PUMP START UP

For, Mechanical Seal

-- G. K. Pandey

GKP Sealing Solutions

GENERAL INSTRUCTIONS
 PUMP must be used only for the condition for which it is
procured.
  Electrical connections on the motor or accessories must
ALWAYS be carried out by authorised / qualified personnel and
in accordance to the local codes.
  Any work on the pump should be carried out by at least 2 people.
  When approaching the pump ALWAYS be properly dressed
(avoid use of clothes with wide sleeves, neckties, necklaces, etc.)
and/or wear safety equipment (hard hat, safety glasses, safety
shoes, etc.) adequate for the work to be done.
 Be ALWAYS informed on locations of first aid sites inside the
company and carefully read safety and medical first aid
prescriptions in force.
GENERAL INSTRUCTIONS
  ALWAYS disconnect the power to the motor prior to working or
removing the pump from the installation.
  NEVER work on the pump when it is hot.
  DO NOT attempt to remove the safety guards when the pump is
operating.
  After completion of the work ALWAYS re-install the safety guards
previously removed.
  NEVER touch pump or piping with temperatures higher than 80°C.
  ALWAYS be careful when handling pumps that convey acids or
hazardous fluids.
  ALWAYS have a fire extinguisher in the vicinity of the pump
installation.
GENERAL INSTRUCTIONS
 DO NOT operate the pump in the wrong direction of rotation.

  NEVER put hands or fingers in the pump openings or holes.

  NEVER step on pump and/or piping connected to the pump.

  Pump and piping connected to the pump must NEVER be under

pressure when maintenance or repair is carried out.
GENERAL INSTRUCTIONS
 In the event of pump break-down and/or loss of pumped
fluid, immediately disconnect the electrical power to the
motor
and
contact the responsible personnel in charge of the
installation, which should intervene with at least two people
paying particular attention to the fact that the pump may be
handling dangerous fluids, hazardous to the health and
environmentally unsafe.
 After the causes for the emergency have been addressed
and resolved, it will be necessary to follow the starting
procedures for the start-up of the pump/motor assembly.
GENERAL INSTRUCTIONS

BASIC FIRST AID

 In the event dangerous substances have
been inhaled and/or come in contact with
the human body, immediately follow the
instructions given in the company’s
internal medical safety procedures.
ALIGNMENT
 Flexible couplings must be properly aligned. Bad
alignments will result in coupling failures and damage
to pump and motor bearings.
 For high temperatures cthe coupling alignment may
get upset, it is necessary to check the alignment to
secure proper working operation at such operating
temperatures.
ELECTRICAL CONNECTIONS
 Electrical connections must be made
exclusively by qualified personnel in
accordance with the instructions from the
manufacturer of the motor or other
electrical components and must adhere to
the local National Electrical Code.
 BEFORE DOING ANY WORK TO THE
INSTALLATION DISCONNECT ALL
POWER SUPPLIES.
ELECTRICAL CONNECTIONS
 It is recommended that electric motors and eventual connected accessories be
protected against overloading by means of circuit breakers and/or fuses.
 Circuit breakers and fuses must be sized in accordance with the full load
amperage appearing on the motor nameplate.
 It is advisable to have an electrical switch near the pump for emergency
situations.
 Prior to connecting the electrical wiring, turn the pump shaft by hand to make
sure that it rotates freely. Connect the electrical wiring in accordance with local
electrical codes and be sure to ground the motor.
 Motor connection should be as indicated on the motor tag (frequency, voltage,
poles and max consumption) and as discussed in the motor instruction
manual.
 It is recommended that motors over 7.5 kW be wired for Star-Delta start-up, to
avoid electrical overloads to the motor and mechanical overloads to the pump.
ELECTRICAL CONNECTIONS
 Check the direction of rotation before the
motor is coupled to the pump
 Rotation in the wrong direction and/or
pump running dry may cause severe pump
damage
 Electrical instrumentation such as solenoid valves, level
switches, temperature switches, flow switches, etc.
which are supplied with the pump or systems must be
connected and handled in accordance with the
instructions supplied by their respective manufacturers.
SUCTION AND DISCHARGE PIPING
 Avoid using piping turns and especially short radius elbows.
 To prevent foreign matters from entering the pump during
installation, do not remove protection cap from flanges or cover
from openings until the piping is ready for hook-up.
 Flange gaskets should be properly centered between the flange
bolts so that there is no interference with the flow of the liquid.
 There should not be any tensions, deformations or misalignment
of the piping when loosening the bolts holding the flanges
together.
 Any thermal shocks and/or excessive vibrations should be
controlled by means of expansion joints, flexibles, etc. having
same size as the piping.
PIPE CLEANING

