PUMP TECHNOLOGY

ABOUT PUMPS

Contents

Objectives 3

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Types of Pumps 4-6

Parts of Pumps 7-9

Shaft Sealing 10-16

Classification of Centrifugal pumps 17-18

Sources of Pump Noise 19

Fastening 20-26

Pump Trouble Shooting 26-30

Lubrication 30-31

Objectives.

At the end of the program participants will be able to.

-Identify types of Pumps and their parts

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-Explain pump Shaft Sealing mechanisms

-Assemble and disassemble pumps using appropriate fasteners

-Carry out Pump trouble shooting

-Implement appropriate lubrication methods on Pumps.

Types of pumps
Positive displacement pumps

Gear Pump

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Oil is trapped between the gear teeth and housing from the suction side and delivered to the
discharge line.

Vane Pump

Pumped media is trapped between the vanes and housing and delivered to the discharge line.

Piston Pump

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When the suction valve opens the piston axial movement draws in pumped media during the
downward stroke. When the piston moves upwards the suction valve closes and the delivery
valve opens allowing pumped media to be deposited into the delivery line. The to and from
movement of the piston sustains the continuous flow of the pumped media.

Non-Positive Displacement Pumps

Centrifugal Pumps

Advantages of using a centrifugal pump

-Gives a steady flow at uniform pressure without the pressure surges of the reciprocating pumps.

-Can operate without the use of a safety valves

-Provides a great deal of flexibility, as its delivery can be controlled either by varying the speed
of operation or by throttling valves

Centrifugal Pump continued

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Principle of operation of a Centrifugal Pump

A Centrifugal Pump is a machine which consists of a set of vanes which rotate in a casing
imparting centrifugal force to the fluid. The media is pumped through positive or negative
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suction.

Parts of a Centrifugal pump.

a) Impeller.

-Heart of the pump which imparts centrifugal force to the fluid

-Determines working pressure of pump

-Can be single or double suction

-Can be open, semi-closed or closed

Shaft sleeve; protects the shaft from corrosion, erosion, and wear

Stuffing box;

-Prevents leakage of liquid from the pump and leakage of air into the pump Provides a reservoir
for coolant and lubricant for packing

-Prevents outflow of pumped fluid into the atmosphere e.g., chemicals, flammable, and
dangerous fluids

Lantern ring:

Forms a chamber where water is pumped forming an effective seal beyond which air cannot pass
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into the pump

Positioning of Lantern Ring in the Staffing Box

Packing; (asbestos, graphite)-Should not damage sleeve

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-Some pumps do not have staffing boxes but have mechanical seals

Shaft; this is where bearings and impeller are mounted

Bearings; Supports shaft in correct alignment to the stationery parts.

Coupling; Connects pump to the driver.

-Coupling can be flexible or rigid e.g., Falk, dog, fanner

Liners; Protects the pump casings on the wet end and frame plate.

SHAFT SEALING

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Sealing Types

1. Centrifugal Sealing (Also known as hydrodynamic or dynamic sealing)

Figure 1: physical arrangement of a centrifugal seal

Physical Arrangement and Operational Principle

A vanned expeller is mounted directly behind the pump impeller as shown in Figure 1 above.

Figure 2: Fluid engulfing impeller and expeller and leaking through shaft crevices

When the pump is stationary, fluid from the pump inlet engulfs both the impeller and expeller
and seeps through the crevices between the pump drive shaft and impeller housing. Ultimately
the fluid leaks through these crevices in what is commonly referred to as “pump leakage”.
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Once the pump starts running, the rotating expeller exerts hydrodynamic centrifugal force
onto the fluid forcing the fluid radially outward and away from the drive shaft. This creates
an air pressure ring around the back of the impeller which prevents the fluid from flowing
down the drive shaft towards the secondary seal area and eventually leaking out.

This type of seal only operates when the pump is rotating and has no seal effect when the
pump is stationery. A Secondary Seal maintains the liquid within the pump when it is
stationery. The centrifugal seal consists of expelling vanes on the back of the impeller located
in a separate chamber behind the impeller. The impeller acts as a turbine to reduce the
pressure of the slurry attempting to escape around the back of the impeller. The expeller
forms a pressure ring within the expeller chamber and prevents the slurry from passing into
the secondary seal area. The type of seal is effective and simple but is limited by inlet
pressure and the pump speed.

2. Gland Packing

The Gland Seal consists of a few soft packing rings, compressed in the staffing box
compressed against a protective wear sleeve which is fitted to the pump shaft. The seal
requires continuous supply of liquid for cooling purposes.
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 Figure 3: Cross-sectional illustration of Gland Packings

3. Mechanical Seal

These are not widely used in slurry applications, but their use in special circumstances is
increasing. The illustration below shows a leaking pump without a mechanical seal fitted on it.

