.

41

Fig.4.16
Axial thrust balancing in multistage pump are done as follows:
1. Several single-suction impellers may be mounted on one shaft, each
having its suction inlet facing in the same direction and its stages
following one another in ascending order of pressure (Fig.). The axial
thrust is then balanced by a hydraulic balancing device.
2. An even number of single-suction impellers can be mounted on one shaft,
one half of these facing in an opposite direction to the second half. With
this arrangement, axial thrust on the one half is compensated by the thrust
in the opposite direction on the other half (Fig.). This mounting of singlesuction impellers back-to-back is frequently called "opposed impellers."
An uneven number of single-suction impellers may be used with this
arrangement, provided the correct shaft and inter stage bushing diameters are
used to give the effect of a hydraulic balancing device that will compensate for
the hydraulic thrust on one of the stages.
It is important to note that the opposed impeller arrangement completely
balances axial thrust only under the following conditions:
1. The pump must be provided with two stuffing boxes.
2. The shaft must have a constant diameter.
3. The impeller hubs must not extend through the inter stage portion of the
casing separating adjacent stages.
Except for some special pumps that have an internal and enclosed bearing at
one end, and therefore only one stuffing box, most multistage pumps fulfil the
first condition. But because of structural requirements, the last two conditions
42

are not practical. A slight residual thrust is usually present in multistage

opposed-impeller pumps, unless impeller hubs or wearing rings are located on
different diameters for various stages. Because such a construction would
eliminate axial thrust only at the expense of reduced interchange ability and
increased manufacturing cost, this residual thrust, being relatively small, is
usually carried on the thrust bearing.
4.3.1. Hydraulic Balancing Devices
A single-suction impeller is subject to axial hydraulic thrust caused by the
pressure differential between its two faces. If all the single-suction impellers
of a multi- stage pump face in the same direction, the total theoretical
hydraulic axial thrust acting towards the suction end of the pump will be the
sum of the individual impeller thrusts. The thrust magnitude (in pounds) will
be approximately equal to the product of the net pump pressure (in pounds per
square inch) and the annular unbalanced area (in square inches). Actually the
axial thrust turns out to be about 70 to 80 per cent of this theoretical value.
Some form of hydraulic balancing device must be used to balance the axial
thrust and to reduce the pressure on the stuffing box adjacent to the last-stage
impeller. This hydraulic balancing device may be a balancing drum, a
balancing disk, or a combination of the two.

43

Chapter-5
OPERATIONS OF CENTRIFUGAL PUMPS

5.1

INITIAL START
Starting a centrifugal pump for the first time can be a trouble some experience
unless the plant crew has made a thorough check of the unit during & after
installation. Factors to be considered in starting any centrifugal pump include
pipe cleanliness, pump alignment, rotation, lubrication, position of valves,
stuffing box leakage, effect of speed changes, bypass quantities, throttling of
the discharge & performance checks.
Factor to be checked in first start of any centrifugal pump are as follows:
1.
2.
3.
4.
5.
6.

7.

8.

9.

Pipe cleanliness.
Alignment and freeness of rotating assembly.
Rotation: Proper direction of rotation.
Pump bearings: should be inspected, cleaned & lubricated. Oil level
checked.
Lube oil system: cleaned, components commissioned, cooling system
checked.
Pump exterior: clean external surfaces of the pump and this driver. Check
tightness of all joints & foundation bolts. Ensure area around the pump set
is clean.
Pump drive: Check the prime over that it lubricated and ready to operate.
If possible run the drive independently of the pump to see it is in good
operating order.
Priming: Prime the pump by any appropriate method. Take care to see that
suction line is full of liquid and there is enough reserve in the supply
system to keep the line full, while pump operates.
Position of valves: open the suction valve wide open. Position of discharge
valve is base on power characteristic of the pump and should be as
follows:

Radial flow pump: start with discharge valve closed since it takes low
power at low flow, then open the valve, when pump attains full speed.
Mixed flow pump: Often requires greater power, when operated with
closed discharge, hence start with open discharge valve.
Axial flow pump: always take more power when started with discharge
valve closed. So that this pump with discharge valves open.

10. Pump warm up: with pump handling hot liquid, the casing, rotor, and other
parts must be brought to within a temperature of 0 to 100 0 F of the liquid
before unit is started.
44

5.2

PIPE CLEANLINESS
Multistage pumps and many single-stage pumps have close clearance running
parts which must be protected from abrasive particles often found in new
piping systems.

5.3

ALIGNMENT:
Bring the pump to operating temperature by admitting liquid to the casing.
Check the alignment as explained earlier. Turn the pump over by hand. It
should turn freely, without binding, scraping or making any noise. Inspect the
pump footings to see that any device for expansion of the casing are free & is
good working condition.

5.4

ROTATION
The pump must be run in the direction indicated by an arrow on the casing,
which is always toward the discharge nozzle. You will note that the impeller
rotates in the direction away from the vane curvature. Check the driver &
pump rotation. Touch the motor starter just long enough to make the motor
turn a few revolutions. The pump shaft should turn in the direction of the
arrow on the casing, Fig a shows how to determine the direction of rotation of
a horizontal centrifugal pump. Stand at the driver end, facing the pump. If the
top of the shaft revolves from left to right, when viewed from this position, the
rotation is clockwise.

5.5

PUMP BEARINGS
Before any pump is started its bearings must be carefully inspected, cleaned &
lubricated, with oil lubricated sleeve bearings, remove the cap, thrust shoes (if
used) & drain plug. Flush out the housing, oil piping, cooler pump and sump
tank with kerosene, carbon tetrachloride or safety solvent. Wash the bearing
parts thoroughly & reassemble them in the housing. Flush the entire system
with lube oil and allow it to drain to waste. This will ensure removal of any
dirt, metallic or waste particles present in the bearings or lube system. Replace
the drain plug, caps & other parts & fill the bearing as directed by the
manufacturer.
Grease-lubricated ball, roller & needle bearings are usually packed with grease
at the factory before the pump is shipped. So no lubrication may be necessary
before starting the pump. Check the condition of the greases by removing the
bearing housing cover. See that there is grease in the bearing. An over greased
bearing may over heat soon after the pump is started.
Never start a pump equipped with kingsbury type thrust bearings without first
pouring oil into the bushing to protect the thrust shoes. Extreme care must be
45

exercised with all types of bearings on pumps to see that they have enough
clean lubricant.
When there is a forced feed lube oil system exists, fill the supply line to the
bearings so it will be full when the pump start & here will be no delay in the
oil reaching the bearings.
Bearing housings with oil both lubrication or with an oil sump which is to be
filled to a given level, ordinarily are equipped with oil gauges or sight gauges.
Oil is added when the oil level, due to loss, has dropped below the established
low limit. In general, the oil level should never reach higher than the centre of
the lowest rolling element when the bearing is not rotating.
For regreasing, in a new or used anti friction bearing, remove the bearing from
the shaft. Using a brush, wash the race, balls & other parts with kerosene or
carbon tetrachloride. Soak the bearing in one of these solvents until the grease
off the bearing parts.
5.6

PUMP DRIVE
Check the motor, turbine, engine or other drive to see that it is lubricated &
ready to operate. Whenever possible, run the drive independently of the pump
to see that it is in good operating order. See the manufacturers instructions for
drive operation.

5.7

PRIMING:
Prime the pump by one of the methods stated earlier. Take care that the
suction pipe is full of liquid & that there is enough reserve in the supply
system to keep the line full while the pump operates. Reduced flow into the
suction pipe of a centrifugal pump can lead to overheating & extensive
damage to the pump.

5.8

POSITION OF THE VALVES :

Open the suction valve wide. Never use it as a throttling device for pump flow.
With a medium or high head centrifugal pump it is best to start with the
discharge gate valve closed this is because the pump requires less power input
when primed & operated at full speed with the discharge valve closed.
Mixed flow type centrifugal pumps often require greater power input when
started with the discharge valve closed than when it is open. Axial flow type
centrifugal pumps almost always take more power when started with the
discharge valve closed. So it is a common practice to start these two types
with the discharge gate valve open. But to the certain, check with the pump
manufacture.

5.9

PUMP WARM UP
46

With pumps handling hot water or other how liquids, the casing, rotor & other
parts must be brought to within a temp. of 500 to 1000 F of the liquid before the
unit is started. This prevents unequal expansion, with the possibility of contact
between the moving & stationary parts.
Open the vent valve on top of the casing & admit warm liquid to the pump.
Use one or more casing drains to increase the liquid flow from the pump,
thereby reducing the time required for warm up. In pumps like boiler feed
pumps. This is not economical, instead, a jumper line around the discharge
check valve is used. Hot liquid flows through this line, into the pump & out
the suction pipe.

5.10

STARTING THE PUMP

The following steps are usually suitable for starting a centrifugal pump in
good operating condition:
i.

Turn on the cooling water system for the pump bearings, stuffing
boxes & mechanical seals, if these parts are liquid cooled.

ii.

Start the auxiliary lube oil pump, if one is fitted & check the oil flow to
the bearings & other parts of the pump.

iii.

One the suction gate valve & close or open the discharge gate valve,
depending on the starting procedure to be followed.

iv.

Close all the drains in the casing & suction & discharge piping.

v.

Prime the pump.

vi.

Open the warm up valve if the pump is not at the right temp.

vii.

Open the recirculating valve.

viii.

Start the driver & bring the pump into speed.

ix.

As soon as the pump is upto rated speed, open the discharge gate valve
slowly.

x.

Check the leakage from the stuffing boxes.

xi.

Adjust sealing liquid flow to ensure packing lubrication. A flow of 1 to

2 gpm. to each stuffing box is usually sufficient.
47

xii.

Check the pump bearings for lube oil flow.

xiii.

When there is sufficient flow through the pump, close the recirculating
valve.

xiv.

Check the pump suction discharge, lube oil, cooling water & sealing
water pressures & temps.

Bearing temp generally should not exceed 1500 F during pump operation.
The above steps are suitable for almost centrifugal pumps. Some steps may be
omitted with smaller units having separate cooling & oils systems. If the
pumps show any signs of trouble while being started, overheated bearings or
packing, excessive vibration or noises stop the unit immediately. Inspect the
pump for the cause of the trouble & take corrective action before starting the
pump again.

5.11

OPERATING CHECKS:
While the pump runs make the hourly checks listed below bearing temp,
suction & discharge pressure, lube oil temp & pressure, leak off flow,
discharge flow meter, stuffing box leakage, cooling water suction & discharge
temp & pressure in put to pump driver & the oil level in the pump & driver
bearings. Keep an hourly record of all these readings, using the logbook.

5.12

PUMP SHUTDOWN
When the liquid supply is above the pump centre line, close the discharge gate
valve, then the suction gate valve. Shutoff the power immediately. When the
liquid supply is below the pump (suction lift), close the suction gate valve,
then the discharge gate valve. Immediately after, shut off the power or steam
to the driver. This procedure keeps liquid in the pump, preventing damage
should the unit be started before being primed. If the pump has a recirculating
line, close its valve before the pump stops. Open the warm up valve if the
pump is to be kept warm.
When a pump operates against a high discharge pressure, it should be stopped
in three steps:
1. Partially close the discharge valve.
2. Shut off the power.
3. As soon as the power is off.

