Section B -- Pump Application Data B-1 Corrosion & Materials of Construction Selecting the right pump type and

sizing it correctly are critical to the success of any pump application. Equally important is the selection of materials of construction. Choices must be made between metals and/or non-metals for pump components that come into contact with the pumpage. In addition, gas ets and !-ring material selections must be made to assure long lea -free operation of the pump"s dynamic and static sealing #oints. $o assist in proper selection, included in this section is a brief discussion of specific types of corrosion and a general material selection guide. Corrosion Corrosion is the destructi%e attac of a metal by chemical or electra-chemical reaction with its en%ironment. It is important to understand the %arious types of corrosion and factors affecting corrosion rate to properly select materials. TYPES OF CORROSION &. 'al%anic corrosion is the electro-chemical action produced when one metal is in electrical contact with another more noble metal, with both being immersed in the same corroding medium called the electrolyte. ( gal%anic cell is formed and current flows between the two materials. $he least noble material called the anode will corrode while the more noble cathode will be protected. It is important that the smaller wearing parts in a pump be of a more noble material than the larger more massi%e parts, as in an iron pump with bronze or stainless steel trim. )ollowing is a gal%anic series listing the more common metals and alloys. Corroded End *(nodic, or least noble+ ,agnesium ,agnesium (lloys -inc (luminum .S Cadmium (luminum &/0$ Steel or Iron Cast Iron Stainless Steel, 122 Series *(cti%e+ Stainless Steel, $ype 321 *(cti%e+ Stainless Steel, $ype 3&4 *(cti%e+ 5ead-tin Solders 5ead $in 6ic el *(cti%e+ 6ic el base alloy *acti%e+ 7rasses Copper 7ronzes Copper-6ic el (lloy ,onel Sil%er Solder 6ic el *8assi%e+ 6ic el 7ase (lloy *8assi%e+ Stainless Steel, 122 Series *8assi%e+ Stainless Steel, $ype 321 *8assi%e+ Stainless Steel, $ype 3&4 *8assi%e+ Sil%er

'raphite 'old Platinum Protected End *Cathodic, or most noble+ .. 9niform Corrosion is the o%erall attac on a metal by a corrod-ing liquid resulting in a relati%ely uniform metal loss o%er the e:posed surface. $his is the most common type of corrosion and it can be minimized by the selection of a material which offers resistance to the corroding liquid. 3. Intergranular corrosion is the precipitation of chromium carbides at the grain boundaries of stainless steels. It results in the complete destruction of the mechanical properties of the steel for the depth of the attac . Solution annealing or the use of e:tra low carbon stainless steels will eliminate intergranular corrosion. 1. 8itting Corrosion is a localized rather than uniform type of attac . It is caused by a brea down of the protecti%e film and results in rapid pit formation at random locations on the surface. 0. Cre%ice or Concentration Cell Corrosion occurs in #oints or small surface imperfections. 8ortions of the liquid become trapped and a difference in potential is established due to the o:ygen con-centration difference in these cells. $he resulting corrosion may progress rapidly lea%ing the surrounding area unaffected. 4. Stress Corrosion is the failure of a material due to a combina-tion of stress and corrosi%e en%ironment, whereas the material would not be affected by the en%ironment alone. /. Erosion-Corrosion is the corrosion resulting when a metal;s protecti%e film is destroyed by high %elocity fluids. It is distinguished from abrasion which is destruction by fluids containing abrasi%e solid particles. pH VALUES $he p< of a liquid is an indication of its corrosi%e qualities, either acidic or al aline. It is a measure of the hydrogen or hydro:ide ion concentration in gram equi%alents per liter. p< %alue is e:pressed as the logarithm to the base &2 of the reciprocal of the hydrogen ion concentration. $he scale of p< %alues is from zero to &1, with / as a neutral point. )rom 4 to zero denotes increasing hydrogen ion con-centration and thus increasing acidity, and from = to &1 denotes increasing hydro:ide ion concentration and thus increasing al alinity. $he table below outlines materials of construction usually recommended for pumps handling liquids of nown p< %alue pH Value Material of Construction &2 to &1 = to &2 4 to = 1 to 4 2 to 1 Corrosion >esistant (lloys Iron, Stainless Steel, 7ronze, Carbon Steel

