Training of API Pumps

Deep Blue
大连深蓝泵业有限公司
DALIAN DEEP BLUE PUMP CO.,LTD
Training of API pumps
11.2015
先进的技术优质的产品完善的服务

Advanced Technology Excellent products Perfect Service
大连深蓝泵业
1. What is Centrifugal Pump?
• A centrifugal pump is a kinetic machine conve

rting mechanical energy into hydraulic energy
through centrifugal activity.

Advanced Technology, Excellent products, Perfect Service
大连深蓝泵业
2. Types of Centrifugal pumps
2.1 Impeller overhung type(OH)

The impeller (or impellers) is mounted on the end of a shaft th
at is cantilevered or "overhung" from its bearing supports.

大连深蓝泵业
2.2 Impeller between bearing type(BB)

The impeller (or impellers) is mounted on a shaft with bearing
s at both ends. The impeller is mounted "between bearings."
Stablized pumps and export pumps are BB type.

大连深蓝泵业
2.3 Impeller vertically suspended type(VS)

Vertical-axis pump whose liquid end is suspended from a colu
mn and mounting plate.
Export boost pumps are VS type.

大连深蓝泵业
3. Main pump's parameters
3.1 Rate of flow (capacity)
The rate of flow of a pump is the total volume throughput per

unit of time at suction conditions. The term "capacity" is also u
sed.

大连深蓝泵业
3.2 Speed
The number of revolutions of the shaft in a given unit of time.

Speed is expressed as revolutions per minute.
3.3 Total head (H)
This is the measure of energy increase per unit weight of the l

iquid, imparted to the liquid by the pump, and is the difference
between the total discharge head and the total suction head.

大连深蓝泵业
3.4 Pump efficiency
This is the ratio of the energy imparted to the liquid by the pu

mp (P w ) to the energy delivered to the pump shaft (P p ) exp
ressed in percent.

大连深蓝泵业
4.0 Preparation of operation
4.1 Lifting
A 、 Lift position requirements
Note ： The lifting positions of various types of pumps are different.
B 、 There is a demand of lifting weight:it is forbidden to lift the complete pu
mp if the weight of it is over 7.5 ton , lift the pump, motor , baseplate singly .
Finally , assemble on the basis of equipment in the field .
Note ： The lifting weights of various types of pumps are different.

大连深蓝泵业
4.2 Alignment
The alignment of coupling should be proceeded after the base has been fixe
d absolutely. Non-alignment might lead to damage of coupling, even pump a
nd drive device.
NOTE: Gagging bolt of Metastream coupling should be removed after alig

nment.

大连深蓝泵业
Alignment Requirement
Hub diameter of Radial displacement Axial declivity
coupling （ mm ） y （ mm ） Z （ mm ）
≤200 ＜ 0.05 ＜ 0.2/1000
200 ＜ D≤300 ＜ 0.08 ＜ 0.3/1000
300 ＜ D≤400 ＜ 0.10 ＜ 0.4/1000
400 ＜ D≤600 ＜ 0.10 ＜ 0.5/1000

大连深蓝泵业
Correcrt Suction Piping Arrangment

大连深蓝泵业
4.3.2 Discharge piping
Generally both a check valve and a gate valve are installed in the discharge l
ine. The check valve is placed between the pump and the gate valve and pro
tects the pump from reverse flow in the event of unexpected driver failure or f
rom reverse flow from another operating pump. The gate valve is used when
priming the pump or when shutting it down for inspection and repairs. Manua
lly operated valves that are difficult to reach should be fitted with a sprocket ri
m wheel and chain. In many cases, discharge gate valves are motorized and
can be operated by remote control.

大连深蓝泵业
4.3.3 Vent piping
Except self-vent pump all the pump should be installed vent piping for startin
g up. Vent piping also should be designed on the pump piping to avoid air loc
k. The vent piping can vent directly or vent to a closed vent system accordin
g to the pumping medium.
Vent piping including: Discharge piping top vent
Boost pump Can vent
Boost pump seal vent

大连深蓝泵业
4.4 Instrumentation
There are a number of instruments that are essential to maintaining a close chec
k on the performance and condition of a pump.
All the instruments should be setted correctly.
Pumps' related instruments alram and trip are as listed.
YAP1-JS-NM-LE-65
01 attachment EXPORT PUMP.xls

大连深蓝泵业
5. Operation
5.1 The inspection before commissioning/Start-up
A.Ground bolts should have been fixed. The second grouting should meet the d
esigning requirement, surface work should be finished.
B.Cooling, pre-heating, lubricating, seal washing systems and process lines are
connected correctly, without leakage.
C.All gauges are sensitive and precision.
D.Motor’s insulating resistance and rotation direction should comply with the des
ign specification (rotating direction should be subject to pump’s direction arrow),
disassemble the coupling to confirm the direction of the driver. Start the driver c
ommissioning first, if drived by motor, it should run with no-load more than two h
ours;

大连深蓝泵业
• E.Add lube or grease comply with the technical documents to the lubrication
location;
• F. Final check the alignment .

