Oil and Gas Plant Procedure &

Question and Answers

Prepared By
Khawar Shahzad Khan
Pump Supervisor
Dated: - 12-05-14 to 01-06-14

Page 1 of 35
 Contents
Sr. No Subject Page No

1- Introduction/Procedure 03

2- Safety Meeting Points 04

3- Centrifugal Pumps 07

4- Bearings 17

5- Seals 21

6- Coupling 26

7- Troubling Shooting 27

8- Alignment 29

9- Maintenance 31

10- Positive Displacement Pumps 32

11- Permit 34

12- Valves, Flanges etc… 35

Page 2 of 35
 Introduction/Procedure

Page 3 of 35
 Safety Meeting points
Total No’s of Module of HSE meeting = 13

What is MSDS?

1- Material Safety Data Sheet

A- In Confined space 20.9% Qty of Oxygen must be there not minimum of this amount and not
Max. Of this Qty If its Minimum you are not able to take breath and if max. than you can’t
breathe proper
B- After Height of 1.8 Mtr it considers Work at Height.
C- No camera and No cell phone allowed in the plant only recommended phone allowed.

What is Ergonomic?

Continuous working one place or continuous concentrate on one place

If some emergency occur in the field what you will do:-

1- Call to MCR (33733) if calling from phone (02-6033733)

2- Call to Fire station (33622) if calling from phone (02-6033622)
3- Tell your name and company name
4- What is Incident Occur
5- Specify the Location
6- Specify the assistance such as Ambulance

If you are going to work in area you have to check the Assembly Point First.

Types of Alarms, colors and ringing timing:-

1- Fire Alarm ------- Red ------------- Ring for 02 Minutes

2- Hydrocarbon Gas Alarm -------------- Blue ---------------- Ring for 02 Minutes
3- H2S Gas Alarm ------------------------ Yellow --------------------- Continuous Ringing
4- All Clear alarm ------------------------- Just for 30 Sec

If H2S Gas Leak what you will do?

1- Don’t be Panic
2- Shutdown your Tools and Tackles and Wear the escape Mask
3- See the Windsock to check the Wind direction if you are not able to see the Windsock than you
can take small Qty of sand in your hand and slowly drop sand from your hand than you can see
the wind direction.
4- After identifying the wind direction you have to go to the cross direction of the air at H2S Leakage
90 Degree. (See Figure)
5- Go to the nearest Assembly Point Air
You

Page 4 of 35
What is H2S (Hydrogen Sulfide) Gas?

H2S is a Taxis Gas or a killer Gas. It has No Color (Invisible) and it smells like Rotten Eggs at
1PPM. It is formed under low oxygen conditions when sufficient amount of sulfur and bacteria are
present. (Known as: - Silent Killer, Sour Gas, Rotten egg gas, Swamp Gas)

1PPM = 1 part per million

Where H2S Formed?

H2S can be formed in many places such as:-

1- Oil and gas reservoirs

2- Sewers and sewage processing facilities
3- Dark and Damp places where bacteria is present

FeS + 2HCL ----------------- FeCL2 + H2S

What is Hydrocarbon?

Hydrocarbon gas is Flammable gas.

What are the PPE’s required in the Job:-

1- Safety Helmet with ear Muff

2- Safety Goggles
3- Safety Shoes
4- H2S Gas Detected Monitor
5- Escape mask
6- Hand gloves
7- Coverall

What is RWC?

Restricted Work condition

What is EUV’s?

Electrical Utility Vehicles

Blue = Maintenance

Yellow = Operation

Red = Safety

What are LEL and UEL?

LEL = Low Explosive Limit

UEL = Upper Explosive Limit

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H2S Locations:-

1- Wellheads 2- Piping System, Pipelines 3- Tanks 4- Pits, Sewers etc….

From Flanges, Valves, Instruments and equipment failure its gets leaked…..

Specific Gravity of H2S:-

H2S is Heavier than air

H2S = 1.189 and Air = 1

(Auto Ignition Temp. table below)

H2S (Hydrogen Sulfide) 260 Co

Ethane 515 Co
Methane 580 Co
Butane 420 Co
Propane 480 Co

Concentration in PPM to Percentage% - (10,000 PPM = 1 % in air)

1- Don’t attempt to rescue anyone unless you have been trained in H 2S training of proper PPE’s
2- When you are working in confined space you have to use the buddy system
3- H2S have no smell at high concentration
4- At 10PPM Possible eye Irritation
5- Speed limit in plant 30km/hr. and outside plant security area 60km/hr.
6- Always done reverse parking and keep all the gates unlock and when you are in plant area also
left the key with vehicle in case of emergency any one can use that vehicle.

What is EEBD?

Emergency Escape Breathing Device with Full Face it is a small air cylinder (Normal
Compressed Air) and it will be useful for 10 to 15 minutes.

Shortcuts Defined the Equipment’s and Gases in the Plant:-

Shortcut Equipment Shortcut Gases

K Compressors C2 Ethane
G Pumps C3 Propane
C Columns C4 Butane
V Valves C5 Pentane
F Furnace
C5+ Pentane + Other Gases
E Exchanger

Page 6 of 35
 Centrifugal Pumps
1- Pump is a machine which transfers the liquid from one place to another place & it also adds
energy to the liquid.
2- Pump is a device which is used to convert Mechanical energy to hydraulic energy.
Pumps are commonly rated by Horse power, Flow rate, Outlet pressure in Meter, feet of Head.

Types of Pumps:-

1- Dynamic Pumps
2- Positive Displacement pumps

Dynamic Pumps

1- Centrifugal Pumps:-

A pump is working under the principle of Centrifugal force is called Centrifugal Pumps.

