UNIT 1

PUMPS
Unit Outcome

When you complete this unit you will be able to…

Describe the various types of pumps found in buildings and industrial plants.

Lesson Objectives

Here is what you will be able to do when you complete each lesson.

1. List common applications of pumps in the power industry.

2. Define the terms associated with pump performance.
3. Sketch and describe the common types of pumps used in the power industry.

Introduction

One of the first pieces of powered machinery to be invented at the dawn of the industrial
age was a crude form of pump. The pump has since evolved into an endless variety of
types, sizes, and applications. This unit will give an overview of the general types of
pumps that are in common use in buildings and industrial plants.

Operators should become familiar with the diversity of pumps that are in existence as
they may be required to safely operate pumps in the normal course of their daily
routines. A functional understanding of pumps, their use, and application, is essential to
understanding how most processes are handled in plants today.
LESSON 1

Definition, Application and Location

1- Definition

A pump is a mechanism that is used to transfer a liquid from one place to another
by imparting energy to the liquid being transferred.

2- Applications

Pumps are used in numerous locations for many purposes. A car may contain several
different types of pumps: one pumping fuel, one pumping lubricating oil, one pumping
engine coolant, possibly another pumping high pressure hydraulic fluid for power
steering, and a hydraulic pump attached to a foot-pedal which activates the brakes.

Pumps are employed to move materials ranging from molten metals at very high
temperatures, to cryogenic materials at extremely low temperatures. They are used to
generate pressures so small as to be barely perceptible or pressures so high that the
liquid being pumped is capable of cutting through material as though it were a saw.
Also, they are designed to supply quantities from as small as one drop per day to four
billion litres per day. They have power requirements from a few watts to nearly 75
megawatts.

Some of the more common types of pumps required in industrial plants are:

1. Boiler feedwater pump - supplies the boiler with feedwater as required. It must be
capable of forcing this water into the boiler against the pressure existing in the
boiler.
2. Fuel oil pump - used in oil-fired boilers to pump fuel oil to the burners.
3. Lubricating oil pump - used to circulate oil to the bearings of a machine such as a
turbine, engine, pump, or compressor.
4. Circulating water pump - also called a cooling water pump. It is used to pump
water through a heat exchanger such as a condenser or an oil cooler.
5. Chemical feed pump - small capacity units are used to pump chemicals into
boilers; larger units are used as process pumps.
6. Fire pump - used to supply water to plant fire lines.
7. Domestic water pump - used to supply water to plant washrooms, etc.
3- Pump Location

Pumps may be small enough to be suspended by the pipework that they are
servicing, but are usually anchored to a firm location. Large pumps are supported
by reinforced concrete foundations for stability and vibration control. Pumps are
generally located where they can be easily accessed for operation and
maintenance, however, some pumps may be on the bottom of a lake, down a well,
or on the inside of a pipeline or vessel.

4- Pump Drives

The source of power for a pump could be an electric motor, a gas or diesel
internal combustion engine, a gas, water, or steam turbine, a steam engine, or a
steam operated piston. Small pumps may be operated by hand or foot, by air
pressure or another fluid pressure, or an electromagnet.
LESSON 2

Theory of Pumping
1- Static Suction Lift

Let us assume that a pump is used to move a certain amount of water and that this
pump is located above its source of supply which may be a pond, tank or other
source
(Fig. 1(a)). The pump has to lift the water through the suction line. The distance,
measured vertically, that the intake of the pump is placed above the surface of the
water is called the static suction lift.

Figure 1. Static Suction Lift

The pump is able to lift water because of the downward pressure of the air or
atmosphere on the surface of the water in the supply tank or pond.

When a pump is started, the plungers or pistons, moving to and fro, exhaust the air from
the pumps body and create a partial vacuum in the pump cylinders and suction pipe
whereupon the atmospheric pressure on the surface of the water in the supply tank,
being now unbalanced, forces water up the suction pipe and into the pump.

The revolving impellers in a centrifugal pump also exhaust the air from the pump body
and suction pipe to some extent but, as they are not an airtight fit, the vacuum obtained
is not very high, hence the reason for placing centrifugal pumps either close to or below
the surface level of the water supply.
Rotary pumps, due to the close clearances between the casing and the lobes, vanes, etc.,
are quite efficient in regard to lifting water.
We have learned that the atmospheric pressure varies with the altitude or height above
sea level. At sea level, the pressure is approximately 101.3 kilopascals (14.7 psi) or 760
millimetres of mercury (30 inches) which is equivalent to the pressure exerted by a
column of water 10.34 metres (34 feet) high. At an altitude of 1100 metres (3600 ft) the
atmospheric pressure is only approximately 89 kpa (12.9 psi) or 667.7 mm Hg (26.35
inches of mercury) which is equivalent to approximately 9.1 metres (29.8 feet) of water.

Theoretically, the maximum lift of a pump figures out at 10.34 metres at sea level and
9.1 metres at 1100 metres altitude, but in practice this cannot be attained because of
friction in the pump and piping, and leakage past the piston or plunger and valves. At
this high altitude, a reciprocating pump would be doing very well to lift water 6 metres,
(say 20 feet) but no pump should be set very high above the water supply if it is at all
possible to set it lower. Centrifugal pumps, particularly, have a much poorer suction
than piston or plunger pumps and should always be placed close to, or preferably below
the water supply.

2- Static Discharge Head

The vertical distance, in metres or in feet, from the centre line of the pump to the free
surface of the water in the discharge tank is called the static discharge head.

3- Total Static Head

The vertical distance from the surface of the source of supply to the surface of the water
in the discharge tank is called the total static head. This is the sum of static suction lift
plus static discharge head, thus it is the total height the water is raised by the pump.

When the water is discharged above the level of the water in the tank, the discharge
head is measured from the centre line of the pump to the point of free discharge
(Fig. 1(b)).

4- Static Suction Head

In many pump systems the source of supply is located above the pump and
the water flows toward the pump by gravity (Fig. 1(c)). The distance from the
free surface of the supply tank to the centre line of the pump is called the static
suction head and the total static head is then the difference between static
discharge head and static suction head.

5- Friction Head
When the pump puts the water in motion, this water will meet resistance in the
pipes, valves and fittings. To overcome this resistance a certain amount of
pressure is required. This pressure is called the friction head and is also expressed
in metres or feet of water.

6- Velocity Head
A force is required to put the water in motion. This is called the velocity head.
7- Pressure or Equivalent Head
When the pump discharges the water into a vessel under pressure, such as a
boiler, it has to impart additional pressure to the water in order to overcome the
boiler pressure. This extra pressure is called the pressure or equivalent head.

8- Dynamic Head
Friction, velocity and pressure head are required to move the water from the
source of supply into the discharge vessel. For this reason we call the sum of
these heads the dynamic (force in motion) head.

9- Total Head
The total head required to move the water from the source of supply to the point of
discharge is the sum of static and dynamic head.
The power required to drive a pump is determined by the amount of liquid
pumped and the total head against which the pump operates.
LESSON 3

Types of pumps
Pumps can be broadly classified into three groups: reciprocating, rotary, and centrifugal.

