PUMPS

A- Centrifugal pumps The principles of pumps operation. The basic function of a pump is to transfer liquids from one vessel to another. A centrifugal pump does this by imparting energy to the liquid. The energy of motion is changed to that of pressure in the pump. For centrifugal pumps check the following: Discharge pressure. Suction pressure. ressure differential at suction strainer. !earing temperature. "oise #cavitation$ %echanical seal leakage. &ooling medium temperature. 'ube oil system # (T and level$ ower consumption in Amps. #means pump loading$

The pump operation. The operator can prolong the life of his centrifugal pumps and lower the maintenance frequency and cost by using sound orderly procedures for starting and stopping centrifugal pumps. A. Starting Procedure ). The operator should check where applicable: a. &ooling water supply to pedestal is commissioned. b. ump *acket cooling water supply is commissioned. &. %otor cooling is commissioned. d. +land flush is commissioned. e. Seal quench is commissioned. f. 'ubrication , pump and motor bearings , have the right type of lubrication and that there are lube oil levels. g. -f possible( rotate pump shaft. )

h. &heck that the electric supply is available i.e.( the switch gear is reset and okay. -f pump is in hot service( allow time to warm up pump and ensure that the pump is hot. .. Starting from the position that the Suction and Discharge /alves are closed: a. &heck that the pump case drain is closed. b. &heck that the pump vent is closed. &. 0pen pressure gauge tapping. d. &rack open suction valve and pressure up pump case. Then vent any gas from pump case,until pump case is liquid full. Then open suction valve fully. e. &rack open discharge valve , if the pump is in hot service( it should now be allowed to warm up. This means that there must be some way provided to by,pass the non,return valve( either a small hole drilled in the non,return valve or a small line bypassing the non,return valve. NOTE: -t depends upon production practice( but in most cases( the spare pump in any service should be left with the suction valve open and the pump under suction pressure. This should not stop the operator carrying out all the routine checks before starting the pump. There is no e1cuse not to check oil levels or cooling water( etc. before starting a pump. 2. 3ith the discharge valve cracked open( start the pump , if electric( by pressing the button. 4. 3atch discharge pressure gauge reading come up to normal. -f the pump motor has an amp meter check the load. -f the load remains higher than normal or if there is no discharge pressure( check for the reason and shut down if this condition remains. Shut down the pump and inform your supervisor immediately. 5. -f the pressure is normal and the motor load is normal( open the discharge valve slowly. 6. 78%8%!87 T0 &98&: ;% 78+;'A7'< for bearing lubrication and temperature and any unusual noises.

B. Stopping Procedure ). Stop the pump. .. &lose the discharge valve. 2. Depending for what reason the pump was shut down( carry out any special instructions that might be given. 4. -f the pump is to be worked on( make sure that it is isolated correctly and it is safe so that no in*ury can happen to the person working on it. 1. ailure to !eli"er #i$uid A. ump not primed !. -nsufficient speed &. Discharge head too high D. Suction lift too high #over )5 feet$( check with vacuum gauge 8. -mpeller passages partially clogged F. 3rong direction of rotation %. Pump O"erloads !ri"er A. Total head '0387 than rating ,pumping too much liquid !. 'iquid pumped of different specific gravity and viscosity than that for which pump is rated &. %echanical defects )$ Shaft bent .$ 7otating element binds 2$ 3orn bearings &. 'nsufficient Pressure A. Speed too low !. Air in liquid &. %echanical defects 3earing rings worn -mpeller damaged -nternal leakage due to defective gasket

(. 'nsufficient Capacit) A. Air leaks in suction or stuffing bo1es !. Speed too low &. Total head higher than that for which pump is rated D. Suction lift too high #over )5 feet$( check with vacuum gauge 8. -mpeller passages partially clogged F. -nsufficient suction head for hot liquid +. %echanical defects 3earing rings worn -mpeller damaged -nternal leakage due to defective gasket 9. Foot valve too small or restricted by trash -. Foot valve or suction pipe not immersed deeply enough =. Suction strainer blocked *. Pump #oses li$uid after Starting A. 'eaky suction line !. Suction lift too high #over )5 feet$ &. Air or gases in liquid D. Suction strainer plugged +. Pump ,i-rates A.%isalignment !. Foundation not sufficiently rigid #grouting broken$ &. -mpeller partially clogged( causing imbalance D.%echanical defects Shaft bent 7otating element binds 3orn bearings D. /apori>ing in suction 8. 81cessive capacity F. Suction strainer plugged .. Surges in Performance A. Air leak in suction line. !. Air pocket in suction line. &. "ot enough " S9 #net positive suction head$ available. D. Air or gases in liquid. 8. -mpeller plugged.