Types of Centrifugal Pumps:-

1- Stage Wise
i) Single Stage (90°) ii) Multistage Pumps (90°)
2- Flow Wise
i) Radial Flow ii) Axial Flow iii) Mixed Flow
3- Casing Wise
i) Volute Casing ii) Vertex Casing
4- Head Wise
i) Low Head (10-15 Mtr) ii) Medium Head(15-25 Mtr) iii)High Head (above 25Mtr)
5- Impeller Wise
i) Open ii) Semi Open iii) Closed
6- Design Direction
i) Vertical ii) Horizontal
7- Suction Wise
i) Single Suction ii) Double Suction
8- Specific Speed
i) Low ii) Medium iii) High
9- Propeller Pumps (180°)
10- Turbine Pumps (45°)

Types of Single Stage Pumps:-

1- Overhung Pumps
2- Between Bearing Pumps

Single stage Pumps:-

A pump with single Impeller is called single stage pump.

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Overhung Pumps:-

A pump which one end supported with Impeller and other is supported with bearings is called
Overhung Pumps.

Between Bearing Pumps:-

Impeller mounted on the center of the shaft and both end supported with the bearings is called
b/w bearing pump or both end supported pump.

Multistage Pumps:-

A pump has two or more Impellers installed on the shaft in series is called multistage pump and
it’s used for higher Discharge head.

Main Parts of Centrifugal Pumps:-

It depends on the specific pump

1- Casing I ) Volute II) Concentric

2- Impeller I ) Open II) Semi Open III) Closed
3- Shaft
4- Shaft Sleeve
5- Bearings with lock nut and washer
6- Mechanical Seal I) single II) Double III) Tandem
7- Impeller and casing wear rings
8- Bearing Housing
9- Stuffing Box
10- Diffuser
11- Keys
12- Coupling
13- Suction Nozzle
14- Discharge nozzle
15- Spiders
16- Rubber Bushes / Cutlass Bearings
17- (Gland Packing) if mechanical seal is not in the pump
18- (Lantern Ring)
19- (Gland Housing) etc……..

What is Diffuser?

It is the casing like stationary component used in centrifugal pumps. It converts velocity head into
pressure and also guides the liquid to the eye of the next stage Impeller.

What is Suction Head?

At what level the fluid is flowing to the suction of the pump is called suction head. See Figure

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What is Discharge Head?

Maximum height where a pump can deliver is called Discharge head.

What is Suction Lift?

If the pump is located above the suction tank the liquid must be lifted up to
the pump. The distance the liquid to be lifted up to the pump is called suction lift.

What is total Head?

Total head = Discharge head – Suction Head (Or) Discharge Head + Suction Lift

Minimum & Maximum Clearance of the pump wears rings.

Depend upon the Medium of the pump and the manufacture data sheet

For example: - Cold Medium = under 0.5mm Hot medium = 1mm

How the Vibration Occurs in the Pump?

There are many reasons for vibration but maximum Due to Failure of Bearings.

How to check the Vibration of the pump?

We will check the vibration with vibration meter from 2 to 3 places of the pump and note the
readings.

In plant there is one reliability department for the checking of these types of problems we called them to
check the vibration and note the readings
NPSH
What is NPSH (Net Positive Suction Head)?

Distance between Suction Reservoir to the center of the shaft. Or

Minimum head is required to pump the liquid through impeller eye .

What is Cavitation (Water Bubbles)?

Cavitation is the boiling of a Liquid caused by decreasing Pressure rather than Increasing
Temperature. Cavitation occurs when the Pump Suction Pressure drops or when the temperature of liquid
rises causing some liquid to vaporized and form Bubbles. An Abnormal Sound Produce and vibration
Increases. Or due to low pressure in the pipe
Cavitation
How to protect from Cavitation?

Maintain the NPSH and coating inside the pump, Vertex

breakers/Cavitation Plates on Suction Flange.

1- Interference between Shaft and Bearing Bore/ID in 0.01 to 0.03mm

What are Transition, Interference and Clearance Fits:-

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 1- If the 1st object Dia and 2nd bore/ID is also the same that’s called Transition Fit.
2- If the 1st object Dia Bigger than 2nd Object bore/ID is called Interference Fit.
3- If the 1st object Dia Less than 2nd Object bore/ID is called Clearance Fit.

What is priming?

Before starting the pump we have done this procedure to avoid the cavitation this procedure we
have done to open the drain or vent valve to release/drain the air, oil, water what else in the pump is
called priming. Or Priming of any pump is the same - it means filling the pump with liquid to get it to
pump because the pump will not fill itself with liquid from being dry (it won't self-prime).

What are different types of vanes used in centrifugal pump?

There are three major types vanes are used for centrifugal pumps those are

1- Forward curved vanes 2- Backward Curved Vanes

2- Flat vanes

What is the difference between a P.D pump and centrifugal pump?

Centrifugal Pump P.D Pump

Main part Impeller Main Part Plunger/Piston
High Flow Low Flow
Low Pressure High Pressure
For Normal Medium For High Viscosity Medium
Continuous Discharge Pulsating Discharge

Why the centrifugal pump is called high discharge pump?

For a simple reason because it has high discharge than any other available pump The centrifugal
pump uses the centrifugal force to push out the fluid

Centrifugal force = (mass *velocity2)/radius.

How do you check the misalignment in centrifugal pump?

1- First check vibration reading.

2- If A side reading high means axil play of shaft run out.
3- if V and H side reading more min. bearing failure or impeller out
4- After that stop the pump and check coupling spider first.
5- Check the shaft run out
6- Check foundation bolts.
7- Check the bearings

How do you open centrifugal pump?

