Pump Maintenance

Presented By
NAUSHAD AHMAD
Department: Mechanical Maint.
 WHAT IS THE PUMP?

Its purpose is to convert energy of a prime mover (Electric motor) first into velocity
or kinetic energy and then into pressure energy of a fluid that is being pumped.

Pumps enable a liquid to:

1. Flow from a low pressure to high pressure.

2. Flow from a low level to a higher level.

3. Flow at a faster rate.

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Categories of pump:
 Rotodynamic pumps.
 Positive displacement pumps.
PUMP

Positive
Rotodynamic displacement

Centrifugal

Rotary Reciprocating
Axial flow

Mixed flow
Gear Piston

Lobe Diaphragm

Sliding Vane Plunger

Screw

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Centrifugal Pumps
Centrifugal pumps have a rotating impeller, also known as a blade, that is immersed
in the liquid. Liquid enters the pump near the axis of the impeller, and the rotating
impeller sweeps the liquid out toward the ends of the impeller blades at high
pressure.

Positive-displacement Pumps
A positive-displacement pumps are generally consisting of a rotating member with a
number of lobes that move in a close-fitting casing. The liquid is trapped in the
spaces between the lobes and then discharged into a region of higher pressure.

A common device of this type is the gear pump, which consists of a pair of meshing
gears. The lobes in this case are the gear teeth

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 Pump Terminology

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General Components of Centrifugal Pumps
A centrifugal pump has two main components:
 Rotating component- Impeller and a shaft

 Stationary component - Casing, Casing cover, and Bearings

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 Impeller and Its Types
Impeller is the main rotating part that provides the centrifugal acceleration to the fluid.

Classification -:
 Based on direction of flow
 Radial flow
 Axial flow
 Mixed flow

 Based on suction type

 Single-suction: Liquid inlet on one side.
 Double-suction: Liquid inlet to the impeller symmetrically from both sides.

 Based on mechanical construction

 Closed: Shrouds or sidewall enclosing the vanes.
 Open: No shrouds or wall to enclose the vanes.
 Semi-open or vortex type.

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Important Terms used in Pumps
1. Capacity
Capacity means the flow rate with which liquid is moved or pushed by the pump to
the desired point in the process. It is commonly measured in either Liter per
minute (Lpm) or cubic meters per hour (m3/hr).

Capacity depends on a number of factors like:

 Process liquid characteristics i.e. density, viscosity
 Size of the pump and its inlet and outlet sections
 Impeller size
 Impeller rotational speed RPM
 Size and shape of cavities between the vanes
 Pump suction and discharge temperature and pressure conditions

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 2. Head-
 The pressure at any point in a liquid can be thought of as being caused by a
vertical column of the liquid due to its weight. The height of this column is
called the static head and is expressed in terms of METER of liquid.

 The same head term is used to measure the kinetic energy created by the
pump. In other words, head is a measurement of the height of a liquid column
that the pump could create from the kinetic energy imparted to the liquid.

Significance of using the “head” term instead of the “pressure” term

 The main reason for using head instead of pressure to measure a centrifugal pump's
energy is that the pressure from a pump will change if the specific gravity (weight) of the
liquid changes, but the head will not change.

100 m

Pressure
Gauge

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Conversion Factors Between Head and Pressure

 Head (meter of liquid) =Pressure in KPa / Sp. Gr.X Gravity

 Pressure in Kg/Cm2 = Head x Sp. Gr. X Gravity (g)

1 Kg/cm2 = 98.06KPa

 Sp. Gr. is Specific Gravity which for water is equal to 1

 For a fluid more dense than water, Sp. Gr. is greater than 1s

 For a fluid less dense than water, Sp. Gr. is less than 1

 Density of Water= 1g/cm3

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 3. NPSH- Net Positive suction Head
What is Net Positive Suction Head
The margin of pressure over vapor pressure, at the pump suction nozzle, is Net
Positive Suction Head (NPSH). NPSH is the difference between suction pressure
(stagnation) and vapor pressure. In equation form:

NPSH = Ps - Pvap
 NPSH as a measure to prevent liquid vaporization

Types of NPSH

1.Net Positive Suction Head Required, NPSHr

 NPSHr is a function of pump design.