/. E0cessi"e Po1er Consumption A. Speed variation , check whether or not motor is across the line and receives full voltage. !. 9ead too low , pumping too much liquid. &. Specific gravity or viscosity of liquid pumped is too high. D. %echanical defects: Shaft bent. 7otating element binding. 3rong rotation. 2. Nois) Pump Operation A. 9ydraulic noise: &avitation. -nsufficient " S9. #"et positive suction head$ Suction lift too high. Air in liquid !. %echanical defects: Shaft bent. !earings warn. 7otating parts binding. ump operation in series. 0ccasionally two or more centrifugal pumps are operated in series. The combined head capacity curve for two centrifugal pumps operating in series is shown in Figure attached. The total head at any given capacity is that of the individual heads.

pump operation in parallel. 0ccasionally two or more centrifugal pumps are operated in parallel. The combined head capacity curve for two centrifugal pumps operating in parallel is shown in Figure attached. 9ere the total capacity at any given head is the sum of the individual capacities.

the pump operation. Although a large number of centrifugal pumps use braided packing in stuffing bo1es( mechanical seals have gained acceptance in the petroleum industry. They: #)$ require no leakage which is very important when pumping hydrocarbons because of the potential safety ha>ard( #.$ last much longer than packing( and #2$ require less maintenance. These are real advantages if the pump is in a hard to reach or inaccessible location. There are many different types of mechanical seals available? however( all mechanical seals have similar basic components and operate similarly. A typical mechanical seal consists of rotating parts attached to the shaft and stationary parts secured to the seal plate( which is bolted directly to the casing. The highly polished sealing faces of the rotating and stationary parts are held in contact by one or more springs. The cavitations phenomenon and how to rectify. Ca"itation This is caused by poor suction conditions especially in pumps with screens. The screens should be checked for blockage if cavitation occurs. -n columns where there is a large difference in the boiling range from the overhead product to the bottoms product( cavitation sometimes occurs during startup and in @up,set@ conditions when large quantities of the overhead liquid are mi1ed in with the bottom product. This light material will then vapor lock in the pump. The only way to get the pump back to normal is for the control room operator to bring the column back to normal conditions and eliminate the light material from the bottoms liquid.

ump operation.

#u-rication
-n most cases( lubrication of bearings is by a pump #termed pressure fed$( which circulates oil from a reservoir around the bearings and back to the reservoir via a cooler to keep the oil at a constant temperature. There is also some form of heating device so the oil can be brought to the operating temperature before commissioning. The correct level of oil in the bearing housing is kept by the lubricating oil level bottle provided that the bottle contains an oil level.

Cooling S)stem
9eat generation is sometimes a problem in centrifugal pumps( particularly in large pumps or in pumps moving high temperature fluids. 81cessive heat is most damaging at bearing locations and in packing glands. -n many applications( this heat is carried away by ambient air or fluid being pumped? however( in some applications where additional cooling is needed( water *ackets are commonly used. 3ater *ackets are channels located in the casing near bearing housings and packing glands. 3ater or other coolants are pumped through these channels to absorb the heat. Then the water or coolant is either piped to the sewer or pumped to a heat e1changer to be cooled before recycling it back through the water *ackets.

the recycle system in the process area. There are different features of pump recycle system. ), &ontrol /alve. ., %inimum orifice flow. Those device allows the pump run properly with sufficient " S9 or without pressure if the discharge line equipped by control valve as shown in different system. 7ecycle system for centrifugal pumps called ##%inimum Flow$$ to prevent low flow through the pump and to avoid overheating for pump due to low flow.

B- Positi"e displacement pump. The principles of positive displacement pumps. The positive displacement pump works in the same way as putting a block in bucket of water. The block will displace a volume of liquid equal to the volume of the block. As a plunger moves into a cylinder( it displaces a volume of liquid. The plungerDs displacement is positive. A pump that displaces a constant volume of liquid is called a positive displacement pump. This type of pump first traps a volume of liquid in the cylinder. The piston or plunger then displaces a volume of liquid from the cylinder by moving forward. -f liquid is displaced on the forward stroke only( the pump is single,acting. -f the pump displaces liquid on both the forward stroke and the return stroke( it is a double,acting pump.

