MAINTENANCE OF M/L PUMP

TOPICS COVERED

 MAINTENANCE OF MAINLINE PUMPS

 TROUBLE SHOOTING OF MAINLINE PUMPS

WHAT IS A PUMP ?

A Pump is a machine which enables to transfer some liquid from one

place to another or to maintain a required flow in a closed circuit /
conduit.
Pumps can be classified in several types like centrifugal/ reciprocating
or single stage/multi stage etc.
VIEW OF TOP CASING OF 2 STAGE PUMP
VIEW OF 2 STAGE ROTOR
 PARTS OF CASING OF M/L
PUMP
• Horizontally split casing consists of two halves of
casing.
• Lower casing consists of double volute for double
suction.
• Upper casing consists of diffuser for discharge.
• Both the halves of casing are joined together by bolts
and nuts with 0.5 mm non metallic gasket.
• Housings of bush bearings are connected to both the
halves of casing.
 PARTS OF M/L PUMP
• Rotor assembly with casing wear rings
• Bush bearings & intermediate support bushes on DE
& NDE side
• Thrust bearing on NDE side
• Mechanical seal assemblies on DE & NDE side
• Housings of bush bearings & thrust bearing
PARTS OF ROTOR ASSEMBLY
OF M/L PUMP
• Shaft having key way at the center
• Impeller with vanes & Impeller wear rings
• Key for connecting impeller with shaft
• Spacer sleeves-2 nos
• Mechanical seal sleeve-2 nos
• Locknut for seal sleeve-2 nos
• Compression unit- 2 nos
MAJOR COMPONENTS, THEIR MATERIAL OF CONSTRUCTION & THEIR
FUNCTION

COMPONENT MATERIAL FUNCTION & REQUIREMENT

VOLUTE ASTM MEANS SPIRALLY CASED CASING SURROUNDING IMPELLER
CASING A 216 Gr W.C.B. COLLECTING LIQUID DISCHARGED CONVERTING IT IN
PRESSURE ENERGY.
IMPELLER ASTM A 351.Gr DISCHARGES LIQUID AT ITS PERIPHERY AT HIGHER VELOCITY
CF-8/CF 8M -SINGLE / DOUBLE SUCTION
-OPEN/SEMI OPEN/ CLOSED
IMPELLERS SHALL BE DYNAMICALLY BALANCED & SECURED TO
SHAFT AGAINST MOVEMENT BY KEYING
WEAR RINGS AISI 410 PROVIDES AN EASILY & ECNOMICALLY RENEWABLE LEAKING
JOINT
WEAR RING ARE FITTED BY PRESS FITING, LOCKED WITH
PINS/THREADED DOWELS
RUNNING CLEARANCES BETWEEN WEAR RING & MOVING PART
SHALL BE SUFFICIENT TO AVIOD SEIZURE
PUMP SHAFT ASTMA 322 Gr TO TRANSMIT TORQUE ENCOUNTERED IN STARTING & DURING
AISI 4140 OPERATION WHILE SUPPORTING IMPELLER & OTHER PARTS
IN SHAFT MAXIMUM ALLOWABLE DEFLECTION, SPAN & LOCATION
OF LOAD IS TO BE CONSIDERED.
WHEN SHAFT ROTATES AT A SPEED CORROSPONDING TO
NATURAL FREQUENCY IS CALLED CRITICAL SPEED