Corrosion >esistant (lloys

$he p< %alue should only be used as a guide with wea aqueous solutions. )or more corrosi%e solutions, temperature and chemical composition should be carefully e%aluated in the selection of materials of construction. B-2 Material Selection Chart $his chart is intended as a guide in the selection of economical materials. It must be ept in mind that corrosion rates may %ary widely with tem-perature, concentration, and the presence of trace elements or abrasi%e solids. 7lan spaces in the chart indicate a lac of accurate corrosion data for those specific conditions. In general, the chart is limited to metals and nonmetals regularly furnished by I$$-'oulds. Note: ,a:imum temperature limits are shown where data is a%ailable. Contact a 'oulds representati%e for temperature limits of all materials before final material selection. Code:
A Recommended

B X Steel Brz 316 A-20 Allo$ 220% Allo$ 220% C-2&6 ,i -,..R1 -1!# .7#1

Useful resistance Unsuitable Carbon steel, cast iron and ductile iron Carbon steel, cast iron and ductile iron Stainless steel Car enter stainless

C!"#Cu C!"#Cu stainless steel 220% Allo$ 220% stainless steel Allo$ 220% stainless steel 'rou()t *astello$ + C-2&6 allo$ ,itanium unallo$ed -t)$lenetetrafluoro-et)$lene /,efzel + 0 .1 .luoro ol$mers /e2(2,,eflon + 0 includin( erfluoroal3o4$ /1.A0, ol$tetrafluoroet)$lene /1,.-0 and fluorinated et)$lene ro $lene /.-10 .iber-reinforced lastic /5in$lester resin0 -t)$lene ro $lene rubber /6ordel + 0 Standard (rades8 di ol$mers of )e4afluoro ro $lene /*.10 and 5in$lidene fluoride /9. 2 0 /9iton + 0 S ecialt$ (rades8 ter ol$merscom risin( at least t)ree of t)e follo:in(; *.1, 9.2 , tetrafluoret)$lene /,.-0, erfluoromet)$l5in$l et)er /1#9-0 or et)$lene /-02 S ecialt$ (rades ma$ )a5e si(nificantl$ im ro5ed c)emical com atibilit$ com ared to standard (rades in man$ )ars) c)emical en5ironments /9iton + 02 Co ol$mer of ,.- and 1#9- /7alrez + 0 1ol$5in$lidene fluoride /7$nar + , Solef + 0

.7#2 ..7# 19!.

1 Com atibilit$ is de endent on s ecific freon2 Contact elastomer manufacturer2

Section B -- Pump Application Data

B-4A Sealing $he proper selection of a seal is critical to the success of e%ery pump application. )or ma:imum pump reliability, choices must be made between the type of seal and the seal en%ironment. In addition, a sealless pump is an alternati%e, which would eliminate the need for a dynamic type seal entirely. Sealin Basics $here are two basic inds of seals? static and dynamic. Static seals are employed where no mo%ement occurs at the @uncture to be sealed. 'as ets and !-rings are typical static seals. Aynamic seals are used where surfaces mo%e relati%e to one another. Aynamic seals are used, for e:ample, where a rotating shaft transmits power through the wall of a tan *)ig. &+, through the casing of a pump *)ig. .+, or through the housing of other rotating equipment such as a filter or screen.

Fig. 1 Cross Section of Tan an! Mi"er

Fig. 2 T#$ical Centrif%gal P%&$ ( common application of sealing de%ices is to seal the rotating shaft of a centrifugal pump. $o best understand how such a seal functions a quic re%iew of pump fundamentals is in order. In a centrifugal pump, the liquid enters the suction of the pump at the center *eye+ of the rotating impeller *)igures 3 and 1+.

Fig. ' Centrif%gal P%&$( )ig%i! En!

Fig. * Fl%i! Flo+ in Centrif%gal P%&$ (s the impeller %anes rotate, they transmit motion to the incoming product, which then lea%es the impeller, collects in the pump casing, and lea%es the pump under pressure through the pump discharge. Aischarge pressure will force some product down behind the impeller to the dri%e shaft, where it attempts to escape along the rotating dri%e shaft. 8ump manufacturers use %arious design techniques to reduce the pressure of the product trying to escape. Such techniques include? &+ the addition of balance holes through the impeller to permit most of the pressure to escape into the suction side of the impeller, or .+ the addition of bac pump-out %anes on the bac side of the impeller. <owe%er, as there is no way to eliminate this pressure completely, sealing de%ices are necessary to limit the escape of the product to the atmosphere. Such sealing de%ices are typically either compression pac ing or end-face mechanical seals. B-4A Stuffing Box Packing ( typical pac ed stuffing bo: arrangement is shown in )ig. 0. It consists of? (+ )i%e rings of pac ing, 7+ ( lantern ring used for the in#ection of a lubricating and/or flushing liquid, and C+ ( gland to hold the pac ing and maintain the desired compression for a proper seal.