48

Close the discharge valve rapidly. The discharge valve should be tightly
closed by the time pump stops rotating. Then there is no possibility of back
flow causing the pump to turn in a reverse direction. This procedure also
prevents water hammer in high-pressure lines.
If the pump is not to be started, hang a suitable tag on it. Do not shut-off the
cooling & sealing liquid supply until the pump shaft has stopped turning.
Remember that an idle pump will partially drain through the glands while not
operating. So be sure to prime it before starting again. Never run any
centrifugal pump dry. Serious damage will almost always result.

49

Chapter-6
MAINTENANCE OF CENTRIFUGAL PUMPS

6.1

GENERAL
Centrifugal pumps whether horizontal or vertical can be considered to have
two basic types of parts rotating and stationary. Rotating parts include the
impeller, shaft, wearing rings, shaft sleeves, bearings and mechanical seals.
Stationary parts include the casing, bearing housing, suction and discharge
flanges, packing, leak off tubing, and base plate. Most maintenance work on
centrifugal pumps is concerned with the rotating parts, but some work is also
performed on the stationary parts.

6.1.

ROTATING PARTS

6.1.1. IMPELLER
Immediately after removing the impeller from a pump inspect its eye, vanes,
shrouds, wearing rings, passages, hub and other parts. Wear may occur at the
eye, vanes, shrouds and other impeller parts. Corrosion, cavitation and erosion
are generally accompanied by a wasting away of the impeller or vane surfaces.
Where the attack is severe, the thinned section impeller may be sprayed with a
rubber, plastic or metallic coating., which is done by an organization
specializing in it. If cavitation is severe, it may be necessary to change the
suction conditions or install an impeller suitable for the existing suction
conditions.
If the impeller is dirty when it is removed from the pump, clean it carefully
before making an inspection. Use a soft wire brush or a steam lance to remove
thick gummy residues. Scale, coke and other deposits can be removed by
chemical cleaning or sand blasting. In either case, precautions must be taken
to see that the impeller material is not damaged by the cleaning method
chosen. Pitting of the impeller may be caused by cavitation, which can occur
without audible noise.
While it is possible to recondition an impeller that is worn or corroded, it is
often better to replace it with a new one suitable protected to resist wear or
corrosion.
Often, before the impeller can be removed for inspection, scale and burrs must
be removed from the soft with a file. To prevent damage of the packing and
fittings, clean the shaft thoroughly.
If a bronze impeller is a shrink fit on the shaft, as many are, slip a metal sleeve
over shaft and against the impeller hub, to protect the shaft while the impeller
is heated. Start heating the impeller with a torch from the outside of the shroud
working toward the hub. Revolve the impeller while heating it so its
50

temperature will be equalized. When the impeller is loose, pry it off the shaft,
being careful to press only against the shroud. Wear asbestos gloves when
lifting the hot impeller.

IMPELLER RUNOUT
With pumps having bearings at each end of the shaft, mount the impellers,
wearings rings, spacer and shafts sleeves on the shaft and support the
assembly between centres (Fig.6.1). Set a dial gage at zero and take readings
near each end and at the centre of each shaft sleeve. Also take similar readings
at each impeller-wearing ring. For most pumps, if the run out is not more than
0.0015 in, the assembly can be considered accurate and the shaft installed as
is. If the reading is greater, check for a bent shaft, out-of-square, dirty or
burned impeller end of a shaft or spacer sleeve.

Fig. 6.1
BALANCING
Badly worn or corroded impellers may vibrate excessively. While the presence
of vibration is usually easy o detect, a special balancing machine (Fig.6.2) is
needed to detect how much unbalance exists. It is usually necessary to return
the impeller and shaft to the manufacturer for a check of this type.
To balance an impeller by hand, press it on an arbor, the ends of which rest on
two parallel and level knife-edges. If out of balance, the impeller will turn and
come to rest with its heavy side down. To balance the impeller, metal must be
removed from the heavy side. This must be done without impairing the pump
performance or accelerating erosion. For this reason, drilling holes in the
heavy side is undesirable.
51

The best practice is to mount a shrouded impeller off centre in a lathe and take
a cut from the shroud, deepest at the rim. This may be done on one or both
shrouds, depending on their thickness and the amount of metal to be removed.
The semi open impellers remove metal from the shroud if the design permits,
or from the underside of the vanes of open impellers.

Fig. 6.2
6.1.2. SHAFTS:
Check for a bent shaft by means of a dial gauge. Badly bent shaft should be
returned to the pump manufacturer for straightening because the average plant
does not have the necessary facilities. A shaft may also be checked for trueness by swinging between lathe or other centre and checking the run out with a
dial gauge.
Tap the impeller shaft key to see that it is tight. Twist of the shaft under load,
expansion, or corrosion will progressively loosen the impeller.
RECONDITIONING A SHAFT:
Centrifugal pump shafts wear while in use. Typical wear points are at the
packing box and other places where the friction load is high. Keep the friction
wear low by using a good grade of packing and adjusting the glands evenly.
Be sure that the gland follower does not ride on the shaft. As soon as the
packing becomes dry, replace it.
It a new shaft is costly, or wears is rapid, it may pay to add a tougher wear
resisting surfaces to the shaft at the points of sliding or rotating contact. This
process is known as hard surfacing and can increase the life of some parts
from four to thirty times.
52

Center the shaft in a lathe supporting it in a steady rest located near the point
of work, if necessary. Use calipers to measure any unevenness to find the
depth of cut needed to give the necessary thickness of metal overlay.
When the build up is done by welding keep the welding deposits low and lay
the bead longitudinally along the shaft. For two inch and smaller shafts,
alternate the beads at 900 intervals until the shaft is completely covered at its
worn section.
Before spraying a shaft with metal, take a rough thread cut of 24 threads per
inch. Then break the apex of the thread with a knurling tool. Mount the gun on
the tool post with the nozzle about 6 in from the work. Hold the gun by hand
when spraying the undercut or dovetail section at each end of the machined
area.
Take a rough finishing cut, leaving enough metal for filing and lapping of the
shaft to its final size. File lightly moving the file back and forth as the shaft
revolves. When the shaft, is correctly filed, polished it with No. 0 and 00
emery cloth. The shaft is now ready to be replaced in the pump. There are
other methods of hard-surfacing shafts. For best results, consult the
manufacture of the equipment for this work.
6.1.3. WEARING RINGS:
Wearing ring clearance is of extreme importance because, as the clearance
increases in a given pump leakage of liquid past the rings becomes greater,
reducing the efficiency of the pump. For wearing rings typical none all
combinations are:
1.
2.
3.
4.
5.

Bronze with a dissimilar bronze.

Cast iron with bronze.
Steel with bronze
Monel metal with bronze and
Cast iron with cast iron.

There is less leakage after accidental contact between casing and impellerwearing rings made of these materials. Figure 2.8 shows typical wearing ring
clearance, recommended by one manufacturer. One method of measuring
wearing-ring clearance is shown in Fig 6.3.

53

.
Fig. 6.3
WEARING RING INSTALLATION:
Centrifugal pumps fitted with wearing rings come supplied with the rings. So
it is not necessary to install rings on a new pump. Once the rings wear, they
must be replaced. To do this, first secure suitable replacement for the rings in
the pump from the manufacturer. Remove worn impeller rings which are
threaded or shrunk in place, by heating the ring with a torch, be careful not to
heat the impeller. Or insert a few pieces of dry ice in the impeller eye to shrink
the impeller away from the ring. The casing wearing rings to be removed
using similar methods.
Since many impeller rings are shrink fits, heat the ring before slipping into
place and pinning. For ring diameters of 2.5 to 6in., interference between the
ring and the impeller is 0.001 to 0.0015 in. between 6 and 12 in., interference
is 0.002 and 0.0025 in. insert the pin after the ring is in place. Figure shows
the methods and tools used in taking measurements of the impeller and casing
wearing rings.
To restore the clearance in a pump having a single wearing ring, obtain a new
ring bored undersize and true up the impeller hub by turning it down in a lathe.
Sometimes it may be possible to build up either the casing ring or the impeller
hub, machining both to give the correct clearance. This is difficult and feasible
only if the pump is large and the equipment to do the work is available.
Pumps with double wearing rings can have their clearance renewed in three
ways:
1. Obtain a new oversized impeller ring and use the old casing ring, bored
true to the larger diameter.
2. Obtain a new casing ring bored undersize and use the old impeller ring
turned to a smaller diameter.
3. Renew both rings, if necessary.
When a new wearing ring is put on an impeller, its surface is often off-centre
with the shaft. So, after mounting a new ring, check its wearing surface.
Machine, if necessary. Do this whether the ring is pressed, bolted, or screwed
on the impeller.
54

Measure the clearance of flat wearing rings with a feeler gauge between the
stationary and rotating parts. In multistage pumps, where the wearing ring may
be L-shaped, the lip of the L prevents using the gauge. A fairly close check of
the clearance may be made by mounting a dial indicator on the impeller and
setting it to zero with the casing ring resting on the impeller wearing ring hub.
Without moving the impeller or dial indicator, push up on the stationary ring
from below and record the maximum dial reading. This is the diametral
clearance. Divide by 2 to get radial clearance, tolerances are always plus for
casing wearing rings, minus for impeller wearing ring.
6.1.4. SHAFT SLEEVES:
These wear when packed too tightly. They may be reconditioned by welding
or metallizing in the same manner as described above for shafts. Where wear
is extreme, replacement of the worn sleeve with a new one is often
recommended. Use a sleeve puller to remove old sleeves from the shaft. When
the sleeve is rusted to the shaft, use the impeller nut to help loosen the sleeve.
In extreme cases a hammer and chisel may be needed to split the sleeve before
removal. Be careful not to damage the shaft with the hammer or chisel. After
installing a new shaft sleeve, check its concentricity on the shaft.

6.1.5. BEARINGS:
Feed pump and the ring oiled sleeve bearing and pressure lubricated
Kingsbury thrust bearing opened for inspection and maintenance. Check the
journal and thrust bearings as shown in fig. Ball bearings may be checked as
shown in fig.
Clearance between the shaft and the babbit of sleeve bearings should not
exceed 150% of the original value.
SLEEVE BEARINGS:
These can be re-babbitted in the field, if desired, but this practice is generally
confined to larger plants. To replace the metal in babbit-lined bearings:
1. Machine or melt out the old metal and place it with new metal in a melting
pot.
2. Wash the shell in a week solution of lime and water. Rinse in clean
running water. Do not touch or wipe the area to be metalled. Dry with
compressed air.
3. Dip the shell in a bath of hydrochloric acid (1 part acid to 5 parts water)
for 10 min, or paint with this solution, using an old but clean brush. Rinse
in water.