1- Reciprocating Pumps

In this type of pump the pumping action is produced by the to and fro (reciprocating)
movement of a piston or plunger within a cylinder. The liquid being pumped is drawn
into the cylinder through one or more suction valves and then forced out through one or
more discharge valves by direct contact with the piston or plunger.

Fig. 2 illustrates a plunger type reciprocating pump while Fig. 3 shows the piston type.

Referring to Fig. 2, when the plunger moves from right to left the liquid is drawn into
the cylinder through the suction ball check. When the plunger reverses and moves from
left to right, the liquid is forced out through the discharge ball check. The discharge ball
check is forced open by the pressure of the liquid and, at the same time, the suction ball
check is forced closed.

The movement of the plunger in the cylinder in one direction is called the stroke of the
plunger. The distance the plunger moves in and out of the cylinder is called the length
of the stroke.

Figure 2. Single-Acting Pump

As can be seen in the sketch, only one side of the plunger takes part in the pumping
action and water is discharged only during one out of every two strokes. For these
reasons the pump is called single-acting.

Fig. 3 shows a basic diagram of a double-acting, piston type reciprocating pump. The
pump has two discharge valves D.A. and D.B. and two suction valves S.A. and S.B.
When the piston moves from left to right as shown in Fig. 3(a), the liquid will be drawn
in through the suction valve S.A., while at the same time liquid is being forced out
through the discharge valve D.B. Then when the piston reverses and moves from right
to left as in Fig. 3(b), liquid is drawn in through the suction valve S.B. and at the same
time, liquid is being forced out through the discharge valve D.A.

Figure 3. Double-Acting Pump

With this arrangement both sides of the piston take part in the pumping action and
liquid is discharged when the piston moves in either direction, hence it is called double-
acting.
2- Centrifugal Pumps

A centrifugal pump may be defined as a pump which uses centrifugal force to develop
velocity in the liquid being handled. The velocity is then converted to pressure when the
liquid velocity decreases. As kinetic energy is decreased, pressure is increased.
Centrifugal pumps can be subdivided into the following types: volute, diffuser, axial
flow, mixed flow, and regenerative. Although the regenerative pump is not truly a
centrifugal pump, it will be considered in this classification.

The general construction of the volute centrifugal pump is shown in Fig. 4. The liquid
being pumped is drawn into the centre or eye of the impeller and is discharged from the
impeller periphery into the volute casing. The volute casing has an increasing cross-
sectional area as it approaches the pump discharge. In this area, the velocity of the
liquid discharged from the impeller is lowered and converted to pressure. To make the
conversion from velocity to pressure more effective, stationary diffuser vanes can be
installed around the rim of the impeller. This construction gives rise to the term diffuser
centrifugal pump as shown in Fig. 5.

Figure 4. Volute Centrifugal Pump

Figure 5. Diffuser Centrifugal Pump
The combination of centrifugal force and pressure created by velocity decrease accounts
for the total pressure developed by the volute or diffuser pumps.
A very popular pump used to provide forced circulation in hot water heating and chilled
water cooling systems of small and medium capacity is illustrated in Fig. 6. It is known
in the trade as a circulator. The pump is driven by an electric motor attached by means
of a flexible coupling to the pump frame. The pump is directly installed in the piping
and, therefore, is also known as an in-line pump. A circulator must be capable of
operating quietly and reliably for long periods of time without shut down.
 Figure 6. Centrifugal Circulator

Centrifugal Pump Characteristics

Reciprocating and rotary pumps are classified as positive displacement pumps, which
means that at a constant speed they move a specific amount of liquid regardless of pump
head. The capacity of a centrifugal pump, however, changes with a change in head, thus
this pump is not a positive displacement pump.

When the head is increased, the capacity of the centrifugal pump decreases and when
the head is lowered, the capacity increases. When the head is increased so much that it
exceeds the design head for the pump, the output drops to zero.

It is, therefore, vitally important that the designer of a pumping system carefully
calculates the total head of the system in order to be able to select a centrifugal pump
that can deliver the required amount of liquid against this head.

The flow of a centrifugal pump can be regulated by adjusting the discharge valve.
Throttling the discharge valve increases the flow resistance, thus enlarges the friction
head, and the flow will be reduced. The discharge pressure gage on the pump will show
an increase in pressure, however this increase is moderate and there will be no danger to
the pump as with positive displacement pumps. Even with the discharge valve
completely closed the pressure build-up will be well within safe limits.

When the flow is throttled down, the power requirement of the pump is also reduced,
notwithstanding the resulting pressure increase. We take advantage of this fact by
starting large centrifugal pumps with a closed discharge valve. Since the no-flow power
requirement is relatively small, excessive power surging during start-up of the pump can
be avoided. This is very important in buildings with a large electric light load, such as
large office buildings, where severe dimming of lights due to a power surge can be
disturbing.
CAUTION:

1. Never run a centrifugal pump continuously with the discharge valve completely
closed. The mechanical power applied to the impeller is dispelled as friction to the
water trapped and churned about in the casing. This friction causes overheating of
the water to the point where it turns into steam which may result in damage to the
pump.

2. Always operate a centrifugal pump with its suction valve wide open. Never use it
for flow control. Throttling or closing of this valve starves the impeller of its
water supply and the casing becomes partially empty resulting in excessive
vibration which may ruin the bearings. The lack of liquid also affects stuffing
boxes and seals which require a certain amount of liquid for lubrication and
cooling.

Cavitation

When the pressure at any point inside a pump drops below the vapour pressure
corresponding to the temperature of the liquid, the liquid will vaporize and form vapour
bubbles. These bubbles are carried along with the flow until they reach a region of
higher pressure where they collapse, producing a shock wave. This phenomenon is
called cavitation. When the bubbles are carried onto the surface of the impeller and
collapse there, the impact will damage the metal surface. When this action is repeated in
rapid succession, the metal is worn away and other mechanical effects, such as noisy
operation and vibration will also be produced. This may result in the mechanical
destruction of the pump. Cavitation occurs mainly on the suction side of the pump or in
the inlet portion of the impeller.
3- Turbine (Regenerative) Pump

Fig. 7 shows a regenerative pump or turbine pump as they are also called. The liquid
being pumped enters at the pump suction and is circulated almost 360 degrees by the
impeller to the pump discharge. The impeller vanes travel through a channel in the
pump casing. The liquid being pumped receives continuous impulses from the fast
moving vanes, and the pressure increases substantially as the liquid approaches the
pump discharge. The regenerative pump can develop pressures several times that of a
centrifugal pump of similar size and speed.

Figure 7. Turbine Pump Casing and Impeller

NOTE: In this introductory unit, the discharge from pumps has been referred to as
pressure. In future unit's the term head will be more accurately applied,
meaning the differential pressure between the pump intake and the pump
discharge.

