You are on page 1of 54

PEP SESSION ON

CONSTRUCTION & MAINTENANCE OF


CENTRIFUGAL PUMPS

Khurram Majeed / Najam-us-saqib


Area Engineer

/ Maintenance Technician

Engro Chemical

COURSE CONTENTS

What is a pump ?
Types of pump
Centrifugal pumps-single & multi stage
Parts of centrifugal pump
Important terms & definitions
Pump performance curves
Pumps troubleshooting & maintenance
Preventive Maintenance Checks
Typical Questions & Answers
Pump overhaul procedure
Parts Identification & Practical session
Khurram Majeed / Najam-us-saqib

WHAT IS A PUMP ?

Pump is used to add energy to the fluid to move it


from one point to another

Pump is used to move the liquid from lower elevation


to higher elevation or from low pressure area to high
pressure area

Pump is used to increase the flow rate of the liquid

Khurram Majeed / Najam-us-saqib

TYPES OF PUMPS
1. Positive Displacement Pumps
2. Dynamic Pumps
POSITIVE DISPLACEMENT PUMPS
A pump that first traps liquid and then delivers is called
positive displacement.

DYNAMIC PUMPS
A pump that works on the basis of centrifugal force is
called dynamic pump or centrifugal pump

Khurram Majeed / Najam-us-saqib

PUMP TYPES ORGANOGRAM


PUMP

Positive displacement
Pump

Reciprocating Pumps

Dynamic Pump

Rotary Pumps

Plunger Pumps

Gear Pumps

Diaphragm Pumps

Screw Pumps

Centrifugal Pumps

Impeller Pumps
Propeller Pumps

Sliding vane Pumps


Turbine Pumps
Lobe Pumps
Khurram Majeed / Najam-us-saqib

CENTRIFUGAL PUMP
A pump that operates by centrifugal force and
develops pressure of the liquid is called
Centrifugal Pump

CLASSIFICATION
BY PRESSURE
1. Single stage Centrifugal Pump
A pump that is based on one Impeller is called single stage
centrifugal pump. It is used for relatively low pressure applications.

2. Multi stage Centrifugal Pump


A pump that is based on two or more than two Impellers is called
Multi stage centrifugal pump. It is used for high pressure
requirements

Khurram Majeed / Najam-us-saqib

CENTRIFUGAL PUMP CLASSIFICATION


BY FLOW
1. Single Suction Centrifugal Pump
A pump in which its Impeller has only one suction eye at one of its
side is called single suction Centrifugal Pump. Liquid entry from one
side , hence used for relatively low flow applications.

Thrust due to pressure Imbalance

2. Double Suction Centrifugal Pump


A pump in which its impeller has suction eye on both the sides
is called double suction Centrifugal Pump. Liquid entry from
both ends, hence meets high flow requirements.
Khurram Majeed / Najam-us-saqib

CENTRIFUGAL PUMP CLASSIFICATION


BY INSTALLATION
1. PARALLEL ARRANGEMENT
Pumps are installed in parallel to obtain high flow and same
pressures. Eg: P-25201, P-299.

2. SERIES ARRANGEMENT
Pumps are installed in series to obtain high pressure and same
capacity. Eg: Booster Pumps

Khurram Majeed / Najam-us-saqib

CENTRIFUGAL PUMP CLASSIFICATION


BY CASING ARRANGEMENT
1. VERTICAL SPLIT
A pump in which casing split is vertical with respect to ground level

2. HORIZONTAL SPLIT
A pump in which casing split is horizontal with respect to
ground level

Khurram Majeed / Najam-us-saqib

CENTRIFUGAL PUMP NOMENCLATURE


I/B
Bearing

O/B
Bearing

Shaft

Sleeve

Discharge
Nozzle

Casing

Impeller
Lock Nut

Impeller
suction eye

Impeller

Gland Packing
Khurram Majeed / Najam-us-saqib

10

CENTRIFUGAL PUMP NOMENCLATURE


SHAFT
The basic function of a centrifugal Pump shaft is to transmit the
torques encountered in starting and during operation.
It also supports the impeller and other rotating parts.
Impeller

