Sie sind auf Seite 1von 8

1/5 SKILL NOTE Fundamental of pump Technology Lecture by Toba San Course The date of submission: August 25,

2008 Staff

Process Course P - 12

Name SUGIANTA

. a. Our lives and Pump Pumps were originally developed as means of pumping up water from low to high elevations. There is a various kinds of pumps which exist the volute pump is currently the most advanced. It has a large capacity and a wide range of applications. Feature of the volute pumps: High speed direct couple drive to a motor is possible. It is compact and low priced. It is high efficiency Simple construction for Maintenance and inspection. Simplify piping Wide range of flow rate. b. Principles of Operation of the Volute Pump The centrifugal force in pump is proportional to the square of the speed. When the impeller of the pumps turns the internal pressure of the water is increased owing to centrifugal force and thus water is continually discharged outside. The specific gravity of water is lower than mercury. So 1 atm = 76 cm Hg = 10.3 m Aq (Water at 4 0C). The impeller rotation produce both a vacuum and centrifugal force that continuous simultaneously permits water tobe raised from low level to a high level. c. Construction of the Volute Pump The storage action of the volute pump is performed by four components : Impeller (produce centrifugal forces) The type of impeller which are most generally used on the volute pump include the enclosed and semi-open types. Enclosed type is only for fresh water, semi-open type can be used for foreign matter without clogging. Casing (Effectively converting the centrifugal force) Generally employ single-volute and double volute casing. Suction and (Suck in the water) discharge port (discharge the water) In addition, the following components are essential to the operation of the volute pump. Pump Shaft Bearings

Casing Ring Gland packing and Mechanical seal Comparison table of Gland Packing and Mechanical Seal

Leakage Power Consumption

Maintenance

Conventional Gland Packing Nearly impossible to prevent leakage completely Friction between the packing and shaft is large, possible amount of mechanical friction loss. Need to tightened down sometimes, easy removed, possible to temporary measure Initial cost is low

Mechanical Seal Possible to prevent leakage Smaller than gland packing

Cost

Longer live, no need retightened, difficult to temporary measure, when leakage happen must be removed up to shaft Is not cheap

Coupling Air vent and priming funnel

d. Characteristics of the Volute Pump Generally, the characteristic of the pump are given in terms of discharge capacity, head, shaft power and efficiency. Discharge Capacity This is the water volume which is discharged from the pump per unit of time. The unit Is m3/min or liter/min. Pump size is based on suction opening diameter. Head This is the pressure which the pump produces .it is customary to represent head in terms of water (height of water column) and use the unit (m). Relation between Head and pressure is H = P/ Where H = head (m) P = pressure (kgf/m2) = specific weight of liquid (kgf/m3) Shaft Power A prime mover is necessary to operate the pumps. The power which the prime mover imparts to the pumps is known as the shaft power. Efficiency The ratio of works performed by the pump (referred to as theoretical hydraulic power) to the shaft power is known as the efficiency and represented as percentage (%).

= W/S where, = pump efficiency W=Theoretical hydraulic power S = Shaft power Speed Normally electric motor is used as the prime mover with the speed varying depending upon line frequency. e. Pump Performance Variation Performance variation with impeller diameter If the impeller diameter increases, work capacity and hence the shaft power will also increases . Performance variation with a number of impellers The performance of a pump varies with the number of impellers. Performance variation with speed. For a given pump, the performance will vary as the speed increases or decreases. Recently pumps fitted with a variable speed motor enabling the performance to be changed at will have begun to make their appearance. f. Head and Friction Loss If the velocity of solution in pump increases, friction loss of pipe will increase too. g. Parallel and Series Operation Pump that have same characteristic can be set in Parallel or series operation, If set parallel, the flow of water will increase twice, if series the head theoretically become double. h. Suction Performance When the pump raising water the pressure drops the instant water enters the impeller and hence this point has the lowest pressure when the inlet pressure becomes lower than saturated vapor pressure of the liquid, the liquid boils and change to vapor. The vapor fed to impeller, crushed at the point where the pressure increase. This condition accompanied by vibration and noise, and can reduce the performance of the pump. If this condition happen, its called cavitation. i. Operation of The Pump a. Caution before starting operation Ensure lubricating oil is to the specified level on the level gauge. Check the auxiliary pipes (cooling pipe, flushing pipe, sealing pipe e.t.c.) are installed, check for secure installment. Turn the shaft by hand, if something wrong happen, locate the cause and eliminate. Operate only the driver by inching operation to confirm the direction of rotation. Then connect the shaft coupling and install shaft coupling guard. If the cooling , flushing and sealing pipes are installed, open each valve. Fill the cooling and quenching pipe with antifreeze solution as required. Prime the pump. If the temperature of the pump liquid reach 80 0C, perform sufficient warming up around 2 3 minute. Turn the shaft by hand again before turning on the switch.