1- It’s having high speed electrical motor. With joint of centrifugal casing.

Page 10 of 35
 2- So first of all open this centrifugal casing by spanners.
3- then do disassembly

How NPSH of a centrifugal pump is increased?

If you are pumping from a tank you have to lower the pump in relation to the height of the water
in the tank. The more feet of water above the center of the pump, the greater your net positive suction
head. If that is not possible you have to have a pump to increase the pressure of the water coming into the
eye of the pump impeller.

How do you increase efficiency of the centrifugal pumps?

By making it vanes variable direction so that it can work from both sides

What is the difference between volute centrifugal pump and turbine centrifugal pump?

Volute converts the pressure into velocity and the mixture of propeller and impeller is called
Turbine pump.

What is the use of centrifugal pump in the ship?

To pump out liquid or gas in higher quantity

How do you specify centrifugal pump?

There are two main parameters. Pressure and flow you request them for a single point or more.

What is eddies in volute casing of a centrifugal pump?

In Volute Casing, area of flow increases gradually, Due to this, the amount of movement of water
opposite to the general flow of water is more This movement of water against the actual flow of water is
called EDDIES in Volutes casing of Centrifugal pump. Where as in Vortex casing area of flow is uniform
and effect of formation of eddies is very less.

Why velocity diagram are required for centrifugal pumps?

Velocity diagram indicate the effect of vane angle, effect of jet angle on impeller speed

Where does the liquid move the fastest in a centrifugal pump?

At the impeller tips where the linear velocity is highest as it farthest from the shaft center. In case
of multiple impeller pumps it is at the tip of the last impeller.

Difference between centrifugal compressor and centrifugal pump:-

Pump is used for pumping the liquid and compressor is used for compressing the air.

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What will happen if you stop centrifugal pump delivery valve in running condition?

If delivery of centrifugal pump is stopped and pump is running then suction will be stopped and
no flow will take place therefore fluid inside the pump will be heated up and motor will be overloaded
and finally will be short circuited.

What are characteristics of centrifugal pump?

Centrifugal pump is that machine which converts the mechanical energy into pressure energy .

1- It produces the pressure energy by applying the centrifugal force.

2- Flow in it is radial outward direction.
3- the pressure head at the outlet is more than the at inlet, so fluid can be lifted to very high .level in
case of centrifugal pump,
4- Discharge is proportional to speed in R.P.M)
power is proportional to (speed in R.P.M)
head is proportional to (speed in R.P.M)
5- It is subjected to cavitation.

How can you overhaul centrifugal pump?

The following steps describe the entire process in a chronological order

1- Switch off supply from the control room and isolate breaker with masking tape and place a safety
board
2- Close suction and discharge valves and lash them with rope.
3- Drain the suction pipe and ensure water is not coming, then loosen or crack open the joints and
ensure that pump is safe for opening
4- Fix chain block and ensure its cable length and strength is satisfactory.
5- Mark on coupling and casings and then remove the coupling bolts.
6- Manufacturers And Suppliers of Industrial Pumps Call
7- .Now motor input supply wire can be marked and disconnected as per drawing .
8- Motor can be lifted by chain block.
9- Disconnect all external fittings and pump casing e.g. cooling pipe, pressure gauge, purging cock .
10- Remove top cover and jack it for removal.
11- Now the pump shaft with impeller can be lifted.
12- Dismantle the impeller, liner and remove the wear ring.
13- Remove the gland packing.

Which pump is more efficient Centrifugal pump or reciprocating pump?

Positive displacement pumps will always be more efficient than centrifugal pumps due to a
centrifugal inherent internal fluid slip recirculation and losses .

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Why we use the Key in Impeller or Coupling etc….?

We use the key to lock the part and also transmit the power to the part to work.

What is RTD & BEP?

RTD = Resistance Temperature Dedicator

BEP = Best Efficiency Point

Inspection Procedure:-

1- Impeller, pump shaft and casing to be inspected for erosion, pitting and wear down etc.
2- If required rectify defects with brass putty.
3- Excess worn out parts can be replaced with new ones.
4- Check wear down ring clearance, general practice is to replace with new ring.
5- Check shaft trueness, remove sleeve from the shaft replace sleeve with 'o' ring if required.
6- Check key, key slots, nuts and its threads are ok.
7- Assemble all the pump parts

Procedure to Start the Pump:-

1- Open inlet and out let valves.

2- Purge air and prime the suction line.
3- Turn the shaft coupling and ensure shaft is free to rotate.
4- Connect motor wire R, Y, B.
5- Start and check current drawn by the motor while staring and running.

What is use of centrifugal pump?

Generally, centrifugal pumps are high discharge, low pressure generating pumps .

What is the maximum height a centrifugal pump can pump water?

The maximum height a pump can pump water depends on size of pipe/water column, friction,
power available etc. This is often referred to as the head of the pump.

How to check the efficiency of the Pump?

When we talk about automobiles and discuss efficiency, we mean how many miles per gallon, or
liters per 100 kilometers. When we discuss centrifugal pumps we are comparing the amount of work or
power we get out of the pump to the amount of power we are putting into the pump. As an example:

10 H.P out of pump / 15 H.P into the pump = 0.666 or 66.6% efficiency

Describe four forces in a pump that are counteracted by bearings.

1. Gravity acting on the shaft and impeller.
2. Centrifugal force caused by an imbalance in the rotating element.

Page 13 of 35
 3. Force developed by pressure differences on each side of the impeller or rotor.
4. Force on the shaft if the pump is belt or gear-driven.
How we control the capacity of centrifugal and P.D pumps?