To produce high head, it is usually necessary to direct the discharge from one impeller
into the intake of another impeller. This is called staging. A pump with three impellers
is referred to as a three stage pump. Staging is used for increased differential pressure;
the more stages, the greater the pressure.
4- Rotary Pumps

Unlike the centrifugal pumps discussed previously, rotary pumps are positive
displacement pumps. Instead of propelling the liquid, most rotary pumps transfer
pockets of liquid from the low pressure side of the pump to the high pressure side where
the pockets are forced to empty themselves and return to the low pressure side for
refilling. The capacity of rotary pumps is much less than that of centrifugal pumps.
Some common rotary pumps are gear pumps, lobe pumps, and sliding vane pumps.

Fig. 8 shows a gear pump, also called a spur gear pump or an external gear pump. The
pump consists of a housing, a driving gear, and an idler gear. Arrows indicate the
direction of rotation of the gears. As the gears rotate, they convey pockets of liquid to
the discharge side of the pump. The liquid is expelled from the pockets as the teeth of
the gears mesh, because the liquid and the tooth cannot be in the pocket at the same
time. Further rotation of the gears causes the teeth to unmesh on the suction side of the
pump. Liquid flows in to fill the void created as the gear teeth come out of the pockets.
Gear pumps are used for pressures up to 10 000 kPa.

Figure 8. Gear Pump

Lobe pumps are similar to gear pumps in theory, as liquid is transferred around the
outside of rotating lobes and expelled by the meshing of the lobes. One difference is that
the lobes are both driven by external gears which keep the lobes synchronized. Fig 9
shows a lobe pump.

Figure 9. Lobe Pump

Fig. 10 shows a sliding vane pump. The sliding vane pump consists of a rotor, sliding
vanes held in the rotor, and an eccentric casing. As the vanes are caused to rotate by the
rotor, the vanes slide in and out to conform to the changing proximity of the pump
casing. Pockets of liquid are transferred as indicated by the arrows. As the vanes are
forced to retract by the diminishing clearance with the pump casing, the size of the
pockets is decreased and the liquid is forced out of the pockets. As the vanes rotate past
the minimum clearance with the pump casing, the size of the pockets begins to increase
again and the liquid on the intake side of the pump flows in to fill the increasing void.

Figure 10. Sliding Vane Pump

Rotary pumps deliver high pressure liquid without the pulsations that occur in
reciprocating pumps. Where positive displacement pumps are installed, a means of
pressure relief should be installed in the discharge line before the discharge valve. If the
discharge valve is inadvertently closed, excessively high pressures could be produced,
which could cause damage to the pump or piping.

This unit deals with common types of pumps. Pumps are made for a great variety of
applications, and specialty pumps are discussed in other units.

 
 UNIT 2

PUMP OPERATION AND MAINTENANCE

Learning Outcome

When you complete this unit you will be able to…

Describe all details pertaining to pump operation and various maintenance procedures
performed on pumps.

Lesson Objectives

Here is what you will be able to do when you complete each lesson.

1. Describe the construction and function of pump wearing rings.

2. Discuss pump shaft sealing, and describe the process that is followed when
replacing compression type packing.

3. Sketch and describe the standard types of mechanical seals

4. Describe pump bearings and shaft alignment equipment and procedures.

5. Describe pump start-up and priming procedures.

6. Apply pump troubleshooting steps.

Introduction

This unit discusses the operation of the various types of pumps found in use in power
and heating plants; as well as explains the various maintenance procedures performed
on these pumps.
LESSON 1

Wearing Rings
In order to prevent leakage between the rotating impeller and the stationary parts of the
pump, wearing rings are used. These rings are installed on the impeller or the casing or
both. They reduce the clearance between the rotating impeller and the stationary casing
to a very small amount. The smaller the clearance, the smaller the amount of water
leaking from the discharge side of the pump to the suction side and the higher the pump
efficiency will be. The rings also prevent wear of impeller and casing (hence their
name). When the wearing rings themselves wear, they are easily and cheaply replaced.

Usual materials favored for wearing rings are bronze and cast iron which tend to wear in
a smooth manner.
 Figure 11. Impeller and casing wearing rings.

Fig.11(a) illustrates the clearance space between the pump casing and impeller of a low
cost pump without wearing rings. When wear enlarges the clearance to the point that the
pump efficiency drops off drastically, both casing and impeller have to be replaced. Fig.
11(b) shows a single flat wearing ring threaded on the eye of the impeller, while in Fig.
11(c) a wearing ring is fitted onto a ridge on the casing. Both rings form a flat sealing
joint similar to Fig. 11(a), but the wearing ring can be readily renewed to restore the
original clearance. Fig. 11(d) shows the arrangement with renewable wearing rings for
casing as well as impeller.

Wearing rings are installed on the hub of the impeller by either threading or shrinking.
Casing wearing rings consist of either a continuous ring or two half rings which are
pressed into place. The continuous ring is used with vertically split casings while
horizontally split casings are equipped with wearing rings consisting of two halves.
Split rings can be fitted onto a ridge or into a groove of the casing which will prevent
any axial movement should the rings work loose.
LESSON 2

Pump Shaft Sealing

In order to reduce leakage around the pump shaft where it passes through the casing,
two means of sealing are presently available. These two means are:
1. Compression or jam type packing
2. Mechanical seals

1- Compression Type Packing

Rings of packing, made of a soft, pliable yet durable material, are placed in the stuffing
box through which the shaft leaves the housing. The packing bears against the pump
shaft and the stuffing box walls and so reduces leakage around the shaft.

Packing is made from a wide variety of materials, some of which are asbestos, nylon,
flax, Teflon, lead, copper and aluminum. Frequently a lubricating material, called the
saturant, such as graphite or grease, is incorporated into the packing material.

Figure 12. Stuffing box and packing.

Fig. 12 shows the basic construction of a stuffing box which holds five rings of packing.
The gland holds the rings in place and can be adjusted to put pressure on the packing by
tightening of the adjusting nuts.

The sealing of the rotating pump shaft by means of packing is no easy matter. As long
as the shaft is perfectly round, has a smooth finish, and is running dead true, no great
difficulty will be encountered. But shafts usually run out a few thousands of an inch due
to clearance in the bearings. Grooves on the shaft make sealing a really tough job
regardless of the high quality of the packing.

Packing in the stuffing boxes of a centrifugal pump is not supposed to stop leakage
entirely, it only should throttle the fluid. The reason for this is that the packing acts as a
bearing and must be lubricated as such. Lubrication comes from slight leakage of fluid
from the pump or, in emergency, from a lubricant in the packing. It is sometimes
necessary to provide lubricant from an outside source.
It is vitally important that the operator has a good understanding of the basic principle
of the sealing action of jam packing. If this principle is not fully understood, wasted
packing, scored shafts, excessive down-time and expensive repair may result.

Sketch A, Fig. 13, shows a ring of new packing before the gland has been tightened.
When saturant is lost, the packing shrinks away from the shaft since its volume is
reduced. This, of course, increases the fluid leakage along the shaft. Should the operator
now tighten the gland so that he stops all fluid flow, no fluid lubrication will be
available, Sketch B, and the shaft and packing will heat up through friction. This will
cause the lubricant in the packing to go to work. The high temperature developed by the
friction starts to melt the lubricant out of the packing which then lubricates the shaft for
this emergency. Because this lubricant leaves the packing, the space taken by the
packing is reduced and the liquid from the casing will start flowing again, supplying the
needed lubrication and carrying away the heat, Sketch C.