Fig. , T#$ical St%ffing -rrange&ent .!escri$tion of $arts/ $he function of pac ing is to control lea age and not to eliminate it completely. $he pac ing must be lubricated, and a flow from 12 to 42 drops per minute out of the stuffing bo: must be maintained for proper lubrication. $he method of lubricating the pac ing depends on the nature of the liquid being pumped as well as on the pressure in the stuffing bo:. Bhen the pump stuffing bo: pressure is abo%e atmospheric pressure and the liquid is clean and nonabrasi%e, the pumped liquid itself will lubricate the pac ing *)ig. 4+.

Fig. 0 T#$ical St%ffing -rrange&ent +hen St%ffing Bo" Press%re is -1o2e -t&os$heric Press%re Bhen the stuffing bo: pressure is below atmospheric pressure, a lantern ring is employed and lubrication is in#ected into the stuffing bo: *)ig. /+. ( bypass line from the pump discharge to the lantern ring connection is normally used pro%iding the pumped liquid is dean.

Fig. 3 T#$ical St%ffing Bo" -rrange&ent +hen St%ffing Bo" Press%re is Belo+ -t&os$heric Press%re Bhen pumping slurries or abrasi%e liquids, it is necessary to in#ect a dean lubricating liquid from an e:ternal source into the lantern ring *)ig. =+. ( flow of from .. to .0 gpm is desirable and a %al%e and flowmeter should be used for accurate control. $he seal water pressure should be from &2 to &0 psi abo%e the stuffing bo: pressure, and anything abo%e this will only add to pac ing wear. $he lantern ring Is normally located In the center of the stuffing bo:. <owe%er, for e:tremely thic slurries li e paper stoc , it is recommended that the lantern ring be located at the stuffing bo: throat to pre%ent stoc from contaminating the pac ing.

Fig. 4 T#$ical St%ffing Bo" -rrange&ent +hen P%&$ing Sl%rries $he gland shown in )igures 0 through = is a quench type gland. Bater, oil, or other fluids can be in#ected into the gland to remo%e heat from the shaft, thus limiting heat transfer to the bearing frame. $his permits the operating temperature of the pump to be higher than the limits of the bearing and lubricant design. $he same quench gland can be used to pre%ent the escape of a to:ic or %olatile liquid into the air around the pump. $his is called a smothering gland, with an e:ternal liquid simply flushing away the undesirable lea age to a sewer or waste recei%er. $oday, howe%er, stringent emission standards limit use of pac ing to non-hazardous water based liquids. $his, plus a desire to reduce maintenance costs, has increased preference for mechanical seals. Mechanical Seals ( mechanical seal is a sealing de%ice which forms a running seal between rotating and stationary parts. $hey were de%eloped to o%ercome the disad%antages of compression pac ing. 5ea age can be reduced to a le%el meeting en%ironmental standards of go%ernment regulating agencies and maintenance costs can be lower. (d%antages of mechanical seals o%er con%entional pac ing are as follows? &. -ero or limited lea age of product *meet emission regulations.+

.. 3. 1. 0. 4.

>educed friction and power loss. Elimination of shaft or slee%e wear. >educed maintenance costs. (bility to seal higher pressures and more corrosi%e en%ironments. $he wide %ariety of designs allows use of mechanical seals in almost all pump applications.

!"e Basic Mec"anical Seal (ll mechanical seals are constructed of three basic sets of parts as shown in )ig. C? &. ( set of primary seal faces? one rotary and one stationary;shown in )ig. C as seal ring and insert. .. ( set of secondary seals nown as shaft pac ings and insert mountings such as 2rings, wedges and D-rings. 3. ,echanical seal hardware including gland rings, collars, compression rings, pins, springs and bellows.