大连深蓝泵业
5.2 Preparation for commissioning/start up
A 、 Priming the pump.
Before start-up, all pumps must priming (the casing must be fully filled wit
h the medium) except submerged pump.
B 、 Lubrication oil or grease has been filled correctly.
C 、 Open the valves in the inlet pipeline and close all the drainage piping
, rotate the rotors slowly, close the vent valves until there is no air bladder
.
D 、 Rotate the shaft by hand to check whether the equipment runs well o
r not;
E 、 Ensure the rotation先进的技术

direction is优质的产品
right; 完善的服务
大连深蓝泵业
5.3 Start-up/commissioning procedure

1.Open the valve in the recirculating line if the pump should not be operated
against dead shutoff. 　
2. Start up the motor.
3. Open the discharge valve slowly until the capacity reaches the given value.
4. For pumps equipped with mechanical seals, check for seal leakage: there
should be none.
5. Check the general mechanical operation of the pump and motor.
6. Close the valve in the recirculating line when there is sufficient flow through
the pump to prevent overheating.

大连深蓝泵业
•Note-The contract motor is selected according to the actual specific gravity of

pumping liquid as required by customers. Before commissioning with water, it s
hould be considered if the motor could stand the water power. If the liquid’s act
ual specific gravity is lower than water, when commissioning with water, please
control the valve’s opening well to avoid the overload of the motor and even da
mage. If necessary please contact the pump manufacturer.

大连深蓝泵业
5.4 Stop procedure

1. Open the valve in the recirculating line.
2. Close the gate valve.
3. Stop the motor.
4. Close the suction valve, open the drain valves, and so on, as required by th
e particular installation or if the pump is to be opened up for inspection.

大连深蓝泵业
5.5 Forbidden action during commissioning/start-up
-Must avoid the overload, because that’s may damage the mechanic
al parts. If the pump is running over its performance scope, that will be ov
erloaded. e.g.
-Exceed the maximum allowable rotational speed.
　　 -Exceed the maximum allowable suction pressure.
　　 -Exceed the maximum allowable temperature.

大连深蓝泵业
• -Exceed or below the pump’s allowbale operation zone.
• -Operate with the residual gas in casing.
　 -Operate without necessary safe guard(emergency valve, over power prot

ection and so on)
• -Operate when the discharge valve shutting of and without the minimum fl
ow equipment.

大连深蓝泵业
Runing in the case of close the inlet valve(dry run)

Runing in the case of materials of pump is not suitable for conveying me
dium
Runing in the wrong turn
Runing in the way of using incorrect or lubricant bearing lubrication
As the above operation mode and other incorrect operation method for
pump and other equipment will produce great damage. Fragments cause
d by the explosion of the pressure parts or hot, corrosive and toxic mediu
m will do great harm to people or the environmen.

大连深蓝泵业
5.6.Inspection and acceptance of pump commissioning
-Pump should be carried out under the rated load during commissioning. It allows to u
se water as a medium for commissioning.
-During the pump running, the temperature rise of the rolling bearing temperature ris
e shall not exceed 40 ℃, the highest temperature should not exceed 80 ℃
-Pump vibration value should comply with the provisions of the technical documentati
on or relevant standards,Horizontal pump less than 3mm/s;Vertical pump less than 5
mm/s;
-Motor working current shoud be still less than the rated current in nameplate.Overloa
d is not permitted in anytime. When use water for commissioing, should control the cu
rrent shall not exceed the rating of the motor;

大连深蓝泵业
6.The operation of pump
Since the commissioning medium is different from the pumping medium, drainage
all the commissioning medium and then clear the chamber and the piping, if necessa
ry disassemble the pump to check.
All the start and stop procedure is same as commissioning.