The emergency is now over, but here is where trouble may start. A slight leakage is
needed to lubricate shaft and packing but should the operator tighten the gland again in
the mistaken idea that the packing should be leakproof, the same procedure described
above will take place again. However, packing only contains a limited amount of
lubricant and tightening up can only be repeated a limited number of times before the
point will be reached where all saturant has left the packing and its volume cannot be
reduced anymore.
 Figure 13. Gland packing.

When the gland is tightened again to stop leakage, the excessive heat caused by the
friction will burn up the packing and score the shaft, Sketch D. A full understanding of
this simple principle will stop the operator from over-tightening the gland and will help
him to get the maximum service expected from the packing.

Often the pressure inside the pump at the stuffing box is below atmospheric pressure
and instead of water leaking out through the packing, the tendency is for air to leak in.
When this is the case the stuffing box is provided with a sealing water connection and a
lantern ring as shown in Fig.14
 Figure 14. Stuffing box with lantern ring.

The lantern ring (also called the seal cage) is a metal ring having radial holes and it
serves to distribute the sealing water to the packing. The sealing water not only helps to
prevent air leakage but also lubricates the packing and this water is usually supplied
from a higher pressure section of the pump. In cases where the pump is pumping water
containing sand or grit or other abrasives, then clean sealing water may be supplied
from a separate source.
Replacing Pump Packing

Pump packing has to be replaced periodically due to its deterioration from being
compressed and from loss of saturant. How often this has to be done will depend upon
the operating conditions of the pump, the quality of the packing used, and the care with
which the packing was installed and adjusted. The frequency of replacement of the
packing may vary between a matter of months in the case of severe operating
conditions, to several years under more moderate conditions.

The recommended steps for replacing packing are as follows:

1. Shut down, isolate and drain pump. Make sure pump motor switch is locked open
or fuses removed and switch tagged with a "Do Not Operate" warning tag.

2. Remove gland adjusting nuts and slide gland away from the stuffing box. Then
remove all the old packing using some type of packing hook (Fig. 15). Make sure
the stuffing box is thoroughly clean and free from any small pieces of old packing.
Check that the sealing water connection to stuffing box is clear.

Figure 15. Removing packing.

3. Check the conditions of the shaft or the shaft sleeve if a sleeve is installed over the
shaft. If the surface is grooved or scored, then it should be replaced as any rough
surface will damage the packing.

4. To determine the correct size (thickness) of packing to use, measure the bore of the
stuffing box and subtract the diameter of the pump shaft and divide the difference
by two.
Example:

The stuffing box bore on a pump is 76.2 mm (3 in) and the shaft diameter is 57.2 mm (2
1/4 in). What size packing should be used?

Solution:

Difference between stuffing box bore and shaft diameter:

76.2 – 57.2 mm = 19 mm (3/4 in)

Packing size (thickness) 19 mm/2 = 9.5 mm (3.8 in) (Ans.)

5. Then wrap a coil of the correct size packing around a rod (same diameter as shaft
and held in a vise) and cut through each turn as shown in Fig. 16. If the packing is
slightly too large, never flatten it with a hammer. Place each turn on a clean
surface and roll it out with a piece of pipe.

Figure 16. Cutting packing ring.

6. Install the packing rings one at a time after putting a light coating of oil or grease
on the inner diameter of each ring. Slide each ring sideways over the shaft as
shown in Fig. 17 to prevent breaking of the ring.
 Figure 17. Sliding Ring onto shaft.

7. Tamp the rings into place one at a time using a split wooden bushing or metal
ring to push each ring into the stuffing box. Make sure the ring joints are
staggered and the lantern ring lines up properly with the sealing water inlet. See
Fig. 18.

Figure 18. Lanturn rings.

8. Put packing follower in place and compress the packing slightly by tightening the
gland nuts. Then slacken off to just finger tight to allow for packing expansion. In
the case of small pumps the shaft should turn freely by hand.
9. The packing should be allowed to leak freely when the pump is first started. After
about twenty minutes of running the follower should be gradually tightened until
only the necessary operating leakage is apparent.

The above method of installation of packing in stuffing boxes is essentially the same for
centrifugal, rotary and reciprocating pumps.
2- Mechanical Seals

Instead of employing a stuffing box with packing, many pumps use mechanical seals to
prevent leakage along the shaft. Mechanical seals have the following advantages over
packing.

1. They require much less maintenance.

2. They do not produce wear of shafts or shaft sleeves as do packing rings.
3. They reduce leakage to a minimum.
4. They can be designed to work under very high temperatures and pressures.

On the other hand, mechanical seals have a greater first cost than packing, and when
they fail, the pump must be taken out of service for a longer period to replace the seal
than would be necessary with the simple stuffing box and packing method.

All types of mechanical seals feature two flat sealing faces which are at right angles to
the pump shaft. One of these faces is called the sealing ring and it is held in position by
a spring. The other sealing face, which is in contact with the sealing ring, is called the
mating ring.

Mechanical seals may be divided into two general types, the rotating seal and the
stationary seal.

2.1 Rotating Mechanical Seal

In the rotating seal sketched in Fig. 19, the sealing ring and spring are held in place by a
shell which is fastened to the pump shaft with a set screw. Therefore the sealing ring
will turn with the shaft. The mating ring, however, is held stationary within the pump
casing.

As the pump shaft turns, the rotating sealing ring is forced against the mating ring, thus
preventing leakage between the faces. "O" ring type gaskets prevent leakage between
the casing and the mating ring and between the shaft and the sealing ring.
Figure 19. Rotating seal.
2.2 Stationary Mechanical Seal

In this type of seal, which is sketched in Fig. 20, the sealing ring assembly is held
stationary within the pump housing. The mating ring is fastened rigidly to the
shaft, usually against a shoulder. As the pump shaft turns, so does the mating
ring. The stationary sealing ring bears against the rotating mating ring and
leakage between the two faces is prevented. "O" ring gaskets are used to stop
leakage between the shaft and mating ring and between the sealing ring and
housing.

Figure 20. Stationary seal.

Sealing Ring Materials

The materials chosen for the sealing and mating rings depend upon such things as the
type of liquid being pumped, its temperature, its pressure, pump speed and seal design.
Materials frequently used by various seal manufacturers are bronze, carbon graphite,
ceramics, stellite, and tungsten carbide.

Care of Mechanical Seals

It is extremely important that the seals never run in a dry condition, otherwise the faces
will become grooved and scored. The following precautions should therefore be
followed:

1. Never run the pump in a dry condition even for a few minutes.
2. Vent any air present from the seal housing before start up.
3. Make sure an adequate flow of quenching or cooling liquid is flowing to the
seal.

A squealing sound is an indication of a dry seal but this sound is not always present if
the seal runs dry.