Fig. 5 - Si&$le Mechcanical Seal Ho# A Mec"anical Seal $or%s $he primary seal is achie%ed by two %ery flat, lapped faces which create a difficult lea age path perpendicular to the shaft. >ubbing contact between these two flat mating surfaces minimizes lea age. (s in all seals, one face is held stationar# in a housing and the other face is fi:ed to, and rotates with, the shaft. !ne of the faces is usually a non-galling material such as car1on-gra$hite. $he other is usually a relati%ely hard material li e silicon-car1i!e. Aissimilar materials are usually used for the stationary insert and the rotating seal ring face in order to pre%ent adhesion of the two faces. $he softer face usually has the smaller mating surface and is commonly called the +ear nose. $here are four main sealing points within an end face mechanical seal *)ig. &2+. $he primary seal is at the seal face, 8oint (. $he lea age path at 8oint 7 is bloc ed by either an 2-ring, a D-ring or a wedge. 5ea age paths at 8oints C and A are bloc ed by gas ets or 2-rings.

Fig. 16 Sealing Points for Mechanical Seal $he faces in a typical mechanical seal are lubricated with a boundary layer of gas or liquid between the faces. In designing seals for the desired lea age, seal life, and energy consumption, the designer must consider how the faces are to be lubricated and select from a number of modes of seal face lubrication. $o select the best seal design, it"s necessary to now as much as possible about the operating conditions and the product to be sealed. Complete information about the product and en%ironment will allow selection of the best seal for the application. Mechanical Seal Types ,echanical seals can be classified into se%eral t%pes and arrangements?

PUSHE&: Incorporate secondary seals that mo%e a:ially along a shaft or slee%e to maintain contact at the seal faces. $his feature compensates for seal face wear and wobble due to misalignment. $he pusher seals" ad%antage is that it"s ine:pensi%e and commercially a%ailable in a wide range of sizes and configurations. Its disad%antage is that ft"s prone to secondary seal hang-up and fretting of the shaft or slee%e. E:amples are Aura >! and Crane $ype C$.

UNBALANCED: $hey are ine:pensi%e, lea less, and are more stable when sub#ected to %ibration, misalignment, and ca%itation. $he disad%antage is their relati%e low pressure limit. If the closing force e:erted on the seal faces e:ceeds the pressure limit, the lubricating film between the faces is squeezed out and the highly loaded dry running seal fails. E:amples are the Aura >! and Crane C$.

C'NVEN!('NAL: E:amples are the Aura >! and Crane $ype & which require setting and alignment of the seal *single, double, tandem+ on the shaft or slee%e of the pump. (lthough setting a mechanical seal is relati%ely simple, today"s emphasis on reducing maintenance costs has increased preference for cartridge seals.

N'N-PUSHE&: $he non-pusher or bellows seal does not ha%e to mo%e along the shaft or slee%e to maintain seal face contact, $he main ad%antages are its ability to handle high and low temperature applications, and does not require a secondary seal *not prone to secondary seal hang-up+. ( disad%antage of this style seal is that its thin bellows cross sections must be upgraded for use in corrosi%e en%ironments E:amples are Aura C7> and Crane .&0, and Sealol 4=2.

BALANCED: 7alancing a mechanical seal in%ol%es a simple design change, which reduces the hydraulic forces acting to close the seal faces. 7alanced seals ha%e higher-pressure limits, lower seal face loading, and generate less heat. $his ma es them well suited to handle liquids with poor lubricity and high %apor pressures such as light hydrocarbons. E:amples are Aura C7> and 87> and Crane C=$ and .&0.

CA&!&(D)E: E:amples are Aura 8-S! and Crane &&22 which ha%e the mechanical seal premounted on a slee%e including the gland and fit directly o%er the ,odel 3&C4 shaft or shaft slee%e *a%ailable single, double, tandem+. $he ma#or benefit, of course is no requirement for the usual seal setting measurements for their installation. Cartridge seals lower maintenance costs and reduce seal setting errors. S(N)LE (NS(DE: $his is the most common type of mechanical seal. $hese seals are easily modified to accommodate seal flush plans and can be balanced to withstand high seal en%ironment pressures. >ecommended for relati%ely clear non-corrosi%e and corrosi%e liquids with satisfactory" lubricating properties where cost of operation does not e:ceed that of a double seal. E:amples are Aura >! and C7> and Crane C$ and .&0. >eference Con%entional Seal. S(N)LE 'U!S(DE: If an e:tremely corrosi%e liquid has good lubricating properties, an outside seal offers an economical alternati%e to the e:pensi%e metal required for an inside seal to resist corrosion. $he disad%antage is that it is e:posed outside of the pump which ma es it %ulnerable to damage from impact and hydraulic pressure wor s to open the seal faces so they ha%e low pressure limits *balanced or unbalanced+.