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MAJOR COMPONENTS, THEIR MATERIAL OF CONSTRUCTION & THEIR
FUNCTION
COMPONENT MATERIAL FUNCTION & REQUIREMENT
SHAFT ASTM A 276 Gr PROTECTING SHAFT FROM WEAR
SLEEVE AISI 410
STUFFING ASTM A216 WCB PRIMARY FUNCTION FOR PROTECTING PUMP AGAINST LEAKAGE
BOX FROM SHAFT WHEN IT PASSES THROUGH CASING
THROAT ASTM A 276 Gr 410 CLOSED CLEARANCE RESTRICTIVE RING AROUND
BUSHING SHAFT/SLEEVE BETWEEN MECH SEAL & IMPELLER
BEARINGS SAE 52100 PLAIN: FULL CONTACT AREA
Sn –93%, ROLLER: POINT OR LINE CONTACT (ANTI FRICTION)
Sb-3.5% BEARINGS KEEP SHAFT IN CORRECT ALIGNEMENT WITH
Cu-3.5% STATIONARY PART UNDER THE ACTION OF RADIAL &
TRANSVERSE LOADS.
IN CASE OF SLEEVE BEARING STARTING, STOPPING & IN
SEVERE RUNNING CONDITION, LUBRICATING OIL FILM CANNOT
BE MAINTAINED & LUBRICATION LARGELY DEPENDS ON
BOUNDARY LUBRICATION.THE CAPACITY TO RETAIN THIS LAYER
IS IMPORTANT FEATURE OF BEARING MATERIAL.FOR THIS
PURPOSE ALLOYING CONSISTS OF HARD CONSTITUENT
EMBEDED IN SOFT METRIX.SOFT MATRIX GIVES ABILITY TO
YIELD UNDER EXCESSIVE LOAD PRESSURE & PREVENT LOCAL
SEIZING.
BEARING LUBRICATION IS BY SPLASH OR FORCE FEED.

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MAJOR COMPONENTS, THEIR MATERIAL OF CONSTRUCTION & THEIR
FUNCTION
COMPONENT MATERIAL FUNCTION & REQUIREMENT
BEARING ASTM A 216 Gr WCB IN CASE OF SPLASH IS WITH RING OILER WITH CONSTANT OIL
HOUSING LEVELLER.
DEFLECTOR AT BOTH SIDES OF HOUSING
IN OTHER CASES LUBRICATION IS FORCE FEED LUBRICATION.
AUXILLARY CAST STEEL: SCH -BEARING COOLING PIPES
PIPING 80 WT -SEAL FLUSHING PIPES
SS: SCH 40 WT -PIPING FOR PUMP PRIMING
CYCLONE FOR MECHANICAL SEAL FLUSHING TO GIVE CLEAR PRODUCT
SEPERATOR RELATIVELY FREE OF FOREIGN PARTICLES.

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 MAINTENANCE OF MAINLINE PUMP

MAINTENANCE OF MAINLINE PUMP

i) Preventive Maintenance

ii) Predictive Maintenance:

 condition monitoring by vibration reading / recording.

 vibration signature analysis.