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The different types of positive displacement pumps.

ositive displacement pumps are used in the petroleum industry for low volume applications or where high pressures are required to move fluids. -n the field( you will find positive displacement pumps performing such diverse *obs as transferring oil from storage tanks to pipeline( rein*ecting salt water into the reservoir( or pumping glycol in a dehydration unit. -n gas plants( positive displacement pumps are commonly used for metered chemical in*ection( pumping lean oil and amine solutions( lubricating compressors( etc. There are two types of positive displacement pumps: ). 7eciprocating pumps which include the piston( plunger and diaphragm types. .. 7otary pumps which include the gear( lobe and screw types. 7eciprocating pumps have a piston( plunger or diaphragm moving back and forth #reciprocating$ in a cylinder. 7otary pumps have gears( lobes or screw,type rotors that rotate within a cylinder to move fluids. ositive displacement pumps may be either power pumps or direct,acting pumps. ower pumps have a separate driver( e.g.( electric motor( internal combustion engine( etc.

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T)pes of Positi"e !isplacement Pumps 1- 3eciprocating Pumps. 1-1 Piston pump 0ne of the most familiar reciprocating pumps is the piston pump. The main components of this pump are the cylinder( piston( piston rings( suction valve( discharge valve( packing( and pump casing. The piston moves back and forth in the cylinder. 8ach complete movement of this piston along the cylinder length is called a stroke. %ovement of the piston toward the driving section of the pump is called the backstroke. A forward stroke is movement of the piston away from the driving section of the pump. A full is the movement of the piston from one end of the cylinder to the other end and back to its original position. 1-% Plunger Pumps A plunger pump operates the same as a piston pump e1cept for a few differences. irst( in piston pumps( the piston fits close to the walls of the cylinder with piston rings sealing the space between the piston and cylinder wall. The piston moves totally within the cylinder. -n plunger pumps( the diameter of the plunger is much smaller than the diameter of the cylinder( and the plunger moves outside the cylinder as well as inside. Second( in piston pumps( the piston( displaces most or all of the fluid from the cylinder during the forward stroke. -n the plunger pumps( the plunger only displaces a part of the fluid.

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lunger pumps are often used for high,pressure service or when the fluid being pumped could cause a piston to stick or scoring of the cylinder. 1-& !iap4ragm Pumps Another type of reciprocating pump is the diaphragm pump. This pump gets its name from the fle1ible diaphragm used to displace fluids. The diaphragm is usually made of a fle1ible( rubber,like material often covered with a thin metal disc where the connecting rod is attached. This metal disc spreads the force from the connecting rod over the diaphragm so holes wonFt be punched in it by the action of the connecting rod. The diaphragm e1tends across the widest part of the pump cylinder( completely sealing one half of the cylinder from the other half. This makes diaphragm pumps ideal for pumping corrosive or abrasive fluids( The diaphragm is connected to a motor,driven eccentric or cam by means of a connecting rod. As the wheel rotates( the connecting rod pushes and pulls on the diaphragm( causing the diaphragm to bulge towards and then away from the suction and discharge valves on successive strokes. %. 3otar) !isplacement Pumps 7otary pumps differ from reciprocating pumps in that they have rotating parts instead of reciprocating #back and forth$ moving parts to move fluids. There are many types of rotary pumps( such as e1ternal and internal gear pumps( lobe pumps and screw pumps. 7otary pumps are best suited for low to medium pressure applications. !ecause of their construction and operation( rotary pumps tend to have a more even discharge pressure than reciprocating pumps and require less maintenance. %ost hydraulic systems use gear,type rotary pumps. 0ther rotary pump service includes compressor and bearing lubrication( engine oil pumping( and chemical in*ection. Screw pumps are usually used as transfer pumps because of their large capacities.

