CENTRIFUGAL PUMP AND TROUBLESHOOTING GUIDE


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CENTRIFUGAL PUMP & TROUBLESHOOTING GUIDE - CONTENT

1. Introduction

2. Pump classification

2.1. Centrifugal pumps

2.2. Mixed flow pumps

2.3. Axial flow pumps

2.4. Type and Construction based on:

2.4.1. Suction design

2.4.1.1. Single

2.4.1.2. Double

2.4.2. No. of stages

2.4.2.1. Single

2.4.2.2. Multistage

2.4.3. Guide vanes

2.4.3.1. Volute

2.4.3.2. Turbine

2.4.4. Casing construction

2.4.4.1. Radially Split

2.4.4.2. Axially Split

2.4.4.3. Double Casing

2.4.5. Impeller shrouds

2.4.5.1. Open

2.4.5.2. Partially Open

2.4.5.3. Closed

2.4.6. Shaft position

2.4.6.1. Horizontal

2.4.6.2. Vertical

3. Centrifugal Pump Basics

3.1. Principle of operation

3.2. Pressure concepts

3.3. Hydraulics - a few basics

3.4. Vapor pressure

3.5. Cavitation

3.6. Net positive suction head

3.7. Pump characteristic curves

4. API – 610 Types and features

4.1. Overhung

4.1.1. Flexibly Coupled

4.1.1.1. Horizontal

4.1.1.1.1. Foot Mounted : OH1

4.1.1.1.2. Center line Mounted : OH2

4.1.1.2. Vertical

4.1.1.2.1. In-line Bearing Frame : OH3

4.1.2. Rigidly Coupled

4.1.2.1. Vertical

4.1.2.1.1. In-line : OH4

4.1.2.2. High Speed Integral Gear : OH5

4.2. Between Bearing

4.2.1. 1st and 2nd Stage

4.2.1.1. Axially Split : BB1

4.2.1.2. Radially Split : BB2

4.2.2. Multistage

4.2.2.1. Axially Split : BB3

4.2.2.2. Radially Split

4.2.2.2.1. Single Casing : BB4

4.2.2.2.2. Double Casing : BB5

4.3. Vertical Suspended

4.3.1. Single Casing

4.3.1.1. Discharge through Column

4.3.1.1.1. Diffuser : VS1

4.3.1.1.2. Volute : VS2

4.3.1.1.3. Axial Flow : VS3

4.3.1.2. Separate Discharge (Sump)

4.3.1.2.1. Line Shaft : VS4

4.3.1.2.2. Cantilever : VS5

4.3.2. Double Casing

4.3.2.1. Diffuser : VS6

4.3.2.2. Volute : VS7

4.4. Wear ring running clearances

4.5. Mechanical seal types / arrangement / plans

4.6. Cooling water piping

4.7. Lube oil system

5. Conventional and Interactive Skill Tests with evaluation

6. Games – Component assembly

6.1. Overhung pump – OH

6.2. Between bearing pump – BB

6.3. Vertical suspended pump – VS

7. Technical Glossary

8. Troubleshooting Guide

This troubleshooting guide, besides being a training package also serves as a day-to-day reference for Operation and Maintenance. Defective pumps will express one or more of the indicated symptoms of failure or deviation of normal operation. This Operation and Maintenance solution package attempts to bring out the root-causes (System/ Operation / Mechanical troubles) by selecting the symptoms that the subject pump is exhibiting

• Failure or deviation symptoms

o Pump does not deliver

o Insufficient capacity delivered

o Insufficient discharge pressure developed

o Pump loses prime after starting

o Pump requires excessive power

o Stuffing box / mechanical seal leak excessively

o Packing / mechanical seal has short life

o Pump vibrates or noisy

o Bearing have short life

o Pump overheats and seizes

• Around 45 specific root-causes have been identified similar to the few listed below:

o Pump not primed

o Suction lift too high

o Insufficient margin between suction pressure and vapor pressure

o Total head required by process lower than pump design

o Specific gravity of liquid different from design

o Operation at very low capacity

o Parallel operation of pumps unsuitable for such operation

o Misalignment

o Bearings worn out

o Wearing rings worn out

o Rotor out of balance causing vibration

o Improper selection, fitting or usage of mechanical seal

o Lack of lubrication

• And this guide stands out exclusively with its enhanced graphical explanation of
   the root-causes, which includes interactivity and extensive animation.

• The learner / user is well guided by a series of questions, which helps him
   to accurately pinpoint the root cause.

• A brief troubleshooting module on mechanical seal is also included.

• The user can avail printouts of the observed failure symptoms and related
   root-cause for record.

• From the glossary the learner / user can avail a good understanding on pump
   related technical terms such as: Affinity laws for pump performance, Air
   entrapment, Air leak, Air pocket, Bearing defects, Bent shaft, Capacity, Cavitation,
   Direction of rotation, Foot valve, Foundation, Gland packing, Hydraulic imbalance,
   Imbalance, Impeller defect, Impeller improper, Internal rubbing, Lubrication,
   Mechanical seal, Misalignment, NPSH and related discussions, Parallel operation,
   Priming, Pump head, Pump performance curves, Pump suction, Shaft sleeve,
   Specific gravity, Speed low, Stuffing box, Suction lift, System resistance curve,
   Thrust, Vapor pressure, Vapor pressure and cavitation, Vibration, Viscosity and
   Wear ring.

Above indicated topics are supported with graphical depiction and animation besides textual description.