大连深蓝泵业
6.1 .Centrifugal pump control philosophy
Pumps in operation process needs to regulate(close or open) discharge val

ve to control the flow and head, theoretical analysis is adjusting site curve to
match the pump's performance curve to reach the rated conditions.
Head of delivery( m)  Density of liquid(kg / m 3 )

Pr essuer( MPa) 
102040
Total Head = outlet pressure- inlet pressure

大连深蓝泵业
6.2 How to adjust pump's working point
The actual pump working point is the intersection of pump curve and site c
urve.
Adjust site curve by controling discharge vlave analysis figure

H R ----Q
R1 ----Q
R2----Q
Analysis:Closing the outlet valve, the working
point move over to the left.Open the outlet val
ve, the working point move to the right
H ----Q

大连深蓝泵业
7. Maintenance
7.1 Daily Observation of Pump Operation
When operators are on continuous duty, hourly and daily inspections sh

ould be made and any irregularities in the operation of a pump
should be recorded and reported immediately.Such as:
Particularly to changes in sound of a running pump;
Abrupt changes in bearing temperatures;
Seal chamber leakage;

大连深蓝泵业
7.2 Semiannual Inspection
The following should be done at least every six months:
The pump and driver alignment should be checked and corrected i

f necessary.
Housings for oil-lubricated bearings should be drained, flushed, an

d refilled with resh oil.
Grease-lubricated bearings should be checked to see that they co

ntain the correct amount of grease and that it is still of suitable con
sistency.

大连深蓝泵业
7.3 Annual Inspection
A very thorough inspection should be performed once a year. In

addition to the semiannual procedure, the following items should be c
onsidered:
1. The bearings should be removed, cleaned, and examined for flaws

and wear.
2. The bearing housings should be carefully cleaned.
3. Rolling element bearings should be examined for scratches and we
ar.
4. Immediately after cleaning, rolling element bearings that are consid
ered acceptable for reinstallation should be coated with oil or grease.
Note: If there is any sign of damage, or if the bearings were damaged
during removal, they should be replaced with new bearings of the corr
ect size and type per the IOM.

大连深蓝泵业
For pumps equipped with mechanical seals, if the seals were indicating si
gns of leaking,they should be removed and returned to the seal manufact
urer for inspection, possible bench testing, and refurbishment.
Anyway, we will study how to solve the simple leakage during on jo

b site training.
When coupling halves are disconnected for an alignment check, the vertic
al shaft movement of a pump with sleeve (journal) bearings should be ch
ecked at both ends with packing or seals removed. Any movement excee
ding 150% of the original design clearance should be investigated to dete
rmine the cause.

大连深蓝泵业
7.4 Mechanical seal and system

大连深蓝泵业
Plan 53B PID

大连深蓝泵业
7.4.1 Plan 53B function
1. To provide seal lubrication

2. Remvove the heat frrom seal and system
3. Monitor inner and outer seal condition
7.4.2 Barrier fluid selection
Barrier should be with stable properties over the operating temperatur

e and pressure condition,and not contain any hazard or potential poluti
on to the environment. Should have godd lubricating properties, viscosi
ty<15cst@40℃ and not compatiblewith process fluid.ISO 21049 /API
682 also offer the selection guiid to the selection of barrier.

大连深蓝泵业
7.4.3 Seal system preparation before commissioning
1. For Plan 53B system, using an accumulator precharge kit to charge

the nitrogen to the rated pressure usually 5~6 barg;
2.Open the barrier filling connection and vent valve.
3. Fill the barrier until it flows from the vent connection.
4.Close the vent valve and continue pressuring the system until and ba
rrier pressure reach the requested in the technical document.
Note: Usually the minimum barrier pressure should be at least 10% or
1 bar above the seal chamber pressure.
5. Carefully check all connection to ensure on leakage.
6. open te pressure gauge and transmitter isolating valves.

大连深蓝泵业
7. Close fill line.

8. Check all the isolating valves in the circut between the reservoir and
seal are fully open
9. Check that all the electrical instruments are correctlly connected.
10 Satrt pump and check the barrier pressure does not rise beyond the
setting one.Usually, working and stop barrier pressure should be no sig
nificant fluctuation.
11. Check the barrier tepmerture below the barrier allowable working te
mperature.Usually it lshould be less than 80℃ 。
Note: If the pump will stop for long time,the system should be de
pressured.

大连深蓝泵业
7.4.4 Plan 53B system maintenance
1. Check all the connection without any leakage.

2. Temprature below the requirement.
3. Mechanical seal can not achieve the zero leakagg,thus barrier press
ure will drop after some time working.Ususally, barrier need to be refille
d every 6 months. The higher barrier pressure, the shorter refilling peri
od.

大连深蓝泵业
7.5 Mechanical seal
7.5.1 Mechanical seal construction

大连深蓝泵业
7.5.1 Mechanical seal philosophy
The hydraulic pressure and the spring force press the axially flexible pri
mary ring against the stationary mating ring. Wear at the primary seal is
minimised by a very thin lubricating film. Lubrication is provided by the s
ealed fluid; in the case of gas.With very low contact loads special seals
can be operated without a liquid lubricant. The leakage is minimised by
flat lapping to a fine surface finish.