PREVENTIVE MAINTENANCE OF MAINLINE PUMP
Preventive Maintenance of pumps are to be done periodically to ensure that
pumps remains in fit for purpose condition. The schedule along with inspection
checks to be carried out are given below:-
A) PREVENTIVE MAINTENANCE OF MAINLINE PUMPS:-
All the mainline pumps should be maintained in accordance with the Instruction
Manual supplied by the respective pump manufacturer. Special attention is to be
paid for the cooling and flushing lines of the pumps and they should be inspected
frequently for chocking. Special attention should also to be paid to mechanical
seals which may create problems due to excessive seal leakage in the pumps.
The pump maintenance should be carried out as per following schedule:
 Every hour by operation shift engineer
 Every month by maintenance group
 After 3000/4000 hrs of running
 After 6000/8000 hrs of running
 After 9000/12000/18000/24000 hrs.of running
PREVENTIVE MAINTENANCE OF MAINLINE PUMP
Every hour: Shift engineer monitors the bearing temperatures, checks for any
lube oil leaks from bearing housings or crude leak from mechanical seals, any
abnormality in mechanical seal temperature & any abnormal sound from pump
etc.
Every month: Maintenance group carry out following checks.
 Checking bearing lube oil condition
 Checking mechanical seal cooling line
 Checking of pump alignment & bearings condition, if vibration level is more or
bearing temp is more
Cleaning of mechanical seal leakage piping and rupture tank
Six Monthly:
 Check alignment of pump / gear box and gear box / diesel coupling
 Check the coupling flexible element assemblies for damage or cracking
PREVENTIVE MAINTENANCE OF MAINLINE PUMP
3000/4000/6000/8000/9000 hours maintenance:
Maintenance group carry out following checks before taking maintenance as well
as during maintenance.
 Checking the vibration of pump prior to taking maintenance
 Checking bearing temperature & lube oil condition
 Checking mechanical seal cooling line & clean cyclone filter
 Checking of pump alignment & bearings condition
 Cleaning of mechanical seal leakage piping and rupture tank
 Replacement of mechanical seal in case of excessive crude leakage
 Adjustment of end play of pump shaft to maintain between 0.02 to 0.12 mm
PREVENTIVE MAINTENANCE OF MAINLINE PUMP
12000/18000 hours maintenance:
Maintenance group carry out following checks before taking maintenance as well
as during maintenance.
 Checking the vibration of pump prior to taking maintenance
 Checking bearing temperature & lube oil condition
 Checking mechanical seal cooling line & clean cyclone filter
 Checking of pump alignment & bearings condition
 Cleaning of mechanical seal leakage piping and rupture tank
 Replacement of mechanical seal in case of excessive crude leakage
 Pump casing will be lifted to check for any abnormality in rotor assembly
 End float of pump shaft will also be adjusted
PREVENTIVE MAINTENANCE OF MAINLINE PUMP

12000/18000 hours maintenance:

In case of abnormality in rotor assembly, the following activities will be done.
 Inspection of all components of rotor assembly & replacement of damaged
components
 Carrying dynamic balancing of rotor assembly
 Carrying out centering of rotor assembly by maintaining correct gap between
pump shaft & gear box shaft
 Adjust end play of shaft by keeping correct thickness of thrust washer & proper
shims
 Check mechanical seal components & fit new ones if required.
 Check bush bearings, thrust bearings condition & fit new ones if required
 Box up the pump casing & tighten the bolts & nuts to specified torque
 Carry out alignment between pump & gear box
 Check vibration level of pump & it has to be maintained less than 10 mm/sec
pk.
 PREVENTIVE MAINTENANCE OF MAINLINE PUMP

(B) PREDICTIVE MAINTENANCE

 Predictive maintenance is based on condition monitoring viz.
vibration levels, seal performance, development of specified heads.
 Increase in vibration levels, seal leakage calls for further analysis and
addressing the maintenance needs.
 Loss of head also calls for proper analysis and thereafter initiating
maintenance activities suitably.
 Monitoring vibration on daily basis by vibration meter and carry out
vibration signature analysis as and when required (when vibration
level increases or frequent seal failure occurs).
 By studying signature analysis we can find out probable sources of
high vibration and accordingly rectification job will be done.
 PREVENTIVE MAINTENANCE OF MAINLINE AND
BOOSTER PUMP
PREDICTIVE MAINTENANCE
Few sources of high vibration are as follows.
 Misalignment between pump shaft & gear box shaft
 Unbalance of pump rotor shaft
 Bearing damage
 Looseness of rotor assembly components
 Excessive clearance between pump shaft and bearing resulting in
Oil whirl problem
 Resonance of rotating components or suction/discharge piping due
to improper pipe supports
 Ball bearing inner race / outer race problem
 Hydraulic imbalance problem due to vanes damage
 Gear teeth backlash more or gear teeth damage
 Flexible coupling problem due to breakage of shims
 ALIGNMENT OF PUMP & GEAR BOX
 Confirm the values of thermal growth of gear box as per OEM.

 Set the alignment limits by taking thermal growth into consideration and
re confirm the values of hot alignment

 Usage of Laser alignment kit for checking alignment and knowing shims
to be adjusted. In case of mis-alignment in hot condition, carry out
alignment jobs .

 Take the vibration signature of pump in hot condition and reconfirm that
there is no misalignment.