 Before installation start-up clean piping

and any reservoirs removing loose
materials and foreign particles.
 Particular attention for cleaning should
be for installations where welding of
piping and components has taken place.
PRESSURE TEST

 When the installation has been

completed it is necessary to test the
piping for both static pressure and
vacuum.
PRESSURE GAUGE
 Pressure and vacuum gauges
must be properly anchored
and connected at the
measuring points located at
pump
 Flanges or near the flanges,
using approx. 8 mm. diameter
tubing with “pig tail”
configuration to reduce
pressure fluctuations.
 For safety purposes, isolating
and vent valves should be
fitted before these instruments
TEMPERATURE GAUGE
 Temperature gauges
should be installed
with thermowells
selected for the
specific purpose and
fitted in strategic
locations where the
reading is required
 MINIMUM FLOW CONTROL
 When the pump operates near the shut-off with
almost no flow, almost all the motor power is
transformed into thermal energy which is absorbed
by the pumped liquid.
 If the capacity is less than the minimum
recommended (10-15% of pump capacity at its best
efficiency point) not only will there be excessive load
on the pump support and bearings but the liquid
could evaporate resulting in damage to the impellers
and wear rings with possibility of the pump seizing.
MINIMUM FLOW CONTROL
 To prevent these problems it is recommended the
installation of a minimum flow valve in the discharge
piping, right after the pump but before the flow
regulating valve.
 In the event the flow regulating valve being
excessively throttled or even completely closed, there
will always be the required minimum liquid flow
recirculated from the pump discharge to the suction
piping of the pump.
 The other device which may be fitted in this by-pass
line (from pump discharge, before flow regulating
valve, to pump
 suction) is a calibrated orifice sized for the minimum
liquid flow required by the pump.
CHECK PRIOR TO START UP
 The pump manual has been completely read, and has
been fully understood?
 The piping system has been flushed of any foreign
particles, welding impurities, etc.?
 Have all piping and pump obstruction been removed e.g.
cooling water line blind flange , lube oil circulation line
blind etc.
 All connections and piping are leak proof and there are no
external forces or moments applied to the piping or pump
flanges?
 Pump and motor are properly lubricated, if required?
 Pump/motor alignment has been checked?
CHECK PRIOR TO START UP
 If mechanical seal requires flushing line / quenching
line has this been connected?
 Check Buffer / Barrier fluid level.
 Vent Plan 23 system.
 Check for venting of Plan 52, Plan 53 A, Plan 53 B
and Plan 53 C system.
 Plan 52 vent valve ( connected to flare / CBD) must
be kept open .
 Check for the Pressure in Plan 53 A and Plan 53 B is
as per requirement.
 Check for Plan 32 pressure and flow.
CHECK PRIOR TO START UP
 In Plan 62 Stem flow should just sufficient to keep
atmosphere away. Stem should come out of gland
throttle bush (along the shaft) as if smoke is coming
out,
 Whether all gauges are in working condition?
 All instrument transmitters indications are appearing
in DCS.
 All valves in the installation are in the correct
position?
 All safety guards are in place?
 Has this pump’s direction of rotation been checked ?
CHECK PRIOR TO START UP
 The pump Stop switch is clear and visible?
 Are pump and installation ready for start-up?
 Check if OIL CUP is installed on bearing housing
 Check for oil level in level glass.
 Oil Breather is installed.
 Check gauge glasses are clear and full flow of
water is coming.
FORCED LUBRICATION SYSTEM

 In forced lubrication system all the safety logic /

trips are effective.
 Check for the pressure drop across oil filter as per
OEM recommendation.
 Check for lube oil supply temperature to the
bearings is as per OEM recommendations
( normally about 40 deg C).
 Check for bearing oil return temperature (Max 75
to 80 deg C in running condition).
START UP
 After completion of installation, before turning on the power to
the electric motor, rotate the pump shaft by hand to make
sure that the pump rotor is free. In the event the shaft does
not turn, try to free it up by applying a torque to the pump
coupling with a pipe wrench.
 In the event the pump does not become free with the above
procedures, fill up the pump with a suitable solvent or
lubricating liquid, let it rest for several hours to allow softening
of the rust build-up inside the pump, drain the pump and
apply torque to the pump shaft as described above to finally
free the rotor.
 NOTE: The selected solvent or lubricating fluid must be
compatible with the pump, seals and gasketing materials.
START UP
 New pumps from the factory and pumps coming from
long term storage are likely impregnated with a rust
preventative liquid; before the start-up, these pumps
should be subjected to fresh water rinsing for
approximately 15 minutes. The liquid mixture coming out
of the pumps should be collected to safeguard the
environment, this liquid should be send for treatment as
a special liquid.
 Preheat hot pumps for a minimum of 2 hours.
 Start steam line ( for quenching / heating) at least half an
hour before starting the pump.
CHECK PUMP-MOTOR COUPLING
ALIGNMENT