Gland Packing / Mech


Seal

O/B Bearing

Coupling

I/B Bearing

SHAFT SLEEVE
The basic function of the
sleeve is to protect shaft
from erosion, corrosion and
wear at stuffing boxes,
leakage joints & internal
bearing areas.
Khurram Majeed / Najam-us-saqib

11

CENTRIFUGAL PUMP NOMENCLATURE


IMPELLER

Impeller is the heart of Centrifugal Pump


It rotates the liquid mass with the peripheral speed of its vane tips.
The whirling movement of Impeller imparts centrifugal force to the
liquid
and increases the velocity head.
Impeller does not increase liquid pressure. High velocity head is
converted to pressure head in the volute
Increase in velocity is directly proportional to Impeller diameter &
Pump speed.

Khurram Majeed / Najam-us-saqib

12

CENTRIFUGAL PUMP NOMENCLATURE


PARTS OF IMPELLER
Impeller Hub
Central part of Impeller, bored out according to the shaft
diameter.
Suction Eye
The impeller inlet just ahead of the vanes is called the
suction eye.
Impeller shroud
Impeller shroud or enclosing sidewalls totally enclose the
impeller water ways from the suction eye to the periphery.

Wear rings
Wear rings provide
Impeller Vanes
protection and an
Vanes are the parts that pick up the liquid and
economically
accelerate it to high velocity. Increase in length of
renewable leakage joint
vanes or Impeller dia will increase the liquid velocity,
between the impeller
hence pump discharge pressure.
and casing.
BALANCING HOLES
These holes are located throughout a single suction impeller for the balancing of
thrust

Khurram Majeed / Najam-us-saqib

13

CENTRIFUGAL PUMP NOMENCLATURE


TYPES OF IMPELLER
Semi Open / Closed

Closed

Consisting of Vanes only

Shroud on one side only

Shroud on both sides

No shrouds or sidewalls

Least water slippage

Water slippage exists

Water slippage exists but


less than in open type

Relatively less liquid


velocity

Greater liquid velocity


than open type

Impeller has structural


weakness

Applied in pumps
handling abrasive liquids

Open

Greater liquid velocity


than other types
Applied in pumps
handling clear liquids

Applied in pumps
handling slurries & mud
Khurram Majeed / Najam-us-saqib

14

CENTRIFUGAL PUMP NOMENCLATURE


CASING
An enclosed space where the Impeller rotates with the shaft is called
casing.
The purpose of the pump casing is to guide the liquid to the impeller,
convert high velocity of liquid from impeller into pressure and lead the
flow away from the impeller to the discharge nozzle

TYPES OF CASING
1. Horizontal Split casing
2. Vertical split casing
3. Volute casing
4. Diffuser casing

Khurram Majeed / Najam-us-saqib

15

CENTRIFUGAL PUMP NOMENCLATURE


TYPES OF CASING

VOLUTE CASING

DIFFUSER CASING

Khurram Majeed / Najam-us-saqib

16

CENTRIFUGAL PUMP NOMENCLATURE


STUFFING BOX
A space provided for Gland Packing or Mechanical seal where
the shaft passes out through the pump casing
Primary function is to prevent leakage along the shaft.
Prevent air leakage into the pump and liquid leakage out of the
pump.

GLAND PACKING

It is a pressure breakdown device


JAM TYPE PACKING

AUTOMATIC TYPE PACKING

Adjustable with time

Not adjustable with time

Eg: P-102, P-299, P-201

Eg: P-101
Khurram Majeed / Najam-us-saqib

17

CENTRIFUGAL PUMP NOMENCLATURE


GLAND PACKING
40 dpm is allowable Packing leakage
This amount of leakage between the packing & shaft is necessary for
lubrication / cooling
Packing ring size:

Stuffing Box ID - Shaft OD


2

No of Packing rings:

Depth of Stuffing Box


Packing ring size

LANTERN RING
A metallic cage about the size of a packing
ring that fits around the shaft sleeve inside
the packing box.
Located between the Packing rings near the
center of the packing box, providing
passage to the liquids for lubrication,
cooling and flushing
Khurram Majeed / Najam-us-saqib