D'UBLE *DUAL P&ESSU&(+ED,: $his arrangement is recommended for liquids that are not compatible with a single mechanical seal *i.e. liquids that are to:ic, hazardous Eregulated by the E8(F, ha%e suspended abrasi%es, or corrosi%es which require costly materials+. $he ad%antages of the double seal are that it can ha%e fi%e times the life of a single seal in se%ere en%ironments. (lso, the metal inner seal parts are ne%er e:posed to the liquid product being pumped, so %iscous, abrasi%e, or thermosetting liquids are easily sealed without a need for e:pensi%e metallurgy. In addition, recent testing has

shown that double seal life is %irtually unaffected by process upset conditions during pump operation. ( significant ad%antage of using a double seal o%er a single seal. $he final decision between choosing a double or single seal comes down to the initial cost to purchase the seal, cost of operation of the seal, and en%ironmental and user plant emission standards for lea age from seals. E:amples are Aura double >! and G-.22 and Crane double =&&$.

D'UBLE )AS BA&&(E& *P&ESSU&(+ED DUAL )AS,: Dery similar to cartridge double seals ... sealing in%ol%es an inert gas, li e nitrogen, to act as a surface lubricant and coolant in place of a liquid barrier system or e:ternal flush required with con%entional or cartridge double seals. $his concept was de%eloped because many barrier fluids commonly used with double seals can no longer be used due to new emission regulations. $he gas barrier seal uses nitrogen or air as a harmless and ine:pensi%e barrier fluid that helps pre%ent product emissions to the atmosphere and fully complies with emission regulations. $he double gas barrier seal should be considered for use on to:ic or hazardous liquids that are regulated or in situations where increased reliability is the required on an application. E:amples are Aura '7.!!, ').!!, and Crane .=22.

!ANDEM *DUAL UNP&ESSU&(+ED,: Aue to health, safety, and en%ironmental considerations, tandem seals ha%e been used for products such as %inyl chloride, carbon mono:ide, light hydrocarbons, and a wide range of other %olatile, to:ic, carcinogenic, or hazardous liquids. $andem seals eliminate icing and freezing of light hydrocarbons and other liquids which could fall below the atmospheric freezing point of water in air *3.; ) or 2; C+. H$ypical buffer liquids in these applications are ethylene glycol, methanol, and propanol.+ ( tandem also increases online reliability. If the primary seal fails, the outboard seal can ta e o%er and function until maintenance of the equipment can be scheduled. E:amples are Aura $,7-/3 and tandem 8$!.

Section B -- Vi-ration Anal.sis Dibration analysis equipment enables you to tell when InormalI %ibration becomes IproblemI %ibration or e:ceeds acceptable le%els. It may also allow you to determine the source and cause of the %ibration, thus becoming an effecti%e pre%enti%e maintenance and troubleshooting aid. ( %ibration analyser measures the amplitude, frequency and phase of %ibration. (lso when %ibration occurs at se%eral frequencies, it separates one frequency from another so that each indi%idual %ibra-tion characteristic can be measured. $he %ibration pic up senses the %elocity of the %ibration and con%erts it into an electrical signal. $he analyzer recei%es this signal, con%erting it to the corresponding amplitude and frequency. $he amplitude is measured in terms of pea -to-pea displacement in mils *& mil J .22&I+ and is indicated on the amplitude meter. Some instruments are equipped with a frequency meter which gi%es a direct readout of the predominant frequency of the %ibration. !ther instruments ha%e tunable filters which allow scanning the frequency scale and reading amplitude at any particular frequency, all others being filtered out. ( strob light is used to determine the phase of %ibration. It can be made to flash at the frequency of the %ibration present or at any arbitrary frequency set on an internal oscillator. ( reference mar on a rotating part %iewed under the strob light flashing at the %ibration frequency may appear as a single frozen *or rotat-ing+ mar , or as se%eral frozen *or rotating+ mar s. $he number of mar s %iewed is useful in determining the source of the %ibration. $he location of the mar or mar s is used in balancing rotating parts. $he first step in %ibration analysis is to determine the se%erity of the %ibration, then, if the %ibration is serious, a complete set of %ibration readings should be ta en before attempting to analyze the cause. )ig. & is the typical guide for end suction stoc pumps as published by the <ydraulic Institute. $he amplitudes shown are the o%erall >,S obtained without filtering to specific frequencies. (mplitudes at specific frequencies, such as %ane pass frequency with multi-%ane impellers, should be less than /0K of the unfiltered amplitudes allowed in )ig. & at the operating >8,. )or other pumps, refer to <ydraulic Institute standards or pump manufacturer.