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%.1 5ear Pumps There are two types of gear pumps? the e1ternal gear pump and the internal gear pump. 81ternal gear pumps are probably the most common type of rotary pump used in the petroleum industry. -ts construction is relatively simple when compared to other positive displacement or centrifugal pumps. The parts of an e1ternal gear pump include the casing( gears( suction port( and discharge port. There are two gears: one is driven by a motor or other prime mover and is called the power or drive gear and the other gear is driven by the power gear and is called the idler or driven gear. The fluid is picked up by the teeth of both gears. As these gears rotate( fluid is trapped in the spaces between the gear teeth and the wall of the pump casing. The fluid is carried to the discharge side of the pump and is prevented from leaking back to the suction side by the teeth of the two gears meshing together. There are three types of gear impellers used in the rotary gear pumps? spur( helical and herringbone. Although spur gears are generally used because they are cheaper and cost less to maintain( helical and herringbone gears are also used because they provide a smoother transfer of power which results in smoother fluid flow. Also( helical and herringbone gears are used in larger pumps which handle large volumes and operate at higher speeds. -n contrast to the e1ternal gear pump( the internal gear pump has one gear rotating within the circumference of the second gear. The outer or e1ternal gear is larger than the internal gear. Depending on pump design either the e1ternal or internal gear can be the driver.

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%-% #o-e Pumps 'obe pumps are similar to e1ternal gear pumps in that fluid is moved from the suction side to the discharge side in spaces between the rotors and the pump casing. The term lobe comes from the rounded parts of the rotors( which permit the rotors to remain in contact and form seals as they rotate. The shape and smoothness of the rotors prevent one rotor from driving the other( so timing gears are used to synchroni>e and drive both lobes. %-& Scre1 Pumps Another rotary type pump frequently used in the petroleum industry for pumping oil or other heavy fluids is the screw pump. The screw pump is able to pump large amounts of fluid with ease? however( they are e1pensive and sub*ect to damage from abrasive materials. 7otary screw pumps can be divided into two categories? single,screw pumps and multiple,screw pumps. Single,screw pumps only have one rotor #screw$ and are not commonly used for industrial service. -n operation( these pumps have a power rotor #screw$ which is driven by a motor or other prime mover. The rotor in turn drives one or more other rotors( referred to as idler rotors( which are meshed with the power rotor. As the power rotor turns( fluid is drawn in one end of the pump. Since the threads of the power rotor and idler rotors mate( the fluid is forced along the threads to the discharge side of the pump.

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-t is not uncommon for properly timed pumps to produce an uneven pumping action. To compensate for this( a surge chamber or dampener may be installed on the discharge to smooth out the discharge pressure. -f the discharge line becomes blocked( the piston( plunger( etc. cannot displace the fluid in the cylinder and pressure will build up. 81cessive pressure can cause the pump driver to stall or the pump casing andGor discharge piping to rupture. For safety( positive displacement pumps should always have a safety relief valve and bypass line located a short distance beyond the discharge port.

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7outine checks on displacement pumps are: &heck pump suction H discharge pressure. &heck pump leakage. &heck lube oil system. &heck cooling system. &heck safeguarding system.

or c4emical dosing pumps &ertain activities shall be carried out before attempting the operating of the facilities to ensure that the equipment is properly installed and ready for start up. The completed activities are: All utilities such as power( instrument air etc. shall be made available for use. All strainer and drain valves have been installed. ;nit is electrically grounded in accordance with code requirements. Always be sure that oil lubricated units are filled with the correct grade and quantity of oil before start up. &heck that all control instruments and equipment are in good condition and operational. %ake a careful inspection for any damaged or loose fittings. &heck the pump for any leaks or damage to the housing. 8nsure that the equipment is properly enclosed to prevent access from unauthori>ed personnel to prevent possible accidents. Disconnect and lock out all power sources before initiating any maintenance or repair work. Act with care in accordance with recogni>ed procedures in handling and lifting this equipment( or any part of this equipment. !e familiar with the equipment and read all instructions thoroughly before any operation or maintenance.

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A. Pre-start Up and Operating C4ec6s ). The set stroking length of the pump must be within its operating range( therefore on no account must the manual hand wheel be turned passed its ma1imum position or its >ero mark. &heck that any line valves are in their correct operating position before start up. &heck that the pump gearbo1 oil is at the correct level before start up. Turn the erspe1 cover over on the diaphragm pump head hydraulic fluid oil reservoir( so that the vent opens up into the reservoir. &heck that the level of hydraulic fluid covers the vent and replenishing valve in the reservoir. &heck that the drive motor rotates in the direction of the arrow on the motor cowling. This can be done by flicking the motor starter switch and watching the direction of the motor fan. -f the direction of rotation is incorrect( switch two wires to give reversed direction of rotation. -f suction or discharge dampers are fitted to the process line( check that the pre, charge is correct for operation before start up. -f a line pressure gauge is fitted to the pump discharge line( check the reading is in accordance with that shown on the applicable pump data sheet. -f the discharge pressure is e1cessive or rises after start up( check for blocked pipe work or shut,off line valve. -t is imperative that the fault is rectified immediately to ensure that the discharge pressure does not e1ceed the safe working pressure of the pump head.