55

4. Plug oil holes with heat resistant plastic or other material (fire clay, etc)
coat all the surfaces not to be tinned with a fire-clay wash (made up like a
cement wash).
5. Swab the surface to be tinned with a flux. This can be made by dissolving
zinc in nitric acid until no more will dissolve and the acid is neutralized or
killed.
6. Place the bearing shell in a molten solder bath. Keep it there until it is as
hot as the solder 5750 to 625 0 F remove and inspect the tinning. Any bare
patches must be scraped bright, fluxed and retinned.
7. Place the bearing shell in a previously prepared cylindrical jig of suitable
size and centre an undersized length of shaft in the shell.
8. Pour the babbit at 8000 to 8500 F into the space between the jig and a
mandrel placed inside it. The diameter of the mandrel should be slightly
less than that of the pump shaft. Use a ladle enough to complete the
pouring in one filling.
9. Puddle the molten babbit with an iron wire, working the wire up and
down. This prevents cavities forming during cooling.
10. If the metal shrinks from the edges of the bearing shell, correct by penning
it outward. Clean all the hammer marks when fitting and scraping the
bearings.
Set up large bearings in a lathe chuck and bore to the correct size after the
babbitt is cool. Bolt both halves of the bearing together before the boring is
begun. Make the final fit by scraping and checking. Small bearings can be
bored in a drill press. Use an adjustable double-edge cutting tool. Take fine
cuts to prevent the tool from digging into the metal scrape to size.
ROLLING CONTACT BEARINGS:
Keep all rolling contact bearings clean at all times dirt means damages. Work
on the bearings with clean tools in clean surroundings. Remove all outside dirt
from the housing before exposing the bearing. Handle bearings only with
clean dry hands. Treat a used bearing as carefully as a new one. Use clean
solvents and flushing oils. Lay the bearings on only clean paper. Project
disassembled bearings from dirt; use clean lint free rags if the bearings are
wiped. Keep the bearings in oil proof replacing a bearing. Install new bearing
as removed from their packages, without washing. Keep bearing lubricants
clean when applying and cover containers when not in use.
An arbor press is usually the best tool for removing a bearing. But most field
work is done with some from of bearing putter. To remove a bearing, press or
pull only on the ring which is tight. Press or pull straight and square to keep
56

the ring from cocking. Never press or pull against the bearing shields or
separators.
6.1.6. MECHANICAL SEALS:
Remove the seal cover containing the stationary face and pull the face from
the cover by hand. Using two wire hooks, engage them in the holes provided
and remove the rotating face. Although normally only the faces require repair,
it is a good idea to remove the spring assembly for cleaning and inspection.
Use the same wire hooks as before.
If the stationary face is scarred, it probably has dirt or scale embedded in it.
Take a light clean-up cut to remove the metal to below any possible dirt. If the
face is made of carbon, machine it from the outside, working inward, to
prevent chipping. It is best to use a carbide-tipped tool with a 50 lead angle and
70 rake. Zero rake can be used for bronze faces.
If the rotating face is only slightly scored, lap it without machining. But if the
scoring is deep, take a fine cut in a lathe. If the face is stellite or hardened
chrome steel of 500 brinell or softer, machine it with a carbide-tipped tool
having zero rake and 70 lead angle. If possible, hold it in a four jaw chuck to
avoid distortion.
Next, the faces must be lapped. If good lapping plates are not available in the
plat, it may be possible to purchase them from the pump or seal manufacturer.
The plate should be made of soft close-grained cast iron and properly charged
with diamond powder in paste form. Loose lapping compound should not be
used for carbon or bronze faces. Both are porous and the loose compound fills
the pores, and in effect makes a lap of the sea face. Washing the face is not
always effective.
Use two lapping plates, one charged with 750-mesh powder for roughing and
one with 1,600 mesh for finishing. Apply diamond paste from its tube, and roll
it into the plate surface with a hard roller. The plate is ready for lapping when
the diamond particles are embedded in the iron with the points protruding.
Keep the plate wet with solvent at all times to the wash the residue into the
plate grooves. Use a figure-sight stroke, covering as much of the plate as
possible to obtain a flat face. When finished, a lapped carbon face should
have a high polish. Do not leave loose particles of carbon on the face, they are
abrasive and will cause wear.
The rotating face of a seal can be lapped using the same technique, but with a
light pressure, to avoid damaging the plate. Do not use loose compound on
diamond-charged laps, if an optical flat is available, check the faces for
flatness. Remember, it is impossible to obtain a flat seal face using a lapping
plate that is not flat. When reinstalling the seal, be sure that all parts are
thoroughly clean, use new gaskets.
57

Routine Maintenance may be classed as work done primarily to rectify the

efforts of normal wear in the pump. Over haul and repair operations are
performed to rectify the results of excessive wear, over heating, damage from
solids in the liquid, or injury or wear from any other cause.
6.2

STATIONARY PARTS
6.2.1 CASING
When the pump casing is open, examine the waterways for corrosion and
erosion. If the casing is pitted or eroded, this can often be corrected by
welding brazing, or metal spraying, depending on the material from which the
casing is made and the facilities available for repair. If the signs of wear are
severed, consult the manufacturers on the possibility of using more resistant
materials. Clean and paint the waterways before closing the pump casing.
Most split casing pumps have one or more gaskets between the upper and
lower halves. These should be replaced whenever the casing is opened for
inspection or repairs. To prevent delays during pump reassembly, be sure to
have a new gasket on hand before the casing is opened. New gaskets should be
the same thickness as the original. Trim the inner edges of the gasket
accurately along the inside of the pump water ways. Have the gasket mounting
surfaces absolutely clean before applying the gasket.
Since paper and asbestos gaskets may dry out while a pump is stored or idle,
check and tighten, if necessary, the flange bolts before starting the pump.
Since the gaskets may be further compressed by differential expansion during
pump operation, check the bolts for tightness after the first shutdown and
during periodic inspections. Do not make this check on hot-liquid pumps until
they cool to room temperature.
If the uppercasing half is removed for a lengthy period, moisten the gasket to
prevent drying and cracking. When installing a new gasket, shellac the lower
half of the casing. Do not use oil, grease, or varnish. Place the gasket in
position, replace the upper half of the casing, and tighten the bolts. Allow at
least 3 hour for the gasket to set before removing the upper half of the casing.
With the pump open, finish cutting the gaskets with a knife at the cored
passages and machined fits.

6.2.2 BED PLATE

Clean the bed-plate of grease and oil at regular intervals. Snake out the drain
lines so drainage is not impaired. Paint the bed-plate regularly a clean bedplate makes a neater looking pump and encourages maintenance personnel to
give greater attention to their duties.
58

6.2.3 PIPING
Check the piping regularly for leaks, damaged insulation, water hammer,
defective valves and other defects. When trouble is found, make the necessary
repairs immediately. Defective piping can cripple the best pumps.
6.2.4 FOUNDATION
Keep the foundation clean, and freshly painted. Repair cracks before they
become so wide that the entire block must be replaced. Where the cracking is
excessive, determine the cause and eliminate it, if possible. Poor construction
of the foundation incorrect mix, insufficient setting time, and wrong bolting
procedures are common causes of cracks.
6.3

MAINTENANCE RECORDS
To ensure accurate recording of all the maintenance operations performed on a
given pump, secure or prepare a record card for it. These cards normally have
space on the front for important facts about the pump. These include the S.
No., date shipped, rated conditions, stuffing box data, construction materials
and type of drive used. Keep this record card handy because it is extremely
useful during maintenance and when ordering spare parts. Essential data that
the record should include are the data condition and defect noted, its cause,
who did the repair work, man hours consumed, the number and cost of any
spare parts used, and any remarks concerning the maintenance work or the
trouble encountered in the pump.

6.4

MAINTENANCE INTERVALS
Necessary inspections and checks are done to prevent major failures. In
addition to these checks, there are a number of routine preventive maintenance
operations that should be performed at stated intervals. While there are slight
variations in the recommendations of manufactures as to the work to be
performed, there is in general a good degree o agreement, for both the
intervals and jobs to be done.
The usual intervals recommended for routine preventive maintenance are
monthly, quarterly, semi annually and annually. These checks are satisfactory
for all centrifugal pumps, provided the normally checks are regularly made.
Never neglect maintenance just to adhere to an arbitrary schedule, on the other
hand, do not perform unnecessary maintenance operation because this defeats
the routine preventive programme.
Maintenance intervals are decided according to manufacturers instruction and
experience gained in operation of the pump, in general following are the
checks.

Monthly

Bearing temperature, vibrations, sound oil level.

59

Quarterly

Semiannually

Annually

Change bearing oil, for grease lubricated bearings check

grease condition & regrease, check bearing clearance.
Check shaft packing condition, if excessive leakage &
package in very bad condition- change the packing, check
shaft sleeve wear, check alignment, pipe supports.
Complete stripping of the pump, general inspection for
wear & tear, check wearing ring clearance, recalibrate all
instruments, replace all bearings and running joints whose
clearance has increased more than 100%.

Monthly:
Use a thermometer to check the temperature of each bearing in the pump. The
temperature of any bearing in a centrifugal pump should not exceed 1600 F.
before allowing a bearing to operate at any temperature above the
recommended, it should be checked up with the manufacturer. Much depends
on the type of bearing, its lubricants and the duty the bearing performa in the
pump.
If any bearing is running hot, check for the cause. Ball or roller bearings may
be over lubricated. Remove some grease and test under load. Hot sleeve
bearings may not have enough oil, the oil rings may be stuck or broken, or the
lubricant may be too thick for its job. If the oil is thought to the too thick,
change it. Run the pump again. If the bearing still runs hot, disassemble, wash
and inspect the bearings. Replace worn or damaged parts.
Check the alignment of the pump and its driver. Read just, if necessary. Be sure
to check hot liquid pumps in hot condition.
Quarterly:
Once every 3 months, drain the oil from sleeve-type bearings. Wash out the oil
wells and bearing interior parts with kerosene. Check the oil rings they should
be clean, completely circular, and must turn freely when the pump shaft is
rotated. Repair or replace any defective oil rings. Refill the bearings with the
correct of the recommended lubricant.
Inspect grease lubricated rolling contact and sleeve bearings for saponification
a condition revealed by a whitish colour of the grease. Saponification is
usually caused by leakage of water or other liquids past the bearing shaft seals.
To relieve this condition, flush all grease from the bearings. Use clean warm
kerosene to do this. When the bearing is clean and dry, repack it with new
clean grease of the recommended grade.
Measure the pump sleeve bearings for wear. Most manufacturers
recommended a clearance of 0.002 for each inch or fraction of an inch of
shaft diameter, plus 0.001.