18

CENTRIFUGAL PUMP NOMENCLATURE


GLAND PACKING
Throat bush is installed at pressure side of the stuffing box to break the
initial pressure.
To break the maximum pressure, clearance between throat bush and shaft
should be kept minimum.
Packing ring ends should be cut at 450 to form a sealing joint for minimum
leakage
Packing rings will be installed with ends at 120o apart
Packing is tightened by moving the gland pusher nut by one flat and wait
for 10 - 15 minutes. If required move another flat.
Packing SATURANT is a lubricant which lubricates the packing during
running

Khurram Majeed / Najam-us-saqib

19

CENTRIFUGAL PUMP NOMENCLATURE


MECHANICAL SEAL
An average of 10% to 35% of the allotted pump-engineering time is generally
spent on the mechanical seal system
Prevents major fires, release of toxic materials having safety hazards and
reduces unit down time

FUNDAMENTAL SEALING PRINCIPLE

Fluid is to be sealed in a
container through which a
rotating shaft extends

Khurram Majeed / Najam-us-saqib

20

CENTRIFUGAL PUMP NOMENCLATURE


FUNDAMENTAL SEALING PRINCIPLE

The shaft shoulder is replaced by a separate


piece and another adjacent member is
inserted into the housing wall. These two
members, the primary seal and mating ring,
are the heart of the mechanical seal

Other leakage paths are sealed


with secondary seals such as
O-rings, wedge or bellows

Khurram Majeed / Najam-us-saqib

21

CENTRIFUGAL PUMP NOMENCLATURE


FUNDAMENTAL SEALING PRINCIPLE

The shaft shoulder is replaced by a separate


piece and another adjacent member is
inserted into the housing wall. These two
members, the primary seal and mating ring,
are the heart of the mechanical seal

Other leakage paths are sealed


with secondary seals such as
O-rings, wedge or bellows

Khurram Majeed / Najam-us-saqib

22

CENTRIFUGAL PUMP NOMENCLATURE


FUNDAMENTAL SEALING PRINCIPLE
The precision lapped faces are automatically
kept in constant by the insertion of a spring. A
single or multi springs can be used
The spring is placed under tension by a retainer
which provides positive drive for the seal. This
completes the seal assembly.

Khurram Majeed / Najam-us-saqib

23

CENTRIFUGAL PUMP NOMENCLATURE


TYPE CLASSIFICATION
Pusher or Non-Pusher Seals
In pusher seals, as face wears, the secondary sealing members slide along the shaft to
maintain a seal. These secondary sealing members are commonly dynamic elastomers
e.g. O-rings. In Non-Pusher or bellow type seal, the secondary element does not slide
along the shaft therefore it is far less susceptible for hang-up. I.e. excessive opening of the
seal faces. These seals utilize both elastomer and metal bellows.

Khurram Majeed / Najam-us-saqib

CENTRIFUGAL PUMP NOMENCLATURE

24

TYPE CLASSIFICATION
Inside or Outside Seals
Mechanical seals are described as inside if the hydraulic pressure being contained acts in
closing direction. With an outside seal hydraulic pressure acts inn an opening direction.
The internal seal is a more stable type; The external seal tends to lose face contact with a
sudden surge and quite often it is impossible for it to reestablish face contact

Khurram Majeed / Najam-us-saqib

25

CENTRIFUGAL PUMP NOMENCLATURE


TYPE CLASSIFICATION
Balanced or Unbalanced Seals
Hydraulic balance refers to the relationship between the pressure of the fluid being sealed
and the contact pressure between the seal faces., In the case of an unbalanced seal,
hydraulic pressure is unrelieved by the face geometry so that the face contact pressure is
equal or greater than the fluid pressure. With a balanced seal the design proportions the
radially disposed areas so that the effective contact pressure is always less than the fluid
pressure

Khurram Majeed / Najam-us-saqib

26

CENTRIFUGAL PUMP NOMENCLATURE


TYPE CLASSIFICATION
Single or Double Seals
Single seal has one set of sealing faces and are commonly used as sealing device. Double
seals have two sets of sealing faces are normally recommended for safety and
environmental reasons. The buffer fluid is contained externally in an external auxiliary
seal flushing reservoir. Double Mech seals have following classification.

Back-to-Back
These are mounted one seal facing
inboard towards the pumped liquid,
and the other facing outboard
towards atmosphere. The buffer
fluid is maintained at a pressure
greater than the service fluid
pressure

Tandem Seals
These are used for fluids having
environmental and safety hazards.
The outboard seal has a separate
low pressure buffer liquid into the
space between it and inboard seal.

