PUMPS , VALVE AND COMPRESSOR

1. MUHAMMAD HABID ALWI BIN MOHD ALI

09DKM15F1015
2. MUHAMAD ADZHA BIN MURAD
09DKM15F1016
3. MUHAMMAD NAQIUDDIN BIN SENIN
09DKM15F1017
4. MOHAMAD IZHARUDDIN BIN AHMAD
09DKM15F1023
5. HAIKAL BIN SHAMSUDIN
09DKM15F1038
6. SANTHISEN A/l CHANDRAN
09DKM15F1810

LECTURER NAME : EN. HASRY BIN ABDUL SAMAD

 A pumps is designed to transfer a
f luid from one point to another.
Pumps transfer f luid from low
pressure area to high pressure areas,
low elevations to higher elevations,
and from local locations to distant
locations.
 Liquids have no shape of their own and flow to acquire the
shape of their container
Liquids can be considered incompressible at pressures used
in hydraulic systems
Liquids transmit pressure equally in all directions.
The flow rate of oil from a non-positive pump depends on
the speed of the pump and on the system pressure.
The flow rate of oil from a positive displacement pump
varies proportionally with pump speed but is virtually
independent of system pressure.
Any flow of liquid through a pipe or orifice is accompanied
by a reduction in liquid pressure.
 Drainage - Used to control the level of water in a
protected area.
Sewage - Used in the collection and treatment of
sewage.
Irrigation - Used to make dry lands agriculturally
productive.
Steel Mills - Used to transport cooling water.
 Pump
classification

Kinetic Positive displacement

pump pump

Special
centrifugal effect
rotary
reciprocating
Regenerative
turbine
 Kinetic pumps add energy continuously.
This energy increases the fluid velocity.
The resulting velocity reduction pressure increase.
Pressure does not exceed the system resistance, the
fluid does not move.
This type of pump is a machine that uses the dynamic
principle of accelerating fluid.
 This type of pump is a machine that uses the dynamic
principle of accelerating fluid, through centrifugal
activity, and converting the kinetic energy into
pressure.
Centrifugal pumps will only pump, or build pressure,
to a designed level.
When this level is reached, the fluid no longer moves
and all the kinetic energy is converted to heat.
This heat can cause the fluid to vaporize or build
pressure within the pump, sometimes exceeding its
design limit.
 Centrifugal pumps

Overhung Impeller between

impeller pumps bearing pumps
 Positive Displacement pumps push or pull liquid from one
point to another using various mechanical configurations.
A positive displacement pump will continue to pump fluid
until relieved.
It is only limited by the pressure limitation of the pump
materials and system.
This characteristic means that the pressure will continue to
build until alleviated.
Relief can come in a controlled form at relief valves,
rupture disks or other pressure relief devices.
Positive displacement pumps are classified as Rotary or
Reciprocating. They are often used to pump thick, viscous
fluids or where a finite amount of fluid is required in a
given time.
 A Rotary pump is a positive displacement pump
consisting of a chamber(s) containing gears, lobes,
cams, vanes, screws or similar elements driven by a
rotating shaft.
Close running clearances enable the pump to generate
the proper hydraulics.
As these clearances increase, due to wearing of parts,
the pumps efficiency drops dramatically.
Relief valves are recommended to prevent pressure
from building beyond the pressure limitation of the
system.
 Rotary
pumps

Gear Lobe Vane Screw

pumps pumps pumps pumps
GEAR PUMP
consists of two spur gears meshing together and
revolving in opposite directions within a casing.
LOPE PUMP
Lobe pumps are used in a variety of industries
including, pulp and paper, chemical, food, beverage,
pharmaceutical, and biotechnology.
VANE PUMP
vane pumps are used for liquid transfer applications
from chemicals to liquefied gases.
SCREW PUMP
screw pump assures reliable operation and a long life
because through the pump is positive displacement
type.
 A Reciprocating pump is a positive displacement pump
consisting of a liquid end and a drive end.
The liquid end consists of a device to displace a fixed
volume of fluid for each stroke of the drive end.
Suction and discharge flow is usually determined by
the position of check valves.
 Maintenance Concept : that governs the
maintenance levels and type of maintenance actions to
be performed for a equipment, machine, plant, or
system. (pumps)
 Description Comment

Pumps use and sequencing Turn off or sequence unnecessary

motors.
Overall visual inspection Complete overall visual inspection to be
sure all equipment is operating and
safety systems are in place.

Check lubricating Assure that all bearing are lubricated

per the manufacture recommendation.
Check packing (chamber) Check packing for wear and repack as
necessary. Consider replacing packing
with mechanical seals.
Motor and pump alignment Align the pumps/motor coupling to
allow for efficient torque transfer to the
pump.
Check mountings Check and secure all pump mountings.
Check bearing Inspect bearing and drive belts for wear.
Adjust, repair, or replace as necessary.
Motor condition Check the condition of the motor
through temperature or vibration
analysis to assure long life.
 Heat
Pressure
Noise
Flow
Leakage
Power consumption
Liquid level
Speed (motor , rpm)
 Pump installation
Installation of the pump is the most crucial step that
determines the performance and maintenance
requirements of the pump over a longer period.
 Pump Inspection

It has to mentioned that most of the pumps used are

lubricated by oil and the pump manufacturers do not
export the pumps with oil installed in the bearing
frames.

Oil is added just before initialization of pump operation.