Through the recycle valve we can control the capacity of pumps.

What is impeller back clearance?

The clearance between the backsides of the impeller (shroud) and the stuffing box or crown
(wear) plate Actually this clearance standardize the stuffing box pressure and should be strictly
followed in case of depressurizing vanes on impeller and semi open impellers.

How do you check impeller back clearance?

By the use of feeler gauge and with dial indicator as possible

What is impeller front clearance?

The clearance between the front side of the impeller (crown) and the casing or wear plate.

How do you check impeller front clearance?

By the use of feeler gauge and with dial indicator as possible

What is adaptor sleeve & withdrawal sleeve?

These sleeves used to fix and remove bearings easily on that and to be fixed any accessible place
on the rotor. In adaptor sleeve, bearing is fastened while the adaptor sleeve nut tightened. In withdrawal
sleeve nut is used to withdraw bearing from its position from the withdrawal sleeve

What is rotor free float?

It defines the total axial movement of rotor without thrust bearing.

Explain rotor centering?

It is the process of keeping rotor half of the free-float through the position of thrust bearing in the
bearing housing fixation.

What do you mean by wear rings?

Wear rings are removable rings fixed on either impeller eye and casing or both of them.

What is the purpose of wear rings?

To avoid the change of impeller and casing due to pitting corrosion Or Wear rings can be used to
seal the pressure leakage of the liquid between the inlet of the impeller and the pump casing.

How do you check wear ring clearance?

Clearance = Casing wear ring ID – Impeller Wear ring OD

What the different types of shaft sleeve?

Threaded sleeve, sleeve with locknut, sleeve with Allen lock, straight sleeve, stepped sleeve,
throttle sleeve, throat sleeve etc.

What is the applicable API standard for centrifugal pumps? = API 610

Page 14 of 35
What is torque wrench?
It’s a mechanical tool used for tightening the bolts of equipment’s with proper torques by the help
of the torque indicator attached with it.

What is rotor run out?

Rotor run out defines the accuracy of trueness of the rotor. This should not exceed more than
0.002 inches.

What is the maximum run out value acceptable? = 0.05mm

How do you check rotor run out/TIR (total indicator reading)?

After keeping the rotor/shaft on the V-Blocks, with the use of dial indicator

Few pump manufactures internationally?

1. Flowserve
2. Ebara
3. KSB
4. ITT Gould’s
5. Sulzer
6. Weir
7. Worthington
8. Kirloskar
9. Kubota
10. Hitachi etc.

Name few measuring instruments?

1. Vernier caliper
2. Dial gauge
3. Micrometer (Inside & outside)
4. Bore dial gauge
5. Feeler gauge etc.

What is the least count of dial gauge, Vernier Caliper and Micrometer?
0.01 mm, 0.02 mm & 0.01 mm

What is the purpose of balance drum?

Used to take 90% of thrust load by liquid and the residual thrust is supported by the thrust bearing

Where is balance drum located in a rotor?

The balancing drum is located, behind the last stage of impeller.

What is oil thrower ring?

The ring provided on the shaft in bearing housing to make efficient lubrication.

What are the various ways of impeller fixing arrangements?

Threaded, Sliding fit with key and lock nut, Snug fit with sleeve lock nut.

Few common problems occurring in pumps?

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 1. No delivery
2. Over loading
3. Vibration
4. Bearing temperature rise
5. Mechanical seal leaking
6. Pump over heating
7. Pump Jamming
Differentiate centrifugal pump and reciprocating pump?

Centrifugal Pump Reciprocating Pump

Working in the principle of centrifugal force Working in the principle of reciprocating compression

The main part is impeller The main part is piston/ plunger

In the application of high capacity In the application of high pressure
Constant pressure with variable capacity constant capacity with variable pressure
High efficiency Low efficiency

Bearings
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Bearing is a mechanical device which used to minimize the friction between rotary and stationary parts by
holding and guiding the shaft/rotor.

Types of bearings:-

1- Friction Bearings
2- Anti-Friction Bearings

Friction Bearings:-

Friction bearing is working under the principle of Sliding motion.

Types of Friction bearings: - (Control Sliding Motion)

1- Journal bearing
2- Sleeve bearing
3- Bush Bearing (rubber, Cutlass)
4- Tilting Pad Bearing
5- Babbitt Bearing

Anti-Friction Bearings:-

Anti-Frictional bearings working under the principle of Rotary motion

Types of Anti-Friction bearings:- (Control Rotary Motion)

1- Ball Bearings
i) Angular contact ball bearing ii) Deep Grove ball bearing iii) Single row
Iv- Double row v) Cylindrical
2- Roller bearing
i) Straight Roller ii) Taper Roller iii) Spherical Roller
3- Needle bearing

Thrust Bearing:-

Thrust bearings control axial and radial both float

Types of Thrust bearings:-

1- Kings burn / Thrust pads

2- Two angular contact ball bearings (Face to face) (Back to back)
3- Two Deep Grove ball Bearings (Face to face) (Back to back)
4- Two taper roller bearings (Face to face) (Back to back) (Use for heavy equipment)
5- Two Spherical Roller bearings (Face to face) (Back to back)

What is Axial Float?

Axial Float is a horizontal movement of the shaft front and back.

How we control the axial float?

Page 17 of 35
 Using the Anti-Frictional bearings and also thrust bearings (If float still not control than use shim
in the end of the bearings)

What is Radial Float?

Radial Float is a Vertical Movement of the shaft Up and Down.

How we control the Radial float?