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Figure 4: Leaking pump without mechanical seal

A Mechanical Seal will consist of a stationery face and a rotating face pressed together under
mechanical and hydraulic pressure to prevent leakage as shown below.

The stationary part of the seal is fitted to the pump housing with a static seal. This may be sealed
with an O-ring or gasket clamped between the stationary part and the pump housing as shown in
the image below.

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 O-ring or Gasket

The mechanical seal itself is the interface between the static and rotary portions of the seal. The
mechanical seal is essentially a spring loaded vertical bearing consisting of two extremely flat
faces, one fixed, one rotating, running against each other.  The seal faces are pushed together
using a combination of hydraulic force from the sealed fluid and spring force from the seal
design. In this way a seal is formed to prevent slurry leaking between the rotating (shaft) and
stationary areas of the pump.

The interface between the static and rotary faces of the seal is kept lubricated by maintaining a
thin film of fluid (from the pumped process fluid) between the two faces.

The need for a fluid film between the faces presents a design challenge - Allowing sufficient
lubricant to flow between the seal faces without the seal leaking an unacceptable amount of
process fluid, or allowing contaminants in between the faces that could damage the seal itself.
This is achieved by maintaining a precise gap between the faces that is large enough to allow in a
small amount of clean lubricating liquid but small enough to prevent contaminants from entering
the gap between the seal faces.

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Figure 5: Illustration of mechanical seal lubricating fluid film

The gap between the faces on a typical seal is as little as 1 micron – 75 times narrower than a
human hair.  Because the gap is so tiny, particles that would otherwise damage the seal faces are
unable to enter, and the amount of liquid that leaks through this space is so small that it appears
as vapor – around ½ a teaspoon a day on a typical application.

This micro-gap is maintained using springs and hydraulic force to push the seal faces together,
while the pressure of the liquid between the faces (the fluid film) acts to push them apart.
Without the pressure pushing them apart the two seal faces would be in full contact which would
cause dry running leading to rapid seal failure.

Comparison of seal types

Centrifugal Seal Gland Seal Mechanical Seal

Areas of  High speed continuous  Applicable when  Not suitable for slurry
Application pumping operations handling pumping as slurry is
since the centrifugal aggressively abrasive and grinds away
seal only seals fluid abrasive fluid the primary rotating ring
when the drive shaft is

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 rotating. The media of the mechanical seal
centrifugal seal leaks
when the drive shaft is  Suitable for clear liquid
stationary pumping applications
(Liquids without particles)
 A centrifugal (dynamic)
seal needs to be
combined with a
backup or static seal to
prevent leakage when
the pump is not running
e.g. gland seal (for
slurry applications) or
mechanical seal (for
clear liquid
applications)

Capital Cost Medium Low High

Maintainability Medium Easy Hard

Method of Removing and replacing Removing and repacking Replacement of entire mechanical
expeller once it is worn out gland seals once they are seal. Costly and requires pump to
Maintenance worn out or become over be taken out of service for a
compressed considerable amount of
maintenance time.

Classification of Centrifugal pumps.

a) Direction of flow of the impeller.

Radial flow impeller

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Axial flow impellers

Mixed flow impellers

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b) Types of impellers

-Closed impeller -vanes are enclosed

-Open impeller- vanes are open

-Semi-closed-closed one side

c) Types of Suctions

-Double suction

- Single suction

d) Casing type.

-Volute type

-Diffuser type

e) Axis of rotation of shaft.

-Horizontal or Vertical

Starting Procedure for a Centrifugal Pump.

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Open suction Valve to displace air and flood the pump

Ensure your delivery valve is closed

Start the part for a few minutes

Gradually open the delivery valve

Check your pressure and flow meters for operating parameters

Shutting down procedure for a Centrifugal Pump.

Close the delivery valve.

Switch off the pump.

Lock out the pump if you are carrying out maintenance work.

Drain the pump if it is a slurry pump.

Causes of Pump bearings temperature rise

- Overloading

-Minimum or lack of lubricant

-Too much lubricant

-Bearing damage

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- Misalignment

Sources of pump noise.

-Pump overload

-Poor matching of pump to conditions

-Mechanical looseness

-Cavitation

- Collapsed bearings

-Vibration of pump or its driver

-Transmit ion from poor mounted pipe work

CAVITATION

Cavitation is the formation of bubbles at the pump inlet, followed by their collapse, which can
cause permanent damage to the pump interior surfaces. The Net Positive Suction Head (NPSH)
is the difference between Net Positive Suction Head available (NPSHa) at the pump’s inlet and
NPSH required (NPSHr) by the pump to operate without cavitation. The NPSH margin value
must be positive to avoid cavitation.