 NPSHr increases as capacity increases

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 2. Net Positive Suction Head available, NPSHa

 NPSHa is a function of system design

Significance of NPSHr and NPSHa

 The NPSH available must always be greater than the NPSH required for the pump to
operate properly. It is normal practice to have at least 2 to 3 feet of extra NPSH
available at the suction flange to avoid any problems at the duty point.
NPSHa >NPSHr

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 4. Power and Efficiency

 Pump input or brake horsepower (BHP) is the actual horsepower delivered to

the pump shaft.

 Pump output or hydraulic or water horsepower (WHP) is the liquid horsepower

delivered by the pump.

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 5. Cavitations

Cavitation refers to an abnormal condition inside the pump that arises during pump
operation due to formation and subsequent collapse of vapor filled cavities or
bubbles inside the liquid being pumped. The condition of cavitation can obstruct the
pump, impair performance and flow capacity, and damage the impeller and other
sensitive components.

In short, Cavitations can be termed as “the heart attack of the pump”.

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 The Affinity Laws

Formulas for Refiguring Pump Performance with Impeller Diameter

or Speed Change

Diameter and Speed

Diameter Change Only Speed Change Only
Change

The Affinity Laws are valid only under conditions of constant efficiency.

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 Pump Characteristics Curve

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 Effect of over sizing the pump

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 Axial Piston Pump
Axial piston pumps have a circular piston group which rotates against an angled
swash plate. As the rotary group turns the pistons are pushed forwards and
backwards. A grooved timing plate at the at the top of the pistons controls the way
the fluid is drawn through the suction side of the pump and out through the pressure
side.

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 Pump Maintenance

 The following six parameters should be regularly monitored to understand

how a pump is performing:

 Suction pressure (Ps)

 Discharge pressure (Pd)
 Flow (Q)
 Pump speed (N)
 Pump efficiency (η)
 Power (P)

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  The advantages regular monitoring of the pumps are –
 No dismantling of the pump is necessary.
 Cost savings and energy savings by increasing the pump availability and reliability
coefficients for pumps.
 The time to maintain the pump set maybe predicted and planned more accurately
and in a qualified manner in line with predictive and planned maintenance
strategies.
 If a flow meter is installed to measure process liquid flow, then the pump monitor
is able to verify the accuracy of the meter readings by calculating ‘Q’ from the
empirical formula for power ‘P’.

 In addition, it is very important to monitor some other conditions for centrifugal

pump during normal operation such as:-

 Vibration monitoring.
 Oil level and schedule oil Analysis.

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Pump Inspection Schedule
1. Routine inspections
Perform the following tasks whenever you check the pump during routine inspections:

 Check the level and condition of the oil through the sight glass on the bearing
frame
 Check for unusual noise, and bearing temperatures.
 Check the pump and piping for leaks.
 Analyze the vibration.
 Inspect the discharge pressure.
 Check the seal chamber and stuffing box for leaks.

 Ensure that there are no leaks from the mechanical seal.

 Adjust or replace the packing in the stuffing box if you notice excessive leaking.

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 2. Three-month inspections

Perform the following tasks every three months:

 Check that the foundation and the hold-down bolts are tight.

 Check the mechanical seal if the pump has been left idle, and replace as required.

 Change the oil every three months (2000 operating hours) at minimum.

 Change the oil more often if there are adverse atmospheric or other conditions
that might contaminate or break down the oil.

 Check the shaft alignment, and realign as required.

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 3. Annual inspections
Perform the following inspections one time each year:

 Check the pump capacity.

 Check the pump pressure.
 Check the pump power.

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 Pump Maintenance Schedule
Perform the following tasks whenever you perform routine maintenance:

 Clean bearing bracket from any oil if found.

 Check oil drain plug.
 Lubricate the bearings.
 Inspect suction and discharge flanges for any leak.
 Inspect pump casing for any unusual damage signs.
 Inspect the seal.
 If the pump is offline check the coupling and its shims for any damage.
 Make sure that the coupling guard s well tightened to pump base plate.
 Check that motor alignment bolts are all in place.

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THANK YOU
SURPRISE QUIZ