Khurram Majeed / Najam-us-saqib

27

CENTRIFUGAL PUMP NOMENCLATURE


BEARINGS
The bearings in a centrifugal pump must
Allow the shaft to rotate with practically negligible friction
Hold the rotating element in its proper position relative to the stationary
parts of the pump, both radially and axially, so that the rubbing cannot
occur
Be able to absorb forces that are transmitted to them from the impeller
Give trouble free service for long periods of time
TYPES OF BEARINGS
Friction Bearings
In friction bearings there is little
friction between rotary & stationary
parts because of more contact area
between shaft and bearing

Journal Bearings (Radial & Thrust)

Anti-friction Bearings
To prevent or oppose rubbing, rolling
contact or friction between rotary &
stationary parts anti friction bearings are
used. They have little contact between
balls and races.
Roller Bearings
Ball Bearings
Deep Groove Ball Bearings

Cylindrical Roller Bearings

Angular Contact Ball Bearings

Spherical Roller Bearings

Self Align Ball Bearings

Taper Roller Bearings

Thrust Ball Bearings

Needle Roller Bearings


Khurram Majeed / Najam-us-saqib

28

CENTRIFUGAL PUMP NOMENCLATURE


BALL BEARINGS
Deep Groove Ball Bearings
This type of Bearings has a
deep groove in its outer &
inner race
Carries radial & axial loads.
Operating at high speed.
Support heavy load.
Very limiting capability of
accommodating
misalignment.
Maintains free rolling
contact between balls &
races.

Angular Contact Ball Bearings


This type of Bearings has a collar on one
side of outer race to support the rolling
elements in one direction.
The contact of balls and races is on
angel.
Suitable for angular load, compensate
for alignment, high load carrying
capacity, high running accuracy &
suitable for combined loads (radial &
axial)
Single row (Back to Back, Face to Face,
Tandem arrangement) & Double Row

Single row for medium load


and double row for high
load.
Generally used in motors,
pumps & Gear boxes.
Khurram Majeed / Najam-us-saqib

29

CENTRIFUGAL PUMP NOMENCLATURE


BALL BEARINGS
Self Align Ball Bearings
The outer race of this
bearing is an arc, so it can
tilt over the balls an any
angle and adjust itself
according to the
misalignment of shaft.
Has two rows of balls in
separate grooves in inner
race but has only a single
spherical cage

Thrust Ball Bearings


These bearings have no outer or inner
race.
Rolling elements rotates between two
discs called washers.
Capable for Heavy thrust loads, high
running accuracy & high load carrying
capacity
Single and double direction bearings for
accommodating thrust in one or both
directions

Adjusts itself quickly to a


force from any direction
Suitable for any
misalignment, permits
angular misalignment of
shaft upto 3 degree
Takes, axial, radial &
angular load
Capable for medium loads /
speeds
Khurram Majeed / Najam-us-saqib

30

CENTRIFUGAL PUMP NOMENCLATURE


ROLLER BEARINGS
Cylindrical Roller Bearing
The rolling elements are true cylinders.
Capable of carrying high radial load & high
speed
Assembly is separable hence easy to mount
& dismount.

Spherical Roller Bearings


The rollers have line contact with inner
race and point contact with outer race.
Contains two rows of rollers with a
common outer raceway.
Bearing is capable to accommodate
heavy radial and axial loads.
Run at low temperatures, have long life,
accommodate angular misalignment and
available in taper bore with adapter
sleeve.

Khurram Majeed / Najam-us-saqib

31

CENTRIFUGAL PUMP NOMENCLATURE


ROLLER BEARINGS
Taper Roller Bearing

Needle Roller Bearings

Its inner & outer race are tapered with


tapered rollers in between. Cone & cup
arrangement.

The bearings with 5 mm or less than


5mm of rollers with extra long rollers are
called needle roller bearings.

Capable of carrying high load and


compensate misalignment due to tapered
parts.

Capable of carrying high load


Can be used with or without inner race.