Bolts

The purpose of a bolt assembly is to create some clamping force across the joined parts which
can sustain the operating conditions without loosening. A bolt has some elastic properties. When
load is applied to a bolt through tightening the nut it stretches and tries to retain to its original
length. Consequently, a compressive force is exerted across joints.

Determinants of bolt clamping force

 Bolt diameter
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  Geometry of the thread
 Coefficient of friction that exists in the mating surfaces i.e. thread.

Washers

Washers also exert axial force between the bolt head or nut and the work piece. When a nut is
tightened the washer is compressed. This has the effect of increasing the frictional drag
considerably thus preventing the fastener from becoming loose.

Advantages of using washers

1. Reduction of bearing stress

-Washers reduce the bearing stress on the joined surfaces by distributing the load over the washer
area.

2. Compressive force

-Washers exert compressive forces that prevent nuts and bolts from loosening during operation.

3. Protects bolts from burrs produced during hole drilling process.

4. They help distribute the load over an area larger than the head of the bolt and nut.

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Effects of over tightening or under tightening

Tightening Methods

Tightening of bolts and nuts can be controlled or uncontrolled.

Controlled Tightening
This involves use of calibrated and measurable equipment to tighten nuts and bolts. Prescribed
procedures are followed, and work is carried out by a trained people. This involves use of Torque
wrenches.

Uncontrolled Tightening
This involves use of equipment or procedures that cannot be measured. Tools used can include
spanners, impact wrenches etc.

Advantages of controlled tightening

-Bolt loads are known and can be accurately controlled

-There is uniformity of bolt loads.

-Operation is safe as prescribed procedures are followed.

-Results are reliable and repeatable

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-Maintenance time is reduced resulting in increased up time of Machinery.

-The right results are achieved the first time.

Safe Use of Spanners

The length of the spanner is directly related to the jaw size. This means that there is a protection
against overloading, and for safety reasons spanners should not be extended by using levers,
pipes, tubes etc. to gain extra tightness. If this is done there is serious risk of breaking the
fastener and/or injuring those carrying out the task.

ISO Bolt Grade Markings.

Steel is the most common fastener material. Steel fasteners are available plain as well as with
various surface treatments such as Zinc plating, galvanization, and chrome plating. Steel
fasteners are commonly available in four grades; Grade 2, Grade 5, Grade 8 and Alloy Steel.
Many other grades exist but are used far less often.

Determining Bolt Grade

The grade of a bolt is marked on the head. In addition to grade marking many bolts also have a
manufacturer’s mark. Below are a few selected grades of bolts.

Grade 2

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Grade 2 fasteners are made from low or medium carbon steels. They are the most common grade
of steel fasteners and are the least expensive. Except for a possible manufacturer’s mark, Grade 2
bolts have no head markings. Their class is 5.8.

Grade 5 /Grade F

Grade 5 bolts are made from medium carbon steel which is quenched and tempered. They are
hardened to increase strength and are the most common bolts found in automotive industry.
Some Grade 5 bolts have 3 evenly spaced radial lines on the head. Their class is 8.8. and 9.8.

Grade 8/ Grade G

Grade 8 bolts are made from medium carbon alloy steel which is quenched and tempered and are
stronger than grade 5 bolts. Thus, they are stronger and are used in demanding applications such
as automotive suspensions. They may have 6 evenly spaced radial lines on the head. Grade G is
roughly equivalent to Grade 8 bolts. Their class is 10.9.

Alloy Steel

Alloy Steel bolts are made from a high strength steel alloy and are further heat treated. Alloy
steel bolts are typically not plated, resulting in a dull black finish. Alloy steel bolts are extremely
strong but very brittle. Their class is 12.9 but do not have a grade.

General Torque Table

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Pump Trouble Shooting Guideline

No Liquid Being Pumped

Potential Cause How to Fix

Ensure the pump and volute are completely full of liquid before operating the
Pump is not primed pump. If any air is trapped in the pump,
it will not operate correctly.

Check for leaks in the pump, pipeline, and couplings which

could cause air to enter the pump. If you suspect air in the
Pump loses prime
pump, make sure to vent volute/casing to remove trapped
air before resuming pumping.

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 Check the pipeline for friction losses and ensure the static lift
is not too high. If the static lift is too high, you’ll need to lower
Suction lift is too high
the pump closer to the source material or raise the material
closer to the pump.

Suction line is clogged Remove obstruction.

Static discharge head is

Check pipe friction losses, use larger discharge pipes.
too high

Ensure the motor is receiving the required voltage and

Rotor speed to low
correct frequency if using a variable frequency drive.