A leaking seal may be caused by the following:

1. Seal faces scored or grooved.

2. Seal housing bolts too tight, causing distortion of rings.
3. "O" ring gaskets cut or nicked during installation.
4. Misalignment of piping, causing distortion of pump parts.
5. Excessive pump shaft vibration.
LESSON 3

Pump Bearings
The only moving parts of a centrifugal pump are the impeller and the shaft on which it
is mounted. The shaft is held in place and supported by its bearings which allow it to
rotate with a minimum of friction. Pump bearings can be divided into the following two
general classes:

1. Shell or sleeve bearings

2. Ball or roller bearings

Pump Alignment and Flexible Couplings

The majority of the centrifugal pumps used for various purposes in buildings are driven
by electric motors. Nearly all these motors drive the pumps directly. This means that
pump and motor shafts are coupled together so that pump operates at the same speed as
the motor. Direct drive requires the pump and motor to be lined up in such away that the
centre line of both shafts are exactly in line. This is called a perfect alignment. If perfect
alignment could be achieved and maintained during operation, the shafts could be
connected together by a rigid coupling. Unfortunately, perfect alignment is very
difficult to obtain and practically impossible to maintain.

Two forms of shaft misalignment are illustrated in Fig. 21. Fig. 21(a) shows angular
misalignment. The motor and pump shaft are in line looking down from the top, but
looking from the side the centre lines are at an angle (the angle is exaggerated for the
sake of clarity).

Figure 21. Shaft misalignment.

Fig. 21(b) shows axial misalignment. The shafts are parallel but their axes are beside
each other. Angular and offset misalignment can also appear in combination with each
other.

Misalignment of shafts connected by rigid couplings causes overheating and excessive

wear of the bearings, increased power consumption, severe bending stresses in the
shafts which may lead to shaft failure, vibrations and noise.

The causes of misalignment are various. Poor installation or assembly is one of the main
reasons of unsatisfactory service. Bearing wear, thermal expansion and flexing of shafts
cause misalignment during operation even though the original installation was all right.

To protect the machinery against any of the dire results of misalignment, pump and
motor are connected by a flexible coupling. This coupling should not be considered a
cure-all for misalignment due to poor workmanship, proper alignment is still vitally
important, but rather as a corrective means for the unavoidable misalignment that may
develop during operation.

Most flexible couplings allow a limited amount of angular as well as offset

misalignment, they dampen vibration and allow a certain amount of end float of the
shafts.

Flexible couplings can be divided into two basic groups. The first group contains
couplings consisting of two rigid coupling flanges mounted on the shafts connected
together by a flexible yielding member. The second group contains rigid coupling parts
only, but through mechanical design a certain amount of flexibility is made possible.

Fig. 22 shows a few of the many different types of flexible couplings available on the
market.

Fig. 22 (a) shows a jaw type coupling with a non-metallic spider-like insert with four,
six or eight arms. This insert may be of synthetic rubber, laminated leather or bakelite.

Figure 22a. Flexible coupling

Figure 22b. The triangular coupling members fit into the ends of a rubber-lined metal
sleeve.

Figure 22c. The coupling flanges are fitted with pins which fit into the holes of the
leather disk which forms the yielding member.
Figure 22d. The fork-like coupling flanges are connected by springs.
It was mentioned before that proper alignment of pump and motor drive is necessary
even when a flexible coupling is used. Serious misalignment of equipment connected by
a flexible coupling may not only damage the coupling but it also may result in damage
to bearings, vibration and noise. For couplings with hubs or flanges of the same
diameter and with suitable machined faces, a straight edge can be used to check offset
or axial alignment (Fig. 23(a)). The measurement is taken along the top and side of the
flanges. To check the angular alignment a tapered feeler gage is used (Fig. 23(b)). When
the faces of the flanges are exactly parallel, the measurement at each 90° of the
circumference should be the same. Raise or lower the pump or motor, as necessary,
during alignment by inserting shims under the feet of either unit. Make sure to check the
alignment again after the adjustments are made.

Figure 23. Checking alignment.

The use of straight edge and tapered feelers for alignment will give fairly accurate
results, however, this method cannot be used for all types of couplings due to their
design. A more accurate method of alignment suitable for all types of couplings uses a
dial indicator which measures in thousandths of an inch. Fig. 24 shows how this
indicator is used to measure offset and angular misalignment. The coupling halves
should be marked and a piece of rubber should be placed between them at the centre to
hold them apart. Set the dial at 0 at the top. Rotate the two halves together and take
readings at each 90° angle. If the alignment is out, the amount of misalignment is
indicated by the gage and adjustments can be made accordingly.
Figure 24. Dial indicator.
LESSON 4

Centrifugal Pump Priming and Starting

The term priming, used in connection with pumps, simply means to fill the pump casing
and suction line with water or with whatever liquid is being pumped.

Before starting a centrifugal pump, it must be primed, otherwise the impeller will
simply churn air and will not produce any suction. In addition, the wearing rings will
have no liquid to lubricate them and they may seize. Also, as mentioned previously,
mechanical seals and packing will be damaged by dry running.

Methods of Priming

In the case where the pump is below the source of supply, as in Fig. 25, the pump is
primed in the following manner.

Close the discharge valve and open the suction valve. Then open the air vent valves to
allow the air in the pump casing to escape. When water flows from the vents, they can
be closed and the pump is then in a primed condition and ready for starting.

Figure 25. Flooded suction method.

When the pump is located above the source of supply (pump has a suction lift), various
methods of priming can be used and in each of these the pump suction line is equipped
with a foot valve. The foot valve is a flap type valve which allows water to enter the
suction line but prevents the water from flowing back out of the suction line.
In Fig. 26(a) the priming water comes from an external source. To prime the pump, the
discharge valve is closed and the external supply valve is opened as are the vent valves.
The water flows into the pump and then into the suction line where it is prevented from
escaping by the foot valve. The water fills the suction line and then the pump casing.
When water flows from the vent valves, they and the external supply valve are closed
and the pump is ready for starting.

In Fig. 26(b) the pump is primed by water which is supplied from the pump discharge
line. The discharge valve is shut and the priming valve and the air vents are opened.
Water from the discharge line fills the pump casing and the suction line. When water
issues from the vents the vent valves and the priming valve are closed and the pump is
ready for starting.

Figure 26. Priming methods.

In Fig. 27 a separate hand-operated priming pump is used. The main pump discharge
valve is shut and the priming pump valve is opened. The pump is operated and it
exhausts air from the main pump casing and suction line thus causing water to fill them.
When water issues from the priming pump discharge, then the priming pump valve is
shut and the main pump is ready for starting.
 Figure 27. Suction lift methods.

Installation

Although proper placement of pump and driver on their foundation, alignment and
installation of the connecting piping are the responsibility of the contractor, it is
advisable that the building operator makes himself familiar with these procedures. In
many new plants, troubles develop after a short period of operation which are due to
improper installation.

The best way to become familiar with the proper installation procedures for any
particular type of equipment is by studying the instruction manual supplied with this
equipment by the manufacturer.