Cautions For the time when the feed liquid flow from the pump to the system is reduced, provide a bypass pipe corresponding to the minimum flow described on the data sheet. Be careful not to operate the pump when the flow is less than minimum. This is particularly important when the liquid features a high vapor pressure. If the pump handles a freezable liquid (water, condensate, etc), or if the pump is auto started, reverse liquid from the discharge side at a flow rate about 1m3/H at all time. j. Start-Up Operation Ensure the suction valve is completely open, and discharge valve is closed. Open the minimum flow valve if a minimum flow orifice is installed. Turn the start-up switch on and off once or twice (for checking) Open the vent valve, and exhaust gas if there is any. Turn on the switch again. Open the discharge valve slowly while paying attention to the discharge pressure. If suction pressure less than the value given in the data sheet, locate the cause. If the liquid handle have high vapor pressure, be careful that the pressure of the pump being unstable. First time stop the pump, and repeat the method above. Check each part of the pump and driver for current, voltage, lubricant, at each part, rotating noise, vibration, discharge pressure, suction pressure, etc. A half or one hour after start up, check the pump and the driver again. k. Shut down Operation When by pass line is not provided, slowly close the discharge valve to the minimum flow point (not completely close), when the driver completely stop, close discharge valve and then suction valve completely. When by pass line provided, check by pass line open, and then close discharge valve completely. Turn off the switch. When shutting down the pump for along period of time, Close the suction valve, discharge valve, minimum flow line valve and exhaust piping valve completely. Shut down the cooling, flushing and sealing. When temporary shutting down a pump which handles caustic liquid soda and other liquids which are apt to harden, keep the quenching liquid flowing at all the time. l. A standby pump For the stand by pump operation, open the suction valve, and close the discharge valve completely when bypass line is provided. Keep the discharge valve open to minimum flow quantity, if a bypass line is not provided. Fill the pump with liquid If the pump handle chemical product (Caustic etc), wash the pump completely after stopping and replace with water.

m. General Maintenance

Perform daily maintenance by checking the following to assure the satisfactory of the operation of the pump. 1. Use lubricating Oil ISO VG 46 (JIS K2213 turbine oil) After trial (300 hours) replace oil, or once every 3 months, or as required. 2. Adjust the leak quantity of from the gland packings. 3. Do not start and stop the pump frequently, otherwisw the pump may be damaged. 4. Pressure,current, vibration, noises which differ graeatly from normal values, are symptoms of trouble. Take corrective action. 5. Turn off the switch without fail before cheking the pump. 6. Turn the shaft by hand once every week, if the pump stop for long period. Check lubricating oil. 7. If the internal solution freeze in winter, the pump and piping may break. 8. Replace the consumable according to the following condition (in normal operation) : Consumable Gland packing Shaft coupling Rubber Bearing Gasket Shaft Sleeve Oil seal Reference for changing If water leakeeage can not be stopped by retighttening When rubber deterioted, worn, or worn on one side. When noise are noticeable or abnormal noises detected Each time the pump is diasembled for check When sleeve surface is worn When lubricating oil leaks. Change frequency Once every 6 month Once every year Once every 2-3 years _ Once every year Once every year

m. Trouble shooting of the Pump Problems Causes Solutions Prime Mover doesnot o Defective Prime o Repair of replace rotate mover o Check and repair o Defective power o Check each condition supply o Turn the shaft by hand o Starting condition o Disassemble, clean, and are not established on reassemble. Repair at control panel specialist shop o Contact, rust or o Remove the foreign seizure of rotary parts. substances o Foreign matter is in the motor. Impossible to prime the o Air introduced from o Replace or retighten pump gland assembly gland packings. o Discharged valve, or o Close valve other valve are open