Check the motor rotation direction as indicated by arrows

Rotor spinning the wrong
on the pump casing. Make sure the rotor is spinning in the
direction
correct direction when the pump is in operation.

Rotor is clogged or Disassemble the pump and volute to clear the rotor jam or
jammed clog.
 

Flow Rate is Too Low

Potential Cause How to Fix

If liquid pumped is water, test flanges for leakage with

Air leaks in the

flame or
suction hose
match. For such liquids as gasoline, the suction line can be
tested by shutting off or plugging inlet and putting the line under pressure. A gauge w
indicate a leak with a drop of pressure.

Air leaks in the Increase the lubricant pressure to exceed atmospheric pressure, effectively locking air
stuffing box out of the stuffing box.

Check Net positive suction head required (NPSHR) is the pressure or energy required fo
the liquid in a pump to overcome the friction losses from the suction nozzle to the eye o
Cavitation
the impeller without) and NPSHa, you may not have enough positive suction head for
what is required.

Defective rotor Open up the pump and volute casing to inspect the rotor
for damages. If the rotor has been damaged, ensure it is

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 repaired or replaced prior to powering on the pump.

Defective packing Inspect and replace packing if sufficiently worn.

Ensure the rotor is spinning in the correct direction by

Rotor spinning the
comparing it with the indicator on volute. A rotor or impeller spinning in the wrong
wrong direction
direction could damage the pump.
 

Low Suction
Potential Cause How to Fix

Clogged suction strainer Clean out the strainer and ensure it is free from obstructions
or inlet which could clog the suction inlet.

Insufficient hydraulic Ensure the pump motor is filled to proper hydraulic fluid levels. Consult the
fluid manual for your hydraulic equipment for proper fluid levels.

Leak in the suction

Inspect and repair pipeline or hose for leaks.
pipeline or hose

Insufficient suction
Raise the liquid tank level closer to the pump.
pressure

Worn check valves Clean or replace broken or worn-out valves to ensure proper operation.
 

Pump Motor Won’t Start

Potential Cause How to Fix

Clean out the strainer and ensure it is free from obstructions which could clog the
Blown fuse or breaker
suction inlet.

Starter overheating Correct cause of thermal overload and reset the motor.

Low line current Inspect lines and fix the problem.

Motor damaged Check for physical damage to motor, repair, or replace as needed.
 

Pump Motor Overheating

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Potential Cause How to Fix

Operating motor in excess of rating Limit discharge pressure to max specified by the motor manufacture

Improper wiring or voltage too low Check power supply vs motor nameplate details for correct specs.

Hydraulic oil too viscous Drain and refill with the correct type of oil.

High ambient temperatures Increase ventilation or relocate pump to a cooler area.

 

Pump Periodic Maintenance Routine

Check temperatures.

Daily Check cavitation & bearing noise.

Check motor current and voltage.

Check suction & discharge pressures.

Weekly Check vibration & noise.

Visual check for seal leakage.

Remove the safety guards and inspect the pump shaft.

Monthly Check for coupling alignment.

Fill lubrication oil.

If the pump is a spare, run the pump and check for any maintenance issues.

Check for any axial movement of the motor shaft.

Annually Remove and clean all auxiliary components including valves, manometers, pipe
and hoses.

Remove couplings and inspect for wear on rubber parts.

Every 2 Years or 10000 Dismantle pump and inspect: impeller, wear rings/plates, O-rings, pump shaft.
Hours Apply coating to un-machined surfaces.

LUBRICATION

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It is the prevention of metal-to-metal contact of surfaces in contact through use of oils and
greases. Lubricants are made from 90%mineral and vegetable oils and 10% additives.

Forms of lubricants.

-Solid-graphite, molybdenum disulphide, Tungsten disulphide

-Semi-Liquid-Greases

-Liquid-Oils

Purpose of Lubricants.

-Reduce friction-2% of lubricant is used for friction prevention-oil thickens when pressurized

-Transfer heat-cooling-98% of lubricant- Gear Box bulk temperature should be less than 95
degrees

-Carry away debris

-Transmit power

-Protect against wear

- Prevent corrosion

-Seals against dirt

Principles/Regimes of lubrication

-Hydrostatic Lubrication-Application of external hydraulic pressure in a bearing to maintain

lubricant film to avoid metal to metal conduct

-Hydrodynamic lubrication-design of the bearing is used to pump lubricant around the bearing to
maintain lubricating films. Bearing can get worn out due to start - stop and reversal of direction.

-Boundary lubrication-load is carried by surface asperities rather than the lubricant

- Electrohydrodynamic lubrication-oil acting as a solid parting agent due to its pressure and
plastic deformation of the mating surfaces in conduct.

Methods of Lubrications

- Flood/Bath

- Force feed

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- Total loss

-Splash

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