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Chapter Two
2.1. Installation:
2.1.5 Foundation:
The base in which pump chases is to rest on is any structure that weight enough a
constant solid base under the overall space of the pump to with stand any shock or any
regular movement above it, concrete frame built on solid ground is the most
convenient for this purpose.
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Pumps and their maintenance
2.1.6 Piping:
After fixing the pump on the base, we start connecting pump curb rings (flanges)
with piping lines as follows:
2.1.10 Instrumentation:
There are many instrument that are important to be equipped on the pump to observe
its performance and condition mostly pressure gauge toward suction pipe and outer
toward discharge pipe at place where it could be monitored easily further more
pumping range gage may be installed if necessary and these gouge may be equipped
with graphometer to print out the pumping condition at any time.
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Pumps and their maintenance
There may be used to equipped spaced , heat vibration, lubrication gage especially if
the operating monitoring is applied away from the pump and the reading of gauge age
needs to be transfer from pumps room to control room to such down the pump if the
reading exceeded the critical ranges .
:Operation .2.2
Pump is selected to pump a certain pumption range with a certain discharge rang
when rotating in the estimated spaced, these indication are specified according to
conditions to cover most of operating priced of the pump.
Pumps with positive displacement can not change its pumping ranges unless by
changing its spaced or by installing return line to by passing. As for centrifugal pumps
it has wide range of pumping ranges beginning from zero to its maximum level.
Pumping range depend upon flow obstacles which decrease or increase the flow rate
another technique used is to increase or decrease the speed of pump to change the flow
rate while restricting to the hydraulic, mechanic and thermo dynamic limits.
:Priming 2.2.1
Most centrifugal pump are designed to be filled completely by fluid leaving no room
for gases vapor and air by sucking them from the highest point in the pump before
start operating especially if it was to be used for the first time. And some pumps are
:designed where no need for such a procedure such as
Self Priming long rotors pumps, low compressor pumps, low speed pumps where it is
not practical prime them. Foot valve installed on the lower vertical edge of the suction
pipe to hold the fluid from leaking are used for this purpose tanks to prime the suction
pipe or return pipeline from discharging to suction or by introducing an inducer to the
.pump propeller
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Pumps and their maintenance
motor, then the procedures recommended to start up a closed discharging valve type
pump as follow:
1. Prime the pump by filling it with fluid and remove air, gases and steams, open
suction valve and close strainer valves.
2. Open brasses cooling valves (If there is any).
3. Open cooling fluid valve of gland box.
4. Open anti stuffing.
5. Open preheating fluid valve until the pump reaches ideal operating temperature
then close it.
6. Open return pipe valve if the pump from the type of working without relief
pumping.
7. Start the motor.
8. Gradually open discharge valve.
9. Monitor purl from the stuffing boxes.
2.3. Maintenance:
Due to variances of the pumps by design, size, power and material used in making the
pump there is no general program for maintenance that why manufacturer's guide book
should by thoroughly revised in case of maintenance of pump.
The steps follows should be taken to maintenance the pump:
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Pumps and their maintenance
economic factor which is determined by comparing the coast of overall to expenses due to
decrease of the pump efficiency and temporary failure due to brake downs. Operating
condition may require a monthly overall or once every four years or more. The need of over
all may occur due to lade of efficiency of the pump, overall on motor irregular sound, over
vibrating. If there was no stand by pump the full overall parts should be kept for
emergencies, there may be need to make the overall in the factory if them was no sufficient
experience or equipment in the site.
The table shown offers probable causes and solutions to the most
common problems encountered.
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Pumps and their maintenance
Pump takes excessive power 23, 17,20. 15, 14
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Pumps and their maintenance
turns in piping pipe too small, piping
misaligned
air in liquid.9 belts too tight.23
overpressure or overspeed.10 driver misaligned.24
dirty liquid.11 condensation.25
dirty environment.12 seals worn.26
water hammer,13 oil level too high.27
valve spring broken.32
cylinder plug loose.33
ring seal damaged-0 .34
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Pumps and their maintenance
submerged bearing
water seal pipe plugged.12 rotor out of balance causing vibration.36
seal cage improperly located in .13 gland too tight resulting in no flow of .37
stuffing box liquid to lubrication pack in
cooling liquid not being provided to water.38
cooled stuffing box
excessive clearance at bottom of stuffing .39
box between shaft and casing causing
packing to be forced into pump interior
System troubles
dirt or grit in sealing liquid leading to .40
souring of shaft sleeve
speed too low.14 excessive thrust caused by mechanical .41
failure inside pump or by failure of hydraulic
balancing device if any
speed too high.15 excessive grease or oil in antifriction .42
bearing housing or lack of cooling causing
.excessive bearing temperature
direction of rotation wrong.16 lack of lubrication.43
total head of system lower than .17 improper installation of antifriction .44
pump designed pump bearing
specifie gravity of liquid different .19 dirt bearing.45
from design
viscosity of liquid different from .20 rusting of bearing from water in housing.46
design
operation at very small capacity.21 Excessive cooling of water cooled bearing .47
resulting in condensation of atmosphere
.moisture in bearing housing
parallel operation of pump .22
unsuitable for such operation
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Pumps and their maintenance
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