This must be done prior to the first start-

up and before every start-up if pump or
motor has been removed from the
installation for maintenance or other
reasons.
 For high temperature pumps alignment
should be checked after few hours of
running and corrected if required.
PRECAUTIONS
 Prior to starting, the suction piping and the pump must
be filled with the liquid to be pumped.
 The entire system must be vented properly.
 Pump should never run dry. It may damage the pump.
PRECAUTIONS
 Single stage pump must be started with discharge
valve closed/ crack open.
 Multi stage pump should be started with discharge
valve crack open (if started in discharge valve closed
condition pump may get damaged due to heat).
 After pump goes to the full speed open the discharge
valve to go to the duty point.
 NEVER CONTROL THE FLOW FROM SUCTION
VALVE.
CHECK POINTS AFTER START UP
 The differential pressure and the capacity are as expected (if
required, adjust the flow regulating valve at the pump discharge side
but NEVER throttle the valve at the suction side).
 The motor amperage does not exceed the value shown on the motor
nameplate.
 The pump/motor assembly does not have unusual vibrations and
noises.
 The seal arrangement works as it should:
if the sealing is by packing there should be continuous dripping from
the stuffing box .
if the sealing is by mechanical seal there should not be any leakage .
 The bearing support temperature, at full operation, is less than
approx. 80°C.
IMPORTANT

NEVER OPERATE
THE PUMP
DRY
IMPORTANT

If at start-up there are suspicions

of abnormal operation it is
recommended to stop the unit
and investigate the causes
SHUT DOWN
 The centrifugal pumps can be shut down by switching off
the power to the motor, with open or closed flow
regulating valve: however if there are no provisions
against liquid hammer it is recommended to close the flow
regulating valve at pump discharge prior to stopping the
pump.
 Before stopping the pump close the discharge valve.
 After pump shut down, close any auxiliary lines such as
flushing, heating, etc.
SHUT DOWN
 After the first start-stop and if necessary, check
pump/motor alignment and make sure that no external
forces or moment rest on pump or piping.
 In the event the pump is shut down for an extended
period of time it is recommended to completely drain
the pump to prevent the possibility of freezing in the
winter time and/or the possibility of corrosion due to
stagnant liquid left in the pump .
PERIODIC CHECK
 Periodically check the good working condition of the
pump by reading the instruments such as gauges, amp
meters, flow meters, etc., the pump should constantly
be performing as the installation requires.
 The operation of the pump should be without abnormal
vibrations or noises, if any of these problems is noticed,
the pump should be stopped immediately, search for
the cause and make the necessary corrections.
 It is good practice to check the pump/motor alignment,
the running conditions of the bearings and of the
mechanical seals at least once a year, even if no
abnormalities have been noticed.
PERIODIC CHECK
 If there is a deterioration of the pump
performance, which is not attributable to
changes in system demands, the pump
must be stopped and proceed with
necessary repairs or replacement.
 When the pump is fitted with auxiliary
supply lines such as cooling, heating or
flushing it is recommended to periodically
check their flow, temperature and pressure.
Routine Maintenance
 Check for unusual noise, vibration and bearing
temperatures.
 Inspect the pump and piping for leaks.
 Check the mechanical seal area for leakage (no
leakage is desired).
 Lubricate the bearings
 Monitor the seals.
 Perform vibration analysis.
 Check the discharge pressure.
 Monitor the temperature
LUBRICATION

 Bearings and lubricants must be free of

any foreign particles such as dirt, dust,
etc. which could cause the bearings to
seize
PUMP REPAIR
 Before working on the pump it is important to:
procure and wear the proper safety equipment (hard hat,
safety glasses, gloves, safety shoes, etc.)
 Disconnect the electrical power supply and, if required,
disconnect the electrical cables from the motor
 Close the pump inlet and outlet isolating valves
 Let the pump cool down to ambient temperature if is
pumping hot liquids
 Adopt safety measures if the pump has been handling
dangerous liquids
 Drain the pump body of the pumped liquid, through the
draining connections, if necessary rinse with neutral liquid.
PUMP REMOVAL
 Isolate electric connections.
 Isolate all the piping connected to pump.
 Remove the coupling guard
 Remove the spacer of the coupling, if there is one.
 If required, remove motor by removing the bolts on the
baseplate, for base mounted assembly.
 Remove the pump from installation without damaging
other system components.
Thank You.

GKP Sealing Solutions