Single, double or multi row bearings

Khurram Majeed / Najam-us-saqib

32

CENTRIFUGAL PUMP NOMENCLATURE


JOURNAL BEARINGS
A Sleeve or Journal bearing provides radial support and positioning of the shaft while permitting it
to rotate

Tilting Pad Thrust Bearing /


Kingsbury Thrust Bearing
Khurram Majeed / Najam-us-saqib

33

CENTRIFUGAL PUMP NOMENCLATURE


COUPLINGS
The device which which joins two separate shafts together is called a coupling
It is a common method of transferring force or torque from one machine to another

Rigid Coupling
A coupling that permits neither radial nor
axial relative motion between the driving
and driven shaft is called Rigid Coupling

Flexible Coupling
A Flexible coupling is a device that
connects two shafts while allowing for the
minor misalignment (angular, parallel or a
combination)
A flexible coupling must also permit some
lateral float of the shafts so that the two
shaft ends may move closer or farther apart
under the influence of thermal expansion

Khurram Majeed / Najam-us-saqib

34

CENTRIFUGAL PUMP NOMENCLATURE


COUPLINGS
Flexible Coupling
Flexible couplings have atleast one part that can flex or give

Khurram Majeed / Najam-us-saqib

35

IMPORTANT TERMS & DEFINITIONS


PRESSURE:
Pressure is the force acting on a unit of
area
HEAD:
Head is the height of liquid
Head =

Pressure

Sp. Gravity x 0.433

Khurram Majeed / Najam-us-saqib

36

IMPORTANT TERMS & DEFINITIONS


NPSH:
Net Positive Suction Head is the absolute suction head minus the vapour pressure head
NPSH Available:
Absolute pressure at the pump suction, changed into head minus the vapour pressure of the
liquid being pumped, changed to head.
NPSH Required:
Minimum head needed at the suction to get the liquid into the impeller without vaporizing
NPSHa must always be greater than NPSHr
NPSH = Absolute pressure at Pump suction - Vapor pressure at pump temperature
Specific Gravity x 0.433
CAVITATION:
Continuos formation & collapse of Vapor bubbles in the casing of pump is called Cavitation
Cavitation could be due to ingression of air inside the casing or due to vaporization of pumping
liquid
CAUSES OF CAVITATION:
Air Ingression, Insufficient suction, Closing of Discharge valves for longer time, Choking of
suction strainer, Discharge Head is more, Suction lift is more, Low efficiency of intercoolers,
Impeller clogging, Wear ring clearances etc
Khurram Majeed / Najam-us-saqib

37

IMPORTANT TERMS & DEFINITIONS


PRIMING:
The filling up of pump casing with liquid before start up is called priming
Liquid is brought into the pump by venting the casing
Care must be taken to make sure that the suction line to the pump remains full of liquid
SHUT OFF PRESSURE:
The maximum pressure produced by a pump is called shut off pressure.
The pump is operated at shut off pressure during start-up to avoid overloading / adequate liquid
delivery to the required point.
VORTEX BREAKER:
A plate installed at pump suction to break liquid whirls, hence provide continuos flow to
impeller
Vortexing can be very damaging as it reduces the NPSHa
PUMP CAPACITY:
Amount of liquid that a pump moves in a given length of time is called Pump capacity.
Expressed in GPM, Barrel / day etc

Khurram Majeed / Najam-us-saqib

38

Khurram Majeed / Najam-us-saqib

39
PERFORMANCE CURVES
When the total Head decreases, the
pump capacity increases, except at
very low capacity.
As the pumping rate increases, the
NPSH required increases
For every pump there is a capacity
where the pump operation is most
efficient and therefore most
economical
As the flow rate increases, the
horsepower required increases
The capacity and head characteristics
of a pump do not change when the
specific gravity of the material being
pumped changes, but the horsepower
required does change
Increase in Impeller dia will increase
NPSHr, Pump capacity & Discharge
Head.
Pump speed will also increase
capacity & Discharge Head

Khurram Majeed / Najam-us-saqib

40

CENTRIFUGAL PUMPS TROUBLESHOOTING


PUMP DOES NOT DELIVER LIQUID
Probable Causes
Pump not primed / pump or suction line not filled with liquid
Suction lift too high
Insufficient margin in-between suction pressure and vapor pressure
Air pocket in suction line
Inlet of suction pipe insufficiently submerged
Speed too low
Wrong direction of rotation
Total head of system higher than Pump design Head
Parallel operation of pumps unsuitable for such operation
Foreign matter in impeller
Choking of Foot valves / suction strainer
Loose impeller / Lock nut
Broken shaft
Khurram Majeed / Najam-us-saqib