Using the Frictional bearings and also thrust bearings (If float still not control than use shim in
the end of the bearings)

Procedure to change the new journal bearings:-

If you are going to change the journal bearing we have to put the blue-match on the shaft and
fully tight the bearings after that again open the journal bearings and you can check its matching or not.

Explain how to measure the Journal Bearing Clearance:-

There are four Methods to measure the Journal bearing clearance

1- Dimension Method 2- Dial/Lifting Method 3- Plastic Gauge Method 4- Mandrel

Dimension Method Balance clearance = Shaft OD – Bearing ID

How do you polish journal bearing?

With the use of special polish oil and 4/0 fine emery sheet or sponge pad. A special tool named as
bearing scrapper used to clear deep able scratches.

What is Run-out?

Shaft is Eccentricity (Dia of the shaft will not change but the axis will change)

What is float bearing?

Bearing fixed with allowable clearance for thermal Expansion.

Where is float bearing located?

1- In back pullout pumps, fans – outboard
2- Double suction single discharge pump – inboard
3- Mixers (agitators) – bottom bearing

What is fixed bearing?

The bearing fixed without any allowable axial clearance to permit thermal expansion.

Where is fixed bearing located?

1- In back pullout pumps, fans – inboard
2- Double suction single discharge pump – outboard
3- Mixers (agitators) – top bearing

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What is Active and In-active side of bearings?

Bearing face/collar is touching the bearing housing is called Active side and other side of bearing
is called In-active side.

How we remove the bearing?

1st we have to heat the bearing with heating torch and then pull the bearings with puller (two leg
puller, three leg, Plate type, Hydraulic Pullers).

Why we use the bearing in bearing housing at one side single and other side is double in overhung
pump?

With the motor coupling side we use double that’s why to control the trek of startup and other
side one bearing for normal use for float control. See Figure

What is the meaning of code number which is given on bearing?

Say, bearing number is 6205z:

(6) stands for the type of bearing i.e. deep groove ball bearing
(2) stand for the OD and width (thickness) of the bearing
(05) stands for the ID of the bearing i.e., 05 x 4= 20 mm bore
(Z) Stands for metallic shield if 2Z means both side shielded
(C1, 2, 3, 4) stands for the internal clearance of the bearing
1- 00 - 10 mm bore 2- 01- 12 mm bore 3- 02- 15 mm bore 4- 03- 17 mm bore
from 04 - 04 x 5= 20 mm bore 6- 05- 05 x 5= 25 mm bore
(6) Stand for Deep Grove ball bearing (7) Angular Contact ball bearing

(2) Spherical roller

What is Difference between Roller bearing and Fluid Film/Journal Bearings?

Roller Bearing Fluid Film/Journal

Roller Sliding Surface
Low Load Heavy Load
High RPM Low RPM
Low Thrust High Thrust

How much about the Max limits of clearance for bearings?

Depends upon the shaft Dia If Dia is 50mm clearance is 0.05 and Inches 1” = 0.001”

Bearing Arrangements (Pairs) Diagram:-

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Why bearing back-to-back arrangement is provided?

The back-to-back arrangement can support combined axial and radial loads and will keep the
pump shaft end movement within acceptable limits. A bearing pair will support an axial load equally in
either axial direction. It should preferably have a slight clearance (0 to 0.002 inches) with the bearing
housing end cover.

Seals
Seal is a barrier to which prevent the leakage from high pressure to low pressure

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Types of Seals:-

1- Static Seals
2- Dynamic Seals

Types of static seals:-

1- Gaskets
i) Spiral wound ii) Asbestos iii) Rubber iv) Ring Joint
2- O-Rings
3- Teflon Rings
4- Gland Packing etc…….

Dynamic Seals:-

A seal which has motion is called Dynamic seals.

Types of Dynamic Seals:-

1- Mechanical seal
2- Lip Oil Seal (Brass, Banon, whiton) (near bearings) (to avoid the leakage along the shaft)
3- Dry Gas Seal (In compressors)
4- Honeycomb Seal Inter stage (In compressors)
5- Carbon Seal
6- Labyrinth Seal Aluminum, Brass, Copper ( In Compressors)

Types of Mechanical Seals:-

1- Cartridge seals (in assembled condition)

2- Non-Cartridge seals (Non-assembled condition)

Types of Non-Cartridge seals:-

1- Single Seal
2- Double Seal
i) Face to face ii) Back to Back
3- Tandem Seal
1- We use booster method for Mechanical seal Lubrication at as per design pressure.

Main Parts of Mechanical Seals:-

1- Retainer
2- Seal Gland
3- Seal Sleeve

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 4- Springs
5- Stationary Face
6- Rotary Face
7- Wedge
8- O-Rings
9- Anti-rotational pin
10- Thrust Plate
11- Teflon/Packing Rings
12- Locking Ring

Diagram of Mechanical Seal:-

12
6 8
10
4

∞∞∞∞∞∞ `
1 2

7 5
Types of Carbon Seal:-

1- Tangential Cut
Usually use to Arrest the leakage and used in Turbine
2- Radial Cut
Use to Decrease the pressure

Types of Labyrinth Seal:-

1- Ordinary
Low Pressure and Low Velocity
2- Interlocking
High Pressure and high Velocity

If Mechanical Seal gets leakage at running pump what we will do:- (Change the seal )

1- Shutdown the pump

2- Flushing the mechanical seal by using methanol or WD-40 (Cleaning liquid)
3- Check the seal coolant line

Page 22 of 35
 4- Increase the seal compression
5- After this we pressurize the pump and check the leakage

(If the leakage still there we have to change (or) service the Seal) (This is procedure to service the seal)