)ig. & (cceptable )ield Dibration 5imits for <orizontal 8umps - Clear 5iquid *>igid Structures+ Se%erity of %ibration is a function of amplitude and pump speedL howe%er, it should be noted that a change in se%erity o%er a period of time is usually a warning of impending failure. $his change is often more important than %ibration in the Islightly roughI or IroughI ranges which does not change with time. Complete pump %ibration analysis requires ta ing %ibration readings at each bearing in three planes *horizontal, %ertical and a:ial+. >eadings at the pump suction and discharge flanges may also be useful in some cases. (fter all data has been tabulated, it can be analyzed to determine the most li ely cause or causes of %ibration and the identifying characteristics of each. 7y analyzing the tabulated %ibration data one or se%eral causes may be found. Each must be chec ed, starting with the most li ely cause or easiest to chec . )or e:ample, assume the a:ial %ibration is 02K or more of the radial %ibration and the predominant frequency is the same as the >8, of the pump. $he chart indicates probable misalignment or bent shaft. Coupling misalignment is probably the most common single cause of pump %ibration and is one of the easiest to chec . If after chec ing, the alignment pro%es to be good, then inspect for flange loading. )inally, chec for a bent shaft. Ca%itation in a pump can cause serious %ibration. Dibration at random frequencies can also be caused by hydraulic disturbances in poorly designed suction or discharge systems. $he use of %ibration equipment in pre%entati%e maintenance in%ol%es eeping a %ibration history on indi%idual pieces of equipment in a plant. ( form similar to that shown in )ig 3 can be used to record the %ibration data on a periodic routine basis. (brupt changes are a sign of impending failure. ( gradual increase in %ibration can also be detected and correcti%e measures can be ta en before it reaches a dangerous le%el.

)ig. 3 Dibration Identification Chart

)ig. 1 Dibration Aata Sheet

En iron!ental Controls En%ironmental controls are necessary for reliable performance of a mechanical seal on many applications. 'oulds 8umps and the seal %endors offer a %ariety of arrangements to combat these problems. &. Corrosion .. $emperature Control 3. Airty or incompatible en%ironments C'&&'S('N Corrosion can be controlled by selecting seal materials that are not attac ed by the pumpage. Bhen this is difficult, e:ternal fluid in#ection of a non-corrosi%e chemical to lubricate the seal is possible. Single or double seals could be used, depending on if the customer can stand delusion of his product. !EMPE&A!U&E C'N!&'L (s the seal rotates, the faces are in contact. $his generates heat and if this heat is not remo%ed, the temperature in the stuffing bo: or seal chamber can increase and cause sealing problems. ( simple by-pass of product o%er the seal faces will remo%e the heat generated by the seal *)ig. .0+. )or higher temperature ser%ices, by-pass of product through a cooler may be required to cool the seal sufficiently *)ig. .4+. E:ternal cooling fluid in#ection can also be used.

D(&!/ or (NC'MPA!(BLE ENV(&'NMEN!S ,echanical seals do not normally function well on liquids which contain solids or can solidify on contact with the atmosphere. <ere, by-pass flush through a filter, a cyclone separator or a strainer are methods of pro%iding a clean fluid to lubricate seal faces. Strainers are effecti%e for particles larger than the openings on a 12 mesh screen. Cyclone separators are effecti%e on solids &2 micron or more in diameter, if they ha%e a specific gra%ity of ../ and the pump de%elops a differential pressure of 32-12 psi. )ilters are a%ailable to remo%e solids . microns and larger. If e:ternal flush with clean liquid is a%ailable, this is the most fail proof system. 5ip seal or restricting bushings are a%ailable to control flow of in#ected fluid to flows as low as &/= '8,. Muench type glands are used on fluids which tend to crystallize on e:posure to air. Bater or steam is put through this gland to wash away any build up. !ther systems are a%ailable as required by the ser%ice. AP" an# CP" Plans (8I and C8I mechanical seal flush plans are commonly used with (8I and C8I process pumps. $he general arrangement of the plans are similar regardless of the designation whether (8I or C8I. $he difference between the flush plans is the construction which pro%ides applicable pressure-temperature capability for each type of pump. (8I plans ha%e higher pressure and temperature capability than C8I plans. Each plan helps pro%ide critical lubrication and cooling of seal faces to ma:imize seal reliability. "-11 Pre#icti e an# Pre entati e Maintenance Progra! $his o%er%iew of 8redicti%e and 8re%entati%e ,aintenance *88,+ is intended to assist the pump users who are starting a 88, program or ha%e an interest in the continuous impro%ement of their current programs. $here are four areas that should be incorporated in a 88, program. Indi%idually each one will pro%ide information that gi%es an indication of the condition of the pumpL collecti%ely they will pro%ide a complete picture as to the actual condition of the pump. PUMP PE&0'&MANCE M'N(!'&(N) $here are si: parameters that should be monitored to understand how a pump is performing. $hey are Suction pressure *8s +, discharge pressure *8d+, flow *M+, pump speed *6 r +,