Initial Start

Starting a centrifugal pump for the first time can be a troublesome experience unless a
thorough check of the unit is made during and after installation. More trouble develops
during initial starting of a pump than at almost any other time. Factors that should be
considered before starting the pump are:

1. Pipe Cleanliness

Many single-stage pumps have close-clearance running parts which must be protected
from abrasive particles often found in new piping systems. To prevent the larger
particles from reaching the pump, install a flat or conical strainer made of 1.5 mm or
1/16 inch mesh screen backed with 6 mm or 1/4 inch mesh screen in the suction line as
close as possible to the pump suction nozzle. When starting the pump for the first time,
watch the suction gage. When suction pressure drops, it indicates that the screen is
clogging. Stop the pump, remove the screens, clean and re-install them. It may be
necessary to clean the screens several times during the first few days of operation. The
screens can be removed permanently if no more clogging occurs.

2. Pump Alignment

The pump and its driver, usually an electric motor in small and medium sized heating
and cooling systems, should be aligned before the pump is put into operation for the
first time. Then, after the pump has run a short while and motor and pump have
assumed their normal operating temperatures, the alignment should be rechecked. The
change in temperature may have changed the alignment. Make sure the connected
piping is properly supported. Its weight should never be supported by the pump. Turn
the pump over by hand. It should turn freely, without binding, scraping or making any
noise. Inspect pump footings to see that any devices for expansion of the casing are free
and in good working condition.

3. Rotation

Always check the driver and pump rotation. Touch the starter button just long enough to
make the motor turn a few revolutions. The pump shaft should turn in the direction of
the arrow on the casing.

4. Bearings

Before any pump is started, its bearings must be carefully inspected, cleaned and
lubricated. With oil lubricated sleeve bearings, remove the cap, linings, and drain plug.
Flush the housing with solvent. Wash bearing parts thoroughly and reassemble them in
the housing. Flush the bearing and housing with lubricating oil. Replace the drain plug,
caps and other parts and fill the bearing as directed by the manufacturer. Grease-
lubricated ball, roller, and needle bearings are usually packed with grease at the factory.
Therefore no lubrication may be necessary before starting the pump, but it is advisable
to check the condition of the grease by removing the bearing housing cover.
Starting the Pump

To start a centrifugal pump in good operating condition, the following sequence can be
followed:

1. Turn on the cooling-water system for pump bearings, stuffing boxes, and
mechanical seals, if these parts are liquid cooled.

2. Check the oil level in bearing housing if pump is equipped for oil lubrication.

3. Open the suction valve and close or open the discharge valve, depending on the
starting procedure to be followed.

4. Close all drains in the casing, suction and discharge piping.

5. Make sure the pump is properly primed.

6. Start the pump and bring it up to speed.

7. If the pump is started with a closed discharge valve, open this valve slowly.

8. Check leakage from the stuffing boxes.

9. Adjust the sealing-liquid flow to ensure packing lubrication.

10. Check the oil rings on sleeve bearings. They must be turning freely.

11. Check the suction and discharge pressures.

12. Feel the pump bearings for overheating.

LESSON 6

Troubleshooting guide
Centrifugal pumps
1- COMPLAINT: No liquid delivered

Possible Causes

 Lack of prime
 Speed of pump driver too low
 Discharge head too high
 Suction lift too high
 Impeller plugged
 Wrong direction of rotation
 Plugged suction strainer

2- COMPLAINT: Not enough liquid delivered.

Possible Causes

 Causes under "No liquid delivered"

 Air leaks in suction line and stuffing boxes
 Suction head too low
 Worn wearing rings
 Damaged impeller
 Undersized foot valve
 Suction bay disturbances
 Oil viscosity-too high
 Worn gaskets

3- COMPLAINT: Pump discharge pressure low.

Possible Causes
 Speed too low
 Worn wearing rings
 Damaged impeller
 Worn packing
 Gas or air in liquid
 Pump water passages obstructed
  Impeller diameter too small
 Wrong direction of rotation

4- COMPLAINT: Pump loses prime after starting

Possible Causes

 Incomplete priming
 Suction lift too high
 Air leaks in suction pipe or packing glands
 Gas or air in liquid
 Suction line not filled completely
 Inlet not completely submerged
 Suction head too low
 Plugged seal-liquid piping
 Lantern ring in stuffing box out of place

5- COMPLAINT: Pump overloads driver

Possible Causes

 Discharge head too low resulting in excessive capacity

 Wrong liquid, viscosity too high
 Speed too high
 Wrong direction of rotation
 Packing too tight
 Distorted casing
 Bent shaft
 Mechanical failures
 Misalignment

6- COMPLAINT: Stuffing box overheats

Possible Causes

 Packing too tight

 Insufficient packing lubricant
 Wrong grade of packing
 Insufficient seal lubricant
 Incorrect installation of packing
7- COMPLAINT: Excessive vibration

Possible Causes
 Gas or air in liquid
 Insufficient suction head
 Pump misalignment
 Worn or loose bearings
 Unbalanced rotor (plugged or damaged)
 Bent shaft
 Non-rigid foundation

8- COMPLAINT: Bearings overheat

Possible Causes

 Oil level too low

 Poor or wrong grade of oil
 Dirt in bearings or oil
 Moisture in oil
 Clogged or scaled cooler
 Insufficient cooling water
 Bearings too tight
 Too much grease in bearings
 Misalignment
 Oil seals fitted too closely

9- COMPLAINT: Bearings wear rapidly

Possible Causes
 Misalignment
 Bent shaft
 Vibration
 Excessive thrust due to mechanical failure
 Lack of lubrication
 Wrong bearings
 Dirt in bearings
 Moisture in oil
 Excessive cooling of bearings
Performance monitoring in centrifugal pumps
 Each pump in your facility should have a
performance curve provided by the pump
manufacturer at the time of purchase1. Unless
otherwise indicated, pump curves show the
pump’s performance characteristics on water.
Curve information usually includes total
dynamic head, pump efficiency, driver output
power and NPSHR, all plotted as a function of
pump flow rate. Provided the pump is
mechanically sound, there is sufficient NPSHA2,
and there is no gas entrainment, the operating
point of the installed pump should fall
somewhere on the published pump curve3.

Not only does the pump have an operational curve, but the system also has an
operating characteristic curve where the total dynamic head required to move
fluid through the system at any given flow rate increases with the square of the
flow rate. This curve depicts the resistance to fluid flow caused by fluid friction,
and other mechanical devices such as valves, fittings, orifices and other
components. These head values, when plotted for a number of different flow
rates, form what is known as a system-head curve, or sometimes just the system
curve. The operating point of the pump in the system is where the characteristic
curve and the system curve intersect.

This factual concept should be kept in mind when troubleshooting pumps. No

matter how poorly a pump may be performing, it is operating at the intersection
of the system and pump curves. If that point is not the rated duty point, then
something has happened to cause one or both curves to move.

Every centrifugal pump always operates at the intersection of its

head-capacity curve and the system curve.

For many pumps there is one operating point that can be verified in the absence
of a flow measurement device; zero-flow. If allowable4, a momentary run at
near zero-flow will permit suction and discharge pressure readings to be
obtained to determine the TDH generated by the pump at that point5. To
determine TDH:

1. Subtract the suction pressure from the discharge pressure. This is the
pressure differential (ΔP). Total dynamic head (TDH, in feet) may be
calculated as shown below.
2. Adjust the head for any difference in elevation between the suction and
discharge gages.
3. Compare the TDH to the pump curve.
 A near shut-off TDH reading that is below the
published pump curve indicates pump wear. A
decrease in the TDH without any change in
motor current also indicates pump wear.