大连深蓝泵业
7.5.2 Mechanical seal installation
Carefully protect the lapped sealing surfaces of primary and mating ring
s during fitting. Minor damages to sensitive surfaces, such as scratches
and chips, reduce the sealing effectiveness of the mechanical seal.
Lubricate shaft with a suitable fluid in the installation area
Lubricate the shaft and housing sealing components with a suitable flui
d
The seal faces should not be lubricated with oil or grease as this may pr
event introduction of the sealed fluid in operation, leading to overheatin
g and failures.

大连深蓝泵业
Ensure the seal arrangement is orientated correctly, according to the ho

using, pipework, and shaft connections (e.g. studs, keyways, pins and d
rive holes).
Slide the seal assembly over the shaft and into position.
Tighten fasteners evenly to the torque levels indicated in the installation
drawing.
For cartridge seal designs that do not have a metal-to-metal contact bet
ween the gland plate and the seal chamber face it is important they are
aligned and the axial gap between them is equal around its circumferen
ce. This can be checked with a gap gauge.

大连深蓝泵业
If possible check for freedom of movement by hand turning the shaft.

Ensure all porting is correctly connected and the intended fluids flow at
the correct flow rate.
All unused connections must be safely plugged with the as-supplied me
tal pipe plugs. Check whether drain connection should be open or piped
to a collection area.
Ensure all pipework on liquid barrier/buffer systems and cooling circuits
are orientated to ensure effective venting.
Visually check for any damage and leaks.
7.5.3 Mechanical seal remove

Removal is essentially the reverse procedure to installation.

大连深蓝泵业
7.4 Records of Inspections and Repairs

The working schedule of the semiannual and anual inspections should be ent
ered into a log that tracks individual pump maintenance history. This log shoul
d then contain a complete record of all the items requiring attention.This log, u
sually electronic, should also contain comments and observations on the cond
itions of the parts to be repaired or replaced, on the rate and appearance of w
ear, and on the repair methods followed. In many cases, it is advisable to phot
ograph badly worn parts before they are repaired.
In all cases, complete records of the cost of maintenance and repairs should
be kept for each pump, together with a record of its operating hours.A study of
these records will generally reveal whether a change in materials or even con
struction may be the most economical course of action to improve pump perfo
rmance, reliability, and life.
大连深蓝泵业
8. Trouble shooting and analysis
Trouble:The installation process are not to be able to aligning

These reason might lead the problems
 the import and export of pipeline stress is too h
igt,
 poor transportation and hoisting lead to deform
ation of the base.
 Pump is not in initial alignment.
Trouble ： Pump turning tight

 Import and export pipeline stress is too high,
especially the single cantilever pump.
 The pump cavity with sundry, lead to friction p
air jamming.
 Pump precooling or preheat does not reach t
he designated position
 Wear ring to beat super poor

大连深蓝泵业
Trouble ： Pump's capacity and head

less than required
 Not completely filled with liquid pump suction pipe
 Effective enough NPSH, pump cavitation phenomenon.
 Suction line contains air bubbles
 Pump in a closed or inlet valve without full open operatio
n
 The inlet piping or filter clogging
 Impeller flow channel plugging
 Pump speed did not reach the design requirements
 Pump rotation error
 The impeller diameter smaller than rules
 The design of the system total pressure head is higher th
an the pump,
 Pump parallel operation is not suitable for use,
 Liquid viscosity is greater than the design conditions
 The friction pair clearance is too large or flow component
s by corrosion. Instrument, instrument is not accurate

大连深蓝泵业
Trouble ： Pitting ,corrosion, abrasion of t

he rotating components
 The material of the pump is not suitable for
conveying fluid
 Medium composition change
 Medium containing particles quantity or
hardness value within the prescribed scope
 Pump serious cavitation phenomenon
Trouble ： Bearing housing leak
 Oil level is too high (self-lubrication form), the
import oil pressure is too high or poor oil retur
n (forced lubrication form).
 Dust-proof plate with gland large clearance or
damage of o-ring.
 Oil cup leakage
 Filling oil method is not correct

大连深蓝泵业
Trouble ： Excessive vibration or noise

 In the running speed and foundation slab or line
produce resonance between natural frequency.
 Piping layout or suppor unreasonablet, lead to
water impact.
 Pump running below the recommended minimu
m flow.
 Pump speed is higher than design value
 Coupling is out of register or pump in different li
ne.
 Inadequate rigidity or base grouting is not suffici
ent
 It occur cavitation phenomenon.
 Friction pair scratches or take the balance of th
e balancing device was damaged.
 Impeller blades and volute tongue or clearance
between guide vane is too small.
 The rotor imbalance.