41

CENTRIFUGAL PUMPS TROUBLESHOOTING


INSUFFICIENT CAPACITY DELIVERED
Probable Causes
Pump or suction pipe not completely filled with liquid

Impeller damaged

Suction Lift too high

Casing gasket defective

Insufficient margin between suction pressure and vapor pressure


Excessive amount of air or gas in liquid
Air pocket in suction line
Air leak into pump their stuffing boxes
Foot valves too small
Foot valves partially clogged
Inlet of suction pipe is not sufficiently submerged in liquid
Speed too Low
Total Head of system higher than Pump design head
Viscosity of liquid differs from that for which designed
Foreign matter in Impeller
Parallel operation of Pumps unsuitable for such operation
Wear rings worn
Khurram Majeed / Najam-us-saqib

42

CENTRIFUGAL PUMPS TROUBLESHOOTING


INSUFFICIENT PRESSURE DEVELOPED
Probable Causes
Excessive amount of air or gas in the liquid
Speed Too Low
Wrong direction of rotation
Total head of system more than pump design head
Viscosity of liquid differs from that for which designed
Parallel operation of pumps unsuitable for such operation
Wear rings worn
Impeller damaged
Casing gasket defective

Khurram Majeed / Najam-us-saqib

43

CENTRIFUGAL PUMPS TROUBLESHOOTING


PUMP LOSES PRIME AFTER STARTING
Probable Causes
Pump or suction pipe not completely filled with liquid
Suction lift too high
Excessive amount of air or gas in the liquid
Air pocket in suction line
Air leakage into suction line
Air leakage into pump thru stuffing box
Inlet of suction pipe insufficiently submerged
Water seal pipe plugged

Khurram Majeed / Najam-us-saqib

44

CENTRIFUGAL PUMPS TROUBLESHOOTING


PUMP REQUIRES EXCESSIVE POWER
Probable Causes
Speed too high
Wrong direction of rotation
Total head of system higher than pump design head
Total head of system lower than pump design head
Specific gravity of liquid different from that for which designed
Viscosity of liquid different than design
Foreign matter in Impeller
Misalignment
Shaft Bent
Wear rings worn
Rotating part rubbing on stationary part
Packing improperly installed
Incorrect type of packing
Gland too tight, resulting in no flow of liquid to lubricate packing
Khurram Majeed / Najam-us-saqib

45

CENTRIFUGAL PUMPS TROUBLESHOOTING


STUFFING BOX LEAKS EXCESSIVELY
Probable Causes
Misalignment
Shaft bent
Shaft or shaft sleeve worn or scored at the packing
Packing improperly installed
Shaft running off-center due to worn bearings or misalignment
Rotor out of balance resulting in high vibration
Failure to provide cooling liquid to water cooled stuffing boxes
Excessive Packing clearances at bottom of stuffing box between shaft and casing,
causing packing to be forced into the pump
Dirt in sealing liquid, leading to score the shaft or sleeve

Khurram Majeed / Najam-us-saqib

46

CENTRIFUGAL PUMPS TROUBLESHOOTING


PACKING HAS SHORT LIFE
Probable Causes
Water seal pipe plugged
Misalignment
Shaft bent
Bearings worn
Shaft or shaft sleeve worn out
Packing improperly installed
Incorrect type of Packing
Rotor out of balance
Gland too tight, resulting in no flow of liquid to lubricate packing
Failure to provide cooling liquid to water-cooled stuffing boxes
Excessive clearance at bottom of stuffing box between shaft and casing, causing
packing to be forced into the pump
Dirt in sealing liquid

Khurram Majeed / Najam-us-saqib

47

CENTRIFUGAL PUMPS TROUBLESHOOTING


PUMP VIBRATES OR IS NOISY
Probable Causes
Pump or suction pipe not completely filled with liquid
Suction lift too high
Insufficient margin between suction pressure and vapor pressure
Foot valve too small
Foot valve partially clogged
Inlet of suction pipe insufficiently submerged
Operation at very low capacity
Foreign matter in Impeller
Misalignment
Foundation not rigid
Shaft bent
Rotating part rubbing on stationary part
Bearing worn

