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Pumps - Theory, Practice and Maintenance |
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M01 – Pumps - Theory, Practice and Maintenance Defining pumping systems
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Most important characteristics of a pumping system
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Types of pumps
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Positive Displacement family tree
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Basic difference between Centrifugal and PD pumps
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Rotary pumps
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Market applications and Selection of Pumps
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Applications of PD pumps
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General guidelines for pump selection
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Pump characteristics v/s market applications
- Application – High Viscosity, Low and variable viscosity
- Application – Low shear pumping, Solids handling capability
- Application – Multi-phase flow
- Process Condition – High pressure
- Process Condition – Low flow, Efficiency
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Process Condition- Combination of high pressure / low flow and efficiency
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Process Condition - Flow control
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Environmental system requirements
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Centrifugal Pump
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Basics
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Types (Construction based)
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Construction of an impeller
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Types of impellers
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Seal chamber and stuffing box
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Defining Suction Head
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Capacity, Input horsepower, output horsepower, Efficiency
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Pump Fundamentals
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Pressure
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Head v/s Pressure
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Effect of specific gravity on Head
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Kinetic energy
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Design of volutes and flow patterns
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Specific gravity and pump performance
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Effect of fluid velocity
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Gauge height correction
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What is TDH and TH
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Pump Performance parameters
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Head-Flow characteristics
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Power-Flow characteristics
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Pump Efficiency
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Efficiency v/s Flow
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Net Positive Suction Head (NPSH) and its Characteristics
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NPSH and Cavitation
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Cavitation process
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Cavitation damage
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Preferred operating range of a centrifugal pump
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Allowable operating range
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Pump characteristic curves
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Effect of RPM
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System curves
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System Head
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Energy requirements to lift the fluid
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Power required to lift the fluid
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Static Head
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Dynamic Head
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Sources of Friction
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Parameters influencing frictional losses
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Standard Pipe Head Loss Tables
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Calculating frictional losses
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Frictional loss coefficients
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Pipe lengths and associated Heads
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Types of System Curves
- System Curve – No control valve
- System Curve – With control valve
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Parallel pumps
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Parallel pumping system
- Parallel pumping system – Low friction
- Parallel pumping – Mismatched pumps
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Series pumping
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Pump vibration
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New generation pump example
- How pumps get damaged – 10 Ways
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Monitoring and Predicting Centrifugal Pump performance
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If the pump does not deliver enough water
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If the pump does not deliver enough pressure
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If the pump does not prime properly
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If the pump is drawing too much amperage
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Monitoring Wet end of the pump
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Monitoring Stuffing box and Seal area
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Monitoring Bearing case
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Predicting pump performance
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Preventive maintenance
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Preventing bearing and seal failures
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Good maintenance practices for seals and bearings
- Recommended daily preventive maintenance checks for centrifugal pumps and drives
- Recommended monthly and 6 monthly preventive maintenance checks for centrifugal pumps and drives
- Recommended yearly preventive maintenance checks for centrifugal pumps and drives
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Trouble shooting of centrifugal pumps
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The pump is hooked up to the piping and it is running
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The pump is still hooked up to the piping, but it is not running
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The pump has been taken into the workshop, but has not yet been disassembled and you will be present at the disassembly
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The pump has been disassembled. You were not present, but the parts are available for your inspection
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Troubleshooting four possibilities of rub or wear marks
- Centrifugal pumps – Troubleshooting guide
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Trouble shooting of Reciprocating Pumps
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Alignments Techniques
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What is coupling alignment?
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Types of coupling
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Co-linearity
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Types of Misalignment
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Offset, or Parallel
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Angular
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Measurement Conventions
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Pre-alignment Steps
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Alignment Tolerances
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Thermal Growth Targets
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Not correcting for soft foot
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Not roughing in
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Usage of shims
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Not controlling backlash or unwanted movement
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Incorrect sequence of moves
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4 steps of alignment
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Angular misalignment in the Vertical Plane
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Parallel Offset in the Vertical Plane
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Angular misalignment in the Horizontal Plane
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Parallel Offset in the Horizontal Plane
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Things to watch if alignment still does not happen
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A few helpful tips
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Housekeeping pads
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Inertia bases
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Base plate selection
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Foundation preparation
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Base plate installation
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Grouting
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Pump and Motor Installation
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Pipe Installation
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Pipe strain
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How to start a pump
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Pump rotation
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Motor Solo
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Couplings
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Other Startup Considerations
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Pump Start up
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Final Vibration Acceptance
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Checklist
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