pumpage properties, and power. 8ower is easiest measured with a clip on amp meter but some facilities ha%e continuous monitoring systems that can be utilized. In any e%ent, the intent is to determine the 7<8 of the pump. Bhen using a clip on amp meter the degree of accuracy is limited. It should not be used to determine the efficiency of the pump. Clip on amp meters are best used for trouble shooting where the engineer is trying to determine the operating point of the pump. $he most basic method of determining the $A< of the pump is by utilizing suction and discharge gauges to determine 8S and 8d. $he installation of the taps for the gauges is %ery important. Ideally, they should be located normal to the pipe wall and on the horizontal centerline of the pipe. $hey should also be in a straight section of pipe. (%oid locating the taps in elbows or reducers because the readings will not indicate the true static pressure due to the %elocity head component. (%oid locating taps in the top or bottom of the pipe because the gauges can become air bound or clogged with solids. )low measurements can be difficult to obtain but e%ery effort should be made to do so, especially when trouble shooting. In some new installations permanent flow meters are installed which ma e the lob easier. Bhen this is the case, ma e sure the flow meters are wor ing properly and ha%e been calibrated on a regular schedule. Bhen flow meters are not installed, pitot tubes can be used. 8itot tubes pro%ide a %ery accurate measure of flow, but this in an obtrusi%e de%ice and pro%isions must be made to insert the tube into the piping. $he other method of determining flow is with either a doppler or transitime de%ice. (gain, pro%isions must be made on the piping for these instruments, but these are non-obtrusi%e de%ices and are easier to use than the pitot tube. Caution must be e:ercised because each de%ice must be calibrated, and independent testing has shown these de%ices are sensiti%e to the pumpage and are not &22K accurate. (n accurate power measurement reading can also be difficult to obtain. Clip on tap meters are the most common tool a%ailable to the )ield Engineer who is trouble shooting a pump problem. In most cases this has pro%en to be accurate. <owe%er, as pre%iously mentioned, this tool must be used and applied properly. Clip on tap meters are not accurate enough to determine the actual efficiency of a pump. If accurate horsepower readings are necessary, a torque shaft must be installed but is not %ery practical in an actual field installation and lends itself to use in a laboratory en%ironment much better. In some critical installations where the user has pro%ided a permanent power monitor, these ha%e %arying degrees of accuracy and they must be understood up front. )inally, the properties of the pumpage must be nown to accurately determine the actual pump performance. 8umpage temperature *$ 8 +, %iscosity, and specific gra%ity *S.'.+, must be nown. Bhen all of the abo%e parameters are nown, it becomes a simple matter of calculating the pump performance. $here are instances when it pro%es to be a %ery difficult if not an impossible tas to determine all of the abo%e parameters in the field, therefore, the )ield Engineer must rely on his or her ability to understand where a compromise must be made to get the lob done. $he basic document the )ield Engineer must ha%e is the pump performance cur%e. Bith this it can be determined where the pump is performing in some cases without all of the information. PUMP V(B&A!('N AND BEA&(N) ANAL/S(S Dibration analysis is the cornerstone of all 88, programs. 8erhaps the question as ed most often is Bhat is the %ibration le%el that indicates the pump is in distress;I. $he answer is that there is no absolute %ibration amplitude le%el that is indicati%e of a pump in distress. <owe%er, there are se%eral guidelines that ha%e been de%eloped as target %alues that enable the analyst to set alarm le%els. (lso many users ha%e de%eloped their own site criteria that is used as a guideline. Institutions such as the <ydraulic Institute and (8I ha%e de%eloped independent %ibration criteria. Caution should be e:ercised when applying the published %alues. ..each installation is unique and should be handled accordingly. Bhen a machine is initially started, a baseline %ibration reading should be ta en and trended o%er time. $ypically, readings are ta en on the motor outboard and inboard bearing housings in the %ertical and horizontal directions and on the pump outboard and inboard bearing housings in the %ertical and horizontal directions. (dditionally, an a:ial %ibration measurement is ta en on the pump. $he inboard location is defined as the coupling end of the machine. it is critical that when the