60

Measure bearing clearance by placing three lengths of soft wire threads of

metallic packing or plastic wire on top of the journal. The wire should not be
more 0.010 thicker than the estimated bearing clearance. Replace bearing cap
and tighten its hold down nuts. Remove the cap and measure the thickness of
each flattened wire with a micrometer. If all leads are the same thickness, the
clearance is uniform throughout the bearings. The thickness of any wire gives
the bearing clearances at the point at which the wire was located.
If the bearing clearance exceeds the recommended valve, replace the upper
and lower halves. Check the clearance and enter it on the pump record card,
along with the data of replacement.
Semiannually:
Check the shaft packing by observing the leakage from it. If the leakage from
the stuffing box is excessive, or the packing is badly worn, replace all the
packing in the box. Never replace just one or two rings they will not seal
effectively. Be certain to use only the grade of packing recommended by the
manufacturer. The recommended leakage through stuffing box varies with the
pump, its service conditions, liquid handled and the type of packing used.
Check the shaft sleeve for wear. If the sleeve is badly scored or worn, replace
it. Use a sleeve puller to slip the sleeve from the shaft. Worn or scored shaft
sleeves accelerate packing wear and increase the maintenance cost of a pump.
If the packing wear is excessive, but the shaft sleeves are in good conditions,
check the shaft run out. If the dial indicator shows a run out of more than
0.003, straighten the shaft, check the bearings for wear, or balance the rotor,
depending on the cause of the excessive run out.
Replace the packing and adjust the gland as already explained.
Other checks to be made semiannually include alignment of the pump and
driver lube level and condition, piping support, and the driver and its various
parts.
Annually:
Disassemble the pump completely and remove the rotating element. With the
pump open, it is thoroughly inspected for wear. Any deposit or scale found in
the pump is removed, using an industrial vacuum cleaner, if necessary. Check
the wearing ring clearances which should not be more than 0.003 per inch on
the wearing ring diameter or double the limit values. Replace worn wearing
rings. Inspect, clean and replace, if necessary, all the other worn internal parts
of the pump, check, flush and rain the sealing water, cooling water and drain
piping of the pump. Recalibrate all the instruments connected to the pump and
run full tests of the pump performance. Replace all bearings and running joints
whose clearance has increased more than 100 percent of the original.

61

Chapter-7
ROTARY PUMP

7.1

GENERAL
Rotary pumps of a number of different types are popular in a variety of
services in plant. Usually rotary pumps consists of a fixed casing containing
gears, vanes, pistons, screws, or similar elements operating with minimum
clearance. Instead of throwing a liquid as in a centrifugal pump, the rotary
pump traps it, pushing it around the closed casing, much like a reciprocating
pump.
Common types of rotary pumps used today include external-gear, internalgear, lobe, screw, sliding-vane.

7.2

GEAR TYPE PUMP

The gear pump is probably the commonest type of positive displacement
rotary pump in use. It has the advantage of being cheap to produce and yet is
capable of high discharge pressure. The action of the gears is to carry a
quantity of fluid from the low pressure region to the high pressure region in
the space formed by two adjacent teeth and the cavity in which the gears
rotate. When the teeth mesh the liquid is discharged into high pressure region.
This type of pump depends on the fine running clearances between the slides
of the gears and the housing, tips of the gears and the housing, and the amount
of backlash between the teeth.
This type of pump must always be installed with a relief valve to limit
pressure on the discharge side. The valve should either return the fluid to the
suction side of the pump or preferably return it to some other low pressure
portion of the system where the volume contained is large. Failure to do this
can result in damage to the pump if the discharge valve is closed.
Gear pumps can be divided into two types as below:
1. External gear pump
2. Internal gear pump

7.2.1

EXTERNAL GEAR PUMP

External gear pump comprises a pair of gear meshing together in a closefitting chamber with an inlet port at one side and the outlet port at other as
shown in figure 7.1. One gear has an extended shaft passing through the
casing in order drive the pump and both gears are mounted on suitable
bearings. As the gear rotate in the direction indicated, fluid is drawn through
the inlet port where the gear teeth are unmeshing and carried round the
periphery of each gear, trapped in the space between each tooth gap and
casing. On reaching the other side, the action of the teeth meshing together
closes the space previously occupied by fluid, thus forcing it through the outlet
port.
62

Gear pumps are used to about 650gpm. and 350psi. They can handle viscosity
approaching 5 million SSU. Internal bearings and timing gears are preferred
because this requires only one single shaft sealing.

Fig. 7.1
7.2.2 INTERNAL GEAR PUMP
Internal gear pumps are generally used for lower pressures upto 100 bars and
operate on a similar principle to external gear pumps.
These pumps consist of an inner and outer gear separated by a crescent
shaped seal. The two gears rotate in the same direction, with the inner gear
rotating faster than the outer.
Fluid is drawn into the pump at the point where the gear teeth begin to
separate and is carried to the outlet in the space between the crescent and the
teeth of both gears. The contact point of the gear teeth forms a seal, as does the
small tip clearance at the crescent.

63

Fig.7.2

7.3

SCREW PUMP
Screw pumps are applied to large flows, since they have capacities upto
4000rpm. and 3,000psi. viscosity capability is about 100million SSU. Screw
pumps have bearing and timing gear requirements similar to gear pumps.
Screw pumps can operate at higher speeds because of relative lower fluid
velocities. The reason is that in this type the flow is axial, as opposed to flow
around the periphery of gear or vane pump.
Single, two and three screw types are available. In the single screw, a helixed
rotor rotates in a stationary housing. Two screw pump consists of two parallel
inter meshing rotors rotating in a housing machined to close tolerances. The
three screw pump consists of a central drive rotor with two meshing idler
rotors, the rotors turn inside a housing machined to closed tolerances.
The fluid that surrounds the rotors is trapped as the rotors rotate. This fluid is
pushed uniformly with the rotation of the rotors axially and forced through the
outlet at the screw's other end. The fluid delivered by screw pumps does not
rotate, but move linearly. The rotor work like endless pistons that continuously
move from inlet to outlet. There are no pulsation even at high speed. The
absence of pulsation and the absence of metal to metal contact results is very
quiet.

Fig.7.3
7.4

SLIDING VANE TYPE PUMP

Sliding vane pump consist a rotor having a number of axial slots and fixed
eccentrically in a casing. The rotor carries vanes in its slots which maintain
contact with housing or casing through the effect of centrifugal force,
64

sometimes assisted by fluid pressure or spring. Fluid enters through inlet port
as the gap between the rotor and casing is increasing and is carried between
each pair of vanes until it is forced through the outlet port as the rotor and
casing converge.
These pumps usually operate upto differential pressure of 50 psi, and
capacities upto about 375gpm. Practical limit on liquid viscosity is
100000SSU.

Fig. 7.4
7.5

LOBE PUMPS
The lobe pump differs from conventional external gear pumps in the way the
gears are driven. In gear pump, one gear drives the other where in a lobe pump
both lobes are driven through suitable drive gears outside of pump casing.
Pumping principles are the same as gear pump.

65

Chapter-8
ROTARY PUMP MAINTENANCE

8.1

GENERAL
There are probably more designs of rotary pump than that any class
reciprocating or centrifugal. But the maintenance of rotary pumps is usually
somewhat simpler than that of reciprocating or centrifugal pumps because
there are fewer moving parts and they can develop less trouble. This of course
is a general statement and may not hold in every case met in practice.

8.2

EXTERNAL- GEAR PUMPS

These are built in a variety of gear types herringbone, spur, and helical. Figure
8.1. shows an external view of a typical herring bone gear pump. Note that
gear type rotary pumps are positive displacement pumps. They trap liquid
between the gear teeth on the suction side and carry it around to the discharge
side from where it is forced out into the discharge pipe. These pumps are
usually fitted with ball or needle bearings. The packing may be either the
standard compression type or mechanical seals may be used.

Fig. 8.1

66

DISASSEMBLY
The usual procedure required to gain access to the internal parts of the pump is
removal of the endplate or plates housing the pump bearing. Tap or slip the
bearings from one or both ends of the shaft, depending on the type of
construction used. Slide the shaft from the pump casing, drawing the idler gear
with it. Be sure not to damage the gears by scrapping or hitting them against
the pump casing.
INSPECTION
Examine the gear teeth for cracks, erosion, scratches, wear and corrosion.
Replace defective gears immediately. If the gears are corroded or eroded,
consult the pump manufacturer to see if a more corrosion resistant material is
available for the gears. If so, use it because there will be fewer emergency
failures and the pump will have a longer life. Examine the shaft for wear at the
stuffing box. If there is a measurable reduction in the diameter of the shaft at
this point, metallizing may be needed to restore the original diameter. Do not
approve a pump for operation if its shaft is worn at the stuffing box because
the packing must be over tightened to reduce gland leakage to an allowable
rate. This in turn increases the shaft wear, and the power needed to drive the
pump.
Replace the packing with new rings of a suitable material. When the pump is
fitted with a mechanical seal, check to see that it has smooth faces. If the seal
leaks, remove the seal, recondition seal faces by lapping and than install back.
RE-ASSEMBLY
Assemble the pump in the reverse order, inserting the packing after the shaft is
in place. Figure shows how the part of a typical external gear pump go
together. In pumps having external bearings, both and of the shaft are sealed
by packing or seals .
8.3

INTERNAL - GEAR PUMPS

Pumps of this type are used for a wide variety of services and are built a
number of different designs for special services. The maintenance instructions
given here are applicable to many designs and should be helpful in all types of
installations.
DISASSEMBLY
If the pump has a relief valve on the head, the valve may be removed to
lighten the weight of the head, if desired. When the valve is left in place, do
not use a chain or cable around the body to support the head during removal.
67

Use jackscrews to back the head away from the casing. The proper diameter
and length of the jackscrews should be used as per pump manufacturer
instruction.. When the head is backed away, remove it from the casing. In
many designs of this type, when the head is being removed the idler stays on
the idler pin. This part will fall off the pin if the head is titled downward. In
case if the idler fall on a hard surface, check it carefully for possible damage
before returning it to the pump. File on smooth all nicked or rough spots.

Fig. 8.2
HEAD GASKETS
If a new set of gaskets is not available, the original gasket can be reused, if
they were not damaged when the head was removed. Immediately after
removing the original gaskets from the head, cover them with a coating of cup
grease to prevent them from drying out and shrinking.
CLEARANCES:
With the head removed the clearance between the rotor and casing, between
the idler bearing and pin and between the idler and the crescent on the head
should be checked. The clearance between the face of the idler and the edge of
68

the crescent should also be checked. This is done with a straight edge and
feeler gage.
Where high temperatures or viscosity are met, extra large clearances may be
recommended by the pump manufacturer. By comparing the actual clearances
in the pump with the recommended values, it is easy to determine the extent of
the wear and whether replacement of worn parts is necessary. Figure 8.2
shows clearance between the rotor and casing. Distances A plus AI equal the
total clearance provided between the rotor and casing.