 After alignment, run the pumping unit till normal operating temp is
attained.
 MAINTENANCE OF PUMPS

1. Seal Failure

2. Bearing Failure

3. Impeller damage

4. Shaft Damage
MECHANICAL SEALS
 CHECK POINTS
SUCTION TROUBLES
 Pump not primed
 Pump or suction pipe not filled with liquid
 Insufficient margin between suction pressure and vapour pressure.
 Excessive amount of air or gas in liquid.
 Air pocket in suction line.
 Air leaks into suction line.
SYSTEM TROUBLES
 Speed too low
 Speed too high
 Total head of system higher than designed head.
 Total head of system lower than designed head.
 Sp. Gravity of liquid different from design.
 Viscosity of liquid differs form that for which designed.
 Operation at very low capacity.
 CHECK POINTS
MECHANICAL TROUBLES
 Foreign matter in impeller
 Misalignment
 Foundation not rigid
 Shaft bent
 Rotating parts rubbing on stationary parts.
 Bearing worn
 Wear rings worn.
 Casing gasket defective permitting internal leakage.
 Seal improperly installed
 Incorrect operating condition.
 Shaft running off centre because of worn off bearings or misalignment.
 CHECK POINTS
MECHANICAL TROUBLES

 Rotor out of balance resulting in vibration

 Seal face pressure too high
 Dirt or grit in sealing liquid
 Excessive oil in antifriction bearing housing or lack of cooing, causing excessive
bearing temp.
 Lack of lubrication.
 Improper installation of antifriction bearing (damaged during assembly, incorrect
assembly of stacked bearings, use of unmatched bearings as a pair, etc.)
 Dirt getting into bearing
 Rusting of bearings.
 Excessive cooling of bearing resulting in condensation of moisture from
atmosphere in the bearings.
 IMPELLER TRIMMING
 Impeller trimming refers to the reduction of the impeller diameter, and thus a reduction of the
circumferential speed at the impeller outlet of a centrifugal pump.
 Trimming the effective diameter of an impeller by cutting its vanes only, and leaving its shroud uncut.
 when a centrifugal pump impeller is trimmed to a smaller diameter the power draw decreases both from
the decreasing "power vs. capacity" curve as described above for valve throttling, plus from the much
larger impact of the "Affinity Laws", which are as below:
when a centrifugal pump impeller is trimmed to a smaller diameter the power draw
decreases both from the decreasing "power vs. capacity" curve as described above for
valve throttling.

Power draw decreases by the third power of the impeller outer diameter reduction. So a
10% diameter reduction (19% head reduction) would result in a 27% reduction in the
power draw, plus any reduction from the lower percent flow rate. This is the same
impact as pump speed, which can, however, be varied during operation.
 TYPICAL CLEARANCES OF CENTRIFUGAL PUMP IN MM
COMPONENTS DIAMETER BORE NEW CLEARANCE RENEWAL CLEARANCE