Procedure to change the Mechanical Seal of the pump in Running Plant

1- Get the Permit for Spading and Purging the Lines

2- Permits required
i) Work Permit (white)
ii) Hot permit (Red) 2nd category (for lifting, hammering etc…)
iii) H2S Gas test Permit (Yellow)
iv) Electrical Isolated Permit (Orange)
v) Valve Isolated Permit (Orange)
3- Purge the Suction & Discharge Line with Nitrogen (N2)
4- Spading the Lines throw the valves (for Spading we use the Spectacle blind Flange=one end open
and one end blind)
5- Suction, Discharge, Drain, vent…. Disconnect all the lines from the pump
6- Remove the coupling spacer mounted between pump & motor coupling
7- We have to check the DBTC (Distance between two coupling hub)
8- Check the Radial and Axial Float and Note it.
9- Remove the coupling hub
10- Remove the bearing housing with bearing from both sides one by one with measurements
11- Remove the Mechanical seals D.E and N.D.E sides one by one
12- Service the mechanical seal
i) Dismantle the Mechanical seal
ii) If some parts damaged change those parts
iii) Issue the parts from ware house
iv) Assemble the Mechanical seal all the parts one by one with same procedure as dismantle
v) Test and Check the Mechanical seal with hydro testing
vi) If Mechanical seal is ok go and assembled at its position
13- Before assembling the seal with pump we have to centralized the shaft with checking the float
axial and radial both
14- Always Put/Fix the tags with the Isolated Items.

How to centralize the Shaft:-

Before assembling all the parts of pump we have to centralize the shaft with dial gauge.

Put the dial magnet base on the motor hub and dial gauge needle in the face of shaft and move the
shaft front and back and what else reading is there divided by 2 and centralized the shaft

Which Mechanical Seal is more effective:-

Tandem Mechanical seal is more effective than other seals.

Sealant points in Mechanical seal:-

Page 23 of 35
 At 5 points seal arrest the liquids.

1- Sleeve O-ring
2- Stationary Face O-ring / Gasket
3- Rotary Face O-ring / Gasket
4- Face to Face of Seal
5- Flange / Gland Gasket

- In Low RPM Stationary face and Rotary face work Same

- In High RPM Stationary Face become Rotary and Rotary Face Become Stationary

What is the Reason mechanical Seal Leakage:-

1- Due to sealant parts got damaged like O-rings, Teflon rings, Gaskets etc…….
2- Not proper cooling and compression

What is seal setting Compression of Mechanical seal?

The seal setting compression given by the retainer in to matting faces as per designed by the suppliers.

What is the Balancing Seal?

Balance seal is that to maintain all the parts on centerline it means all the parts centerline will be same.

What is the difference b/w Rubber O-ring and whiton O-ring?

Rubber O-Ring = Low Pressure, Small Life

Whiton O-ring = High Pressure, Long Life, Heat Resistance

What is Quenching?

API Plan No – 62 - quenching to seal before starting pump bring the seal temp. To the pump Liquid
Temp

How to Repair/Service the Mechanical Seal?

To change the faces and O-rings of mechanical seal

Seal Faces Material:-

1- Silicon Caribe 2- Tungsten Carbide 3- Graphite 4- Carbon Face 5- Teflon

What is Barrier Fluid?

We are using this fluid in between mechanical seal faces its pressure is higher than the Vapor
pressure its control the damaging of seal faces and also helps to prevent the leakage.

Name few seal manufactures?

John crane, Flowserve, Bergmann, Pacific, Borg Warner, Dresser rand, Dura metallic

Page 24 of 35
What are the usual problems faced with mechanical seals?

1- Sleeve fretting corrosion 2- Retainer springs struck 3- Seat or mating ring crack
3- Lack of reliable of secondary packing 5- Excessive wear of mating faces, etc.

Explain the complete dismantling and assembly procedure for a mechanical seal?

1. Remove the gland from stuffing box to access mechanical seal with care after checking
the seal setting compression.
2. Take out sleeve with retainer set and check any vision able effects like carbon crack,
struck, wear on facing area both carbon and seat
3. Remove the seat from gland and justify the condition of secondary packing of seat.
4. Remove retainer set by losing Allen screws before make conform the retainer houses on
the shoulder of sleeve otherwise take measurement of retainer position.
5. Full view of inspection to be done on each and every mechanical seal parts like springs,
thrust plate, drive lugs, snap ring, seat seating area on gland, sleeve surface due to fretting
corrosion, seal matting face of both seat and seal ring.
6. Changing new parts is better than reconditioning (lapping)
7. Assembling is the reverse procedure of dismantling on time the following aspects should
be check:
8. Square ness and rectangularity of seat after fixation on the gland plate
9. Trueness of the shaft and sleeve
10. Correct fit of wedge packing/ “O” ring with backup ring on the sleeve.
11. The recess confined with gland plate and stuffing box.
12. Seal setting compression as per drawings or as same before.

What are API Plans used in Mechanical Seal?

API plan used for the coolant for Mechanical seals Max = API-51(for single seal) 52, 53A, B, C
& 54 (for double seal)

API – 51 =

API – 52 =

API – 53A =

API – 53B = used bladder accumulator

API – 53C = used piston type accumulator for cooling the seal

API – 54 = used pumping system for cooling the seal

Coupling
Coupling is one of the objects which are used to transmit the power from D.E to N.D.E (or) from Motor
to Pump.