ROTOR REMOVAL
Unscrew the pipe plug from the drain hole in the casing. This breaks the
vacuum between the rotor and casing to allow easy removal of the rotor.
Loosen the packing nuts on the packing gland and slide the gland of the rotorbearing sleeve. This reduces the tension on the packing and assists in removal
of the rotor. Straighten the tangs on the lock washer on the shaft. Remove the
lock nut and then drive the rotor forward and out of the casing with a
hardwood block or a piece of soft bronze, hammering on the wood or bronze
at the coupling end of the pump shaft. To remove the pump bearing, loosen the
adjusting nut lock screws and disengage the adjusting nut locks. With a
spanner wrench, remove the adjusting nuts from the bearing housing. Both
bearings can then be removed from the housing for inspection.
BEARING CLEANING
Wash the grease off the bearings in a pail of clean gasoline or solvent. Inspect
the bearing for damage. If they are in good condition store them in a clean
container so they will be ready the pump is reassembled.
PACKING
Remove the thrust bearing nuts and take the housing off. Slide the packing
from the rotor bearing sleeve. Check the condition of the sleeve bushing in the
rotor bearing sleeve. Replace it if it is worn. The bore of the bushing can be
measured with a pair of inside micrometers and checked against the
dimensions recommended by the pump builder.
CHECKING PARTS
When the pump is completely disassembled check all parts. Replace those that
are damaged or worn beyond the limits recommended by the manufacturer. If
the idler pin is worn, replace both it and the idler bushing. The idler pin may
be removed from the head by first taking off the idler pin out and then drying
the pin out of the head.
To install an idler pin, keep it as nearly straight as possible and tap it into the
head. Use a hardwood block so the face of the pin will not be damaged. Turn
69

the nut up tightly on the pin. The oil groove in the idler pin should be installed
facing the center of crescent of the head.
IDLER BUSHING
If this bushing is worn, it may be removed in an arbor press when the idler
disk is in position, press out the idler building and disk from the open end of
the idler. To install a new idler bushing press the bushing in position so the
end next to the head is flush with the surface of the idler. The idler disk may
then be placed in the other end of the idle and pressed securely in position. Be
sure it does not extend beyond the faces of the idler.

CASING
Examine this part, it the dimensions between the casing and the rotor exceed
those recommended by the manufacturer, the casing may be worn. Check its
condition at the seal. This is the surface between the suction and discharge
ports. If this surface is in good conditions, the casing probably can be used.
REPAIRS
When making major repairs, such as replacement of a rotor, it is usually
considered advisable to also install a new head and idler. When making minor
repairs. Where only an idler bushing and pin are required, other new parts
usually are not necessary. When all the needed parts are available, the pump
can be reassembled.
RE-ASSEMBLY
Before placing the rotor in the casing carefully check the rotor shaft and
remove all burrs and rough surfaces that could damage the bushing in the rotor
bearing sleeve. Smear the inside of the rotor bearing sleeve bushing and the
rotor shaft with a thin coat of grease or oil. Place the end of the rotor shaft in
the bushing and slowly turn the rotor back and forth while pushing it into the
casing. Be sure the packing gland and the inner adjusting nut are placed over
the end of the rotor shaft as soon as the shaft protrudes from the stuffing box.
These part cannot be assembled over the end of the rotor shaft when the rotor
is in position. Be sure the drain plug is still out of the casing, this opening
provides as escape for entrapped air. The spanner wrench holes in the
adjusting nut should be on the side next to the packing gland. Force the rotor
back into the casing as far as it will go. Insert bearings in the bearing housing.
Use new head gaskets as per recommended by the manufacturer, place the
idler on the idler on the idler pin and assemble the head in position. In placing
the head on the pump, it is easier if the head is tilted away from the casing
slightly until the crescent enters the inside diameter of the rotor. Then rotate
70

the idler on the idler pin until the idler teeth mesh with the rotor teeth. Raise
the head until the face of the head is parallel with the face of the casing then
work it into position. Care should be exercised so the head gaskets are not
damaged during this operation.
Now screw the inner bearing adjusting nut into the bearing housing enough to
hold it in place. Place the outer adjusting nut in position and turn in about
halfway. Place the bearing collar on the shaft next to the inner race of the
roller bearing. Install the lock washer with the tang in the key way in the shaft.
Starts the lock nut on the thread of the rotor and tighten bend at least one tang
of the lock washer down into the slot of the lock nut.
It is considered good practice to install a new set of packing rather than using
the old packing. New pumps are usually packed with square braided asbestos
packing. This is considered to be a universal type.

8.4

SCREW PUMPS
Figure 8.3 show view of a typical screw pump for handling viscous materials
that do not have lubricating quantities. The pumping action is obtained by
progressive movement of the screws, which rotate in an accurately bored
cylinder. Definite operating clearances are maintained between the screws,
one of which is left hand the other right hand. To balance the hydraulic thrust,
two pairs of screws are used. Each screw is prevented from rubbing against the
meshing one by use of timing gears and from touching the body walls by two
bearings that hold the shaft in a radial position. These bearings and timing
gears are outside the pump body and are lubricated by oil baths. Fill the gear
housing to the correct level with the recommended grade of lube oil before
starting the pump.

71

Fig. 8.3
DISMANTLING THE PUMP
Close the suction and discharge valves. Disconnect the flexible coupling, and
the suction and discharge flanges. Drain the pump. Remove the pump from the
bed plate.
Ease off the gland stud nuts. Remove the timing gear housing and in rear
cover. Mark the rear bracket for re-assembly. Remove the rear bracket, the
bearings and oil seals will remain it. Next remove the timing gear lock nuts
and lock washers. Mark the timing gears for disconnects the front head
bracket, being careful not to damage the lock nut threads. The bearing and oil
seals will remain in the bracket. withdraw the rotating elements from the
cylinder. Remove the bearings and their spacers from the brackets.
TIMING GEAR RENEWAL
If new timing gears are to be installed on the rotating elements, they must be
timed before key slotting. Spare gears are supplied in match pairs with one key
slotted and one not key slotted. The reason for is that the timing gear position
on the shaft determines the critical clearance between the pumping screws.
Take the old timing gears off the shafts and push the new gear halfway onto
their shaft diameter. Put the key in the slotted gear. Intermits the rotating
elements. Adjust the free timing gear until the desired screw clearance is
obtained. Drive the timing gears all the way home. Check the clearances. If
satisfactory, replace the rotating element the body and reassemble the pump
without the stuffing box packing. The pump should now turn freely by hand. If
not, check and repeat the foregoing until proper results are obtained. When
satisfactory, disassemble the pump. Check the screw clearances as before. If
correct, mark the timing gear from the key slot in the shaft. Cut the slot in the
gear with the greatest precision possible. Replace the gear the key in place.
Check the screw clearances as before. If satisfactory, assemble the pump and
check for free rotation. If the key slot cut does not give the proper clearances
cut another key slot to get proper results.
GEAR LUBRICATION
The timing gear housing on these units has been designed for standard
operating conditions of speed and horsepower under these conditions, if the oil
reservoir is filled to the level indicated on the window, ample lubrication will
be provided for the timing gears and the bronze bearings contained in the
housing. However, if the application requires a speed considerably different
from the design speed the builder recommends the following procedure when
starting the unit.
72

PUMP RE-ASSEMBLY
Insert the rotating elements into the pump from the rear end. Replace the front
and rear brackets, using the taper dowel pins to secure the proper alignment.
Install the front bearing spacers, the front bearings, the timing gear spacers and
gears on the shaft. Lock them up with the lock washers and lock nuts. Replace
the rear and ball bearings and lock them in position with the lock washers and
lock nuts.
Check the rotating elements for ease of rotation. If necessary, adjust the
bracket alignment until the pump turns freely. Replace the rear cover. Position
it with the dowel pins. This locks the shaft axially. Check for ease of rotation.
Tighten the gland stud nuts in accordance with the general instructions given
earlier. Replace the timing gear housing. Refill the housing and the rear cover
with suitable oil as recommended by manufacturer. Prime the pump and it is
ready for service. Check the unit frequently for 48 hours after it is put into
service following an overhaul or disassembly.

8.5

SLIDING VANE PUMP

WEAR CHARACTERISTICS
The wear in these pumps occurs in either vanes or casing or both. So most
maintenance works is concerned with care of either the vanes or the casing.

Fig. 8.4
73

VANE REPLACEMENT
Remove the head plate of the pump and pull the vanes out by hand. Since they
fit loosely in the rotor, no special tools are needed for removal. If the vanes are
excessively worn, replace them with new ones.
SHAFT SEALS
The rotor shaft projects into the casing. A closure plate with a shaft seals the
opening in the casing. When the seal is worn out it is necessary to remove the
seal and replace it.

74

Chapter-9
RECIPROCATING PUMPS
9.1

INTRODUCTION
Reciprocating pumps converts mechanical energy into hydraulic energy (or
pressure energy) by reciprocating action. It sucks the liquid into a cylinder in
which a piston is reciprocating (moving backwards and forwards), which
exerts the thrust on the liquid and increases its hydraulic energy (pressure
energy), the pump is known as reciprocating pump.

9.2

WORKING OF A RECIPROCATING PUMP

Fig. 9.1 shows a single acting-reciprocating pump consists of a piston, which
moves forwards and backwards in a close fitting cylinder. The movement of
the piston is obtained by connecting the piston rod to crank by means of a
connecting rod. The crank is rotated by means of an electric motor. Suction
and delivery pipes with suction valve and delivery valve are one way valves or
non-return valves, which allow the water to flow in one direction only. Suction
valve allows water from suction pipe to the cylinder while delivery valve
allows water from cylinder to delivery pipe only

75

Fig. 9.1
.
When crank starts rotating, the piston moves to and from in the cylinder.
When crank is at A. the piston is at the extreme left position in the cylinder.
As the crank is rotating from A to C, (i.e., from =00 to 1800 ). The piston is
moving towards left in the cylinder. The movement of the piston towards right
creates a partial vacuum in the cylinder. But on the surface of the liquid in the
sump atmospheric pressure is acting, which is more than the pressure inside
the cylinder. Thus the liquid is forced in the suction pipe from the sump. This
liquid opens the suction valve and enters the cylinders.
When crank is rotating from C to A (i.e., from =1800 to 3600 ), the piston
from its extreme right position starts moving towards left in the cylinder. The
movement of the piston towards left increases the pressure of the liquid inside
the cylinder more than atmospheric pressure. Hence suction valve closes and
delivery valve opens. The liquid is forced into the delivery pipe and is raised
to a required height.
9.3

MAIN PARTS OF A RECIPROCATING PUMP

The following are the main parts of a reciprocating pump as shown in Fig.9.2.
1. The liquid end consists of the cylinder, plunger or piston, valves, stuffing
box, manifolds, and cylinder head.
2. The power end consists of crank shaft, connecting rods, cross head,
bearings and frame.

76

Fig.9.2a

Fig.9.2b
Cylinder:
The cylinder is the body where the pressure is developed. It is
continuously under fatigue. Cylinders on many horizontal pumps have the
suction and discharge manifolds made integral with the cylinder. A cylinder
containing the passages for more than one plunger is referred to as a single
cylinder. When the cylinder is used for one plunger, it is called an individual
cylinder.
Plunger:
The plunger transmits the force that develops the pressure. It is solid
up to 5 in (127mm) in diameter. Above that dimensions, it may be made
hollow to reduce weight. Small-diameter plungers used for 6000 lb/in2 (414
bar) and above should be reviewed for possible buckling. Plunger speed
ranges from 150 to 350 ft/min (46 to 107 m/s). The finish is 16 rms with a 30
to 58 Rockwell C hardness. Materials of construction are Colmonoy No. 6 on
1020, chrome plate on 1020, 440C, 316, ceramic on 1020 with a 2000 F limit,
and solid ceramic. Ceramic is used for soft water, crude oil, mild acids, and
mild alkalis. The problem with coatings on plungers is that at high pressures
the liquid gets through the pores and underneath the coating. The pressure
underneath the coating will cause it to flake off the plunger.
Stuffing box:
77

The stuffing box of a pump consists of the box, lower and upper
bushing, packing, and gland (Fig.9.3). It should be removable for
maintenance.
The stuffing box bore is machined to a 63 rms finish to ensure packing
sealing and life. The bushings have a 63 rms finish with approximately 0.001
to 0.002 in (0.02 to 0.05 mm) diametrical clearance per inch of plunger
diameter. The lower bushing is sometimes secured in an axial position to
prevent the working of the packing. Bushings are made of bearing bronze, Niresist, or 316.
Packing is V-or chevron-shaped. Some types use metal backup
adapters. Unit packing consists of top and bottom adapter with a seal ring. A
stuffing box can use three to five rings of packing or units, depending on the
pressure and one the fluid being pumped. Packing or seal ring is reinforced
asbestos, Teflon, duck, or neoprene.