D.E. JOURNAL BEARING AND SHAFT. 89.88 90.04 MAX. 0.17 0.22
89.87 90.00 MIN. 0.12

N.D.E. JOURNAL BEARING AND SHAFT. 89.88 90.04 MAX. 0.17 0.22
89.87 90.00 MIN. 0.12

IMPELLER WEAR RING (HUB) 139.37 140.04 MAX. 0.49 0.73

AND NECK BUSH 139.35 140.00 MIN. 0.43

IMPELLER WEAR RING (EYE) 239.47 240.04 MAX. 0.59 0.88

AND CASING WEAR RING 239.45 240.00 MIN. 0.53

CENTRE BUSH AND SLEEVE 135.57 136.04 MAX. 0.49 0.73

135.55 136.00 MIN. 0.43

LEAK OFF BUSH AND SLEEVE 118.59 119.04 MAX. 0.47 0.88
118.57 119.00 MIN. 0.41

TOTAL AXIAL CLEARANCE AT THRUST BEARINGS N/A N/A 0.40-0.60 N/A

 TROUBLE SHOOTING
Symptom Probable Cause
Pump does not Impeller rotating in wrong
generate its direction.
rated delivery Pump not up to rated
pressure speed
Impeller neck rings worn
excessively
Impeller damaged or
choked
Pump gaskets leaking
Pump loses Suction line not full primed
liquid after – air or vapour lock in
starting suction line
Inlet of suction pipe
insufficiently submerged
Air leaks in suction line or
gland arrangement
Liquid seal to gland
arrangement logging ring
(if fitted) choked
Logging ring not properly
located
Action
Reverse direction of rotation
Increase speed
Dismantle pump and restore clearances to
original dimensions
Dismantle pump and renew impeller or clear
blockage
Renew defective gaskets
Stop pump and reprime
Ensure adequate supply of liquid at suction
pipe inlet
Make good leaks or renew gland packing
Clean out liquid seal supply.
Unpack gland and relocate logging ring under
supply orifice
 TROUBLE SHOOTING
Symptom Probable Cause Action
Pump Pump gaskets leaking Renew defective gaskets
overloads Serious leak in delivery line, pump Repair leak
driving delivering more than its rated quantity
unit Speed too high Reduce speed
Impeller neck rings worn excessively Dismantle pump and restore clearances to
original dimensions
Gland packing too tight Stop pump, close delivery valve to relieve
internal pressure on packing, slacken back the
gland nuts and retighten to finger tightness
Impeller damaged Dismantle pump and renew impeller
Mechanical tightness at pump internal Dismantle pump, check internal clearances and
components adjust as necessary
Pipe work exerting strain on pump Stop pump and reprime
Excessive Air or vapour lock in suction Stop pump and reprime
vibration Inlet of suction pipe insufficiently Ensure adequate supply of liquid at suction inlet
submerged
Pump and driving unit incorrectly Disconnect coupling and realign pump
aligned
Worn or loose bearings Dismantle and renew bearings
Impeller choked or damaged Dismantle pump and straighten or renew shaft
Foundation not rigid Remove pump, strengthen the foundation and
reinstall pump
Coupling damaged Renew coupling
Pipe work exerting strain on pump Disconnect pipe work and realign to pump
 TROUBLE SHOOTING
Symptom Probable Cause Action
Bearing Pump and driving unit out of Disconnect coupling and realign pump and
over alignment driving unit
heating Oil level too low or too high Replenish with correct grade of oil or drain down
to correct level.
Wrong grade of oil Drain out bearing, flush through bearings; refill
with correct grade of oil.
Dirt in bearings Dismantle, clean out and flush through bearings;
refill with correct grade of oil
Moisture in oil Drain out bearing, flush through with correct
grade of oil. Determine cause of contamination
and rectify.
Bearings too tight Ensure that bearings are correctly bedded to
their journals with the correct amount of oil
clearance. Renew bearings if necessary.
Too much grease in bearing Clean out old grease and repack with correct
grade and amount of grease
Pipe work exerting strain on Disconnect pipe work and realign to pump.
pump
 TROUBLE SHOOTING

Symptom Probable Cause Action

Bearings Pump and driving Disconnect coupling and realign pump and driving unit.
wear unit out of alignment Renew bearings if necessary.
Rotating element Dismantle pump, straighten or renew shaft. Renew
shaft bent bearings if necessary
Dirt in bearings Ensure that only clean oil is used to lubricate bearings.
Renew with clean oil.
Lack of lubrication Ensure that oil is maintained at its correct level or that oil
system is functioning correctly. Renew bearings if
necessary
Bearing badly Ensure that bearings are correctly bedded to their
installed journals with the correct amount of oil clearance. Renew
bearings if necessary.
Pipe work exerting Ensure that pipe work is correctly aligned to pump.
strain on pump Renew bearings if necessary
Excessive vibration Refer to excessive vibration symptom.