Page 25 of 35
 Types of couplings:-

1- Flexible Coupling
2- Rigid Coupling

Types of Flexible Coupling:-

1- Tyre Coupling
2- Gear Coupling
3- Ripped Coupling
4- Clutch Coupling
5- Universal Coupling
6- Diaphragm Coupling

Types of Rigid Coupling:-

1- Flanged Coupling
2- Muff Coupling
3- Lovejoy Coupling
4- Tapered Shaft Lock
5- Sleeve Coupling

Types of Coupling Spacers:-

1- Plate Type
2- Rubber Type

Material of coupling:-

It’s a composite Material Mixer of two or more materials.

If Spacer of coupling got damaged:-

Medium vibration Occur on the Pump we have to change the coupling spacer ASAP.

What is Difference B/W Coupling and Clutch?

Coupling is used to transfer the power from Driver (Motor) to Driven (Pump)

Clutch is used to transfer the power from Driver (Motor) to Driven (Pump) nut it also protect the
driven equipment if any abstraction or load Increase in driven equipment clutch will slip.

Troubleshooting of Pump
Sr.
Trouble Cause Solution
No

Page 26 of 35
 If Pump Suction Pressure
1- Suction Strainer Chock Open the suction strainer and clean it
gets Low

If Discharge pressure Gets Casing and Impeller Wear ring Open the Pump check the wear ring If
2-
Low clearance increase necessary change it

1-Change the oil quality

2-Check the vibration if it’s still there
Abnormal Sound From in Ball bearings clearance Increase
3- change the bearings
and out board bearings and oil quality problem
3-Check the base bolts and tight the bolts
4-also Check the alignment
1-Pump and Motor Misalign
2-Rotor/shaft Unbalance 1-Allign the pump and Motor If vibration
High Vibration on the
4- 3-Base Bolt loose is still there than balance the Rotor and
Pump
4-Bearing Failure also change the bearings
5-Suction not Proper
1-Suction Pressure Drops
1-Maintain NPSH
2-Temp. of liquid Increased
2-Coating inside the Pump
3-Low NPSH
5- Cavitation (Water Bubbles) 3-Impeller Material as per Medium Req.
4-No vertex breakers/Cavitation
4-Vertex breakers/Cavitation plates on
plates in the line
suction flange
5-No reducer in the Line
1-Due to Misalignment
6- Coupling spacers Damaged 2-Not Proper Tightening of bolts 1-Change the Coupling spacer
3-Vibration Occur
1-Pump not primed, casing and
suction pipes not completely
filled with liquid
7- No liquid delivered 2-speed too low
3-discharge head to high
4-Wrong direction of rotation or
impeller install backward
1-Speed too low
2-Air or gases in liquid
3-Impeller Dia may be too small
4-mechanical defect – Impeller
8- Not enough pressure
clearance too great or impeller
damaged
5-also check the location of
pressure gauge.
Sr.
Trouble Cause Solution
No
9- Pump work a while and 1-Suction line leakage
then quits 2-stuffing box packing or seal
worn
3-Air pocket in suction line
4-not enough suction head for hot
liquids

Page 27 of 35
 5-air of gases in the liquid
6-Obstruction in suction or
discharge line
1-Speed too high
2-Head lower than rating, pumps
too much liquid
Pumps takes too much 3-liquid heavier than anticipated
10-
power 4-Shaft Bent
5-Rotating element binds
6-Impeller clearance too great
7-Impeller installed backwards
1-seal or packing is worn and not
properly lubricate
2-seal or packing is incorrect and
not properly run in.
11- Pump Leaks excessively
3-seal or packing not correct for
liquid handle
4-shaft sleeve scored
5-damaged mechanical seal
1-Pump and driver Misalign
2-Pump capacity too low
3-Improper Lubrication
12- High bearing Temperature
4-Excessive vibration
5-Shaft bent
6-Rotating element binds

Alignment
To centralize the center lines of two shafts is called Alignment. (Or) Reduce the Maintenance factor.

Types of Alignment:-

Page 28 of 35
 1- Rim and Face Method
2- Reverse Method
3- Laser/Graphical Method

Rim and Face Method:-

Formula = Reading x Foot Length / Coupling Dia

Soft foot: - Gap between Motor/Pump foot & Base.

Reverse Alignment:-

F.F = (P + M / 2) x D2 / D1 – (P / 2)

B.F = (P + M / 2) x D3 / D1 – (P / 2)

F.F = Front Foot

B.F = Back Foot

P = Pump

M = Motor

D1 = Distance between Shaft End (Pump Coupling hub to Motor Coupling Hub)

D2 = Distance between Pump Coupling hub to front foot

D3 = Distance between Pump Coupling hub to Back foot

P M

D1 D2
D3
DBSE (Distance between shaft ends)
Types of Misalignment:-

1- Angular Misalignment 2- Radial Misalignment

2- Axial Misalignment

Page 29 of 35
What misalignment will cause?

1. It can cause rotating mechanical seals to move back and forth axially two times per revolution.
The more the seals move the more opportunity for the lapped faces to open.
2. The pump bearings can become overloaded.
3. The wear rings can contact.
4. Results in vibration & jamming of pump

Maintenance
We have done Maintenance to maintain our equipment and keep away our equipment from the failure.
There are many types of Maintenance.

Types of Maintenance:-

1- Breakdown

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 2- Preventive
i) Periodic
ii) Predictive
3- Corrective

Breakdown Maintenance:-

Breakdown means that people wait until equipment fails and after that we have to repair it.

Preventive Maintenance:-

It is a daily maintenance like (Cleaning, Inspection, Oiling and tightening etc…). Design to retain
the health of equipment and prevent failure.

i) Periodic:-
This is a time based maintenance consist of periodically Inspection like Oil changing,
Cleaning, Replacing of Parts to prevent Sudden Failure of Equipment.
ii) Predictive:-
If someone feels that there is a problem occur in the any part of equipment we have to
change it without any plan so that’s called predictive maintenance.