Fig. 9.3

Valves:
There are many types of valves. Which type is used depends on the
application. The main parts of a valve are the seat and the plate. The plate
movement is controlled by a spring or retainer. The set usually uses a taper
where it fits into the cylinder or manifold. The taper not only gives a positive
fit but also permits easy replacement of the seat.
Manifolds:
These are the chambers where liquid is dispersed or collected for
distribution before or after passing through the cylinder. On horizontal pumps
the suction and discharge manifold is usually made integral with the cylinder
(Fig. 2a) Some horizontal pumps and some vertical pumps have only the
discharge manifold integral with the cylinder. Most vertical pumps have the
suction and discharge manifold separate from the cylinder.
Frame:
78

The frame absorbs the plunger load and torque. Frames are usually
close-grain cast iron. Slurry pumps frames, designed for mobile service at
various sites, are usually fabricated steel. The frame is vented to the
atmosphere.
Crank shaft:
The crankshaft varies in construction depending on the design and
power output of the pump. In horizontal pumps, the crankshafts are usually of
nodular iron or cast steel.
Connecting rods:
The connecting rods transfer the rotating force of the crank pin to an
oscillating force on the wrist pin. Connecting rods are split perpendicular to
their centerline at the crank pin end for assembly of the rod onto the
crankshaft.
The cap and rod are aligned with a close-tolerance bushing or bodybound bolts. The rods are either rifle-drilled or have cast passages for
transferring oil from the wrist pin to the crank pin. A connecting rod with a
tension load is made of forged steel, cast steel, or fabricated steel. Rods with a
compression loading are cast nodular steel or aluminum alloy. Connecting rod
finish, where the bearings are mounted, is 32 to 63 rms.
Wrist pin:
Located in the cross-head, the wrist pin transforms the oscillating
motion of the connecting rod to reciprocating motion.
Cross head:
The cross-head (Fig. 2a) moves in a reciprocating motion and transfers
the plunger load to the wrist pin. The crosshead is designed to absorb the side,
or radial, load from the plunger as the crosshead moves linearly on the
crossway. The side load is approximately 25% of the plunger load. For cast
iron crossheads the allowable bearing load is 80 to 125 lb/in2 (551 to 862 kPa).
Crossheads are grooved for oil lubrication with a bearing surface of 63 rms.
Crossheads are piston type (full round) or partial-contact type. The piston type
should be open end or vented to prevent air compression at the end of the
stroke.
Bearings:
Both sleeve and antifriction bearings are used in power pumps. Some
frames use all sleeves, others use all antifriction, and others use a combination
of both.
The main bearings used with full antifriction bearing design are selfaligning spherical roller bearings. These bearings compensate for axial and
radial movement of the crankshaft and are usually mounted in bearing holders,
which in turn are mounted on the frame .

9.4

CLASSIFICATION OF RECIPROCATING PUMPS

79

The reciprocating pumps may be classified as:

i. According to the water being in contact with one side or both sides of the
piston, and
ii. According to the number of cylinders provided.
iii. According to reciprocating part in cylinder.
(i) According to the contact of water:
If the water is in contact with one side of the piston, the pump is known as
single acting. On the other hand, if the water is in contact with both sides of
the piston, the pump is called double acting.
a. Single acting pump, and
b. Double acting pump.
(ii) According to the number of cylinder provided:
a. Simplex pump,
b. Duplex pump, and
c. Triplex pump.
(iii) According to reciprocating parts in cylinder:
a. Piston type
b. Plunger type
c. Diaphragm type
9.5

AIR VESSELS OR ACCUMULATORS

An air vessel is a closed chamber containing compressed air in the top portion
and liquid ( or water) at the bottom of the chamber. At the base of the chamber
there is an opening through which the liquid (or water) may flow into the
vessel or out from the vessel. When the liquid enters the air vessel, the air gets
compressed further and when the liquid flows out the vessel, the air will
expand in the chamber.
An air vessel is fitted to the suction pipe and to the delivery pipe at a point
close to the cylinder of a single acting reciprocating pump:
i.)
ii.)
iii.)

To obtain a continuous supply of liquid at a uniform rate.

To save a considerable amount of work in overcoming the frictional
resistance in the suction and delivery pipes, and
To run the pump at a high speed without separation.

Fig 9.4 shows the single acting reciprocation pump to which air vessels are
fitted to the suction and delivery pipes. The air vessels act like an intermediate
reservoir. During the first half of the suction stroke, the piston moves with
acceleration, which means the velocity of water in the suction pipe is more
than the mean velocity and hence the discharge of water entering the cylinder
will be more than the mean discharge.

80

Fig 9.2
This excess quantity of water will be supplied from the air vessel to the
cylinder in such a way that the velocity in the suction pipe below the air vessel
is equal to mean velocity of flow. During the second half of the suction stroke,
the piston moves with retardation and hence velocity of flow in the suction
pipe is less than the mean velocity if flow. Thus the discharge entering the
cylinder will be less than the mean discharge. The velocity of water in the
suction pipe due to air vessel is equal to mean velocity of flow and discharge
required in cylinder is less than the mean discharge. Thus the excess water
flowing in suction pipe will be stored in to air vessel, which will be supplied
during the first half of the next suction stroke.
When the air vessel is fitted to the delivery pipe, during the first half of
delivery stroke, the piston moves with acceleration and forces the water into
the delivery pipe with a velocity more than the mean velocity. The quantity of
water in excess of the mean discharge will flow into the air vessel. This will
compress the air inside the vessel. During the second half of the delivery
stroke, piston that moves with retardation and the velocity of water in the
delivery pipe will be less than the mean velocity.
The water already stored into the air vessel will start velocity. The water
already stored into the air vessel will start flowing into the delivery pipe and
the velocity of flow in the delivery pipe beyond the point to which air vessel is
fitted will become equal to the mean velocity. Hence the rate of flow of water
in the delivery pipe will be uniform.

81

Chapter-10

CENTRIFUGAL PUMP TROUBLE SHOOTING

Trouble

No liquid delivered.

Cause

Correction

Lack of prime/speed may be

too low.

Prime the pump check the motor

connections and voltage.

Discharge head too high.

Check all valves in the discharge line

to see that they are wide open. Check
the piping for obstructions, from either
solids contained in the liquid or scale
building.

Suction lift too high.

Check the pump inlet for clogging.

Check with gauges. Normal suction
should not exceed 15'.

Impeller and / or piping may

be plugged.

Inspect piping, suction strainer and

impeller.

Wrong direction of rotation.

Check for rotation as already

explained.
Air leaks in suction line or Check the flanges, screwed joints and
stuffing box.
stuffing box for air leaks.
Speed too low.

Check motor rpm.

Discharge head higher than Check design data.

anticipated.

Not enough liquid

delivered

Suction lift too high.

Same as above.

Worn wearing rings.

Inspect the rings. It worn replace it.

Damaged impeller.

Inspect the impeller and replace with a

new one, if required.

Undersize foot valve.

Inspect. Net area should be atleast

equal to that of suction pipe, but
preferably larger.
Check as above.

Wrong direction of rotation.

Viscosity too high
82

Check pump head specified for the

liquid.

Trouble

Not enough discharge

pressure.

Pump loses prime

after starting

Cause

Correction

Worn gaskets

Replace all gaskets and tighten the

hold down bolts.

Impeller eye too small

Speed too low.

Selection problem
Check the motor supply.

Gas or air in liquid.

Remove it by senting.

Pump
water
obstructed.

passages Open the casing and check the water

passages for freeness. Remove any
obstructions and replace the casings.

Impeller diameter too small.

Incomplete priming.

Selection problem.
Do prening.

Too high a suction lift.

Check it and ensure is reduce it.

Air leaks in the suction, pipe Check for any loose connection.
or packing glands.
Gas or air in the liquid, Check it and correct the situetion.
inlet pipe not sufficiently
submerged.
Discharge head too low.
Too much liquid delivered and the
driver overloaded.
Wrong liquid, speed too high Correct as explained earlier.
or wrong direction of
rotation.

Pump over heated

Packing too tight.

Release the gland pressure, then

retighten reasonably. Check for
leakage.

Distorted casing.

Poorly aligned suction and discharge

pipe can distort the pump casing.
Check the piping and drive alignment.
Inspect for worn wearing rings,
replace damaged or worn parts.

Bent shaft.

Thermal distortion damage during

overhaul, or wrong assembly of the
rotating element. Check the shaft
deflection. Allowed 0.003 inch for
high-speed pump and 0.006 inch for a
low speed pump.
83

Trouble

Stuffing boxes
overheat.

Cause

Correction

Mechanical failures.

Check all rotating and stationary parts

for failure, including the pump
bearings, wearing rings, packing
gland, bushing and impeller. Replace,
as necessary.

Misalignment.

Realign the pump and its driver.

Pump speed too high.

Packing too tight.

Check motor supply.

Check it and looser it.

Not enough packing lube.

Lubricate the packings

Wrong grade of packing.

Selection proper grade

Not enough seal liquid.

Check for any seal water blockage

Incorrect installation of the Check for gland packing joint and its
packings.
arrangement.
Misalignment.
Check alignment.
Worn or loose bearings.

Excessive vibration.

Rotor unbalanced.

Because of a plugged or damaged

impeller.
Check by free rotation.

Bent shaft.

Same as above

Non rigid foundation.

Check for any looseness.

Gas or vapour pockets in the Check for any loose connection

suction line.
Too low an oil level.
Check oil level.
Poor or wrong grade of oil.

Check oil quality.

Dirt in the bearings or the Check environmental condition.

oil.
Bearings overheat

Moisture in the oil.

Check for any possibility.

Not enough bearing cooling Check if any provision is given.

water.
Bearings too tight.
84

Check bearing installation.

Trouble

Cause
Misalignment.

Correction
Check alignment.

Oil seals fitted too closely on Check position of oil seal.

the shaft.
Misalignment.

Check alignment.

Bent shaft.

Check

Vibration.
Check vibrations and
Excessive thrust from a
mechanical failure inside the
pump.
Bearings wear
rapidly.

Lack of lubrication.

Check oil level.

Wrong bearing installation Check and confirm to right procedure.

procedures.
Dirt in the bearings.

Check environmental condition.

Moisture in the oil.

Check any possibility.

Wrong section of material.

Correct it is right one.