If the pump does not exhibit a wear

characteristic, then its operating point should be
on the design pump curve. To determine the
flow:

1. Return the pump to its normal operating point.

2. Calculate TDH from the suction and discharge pressure.
3. Find the corresponding flow rate for the measured TDH from the
published pump curve. Unless there is cavitation or gas entrainment, this
should be the flow rate of the pump.

If cavitation or gas entrainment is present, the pump usually will operate on the
design curve near shut-off, but its performance will degrade as flow is
increased. A low motor power combined with a low TDH reading may indicate
gas entrainment or cavitation.

If the TDH is low and motor power does not fall below the design power curve,
it is likely the pump is running at a higher than design flow rate. Power
delivered by a three phase motor may be estimated from the following equation:

For KW use 1000 instead of 746

Average the values of voltage and current for each phase. Motor power factor
and motor efficiency may be estimated from the published motor data.
Generally, this calculation is only an approximation. Motor efficiency and
power factor vary depending on load, motor condition, and plant environmental
factors. A small error in the actual vs. estimated values for these variables will
result in a power calculation error that often represents a significant change in
pump flow. A power calculation may be useful as a performance indicator,
particularly to determine if a pump is restricted by suction conditions or is
operating far out on its curve. However, motor calculations typically are not
well suited as a solitary indicator of pump performance.

With knowledge of the pump’s approximate performance relative to its rated

duty point, one may assess if the pump or a system parameter is the root cause
of the problem. If the process or system has undergone changes that adversely
affect the pump’s performance, the manufacturer should be consulted. In many
situations, modifications may be made to an existing pump to compensate for
system changes and reduce the operational costs associated a pump that is not
performing as expected.

1
If the curve is not readily available, the pump manufacturer can usually
provide one when given the pump model and serial number from the
name plate.
2
Net Positive Suction Head Available – The absolute pressure at the
impeller eye expressed in feet of head. This number must be greater than
the NPSHR (Net Positive Suction Head Required) provided by the pump
manufacturer. For a more complete discussion on cavitation
3
Actual test curves are likely to be more accurate than general catalog
curves. Catalog curve performance may deviate somewhat between
pumps due to casting and manufacturing variances. However, for the
purposes of troubleshooting as described herein, a catalog curve should
be adequate to provide a general indication as to whether a pump or
system problem exists.
4
Always check with the pump manufacturer regarding minimum flow.
Running small industrial pumps near shut-off is generally not a problem.
Running a large pump near shut-off may damage the pump or seals.
5
Horizontal pumps need some flow maintained through the pump to
prevent overheating. For most pumps a near shut-off pressure reading
will be sufficient to determine if the pump is capable of developing its
rated TDH.
 Troubleshooting & performance monitoring of centrifugal pump.

A sensible predictive maintenance program for centrifugal pumps is still an elusive

dream for most plants. Unexpected pump shut down continues to be the rule. Most
premature pump shutdowns are related to seal and bearing failures. The classic
predictive maintenance techniques of machinery history, visual inspection and
vibration analysis do not work well with products that fail prematurely, rather
than wear out.

 Vibration analysis tells you that the destruction has already begun, not that
it is going to happen. To use vibration analysis with mechanical seals we
would have to know the frequency of a seal and with the many designs
available, the wide choice of seal materials and the many fluids being sealed
that is just about impossible.
 Machinery history is only valid if the equipment experiences traditional
wear. Otherwise you are trying to predict an accident. Remember that no
one wears out seals and bearings. They always fail prematurely. The L10 life
of pump bearings is rated in hundreds of years. Seals are supposed to run
until the carbon wears down. When is the last time you saw one of those?
 Back up sealing is valid if you want to prevent unexpected seal shut down,
but outside of purchasing a backup pump this approach is not practical for
the bearings.
 Visual inspection of the remaining face carbon is possible with stationary
seal designs by installing a pin that sticks out the back of the gland. This
information would be valid if carbon faces wore out, but as you well know,
it seldom happens.

If we elected to monitor the pump performance and use this data to predict an
upcoming seal or bearing failure what exactly should we monitor? Lets look at
some of the options:

THE WET END OF THE PUMP

You can monitor:

 The temperature at the pump suction and discharge flanges.

 The pressure at the pump suction and discharge flanges.
 A proximity gage can record the distance between the open impeller and
the pump volute.
 Shaft deflection can be measured by proximity gages around the volute.
 Product flow can be measured by a variety of instruments without
penetrating the piping.
 Strain gages could tell you if the rotating shaft has locked up when the
pump is stopped.
 Vibration can be measured at several locations on the volute.
 Noise is easily detected and a valuable source of emerging problems.
 The amount of amperage being drawn by the motor combined with pump
flow and capacity can be an excellent indication of pump performance.

THE STUFFING BOX AND SEAL AREA

You can monitor:

 Stuffing box temperature.

 Stuffing box pressure.
 Liquid leakage out of the stuffing box, or air leakage in.
 Stuffing box jacket inlet and outlet flow
 Stuffing box jacket inlet and outlet temperature.
 Seal gland flush pressure, flow and temperature.
 The temperature, pressure and flow of the fluid between dual seals.
 Convection tank temperature, pressure and level.
 Quench temperate and flow.
 Vibration.

THE BEARING CASE

You can monitor:

 Oil temperature to let you know if the oil is about to form varnish or coke.
 Oil level.
 Case pressure.
 Shaft movement or thrust
 The amount of water present in the oil.
 Shaft speed.
 Vibration
 Cooling coil inlet and outlet temperature, pressure and flow.

In an ideal preventative maintenance program all of these readouts would be

incorporated into a single multi-pin outlet similar to the type found in all
automobiles manufactured in the past few years. This outlet would then feed the
information into a hand held computer that would be supplied with additional
information retrieved off a bar code, on a tag, hung on the pump.

The bar tag information could be entered by anyone familiar with the process in
addition to information supplied by both the pump and seal supplier. It would
contain data about the fluid you were pumping, critical dimensions, and
information about the bearing lubricant. It could include:

 The specific gravity of the fluid.

 The specific heat of the fluid and bearing lubricant.
 The temperature/pressure at which the fluids would change state and:
o Vaporize.
o Become viscous.
o Solidify.
o Coke.
o Build a film on the seal faces or sliding metal parts.
o Become a non-lubricant.
 The bar tag would also contain information about:
o The correct impeller clearance to the back plate or volute.
o The temperature limit of the bearing lubricant.
o The maximum differential temperature across the pump.
o The temperature limits of any of the seal components including the
faces and rubber parts.
o The pump BEP.
o Desired flow through the cooling/heating jacket. You get this from
the seal supplier.
o Desired level, pressure and temperature in the dual seal convection
tank.
o The specified flush amount.

Now that we have an idea about what we can monitor, exactly what is it we would
like to predict about pump performance? Wouldn't it be great to know the
following?