o Introduction of air from pipe joints. o Defective foot valve o Defective vacuum pump Operate but discharge dos not o Incomplete or no prime o Sluice valve is closed or half open. o Actual head is higher than total head of the pump. o Excessive suction height. o Reverse rotation direction o Low rotation speed o No. of poles of motor differs. o 60Hz pump is operated in 50 Hz district. o Low volteg o Foot valve or strainer clog o Impeller clog o Pipe clog o Air suction

o Locate leak position, and retighten packings. o Check, repair, or replace o Check, repair or replace o Prime o Open the valve o Recheck the plan o Recheck the plan o Correct conection, reffering to the arrow indications. o Check the tachometer. o Check the nameplate. o Check the nameplate. o Check the power supply. o Remove foreign matter o Remove foreign matter o Remove foreign matter. o Check and repair the suction pipe and shaft seal. Check the submersion depth at the end of the foot valve and suction pipe o Remove the air o Check and Repair o Check the liquid quality, and replace the material o Replace the Impeller.

Specified displacement is not obtained

o Air lock in suction pipe o Discharge pipe leak o Impeller corrosion o Excessive Impeller wear. Water gets pump, but soon Insufficient priming stops. Air suction Air lock in the suction pipe Excessive suction height Overload

Prime Check and repair the suction pipe and shaft seal Reconnect the piping Recheck the plan o Excessive rotation o Check the tachometer o No. of poles of motor o Check the nameplate differ. o 50 Hz pump is operated o Check the nameplate in 60 Hz district.

Bearing Overheat

o Voltage drop, and o Check the power supply considerable unbalances, among phasses. o Low head aor excessive o Contact the power water flow. company for suitable solutions. o Centering misalignment o Reduce the opening of the discharge valve. o Entry of foreign matter o Remove the foreign to the pump. matter. o Excessive tightening of o Loosen the gland the gland packings. packings. o Liner ring wear. o Replace. o Bearing damage. o Replace. o Contact of rotating parts o Repair at a specialist or bent shaft. shop. o Excessive specific o Recheck the plan. gravity or viscosity of liquid. o Reverse flow in suction o Contact a specialist. water tank. o Defective motor o Repair or replace. o Insufficient lubricating o Replenish oil o Excessive lubricating oil. o Reduce o Improper lubricating oil. o Deteriorated lubricating o Replace o Replace oil. o Contaminated lubricating o Replace oil. o Centering misalignment. o Center again o Bearing damage. o Excessive time of shut o Replace o Stop the stut off off operation. o No cooling water flow operation. o Flow cooling water o Ben shaft o Repair at a specialist o Improper bearing loading shop. o Adjust at specialist shop. o In adequate foundation. o Repair the foundation. o Installation and centering o Check the installation failure. and centering conditions. o Replace ball bearing. o Bearing damage. o Reduce opening of o Excessive water flow. discharge valve. o Operate the pump with o Discharge water flow is specified flow.

Pump vibrate Excessive operating noise

too small. o Impeller clog

Excesive water leak from the shaft seal

Shaft seal overheat

o Remove the foreign matter. o Correct, reffering to the o Reverse rotation arrow. direction. o Repair at the specialist o Rotary part touches or shop. the shaft is bent. o Contact a specialist. o Cavitation. o Modify the piping o Vibrating piping. o Contact specialist. o Reversed suction pit flow. o Check and repair the o Air suction from suction suction pipe. pipe. o Replace o Shaft coupling damage. o Replace. o Impeller wear o Gland packing failure o Mount the gland packings correctly. o Gland packing damage o Replace o Shaft or sleeve wear o Replace. o Excessive forced o Recheck the plan. pressure o Excessive positive influx o Repair at specialist pressure. shop. o Insufficient positive o Adjust to the inflow water. specified pressure. o Mechanical seal damage. o Replace. o Excessive tightening of o Repair the gland packing. o One-sided tightening of o Repair gland packing. o Improper positive inflow o Set to the specified water pressure. value. o No cooling water flow o Flow the cooling water. o Ben Shaft o Repair at specialist shop o Shaft sleeve wear. o Replace o Lantern ring positioning o Position it correctly. failure. o Excessive forced feed o Recheck the plan. pressure.

Das könnte Ihnen auch gefallen