85

Chapter-11
TROUBLE SHOOTING FOR POSITIVE RECIPROCATING PUMPS
Trouble

Low
Pressure

Probable Cause

Discharge

Worn or fluid cut valve Replace valve assembly

assembly
Valve popped open
Remove popping agent
Remove restrictions from suction
line
Increase level of fluid supply
Improper filling

Fluid slippage

Low Suction Pressure

Gauge reading error

Low head
Charging pump capacity
Retarded fluid flow
Gauge reading error
Air entering suction line
Air entering charging pump

Fluid
Knock
hammer

or

Correction

Air entering suction strainer

Air/ Gas in Pumped Fluid

Same as low discharge

Discharge
pulsation
dampener
Unsupported discharge line
Discharge
Line Same as low discharge
pressure
Vibration
Same as low suction
pressure
Same as fluid knock or
Hammer
Loose valve cover/ cylinder
head
Worn or damaged gasket
Tell tale Leakage
Damaged gasket surface

86

Increase charging pump speed

Decrease pump speed
Prime fluid chambers
Replace piston/ liner or plunger/
packing
Recalibrate or replace gauge
Increase level of fluid supply
Increase charging pump speed
Remove restrictions from suction
Recalibrate or replace gauge
Repair suction line
Tighten or replace shaft packing or
seal
Repair and rebalance
Impose vacuum on supply tank
Allow more settling time
Reduce pump speed
Adjust suction stabilizer
Same as low discharge pressure
Repair and recharge or replace
Provide supports or hangers
Same as low discharge pressure
Same as low suction pressure
Same as fluid knock or hammer
Tighten valve cover / cylinder
head
Replace gasket
Replace valve cover/ cylinder heat
Repair fluid end

Trouble

Probable Cause
Abrasives in fluid
Large particles in fluid
Valve not seating

Short valve life

Correction
Filter pumped product
Screen pumped product
Broken valve spring replace
Worn valve guide replace
Worn valve/ set replace
Same as low suction pressure

Pump not filling

Pulsation
Dampener
Repair or replace
malfunction
Treat pumped fluid
Corrosion
Use different materials for valves/
seats
Filter pumped product 7 flushing
Abrasives in fluid
fluid
Repair flushing system
Friction wear
Use50% oil & 50% diesel fuel to
Short piston/ liner life
flush
Short liner life
Use super Di-Hard Liners
Deteriorated piston
Use regular or oil resistant as
required
Abrasives in fluid
Filter pumped product & flushing
fluid
Lubricate with rock drill oil
Do not overtighten adjustable
Friction wear
packing
Use ceramic plunger if fluid is
clean
Check stuffing box alignment
Short
plunger/
packing life
Check gland alignment
Check plunger alignment
Check packing for foreign
Longitudinal
wear
or
particles
scoring
Replace stuffing box bushing
Replace packing follower
Replace lantern ring
Use recommended packing.

87

Trouble

Diaphragm leakage

Oil seal leakage

Low oil pressure

Probable Cause

Correction

Norn or damaged extension Replace extension rod

rod
Corroded extension rod
Clean and polish or replace
extension rod
Worn wiper rings
Replace wiper rings
Wiper rings improperly Check installation directions
sealing
Clean and polish diaphragm bore
Worn lantern ring
Replace lantern ring
Oil baffle misplaced
Check installation directions
Reservoir in diaphragm Install drain hole at bottom
housing
Clean drain hole
Pressure in crankcase
Clean or replace air breather
Worn sealing lip
Replace seal
Damaged sealing lip
Replace seal
OD Not Seated
Clean and polish bore of oil seal
housing
Foreign Materials at seal Clean and polish shaft
point
Clean and polish or replace shaft
sleeve
Pressure in crankcase
Clean or replace air breather
Low oil level
Check and add oil if necessary
High oil temperature
See observation "High Oil
Temperature"
Contaminated lubricant
Change oil
Relief valve maladjusted
Check and reset
Leakage in piping system
Repair all leaks
Choke washers misplaced
Check installation directions
Oil pump worn
Repair or replace oil pump
Clogged suction screen
Clean screen and change oil
Worn oil pressure ring
Replace ring and housing
Erroneous gauge reading
Recalibrate or replace gauge

88

Trouble
High Oil pressure

High oil temperature

Knock in power end

Probable Cause

Correction

Contaminated oil
Relief valve aladjusted
Oil filter clogged
Restrictions in passageways
Erroneous gauge reading
Heat exchanger malfunction

Change oil
Check and reset
Change filter cartridge
Clean passageways
Recalibrate or replace gauge
Clean tubes and shell
Regulate coolant rate
bearing Check and adjust clearances

Improper
adjustment
Improper
crosshead
adjustment
Incorrect pump rotation
Loose piston/ rod plunger
Loose extension rod
Loose connecting rod cap
Loose bearing housings/
covers
Worn crosshed pin
Worn crosshed pin bushing
Worn crank pin bearing
Work crankshaft
Worn crosshead
Worn main or back up
bearing

89

Check and adjust clearances

Check installation directions
Check and tighten

Replace

Chrome plate and grind or replace

Adjust shoes or guides or replace
Adjust or replace

NUCLEAR POWER CORPORATION OF

INDIA LIMITED
(A Government of India enterprise)
Rajasthan Atomic Power Station
Nuclear Training Centre

Course No. M-MP-2.7

CHECK LIST
FOR
CENTRIFUGAL PUMP MAINTENANCE
PRACTICE

Checked by: P.Puri, STO

Revision No. :0
No. of sheets: 3
Prepared by: R P Saini, SO/E

: CM Mishra, ENC(MT)
Approved by: N Nagaich,TS
Date of work start:
Date of work completed:

Equipment Name: Double suction centrifugal

pump.
Safety Instructions :
1. Ensure electrical and process side isolation before dismantling of equipment.
2. All openings must be blanked properly before leaving the job.
3. Pump internal components must be covered properly before learning the job.
4. Tools and lifting tackles required for maintenance and rigging jobs should be in good
working condition and have been tested within last one year.
5. Use personnel protection to avoid injury.
6. Oil spillage in working area must be cleaned immediately.
7. Use specified cleaning agent only. Kerosene etc used for cleaning must be collected
in a properly tagged air tight container before leaving the job every day.
8. Working area must be free from unwanted materials, oils, water etc.

1.0.
1.1.
1.2.
1.3.

PRE-REQUISITES:
Pre Job briefing
Ensure electrical and process side isolation.
Record any old deficiencies.

2.0.
2.1.
2.2.
2.3.
2.4.
2.5.
2.6.
2.7.
2.8.
3.0
3.1
3.2
3.3

TOOLS & TACKLES:

Spanner set
Screw driver
Hammer
Solid punch and Centre punch
Dial gauge
Feeler gauge,
Vernier caliper,
Micrometer,
SPARE PARTS:
Bearings
Gland Packing
Asbestos Gasket for casing joint and end connections

4.0
4.1

DISMANTLING & CHECKS:

Check mechanical freeness of pump shaft by rotating
coupling manually.
90

Done/Not done
Done/Not done

Normal/ Abnormal

4.2

Check coupling gap and record.

Yes/ No.

4.3

Record alignment reading (Angular & offset).

Yes/ No.

4.4
4.5
4.6

4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15

-----------------------------------------------------------De-couple pump and motor

Removed coupling and key.
Loosen base bolts of motor and keep shims properly.
Record thickness of all shims as per each bolt.
______________________________________________
______________________________________________
Lift the motor and rotate in position by 900 and put back
on motor base.
Remove coupling halves and keep at proper place
Dismantle bearing assembly and remove both side
bearings
Unscrew follower and remove glands.
Unscrew casing bolts and lift upper casing and keep on
wooden block.
Remove casing gasket
Lift rotating assembly with impeller and wearing rings
and keeps on wooden block.
Remove Wearing rings, Shaft sleeve.
Check bearing condition.
List of the Components Replaced:
______________________________________________
_____________________________________________

Yes/ No.
Yes/ No.

Yes/ No.
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
OK/ Replaced.

5.0

CHECKS AND MEASUREMENTS

5.1

Clean coupling face and record following dimension:

Coupling ID.
Shaft OD.
Fit/ clearance.

Yes/ No.

5.2
5.3

Check coupling condition, key and key way condition

Record fit of key
---------------------------------------------Inspect shaft and check for any damage/ wear/ bend etc.
Inspect impeller for any physical damage/ wear etc.
Inspect shaft sleeve for any wear
Record following clearances
Wearing ring and impeller hub
--------------shaft sleeve and lantern ring
----------------

OK/ Not OK
Done /Not Done

Take measurement of stuffing box and find out gland

packing size.

Done /Not Done

5.4
5.5
5.6
5.7

5.8

91

Done /Not Done

Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done

6.0

ASSEMBLY:

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8

6.11
6.12
6.13
6.14
6.15

Check cleanliness of all parts

Assemble impeller on shaft with key
Assemble shaft sleeve on both ends
Insert wearing rings on the shaft
Assemble stuffing box assembly on both sides
Assemble both side bearings
Check cleanliness of casing
Keep rotating assembly on position. and engage in the
casing slot.
Put casing gasket on position
Put upper casing half on position taking care that wearing
ring locking pins taken correct position
Install coupling with key.
Lift the motor and put on position with proper shims.
Tighten base bolts.
Check alignment and gap and record in data sheet.
Couple the motor.

7.0

HOUSE KEEPING:

7.1

Consumables like gasket, seal components, cotton rags

etc. are disposed in waste disposal drum.
Post maintenance Review

6.9
6.10

8.

92

Done /Not Done

Done/Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Done /Not Done
Yes/ No.
Yes/ No.
Yes/ No.
Yes/ No.
Yes/ No.

NUCLEAR POWER CORPORATION OF

INDIA LIMITED
(A Government of India enterprise)
Rajasthan Atomic Power Station
Nuclear Training Centre
CHECK LIST
FOR
ROTARY PUMP MAINTENANCE
PRACTICE

Course No. M-MP-2.7

Revision No. :0
No. of sheets: 2
Prepared by: R P Saini, SO/E
Checked by: P.Puri, STO
:CM Mishra, ENC(MT)

Approved by: N Nagaich,TS

Equipment Name: External Gear Pump
Date of work start:
(Herringbone Gear type pump)
Date of work completed:
Safety Instructions :
9. Ensure electrical and process side isolation before dismantling of equipment.
10. All openings must be blanked properly before leaving the job.
11. Pump internal components must be covered properly before learning the job.
12. Tools and lifting tackles required for maintenance and rigging jobs should be in good
working condition and have been tested within last one year.
13. Use personnel protection to avoid injury.
14. Oil spillage in working area must be cleaned immediately.
15. Use specified cleaning agent only. Kerosene etc used for cleaning must be collected
in a properly tagged air tight container before leaving the job every day.
16. Working area must be free from unwanted materials, oils, water etc.

1.4.
1.5.
1.6.
1.7.

PRE-REQUISITES:
Pre Job briefing
Ensure electrical and process side isolation.
Record any old deficiencies.

