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Pumpmaintenance

The document discusses maintenance philosophy and procedures for pumps. It describes the major components of a pump that require inspection, such as the impeller, mechanical seal, and relief valve. Failure reasons for components like mechanical seals and common maintenance tasks are outlined, including inspecting shaft alignment and wear ring clearances.

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Altamash Tamboli
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65 views35 pages

Pumpmaintenance

The document discusses maintenance philosophy and procedures for pumps. It describes the major components of a pump that require inspection, such as the impeller, mechanical seal, and relief valve. Failure reasons for components like mechanical seals and common maintenance tasks are outlined, including inspecting shaft alignment and wear ring clearances.

Uploaded by

Altamash Tamboli
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MAINTENANCE PHOILOSOPHY:

• Maintenance is done on to the machine in order to improve system


reliability. Maintenance may be :
• Preventive
Predictive (Conditional Monitoring)
Periodic
• Break down
• RCM
Inspection During Maintenance:

• Pump Impeller.
• Mechanical Seal.
• Gland Packing.
• Shaft Sleeve.
• Relieve Valve.
• Pump Element (PD).
PUMP MAJOR COMPONENTS:

• Shaft
• Impeller
• Wear Rings
• Stuffing Box
• Diffuser Casing
• Bearings
Mechanical Seal

 Seal may fail due to lack of


lubrication. Due to which
temperature rises at the sealing faces
that will damage the elastomer part
of the mechanical seal.
 Pump Vibration. Vibration imparts
forces on each part of the seal
components. Vibrations may be due
to worn bearings.
Pump Element Inspection
Gland Packing
Mechanical seal
High-temperature Graphite Braided Packings

General-service Braided Synthetic Packings

High-temperature/Pressure Steam Packing


Relief Valve

• During Pump Maintenance


relief valve is overhaul for
cleaning and inspection
purpose.

• Checking spring stiffness etc.


 Half-yearly Maintenance

 Shaft packing is checked by observing the leakage


from it

 Leakage from the stuffing box is excessive or the


packing is worn  entire packing in the box will
have to be replaced
CONTD…

 Overhauling of stuffing box All the old


packing rings are removed and interior of
stuffing box is cleaned thoroughly

 Shaft and shaft sleeve surface are properly


cleaned before inserting the packing rings
CONTD…

 If shaft sleeve is badly worn or scored, it is replaced

 Straightness of the shaft should be ensured

 Radial clearance between the shaft and the stuffing


box bore is measured

 Packing ring shouldn’t be inserted in a spiral form


CONTD…

 Packing rings are fitted carefully:

o Open them radially until the ends are wide apart as


1/2 the shaft dia.  the ends are turned apart in an
axial direction slide the rings over the shaft 
each ring is pushed in to the stuffing box, inserting
the joint first

o The joints of succeeding packing rings should be


staggered
CONTD…
 Assemble the gland ring and tighten the nuts by
hands or using a spanner

 When the pump is in operation, the nuts are


again adjusted to achieve the desired leakage
from the stuffing box

 If decrease in discharge is found, the pump is


opened and cleaned
2.OVERHAULING OF PUMPS

 Most overhaul work of CF pumps is concerned


with the rotating parts

 Overhauled annually or once in 2 years

 In many situations, the operating conditions don't


permit annual shutdown periods for overhaul
CONTD…

 Situations call for a shutdown of the pumping


plant for trouble shooting, repair and possible
overhaul:

 Fall-off in pump performance

 Excessive noise during pump operation

 Excessive vibration of pump

 Symptoms of corrosion or erosion trouble


Overhauling of impellers

o The eye, vanes, shrouds, wearing rings, passages


and hubs are checked

o Corrosion, cavitation and erosion are accompanied


by the wearing of the impeller vane surfaces

o Corrosion is due to warp or holes in the thinned


surfaces

o Impeller have to be replaced, if cavitation is severe

o Impeller have to be thoroughly cleaned before


inspection
c) Balancing of impeller

o Badly worn or corroded impeller needs


rebalancement

o Balancing of an impeller can be checked by


pressing it on an arbor, the ends of which rest on
2 parallel and level knife-edges, by hand

o If found unbalanced, the metal is removed from


the heavy side
d) Repair of shaft

o Shaft is checked for bending with a dial gauge, by


turning the shaft between lathe centres

o If shaft is badly bent, it should be returned to the


manufacturer

o Reconditioning of the shaft will require welding or


metalling, followed by rough finishing cuts

o Final finishing is done by filing


e) Replacing of wearing rings

o Proper clearance of the wearing ring is important

o Increase in clearance results in leakage which


decreases efficiency

o If wearing rings are worn out, they have to be


replaced
f) Repair of shaft sleeves

o Shaft sleeves often get worn out when packed too


tightly

o Reconditioned by welding or metalizing, followed


by a rough finishing cut

o If wear is excessive, shaft sleeves have to be


replaced
Repair of stationary Components

o Repair is negligible

o Bed plate is kept clean of grease and oil at regular


intervals

o Joints and piping are checked regularly for leakage

o Foundations are kept clean

o Cracks in foundations are repaired in time

o Surface of casing is painted


Shaft Run Out
• Runout checks are made to determine out of roundness conditions (eccentricity)
in a shaft. Whether shaft is concentric or not ?
• Runout occurs due to:
a) Machining Process
b) Dents from handling.
c) Rust patches.
d) Rotor bow / sag due to thermal effects, gravity, or other influences/loads.
e) Defective or worn bearings in the machine or lathe supports
Cont’d
• Moderate to excessive run out will create moderate to excessive
vibration within a pump
(may cause rubbing).
• Firstly shaft itself is checked and then
along with its attached components
(wear ring , impeller etc.)
• Dial Indicator is attached on axially
given points. Variation in readings
indicates:
Balancing & Float Check

• Balancing of a rotor is carried out to eliminate the vibration.

• Balancing correction weights may eliminate the dynamic forces but


they will not resolve the eccentricity issue.

• Correction weights may added or material may remove for the


balancing.
• FLOAT
Cont’d

BACK
Wear Ring Clearances:
• Wear ring provides close clearances to minimize leakage from the discharge to
the suction of the impeller.
• As the wear ring wears with use , leakage will gradually increases , effecting the
pump efficiency.
• The gap is destroyed if there is
misalignment or shaft deflection.
• Clearances is taken through the Feeler
Gauge.
• Material : SS or Bronze
BEARING

• Providing Support to a shaft for smooth Running.


• Lubrication prevents metal-metal contact.
• Thrust Bearings are used to
compensate/bear axial load.

Bearing inspection is very important during


Pump maintenance.
Causes of Bearing Failure:
Flaking , Spalling , Rust & Corrosion, wear ,
Babbit metal remove , loss of lubrication etc.
Shaft Alignment
Shaft Alignment
• Shaft alignment is the process to align two or more shafts with each other to
within a tolerated margin. It is an absolute requirement for machinery before the
machinery is put in service. Therefore pump and motor shafts are aligned before
they put into service.
• Misalignment between the pump and drive can result in premature bearing
failure or other damage.
Cont’d
a) No liquid delivered

o Lack of prime

o Speed of electric motor or engine too low

o Discharge head too high

o Suction lift too high

o Impeller plugged

o Vapor lock in suction line


b) Not enough water delivered

o Air leaks

o Worn wearing rings

o Damaged impeller

o Defective foot valve

o Worn gaskets

o Impeller eye too small

c) Pump losses prime after starting


d) Overloading of Motor / Engine
o Low discharge head
o Packing too tight
o Bent shaft
o Distorted casing
o Pump speed too high
e) Overheating of stuffing box
f) Excessive vibrations
g) Overheating of bearings
h) Rapid wear of bearings

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