 The pump differential pressure, flow and amperage tells us if the pump is
running close to its best efficiency point? If it is of the BEP we're going to
have lots of problems:
o We will get excessive shaft deflection that translates to premature
wear ring, seal and bearing failure. The impeller could deflect into
the volute or back plate causing permanent damage to both pieces.
o The lost power will convert to unwanted heat that can change
critical shaft dimensions and tolerances. This can be a big problem
in the bearing area where internal clearances are very critical.
o You could break the shaft if the force generated is high enough.
 If the suction pressure decreases or the suction temperature increases there
is a probability that we going to have a cavitation problem during the
operation of the pump.
 Is the temperature or pressure change in the stuffing box going to affect any
of the seal components? Many of these affects are non-reversible.
 There are many face combinations used in mechanical seals. Too many of
them are sensitive to changes in temperature and pressure. Some ceramics,
filled carbons and plated hard faces are especially sensitive to temperature
changes.
 The elastomer (rubber part) is always sensitive to a temperature change
either up or down.
 Corrosion always increases with an increase in temperature. This can be
very important in acid applications.
 Seal flatness can be compromised in both high and low temperature
applications.
 A temperature change in the stuffing box can tell us if the product going to
change from a lubricating liquid to a non-lubricating gas or solid. Most of
these changes occur when the pump is shut down or a cleaner or solvent is
being flushed through the lines. Will shut down cause solid particles to
appear in the fluid? Every fluid has a maximum and minimum operating
temperature. Exceed these limits and all kinds of bad things happen. A
change in stuffing box temperature or pressure can cause a lubricating
liquid to :
o Vaporize and blow open the lapped seal faces.
o Crystallize and restrict the seal movement. Caustic is typical of this
type of problem.
o Become viscous and interfere with the seal movement.
o Solidify between the lapped seal faces and destroy them, as well as
restrict the free movement of the seal components..
o Build a film on the sliding seal parts restricting their movement and
separating the lapped faces. Both paint and hard water can do this.
o Become a non lubricant. This is a problem with hot water
applications that will lead to "slip stick" vibration problems between
the lapped seal faces.
o Cause the liquid to form solid particles that will get into the sliding
components and restrict their movement. This is the "coking
problem" we typically experience with all hot oil applications.
 Are the bearings in danger of failing?
 Is the lubricant temperature too high and increasing?
 Is the lubrication level too high or low?
 Has moisture penetrated the bearing case. Moisture can cause hydrogen
embrittlement problems in the bearing.
 Are the seal faces glued together at start up? Any product that can solidify
will cause this failure.
 When do you need an impeller adjustment? If you miss the clearance by as
little as 0.002 inches (0.05 mm) you will lose one percent of the pump's
capacity. This loss will be converted into heat and vibration.
 Do the wear rings need replacement? Internal recirculation wastes power
and increases the pump internal temperature. Ten degrees centigrade
 (18°F) is considered the maximum temperature rise allowable across the
pump volute.
 Are the seal's environmental controls functioning?
 Are you getting too much product dilution?
 Is the quench working?
 Is there enough stuffing box circulation to prevent the seal from being
overheated?
 Is the cooling jacket becoming clogged from a build up in calcium?
 Is the inner seal of a dual seal application functioning?
 Is the flush fluid doing its job?
 Is the stuffing box being maintained at the correct temperature- especially
at pump shutdown?

Now that we know what can be done, and any instrument technician should have
no problem figuring out how to install the indicators, what are you going to do
with the data you can collect? Here are some ideas.

First you need the base information:

 What should be the head, flow and power consumption at the best efficiency
point? You get this information right off the pump curve. You will need the
specific gravity of the fluid to convert the pressure reading from the gauge
to head units so that you can read the pump curve. Be sure to adjust the
numbers for the actual pump speed that you can read with a tachometer.
Use the affinity laws for this.
 What is the maximum and minimum temperatures the product can tolerate
without changing state from a liquid to a gas, crystal, solid, or becomes
viscous ? Your facility knows more about this subject than any one else.
Check with people in the engineering department or chemistry laboratory.
Production people are another source of this information.
 What are the upper and lower temperature limits of the seal elastomer. The
seal supplier can give you this information. Remember that there are
different grades of various elastomers. Be sure you are getting the
information about the grade you are using in your seal.
 Does the seal face combination have a temperature limit more restrictive
than the elastomer? This is a consideration in most metal bellows seal
designs. Make the seal people identify the material grade and have them
supply the temperature limits.
 Some seal designs have restricted pressure or vacuum limits. Check with
your seal supplier for this information. High pressure can cause elastomer
extrusion and deformation of the lapped seal faces.
 What is the maximum pump inlet temperature or minimum suction head to
prevent cavitation? The NPSHR information comes off the curve.
Remember that the curve was generated using water as the pumping fluid.
You will have to add the vapor pressure of your product to this number for
an accurate NPSH required.
  What is the proper open impeller clearance? Get this from the pump
supplier. You want the hot or operating clearance. You will need to use a
cartridge seal if you are going to adjust an open impeller without
interfering with the seal setting.
 What are the seal environmental control limits? The seal supplier has
specified a pressure, temperature and flow in most cases.

Now that we have the base information and the pump readings, we should be able
to prevent some of the most common seal and bearing premature failures.

 Is the pump about to cavitate? Cavitation can injure the seal components
and shorten the bearing life. You must solve the problem before the
cavitation begins. Cavitation can occur if :
o The pump capacity increases.
o The discharge head drops.
o The suction temperature rises.
o The suction pressure drops.
o The outside diameter of the impeller is too close to the volute
cutwater.
o The speed of the pump increases.
o Remember that the pump pumps the difference between the suction
and discharge heads. If the suction head is increased and the
discharge head is not increased the pump is now pumping at a lower
head and the capacity will increase along with the possibility of
cavitation.
 Is the product close to changing state in the stuffing box? If it does change
from a liquid to a gas or solid the seal failure will soon follow.
o Is the stuffing box temperature increasing?
 Maybe the cooling jacket is not functioning. Calcium may be
building up inside the jacket
 Maybe there is too much flow through the cooling jacket.
Remember that the cooling fluid should come into the bottom
of the cooling jacket and out the top.
 Has the shaft axial thrust over compressed the seal faces?
 Was the stuffing box vented in a vertical installation?
 Is there flow between the dual seals. Has convection stopped?
o Is the stuffing box temperature decreasing?
 Maybe the cooling jacket is too effective.
 Is the buffer or barrier fluid between the dual seals at the
correct temperature?
 Is the stuffing box pressure dropping?
 The discharge recirculation line may becoming clogged.
 Is the seal leaking?
 Have you accidentally hooked up suction recirculation instead?
 Is the impeller clearance correct? Too much slippage will generate excessive
heat and vibration. This heat and vibration will translate to premature seal
failure.
 Is the bearing oil too hot? If it is you're going to experience bearing failure.
o Too high an oil level or overfilling with grease is the most likely
problem.
 Face seals can maintain a positive pressure in the bearing case. As long as
you have a positive pressure in the bearing case there is not much fear of
water or solids penetrating into it. Water and solids along with the high
heat caused by over lubrication are the main problems you have to prevent.