baseline %ibration measurement is ta en that the operating point of the pump is also recorded. $he %ibration le%el of a pump is directly related to where it is operating and in relation to its 7est Efficiency 8oint *7E8+. $he further away from the 7E8, the higher the %ibrations will be. See the following chart for a graphical representation of %ibration amplitude- %s- flow.

$he engineer must also loo at the frequency where the amplitude is occurring. )requency identifies what the defect is that is causing the problem, and the amplitude is an indication of the se%erity of the problem. $hese are general guidelines and do not co%er e%ery situation. $he spectrum in the chart is a typical spectrum for a pump that has an unbalance condition. 7earing defect analysis is another useful tool that can be used in many condition monitoring programs. Each component of a roller bearing has its own unique defect frequency. Dibration equipment a%ailable today enables the engineer to isolate the unique bearing defects and determine if the bearing is in distress. $his allows the user to shut the machine down prior to a catastrophic failure. $here are se%eral methods utilized but the most practical from a )ield Engineering perspecti%e is called bearing en%eloping. In this method, special filters built into the analyzer are used to amplify the repetiti%e high frequency signals in the high frequency range and amplify them in the low frequency part of the %ibration spectrum. 7earing manufacturers publish the bearing defect frequency as a function of running speed which allows the engineer to identify and monitor the defect frequency. Similar to con%entional %ibration analysis, a baseline must be established and then trended. $here are other methods a%ailable such as <igh )requency Aetection *<)A+, and Spi e Energy but the en%eloping technology is the latest de%elopment. It is a common practice to monitor bearing temperature. $he most accurate method to monitor the actual bearing temperature is to use a de%ice that will contact the outer race of the bearing. $his requires holes to be drilled into the bearing housings which is not always practical. $he other method is the use of an infrared "gun" where the analyst aims the gun at a point on the bearing housing where the temperature reading is going to be ta en. !b%iously, this method is the most con%enient but there is a downside. $he temperature being measured is the outside surface of the bearing housing, not the actual bearing temperature. $his must be considered when using this method. $o complete the condition monitoring portion of a 88, program, many users ha%e begun an oil analysis program. $here are se%eral tests that can be performed on the lubricant to determine the condition of the bearing or determine why a bearing failed so appropriate correcti%e action can be ta en. $hese tests Include Spectrographic (nalysis, %iscosity (nalysis, Infrared (nalysis, $otal (cid 6umber, Bear 8article (nalysis and Bear 8article Count. ,ost of these tests ha%e to be performed under laboratory conditions. 8ortable instruments are now a%ailable that enable the user to perform the test on site.

PUMP S/S!EM ANAL/S(S 8ump system analysis is often o%erloo ed because it is assumed the system was constructed and operation of the pumps are in accordance with the design specifications. $his is often not the case. ( proper system analysis begins with a system head cur%e. System head cur%es are %ery difficult to obtain from the end user and, more often than not, are not a%ailable. !n simple systems, they can be generated in the field but on more complicated systems this can"t be done. (s has been stated pre%iously, it is imperati%e to now where the pumps are being operated to perform a correct analysis and this is dependent on the system. ( typical system analysis will include the following informationL 68S<(, 68S<> , static head, friction loss through the system, and a complete re%iew of the piping configuration and %al%ing. $he process must also be understood because it ultimately dictates how the pumps are being operated. (ll indicators may show the pump is in distress when the real problem is it is being run at low or high flows which will generate high hydraulic forces inside the pump. C'NCLUS('N ( 88, program that incorporates all of the topics discussed will greatly enhance the effecti%eness of the program. $he more complete understanding the engineer has of the pumping system, the more effecti%e the 88, program becomes.