2.9.
2.10.
2.11.
2.12.
2.13.
2.14.
2.15.
2.16.
2.17.
3.4
3.5
3.6
3.7

TOOLS & TACKLES:

Spanner set
Screw driver
Hammer
Solid punch and Centre punch
Dial gauge
Feeler gauge,
Vernier caliper,
Micrometer,
SPARE PARTS:
Gland packing
Bearing
Asbestos Gasket

4.16

DISMANTLING:
93

Done/Not done
Done/Not done

4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26

Ensure electrical and process isolation

Drain oil from casing
Remove coupling guard .
Unscrew suction and discharge line connections.
Unscrew pump base bolts and remove pump from position.
Remove coupling half from pump shaft.
Unscrew gland follower bolts and remove gland packings.
Unscrew side covers.
Remove bearing from casing
Remove gears from casing.

5.0

CHECKS AND MEASUREMENTS:

5.1
5.2
5.3
5.4

5.5

Clean all dismantled parts

Inspect bearings for wear, score mark, etc.
Inspect gears for any damage, wear.
Measure followings and record
Bearing clearance
Gears tip clearance
Gears backlash
Side clearance
Check fit of coupling key
Check fit of coupling with shaft

6.0

ASSEMBLY

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9

Check cleanliness of all parts

Assemble gears in casing
Assemble bearings in their respective positions.
Assemble side covers
Install gland packings in stuffing box and tighten the gland
follower.
Install coupling half.
Shift the pump on it's position and tighten it's base bolts.
Tighten suction and discharge line with pump.
Install coupling guard.

7.2

HOUSE KEEPING:

7.3

Consumables like gasket, seal components, cotton rags etc.

are disposed in waste disposal drum.
Post maintenance Review

8.

94

Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done

Done/Not Done
Done/Not Done
Done/Not Done

OK/Not OK
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done

Done/Not Done

NUCLEAR POWER CORPORATION OF

INDIA LIMITED
(A Government of India enterprise)
Rajasthan Atomic Power Station
Nuclear Training Centre
CHECK LIST
FOR
ROTARY PUMP MAINTENANCE
PRACTICE

Course No. M-MP-2.7

Revision No. :0
No. of sheets: 3
Prepared by: R P Saini, SO/E
Checked by: P.Puri, STO
:CM Mishra,ENC(MT)
Approved by: N Nagaich,TS
Date of work start:
Date of work completed:

Equipment Name: Screw Pump

Safety Instructions :
1. Ensure electrical and process side isolation before dismantling of equipment.
2. All openings must be blanked properly before leaving the job.
3. Pump internal components must be covered properly before learning the job.
4. Tools and lifting tackles required for maintenance and rigging jobs should be in good
working condition and have been tested within last one year.
5. Use personnel protection to avoid injury.
6. Oil spillage in working area must be cleaned immediately.
7. Use specified cleaning agent only. Kerosene etc used for cleaning must be collected
in a properly tagged air tight container before leaving the job every day.
8. Working area must be free from unwanted materials, oils, water etc.

1.0
1.1
1.2
1.3

PRE-REQUISITES:
Pre Job briefing
Ensure electrical and process side isolation.
Record any old deficiencies.

2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

TOOLS & TACKLES:

Spanner set
Screw driver
Hammer
Solid punch and Centre punch
Dial gauge
Feeler gauge,
Vernier caliper,
Micrometer,

3.0
3.1
3.2
3.3

SPARE PARTS:
Seal
Bearing
Asbestos Gasket

4.0

DISMANTLING:
95

Done/Not done
Done/Not done

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10

Ensure electrical and process isolation

Drain oil from casing
Remove coupling guard .
Unscrew suction and discharge line connections.
Unscrew pump base bolts and remove pump from position.
Remove coupling half from pump shaft.
Unscrew gland seal bolts and remove gland seal and keep
on clean place..
Unscrew non driving side end cover.
Remove idler screws (both) from casing and keep on clean
place.
Remove driving screw from the casing from driving end
side and keep on clean place..

5.0

CHECKS AND MEASUREMENTS:

5.1
5.2
5.3
5.4

5.5
5.6

Clean all dismantled parts

Inspect bearings for wear, score mark, etc.
Inspect screws for any damage, wear.
Measure followings and record
a. Bearing clearance
b. Screw tip clearance
c. Side clearance
Check fit of coupling key and record
Check fit of coupling with shaft and record

6.0

ASSEMBLY

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10

Check cleanliness of all parts

Assemble central ( driving) screws in casing
Insert both non driving screws in casing engaging with
central screw.
Assemble bearings in their respective positions.
Assemble and tighten side covers
Install gland seal in stuffing box and tighten it's locking.
Install coupling half.
Shift the pump on it's position and tighten it's base bolts.
Tighten suction and discharge line with pump.
Install coupling guard.

7.0

HOUSE KEEPING:

7.1

Consumables like gasket, seal components, cotton rags etc.

are disposed in waste disposal drum.
Post maintenance Review

8.

96

Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done

Done/Not Done
Done/Not Done
Done/Not Done
-------------------------------------------------------------------------------------------

Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done

Done/Not Done

NUCLEAR POWER CORPORATION OF

INDIA LIMITED
(A Government of India enterprise)
Rajasthan Atomic Power Station
Nuclear Training Centre
CHECK LIST
FOR
ROTARY PUMP MAINTENANCE
PRACTICE

Course No. M-MP-2.7

Revision No. :0
No. of sheets: 2
Prepared by: R P Saini, SO/E
Checked by: P.Puri, STO
:CM Mishra,ENC(MT)
Approved by: N Nagaich,TS
Date of work start:
Date of work completed:

Equipment Name: Sliding Vane Pump

Safety Instructions :
1. Ensure electrical and process side isolation before dismantling of equipment.
2. All openings must be blanked properly before leaving the job.
3. Pump internal components must be covered properly before learning the job.
4. Tools and lifting tackles required for maintenance and rigging jobs should be in good
working condition and have been tested within last one year.
5. Use personnel protection to avoid injury.
6. Oil spillage in working area must be cleaned immediately.
7. Use specified cleaning agent only. Kerosene etc used for cleaning must be collected
in a properly tagged air tight container before leaving the job every day.
8. Working area must be free from unwanted materials, oils, water etc.

1.0
1.1
1.2
1.3

PRE-REQUISITES:
Pre Job briefing
Ensure electrical and process side isolation.
Record any old deficiencies.

2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

TOOLS & TACKLES:

Spanner set
Screw driver
Hammer
Solid punch and Centre punch
Dial gauge
Feeler gauge,
Vernier caliper,
Micrometer,

3.0
3.1
3.2
3.3

SPARE PARTS:
Set of sliding vanes
Bearing
Asbestos Gasket

97

Done/Not done
Done/Not done

4.0

DISMANTLING:

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8

Ensure electrical and process isolation

Remove coupling guard .
Unscrew pump motor base bolts and remove motor from
position
Remove coupling half from pump shaft.
Unscrew gland follower bolts and remove gland packings
Unscrew non driving side covers.
Remove all sliding vanes from rotor slots.
Remove rotor from casing

5.0

CHECKS AND MEASUREMENTS:

5.1
5.2
5.3
5.4
5.5
5.6

Clean all dismantled parts

Inspect rotor for any wear, score mark, etc.
Inspect pump casing for any wear, score mark, etc.
Inspect bearings for wear, score mark, etc.
Inspect vanes for any damage, wear etc.
Measure followings and record
a. Bearing clearance
b. Rotor tip clearance (at top portion)
c. Side clearance
d. Check fit of coupling key
e. Check fit of coupling with shaft

6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10

ASSEMBLY

7.0

HOUSE KEEPING:

7.1

Consumables like gasket, seal components, cotton rags etc.

are disposed in waste disposal drum.
Post maintenance Review

8.

Check cleanliness of all parts

Assemble rotor in casing
Assemble vanes in slots of rotor .
Assemble side covers and tighten the screws.
Install gland seal in stuffing box portion.
Install coupling half.
Shift the pump on it's position and tighten it's base bolts.
Tighten suction and discharge line with pump.
Install coupling guard.

98

Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done

Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
Done/Not Done
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Done/Not Done
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NUCLEAR POWER CORPORATION OF

INDIA LIMITED
(A Government of India enterprise)
Rajasthan Atomic Power Station
Nuclear Training Centre
CHECK LIST
FOR
RECIPROCATING PUMP
MAINTENANCE PRACTICE

Course No. M-MP-2.7

Revision No. :0
No. of sheets: 2
Prepared by: R P Saini, SO/E
Checked by: P.Puri, STO
:CM Mishra, ENC(MT)

Equipment Name: Triplex plunger pump.

Approved by: N Nagaich,TS

Date of work start:
Date of work completed:

Safety Instructions :
1. Ensure electrical and process side isolation before dismantling of equipment.
2. All openings must be blanked properly before leaving the job.
3. Pump internal components must be covered properly before learning the job.
4. Tools and lifting tackles required for maintenance and rigging jobs should be in good
working condition and have been tested within last one year.
5. Use personnel protection to avoid injury.
6. Oil spillage in working area must be cleaned immediately.
7. Use specified cleaning agent only. Kerosene etc used for cleaning must be collected
in a properly tagged air tight container before leaving the job every day.
8. Working area must be free from unwanted materials, oils, water etc.

1.0

PRE-REQUISITES:

1.1
1.2
1.3

Pre Job briefing

Ensure electrical and process side isolation.
Record any old deficiencies.

2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3.0
3.1
3.2
3.3

TOOLS & TACKLES:

Spanner set
Allen Key set
Screw driver
Hammer
Solid punch and Centre punch
Dial gauge
Feeler gauge,
Vernier caliper,
Micrometer,
Torch
SPARE PARTS:
Crank shaft Bearings
Plunger seals
Asbestos Gasket
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4.0

DISMANTLING:

4.1
4.2
4.3
4.4
4.5
4.4.1

4.5
4.5.1
4.5.2
4.5.3
4.6
4.7
4.8
4.9

Ensure electrical and process isolation.

Drain oil from crank case
Remove belt guard and belts.
Remove pulley from pump shaft
Valve Removal
Open pump suction valves cover plates and take out the
valve discs.
Open pump discharge valves covers plates and take out the
valve discs.
Cylinder Block Removal
Remove plunger seal from all plungers.
Unscrew cylinder block bolt.
Remove cylinder block horizontally out from position.
Unscrew crankcase allen bolts and bearing end cover bolts.
Lift crankcase upper half and keep on wooden flanks.
Unscrew plunger from plunger rod and take out plunger.
Unscrew and remove connecting rod

5.0.

CHECKS AND MEASUREMENTS:

5.1.
5.2.
5.3.
5.4.

Clean all dismantled parts

Inspect plunger for any score mark, dent etc.
Inspect suction and discharge valve seating area for any
damage, wear.
Check blue contact of valve and valve seat.

6.0

ASSEMBLY

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10

Check cleanliness of all parts

Assemble connecting rods.
Assemble plungers and install in position.
Install cylinder block and tighten all bolts.
Install plunger seals.
Assemble suction valves and tighten all bolts.
Assemble discharge valves and tighten all bolts.
Install pulley on the shaft.
Align pump and motor shaft
Install belts and belt guard.

7.0
7.1

HOUSE KEEPING:
Consumables like gasket, seal components, cotton rags etc.
are disposed in waste disposal drum.
Post maintenance Review

4.4.2

8.0

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