大连深蓝泵业
Trouble:Pump bearing temperature to

o high or unable to turn

 pump in the lower than the minimum capa
city point
 Coupling is out of register or pump in diffe
rent line
 Bearing with impurities in the box or oil lev
el not enough in the oven
 Bearing cooling water in terrible circulation
 Bearing clearance is too small
 Bearing improper installation in the wrong
way
 Pump axial force is too large
 The rotor imbalance.
 Lubricating oil viscosity is too large,in terri
ble circulation .

大连深蓝泵业
Trouble ： Pump overload current

 Pump run above the design capacitye poi
nt (export valve opening is too big)
 Medium density or viscosity is too large in
conformity with design conditions
 Instrument, electrical misalignment
 The impeller diameter is larger than the de
sign requirements
 Friction pair scratches or gap is too big

大连深蓝泵业
Trouble ： Mechanical seal leakage
These reason might lead the proble

ms
 Sealing fluid (buffer, spacer) in terrible c
irculation or no rinses, lead to seal face
dry.
 Sealing liquid containing impurities, res
ulting in seal face scratches.
 Mechanical seal form made mistake sel
ection to the main operating mode
 Seal compressed volume adjustment or
installation is not correct
 Pump running under or near the critical
speed

大连深蓝泵业
Thank you!
Company: Dalian Deep blue pump Co., Ltd

Address: Dalian City, Liaoning Province , China
Postcode ： 116031
Website ： http:// www.deepbluepump.com
E - mail: Overseas@ddbp-intl.com
Fax No. ： +86 411-86429455


Training of API Pumps

Uploaded by

Copyright:

Available Formats

You might also like

Training of API Pumps

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Training of API Pumps

Uploaded by

Copyright:

Available Formats

Deep Blue

Training of API pumps

先进的技术 优质的产品 完善的服务

1. What is Centrifugal Pump?

• A centrifugal pump is a kinetic machine conve

先进的技术 优质的产品 完善的服务

2. Types of Centrifugal pumps

2.1 Impeller overhung type(OH)

先进的技术 优质的产品 完善的服务

2.2 Impeller between bearing type(BB)

先进的技术 优质的产品 完善的服务

2.3 Impeller vertically suspended type(VS)

先进的技术 优质的产品 完善的服务

3. Main pump's parameters

3.1 Rate of flow (capacity)

The rate of flow of a pump is the total volume throughput per

先进的技术 优质的产品 完善的服务

The number of revolutions of the shaft in a given unit of time.

3.3 Total head (H)

This is the measure of energy increase per unit weight of the l

先进的技术 优质的产品 完善的服务

3.4 Pump efficiency

This is the ratio of the energy imparted to the liquid by the pu

先进的技术 优质的产品 完善的服务

4.0 Preparation of operation

先进的技术 优质的产品 完善的服务

NOTE: Gagging bolt of Metastream coupling should be removed after alig

先进的技术 优质的产品 完善的服务

先进的技术 优质的产品 完善的服务

Correcrt Suction Piping Arrangment

先进的技术 优质的产品 完善的服务

4.3.2 Discharge piping

先进的技术 优质的产品 完善的服务

4.3.3 Vent piping

先进的技术 优质的产品 完善的服务

All the instruments should be setted correctly.

Pumps' related instruments alram and trip are as listed.

先进的技术 优质的产品 完善的服务

5.1 The inspection before commissioning/Start-up

先进的技术 优质的产品 完善的服务

• F. Final check the alignment .

先进的技术 优质的产品 完善的服务

5.2 Preparation for commissioning/start up

A 、 Priming the pump.

B 、 Lubrication oil or grease has been filled correctly.

E 、 Ensure the rotation先进的技术

5.3 Start-up/commissioning procedure

先进的技术 优质的产品 完善的服务

•Note-The contract motor is selected according to the actual specific gravity of

先进的技术 优质的产品 完善的服务

5.4 Stop procedure

先进的技术 优质的产品 完善的服务

5.5 Forbidden action during commissioning/start-up

-Exceed the maximum allowable rotational speed.

-Exceed the maximum allowable suction pressure.

-Exceed the maximum allowable temperature.

先进的技术 优质的产品 完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

　　 -Exceed the maximum allowable suction pressure.

　　 -Exceed the maximum allowable temperature.

先进的技术优质的产品完善的服务

　 -Operate without necessary safe guard(emergency valve, over power prot

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务

先进的技术优质的产品完善的服务