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B. Start up Procedure 0nce the pumps have been checked for their general integrity( and all nuts and bolts have been checked for tightness( the pumps are ready for start up. ). .. 2. 4. 5. 6. A. Set the stroke length of the metering pumps to >ero. This will ensure that no fluid is pumped upon start up. Start the pump drive motor running. 7un for a period( thirty minutes will suffice( check for any e1cessive temperature rise. Stop the drive motor. 7echeck the oil level. -ncrease the stroke length to half of the ma1imum output capacity( start the drive motor. 0nce a fluid flow has been established in the discharge line set the stroke length to ma1imum to ensure quick venting of the process line. -f no fluid is being pumped( or if output is low refer to the +eneral Fault Finding chart. &heck all connections( flanges( valves( etc. are leak free and tight.

C. 3outine S4ut !o1n ). .. "o attention is required to the pumps if it is for short term shut down. The pumps can be shut down and restarted as a normal process function. -f the shut down is for a long period( or maintenance then any line isolation valves should be closed and the motor isolated.

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ump malfunction shut down and rectify. 1. Pump not up to capacit) A. Suction lift too high. !ubbles form to use up part of pump displacement. !. Suction strainer clogged or of insufficient area &. 8nd of suction pipe insufficiently submerged allowing air to be drawn into pump D. Suction pipe too small( too long( or has fittings to increase pipe friction abnormally and cause liquid to vapori>e 8. Stuffing bo1 improperly packed so air is drawn in F. Air leaks in suction piping +. Speed too low 9. 9ead bypass or return line partly open -. 7elief valve improperly seated or incorrectly set =. ump parts worn %. Pump ta6es too muc4 po1er A. Speed too high !. 'iquid heavier or more viscous than specified for pump &. 0bstruction in discharge line causes pump to operate above rated pressure D. Stuffing bo1 packed too tightly 8. 7otating elements bind and wear e1cessively &. Pump is nois) A. -nsufficient liquid supply !. Suction pipe too small in diameter &. Air leaks in suction or stuffing bo1es D. ump out of alignment 8. 9igh spots on rotating elements. F. 7elief valve chatters (. Pump 1ears rapidl) A. +rit or dirt in liquid !. ipe strain on pump casing. &. ump operating against e1cessive pressures. D. &orrosion roughening rubbing surfaces 8. ump running dry

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*. Pump starts t4en loses prime A. !. &. D. 8nd of suction line not immersed deeply enough 'iquid vapori>ing in suction line Air or gas pockets in system Air leaks in suction line

umps lube oil and cooling systems.

A. #u-e oil s)stem

!ecause of all the moving parts in positive displacement pumps( lubrication is very important. The pumping components are normally lubricated by the fluids being pumped? however( some parts of the pump require oil or grease for lubrication( e.g.( drip systems( splash systems( force,feed lubricators( etc. B. Cooling s)stem -n addition to lubrication( positive displacement pumps need to be cooled. umps may be either air cooled or water,cooled. Air,cooling relies on ambient air to cool the pump while water cooling requires the circulation of water or another coolant through the pump casing. -n larger pumps or in pumps moving high temperature fluids( water *ackets are commonly used. 3ater *ackets are channels located in the casing around the hot sections in the pump( such as bearings and packing locations.

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The different types of bearing and seals. - Pac6ing and seals. Are used to minimi>e the amount of leakage along the shaft by sealing the clearance space between the shaft and casing or between piston rod and stuffing bo1. - Bearings. !earings support the shaft and reduce friction as the shaft rotates in casing these are two important function done by bearings. ), &ontrol the forward and back ward movement #Thrust$ of the shaft #thrust bearing$. ., &ontrol the side to side #7adial$ movement of the shaft #7adial bearing$. T4e isolation procedure .5

Steps guide for 'solation7 )$ .$ 2$ 4$ 5$ Stop the pump. -solate the 8lec. ower &lose suction and discharge valve. Depressuri>e the suction and discharge lines. &arry out required safety procedures as recommended in the work permit.

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