Khurram Majeed / Najam-us-saqib

48

CENTRIFUGAL PUMPS TROUBLESHOOTING


PUMP VIBRATES OR IS NOISY
Probable Causes
Impeller damaged
Rotor out of balance
Excessive thrust caused by a mechanical failure inside the pump
Excessive amount of grease or oil in the housing of an anti-friction bearing or lack of
cooling, causing excessive bearing temperature
Lack of lubrication
Improper installation of anti friction bearings (Damage during assembly)
Dirt getting into bearings
Rusting of bearing due to water getting into housing
Excessive cooling of water cooled bearing resulting in condensation in the bearing
housing of moisture from the atmosphere

Khurram Majeed / Najam-us-saqib

49

CENTRIFUGAL PUMPS TROUBLESHOOTING


BEARINGS HAVE SHORT LIFE
Probable Causes
Misalignment
Shaft bent
Rotating part rubbing stationary part
Bearings worn
Shaft running off center
Rotor out of balance
Excessive thrust caused by a mechanical failure inside the pump
Excessive amount of grease or oil in the housing of an anti-friction bearing or lack of
cooling, causing excessive bearing temperature
Lack of lubrication
Improper installation of anti friction bearings (Damage during assembly)
Dirt getting into bearings
Rusting of bearing due to water getting into housing
Excessive cooling of water cooled bearing resulting in condensation in the bearing
housing of moisture from the atmosphere
Khurram Majeed / Najam-us-saqib

50

CENTRIFUGAL PUMPS TROUBLESHOOTING


PUMP OVERHEATS AND SEIZES
Probable Causes
Pump not primed
Insufficient margin between suction pressure and vapor pressure
Operation at very low capacity
Parallel operation of pumps unsuitable for such operation
Misalignment
Rotating part rubbing stationary part
Bearings worn
Shaft running off center
Rotor out of Balance
Excessive thrust caused by mechanical failure inside the pump

Khurram Majeed / Najam-us-saqib

51

PREVENTIVE MAINTENANCE CHECKS


Define Frequency & Check the following
Pump vibration (Horizontal, Vertical & Axial)
Pump Inboard & Outboard Bearing Temperatures
Gland Packing / Mechanical Seal Leakage (DPM)
Foundation Condition
Mechanical Looseness
Oil Level / Condition / Leakage
Abnormal Sound
V-Belts / Pulley condition
Cleanliness

Khurram Majeed / Najam-us-saqib

52

TYPICAL QUESTIONS & ANSWERS


1. What is the difference between Positive Displacement Pump and
Centrifugal Pump ?
2. What is the difference between Impeller, Propeller & Turbine Pump?
3. Will all the impellers installed in a multi stage pump produce similar flow /
pressure or not ?
4. A pump having 12 Dia Impeller operates at 250 psig. What can we do to
increase the pressure of this pump ?
5. What is the difference between single suction and double suction
centrifugal pump?
6. If four pumps are operating in parallel and producing 400 gpm & 100 psig
each. What will be the operating conditions in the common discharge header
?
7. What is the difference between Pusher and Non-pusher Mechanical Seal ?
8. What is the difference between Inside and outside seal ?
9. What is the difference between Balanced and Unbalanced Mechanical seal
?
10. What could be the effects of excessive Lubrication ?

Khurram Majeed / Najam-us-saqib

53

TYPICAL QUESTIONS & ANSWERS


11. What are the advantages and disadvantages of Vertical pumps ?
12. What are the causes of Pump having loss of flow or no flow problem ?
13. What could be the possible causes of high vibrations in pump ?
14. What is the difference between application of Ball Bearing and Roller
Bearing ?
15. What could be the possible causes of Bearing failures ?
16. What is the difference between application of Grease and oil ?
17. What is Brinelling and False Brinelling ?
18. What are the methods of Bearing mounting ?
19. What are the methods of Pump alignment and what could be the effects of
Misalignment ?
20. What is Soft Foot ?

Khurram Majeed / Najam-us-saqib

You might also like