Corrective Maintenance:-

If Some Problem occurs in equipment like (any parts failure, vibration etc…) then solve /correct
the problem of equipment is called Corrective maintenance.

Procedure to Done the Preventive Maintenance:-

1- Get the Permit

2- Got at Location and see the nature of the job and also check manually check by yourself the
Isolated and Electrically Isolated Items.
3- As per PM Check List perform the Job
i- Housekeep/clean the area properly
ii- De-couple the coupling
iii- Check the alignment
iv- Check the Oil Quality and quantity if required change the oil
v- Check all the gauges & flow meters & all the coolant and lubricant line
vi- If any parts damaged change those parts
vii- Check the boosting pressure
viii- Collect the previous oil and give to Lab for testing
4- After completion give the report to the Supervisor.

Pump preventive maintenance?

1. Daily inspection/check – Oil level, leakages & flow check

2. Weekly inspection/check – Oil level, leakages, flow & fasteners tightness
3. Monthly inspection/check - Oil level, leakages & fasteners tightness flow & vibration

Page 31 of 35
 4. Quarterly inspection/check - Oil level, leakages, fasteners tightness, vibration, flow &
suction/discharge valve check.
5. Half yearly inspection/check – Leakages, fasteners tightness, vibration, flow &
suction/discharge valve check. Oil/grease changing
6. Yearly inspection/check - - Leakages any & fasteners t, vibration, flow & suction/discharge
valve check. Oil/grease changing, alignment check, foundation bolt tightness check.

Positive Displacement Pumps

A pump that 1st Traps then Delivers called Positive Displacement pump.

Types of Positive Displacement Pumps:-

1- Reciprocating Pumps
2- Rotary Pumps

Reciprocating pumps:-

1- Piston, Plunger, Dosing Pump

2- Power/Direct Acting Pumps

Main Parts of Reciprocating Pump:-

1- Plunger or Piston with Piston Rod

2- Suction and Discharge Valves
3- Stuffing Box
4- Gland Packing
5- Liquid Cylinder
6- Cross Head
7- Deflector
8- Crosshead Pin Bearings
9- Crosshead pin
10- Connecting Rod
11- Crank Bearing
12- Power Frame
13- Plunger Well
14- Crank Shaft
15- Breather

Rotary Pumps:-

A positive Displacement Pumps having rotary Motion is called Rotary Pumps.

Types of Rotary Pumps:-

1- Gear Pumps

Page 32 of 35
 2- Screw Pumps
3- Vane Type Pumps
4- Lobe Pumps
1- Gear Pumps:-

The fluid in the gear type pump travels around the outside of the gear teeth. The meshing of the
gear teeth’s prevents the fluid from returning of the suction side. Gear pump can be sub divided
As
I) Spur Gear Pump
II) Helical Gear Pump(used in Larger Pumps & handle larger capacity & high speed &
pressure)
III) Herring Bone gear pump(used in Larger Pumps & handle larger capacity & high speed &
pressure)

All these pumps are the external gear pumps as the fluid is discharged around the outside of the
gear teeth. Only one shaft extends from the casing of the pump. It is called the driving shaft and
other shaft is called driven shaft.

2- Screw Pump:-

This pump with its single or double idler design is able to pump large amounts of oil with relative
ease. In operation the center rotor drives the screw pump.

This type of pumps is suitable to handle oil or heavy viscosity fluids. All the three rotor or screws
are usually made of the same metal (high carbon steel, steel alloy or stainless steel)

3- Vane Type Pump:-

It is another type of rotary pump generally used for transferring hydraulic oils or various
materials such as paints. The vanes of the pump are made of softer material than the pump casing.
They wear less and are replaceable. It is very simple in operation. As the impeller rotates its
offset position above the centerline allows the vanes or blades to extend and draw in fluid one
side. The vanes are placed or mounted within the impeller with a small amount of clearance for
free movement. The vanes are spring loaded to assure complete contact with the pump housing at
all time.

4- Lobe Pump:-

Lobe pump works very much like a gear pump. The lobes are mounted on separate shafts and
rotate in opposite direction. The liquid enters the pump through the suction port and trapped

Page 33 of 35
 between the wall of the casing and rotating lobes. Lobe pumps are used for relatively low
pressure

Permit
Permit is an Authorization Document to work in a specific area on specific equipment…

Types of Permit:-

1- Cold Permit (Blue, White)

2- Hot Permit (1st Category) (Red, Orange)
3- Hot Permit (2nd Category) (Purple, Light Purple)

Documents Req. in Work Permit:-

1- H2s Gas Test Certificate (Yellow)

2- Confined Space Permit (Green)
3- Work at Height Permit
4- Radiography Permit

Hot Work Permit (1st Category):-

1- Welding
2- Cutting
3- Grinding etc….

Spark Job applicable in this Category

Hot Work Permit (2nd Category):-

1- Lifting
2- Scaffolding
3- Hammering etc……

Valves
Page 34 of 35
 Valve is a Mechanical Device which is used to control the flow rate of Medium.

Types of Valves:-

1- Gate Valve 2- Globe valve 3- Butterfly Valve 4- Ball Valve 5- Needle valve

5- Control 7- Relive Valve 8- Check Valve / NRV 9- PSV etc…….

Types of Flanges:-

1- Weld neck 2- Raised face 3- Slip on 4- Blind 5- Spectacle blind

6- Orifice Flange 7- Lap joint 8- Loose 9- Plate

Coupling:-

1- Chicago coupling 2- Quick coupling

Page 35 of 35