Oil should be replaced after the first 200 hours of
operating or every 3 month.

Used the correct oil will smoothen the pump operation

and will not allow the bearing to burn quickly.
 Pump Reassembly
After the initial process of cleaning and inspection of
pump components, it is time to reassemble the pump
unit.

During the reassembly, care should be time taken so

that the various components remain clean and no
remains should build up.
 A valve is a device that regulates,
directs or controls the f low of f luid
(gas, liquids, f luidized solids, or
slurries) by opening, closing, or
partially obstructs the passage of
various
 These valves are to be useful in industries such as:
Refineries
Petrochemical
Fertilizer
Sugar
Cement
Power Plant
Chemical Process Industries
Water Treatment
Oil Treatment
Food
Beverage and others.
 Ball valve
the ball through the hole diameter
that can be rotated to align with the flow
or blocking.
Valve functions can be easily controlled,
and only require rotation to operate.
Can be powered with Pneumatic
and electric Movers.
 Valve plug
Similar to ball valves except
the cylinder used instead of spherical
More expensive but more
robust than the ball valve
Requires more rotation to turn
but still easy to move
 Diaphragm valves
very easy
Plunger and hand wheel is often used for Pressing the
diaphragm
Moved by pneumatic or electric
 Gate valve
A sliding disc slides up and down in and out of
liquid
Good for high pressure drop and high temperature
applications where operation is infrequent
Operating manual or other multi-turn electric
driving is the most common
 Globe valve
A conical plug to move in and out of fluid
Can be used for pressure drop and temperature
applications
There are in the world, angle, and y-pattern
Operating manual or other multi-turn electric
driving is the most common
The pressure drop is easier to repair, but more of a
door or valve plug
 Check valve = allows fluid to pass in one direction only.
Gate valve = for on / off control, with low pressure.
Spool valve = to control hydraulic system.
Ball valve = for on / off control without pressure drop,
and ideal for quick closing.
 Manual = Be activated manually by the operator by
pressing the button provided.
Mechanical = mobilized by mechanical mechanisms
SPT switch wheels.
Pneumatic compression = mobilized by wind
Electrical = be activated by a solenoid
 Use only original spare parts from the manufacturer of the valve
Ensure that the valve springs and suction and discharge stroke right -
Do not mix if different.
Do not grind the valve plate.
Do not change the stroke of the valve springs without consulting the
manufacturer.
Renew the sealing surface. Install new sealing elements and rework the
valve seat.
Follow manufactures specs. for max. wear parts.
Consider the dimensions of which are not to be changed, especially on
the suction valve time.
If in doubt, always replace the parts. Premature failure of the valve is
more expensive than the savings possible with the use of worn parts.
If the valve is to be sent to a repair shop to pack them properly to avoid
damage during transportation.
1 . Always wear rubber gloves when handling Gate Valve
2 . Move the valve to the Open Gate
3 . For safety , remove the air mover
4 . Remove the bolt that holds the actuator assembly Bonnet
5 . Pull Bonnet Actuator Carriage Assembly , careful adjustment of the connective
Current issue
6 . Remove O- Ring or gasket from Bonnet Assembly and discard
7 . Remove O- Ring Gate by choosing plastic , taking care not to scratch the O-
Ring Groove ; Remove O- Ring
8 . Clean O- Ring groove with IPA and dried with nitrogen or CDA
9 . use a light coat of grease L Apezion new O- Ring Gate
10. Install new O- Ring on the door , careful to avoid twisting or deforming O-
Ring
11. use a light coat of grease L Apezion new Bonnet assembly Viton O- Gasket Ring
Copper install dry
12 . Install new O-Ring/Gasket Bonnet assembly , be careful to avoid twisting or
deforming the O- Ring
13. Replace Bonnet Actuator Assembly into the valve body
14. Install the bolts and tighten.
 Compressor is a machine that compresses air or
another type of gas from a (low inlet)/(atmospheric
level) to a higher desired pressure level.
 Accomplished by reducing the volume of gas.
Generate heat increasingly and water will be form.
Air compressors are generally positive displacement
units and are either of the reciprocating piston type or
the rotary screw or rotary vane types.
A typical maximum pressure for the pneumatic system
is 7 to 10 bars.
Gasses can be compressed in the following ways:
Reciprocating piston compressors
Low flow rates
High compression ratios
Rotating centrifugal compressors
High flow rates
Low compression ratios
Several centrifugal stages may be used to
obtain higher compression ratios
Centrifugal Compressors
Radial Flow Compressors (multi-stage)
Axial Compressor
Reciprocating Compressor
 The purpose of the valves in a reciprocating compressor is to
let air in and out of the cylinder during the compression
process.
These valves are considered automatic because they are
operated by the difference in pressure across the valves. The
key to long valve life is to have positive action of the sealing
components with minimum resistance.
Compressor valves serves as check valves for the inlet and
discharge passages of the cylinder and will open and close
once for every revolution of the crankshaft.
For example, if the compressor is running at 500 rpm for 24
hours a day, the valves will open and close 720,000 times every
day!
 If there is a backflow of gas, it will cause an increase
in the temperature of the valve, valve covers and the
cylinder body.
The increase in temperature could also be caused by
prolonged unloaded operation of the cylinders.
Valve ports should be inspected for cracks through the
use of a dye penetrant.
 https://www.flowserve.com/en/products/pumps/betw
een-bearings-pumps

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%20Centrifiugal_Pumps_Overview.pdf

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