Chapter 1

Pumps

Maintenance
All actions necessary for retaining an
item, or restoring to it, a serviceable
condition, include servicing, repair,
modification, overhaul, inspection and
condition verification
Increase availability of a system
Keep systems equipment in working
order

Problems in Maintenance
Lack of management attention to maintenance
Little participation by accounting in analyzing
and reporting costs
Difficulties in applying quantitative analysis
Difficulties in obtaining time and cost
estimates for maintenance works
Difficulties in measuring performance

Pump
A device used to move fluids, such as liquids, gases and
slurries.

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Positive Displacement Pumps

Has an expanding cavity on the suction side and a decreasing
cavity on the discharge side.
Liquid flows into the pumps as the cavity on the suction side
expands and the liquid flows out of the discharge as the cavity
collapses.
The positive displacement pumps can be divided in two main
classes
reciprocating
rotary

Reciprocating pump
A volume of liquid is drawn into the cylinder through the
suction valve on the intake stroke and is discharged under
positive pressure through the outlet valves on the
discharge stroke.
The discharge from a reciprocating pump is pulsating and
changes only when the speed of the pump is changed.
Reciprocating pumps are often used for sludge and slurry.

Rotary pump

The rotary motion of pump component maintains the flow and pressure of
the liquid. The continuous action enables a smooth flow of liquid to be
delivered.

A rotary pump traps fluid in its closed casing and discharges a smooth flow.
They can handle almost any liquid that does not contain hard and abrasive
solids, including viscous liquids. They are also simple in design and
efficient in handling flow conditions that are usually considered to low for
economic application of centrifuges.

Example:
Rotary pumps find wide use for viscous liquids. When pumping highly
viscous fluids, rotary pumps must be operated at reduced speeds
because at higher speeds the liquid cannot flow into the casing fast
enough to fill it.

Construction of rotary pump

INTERNAL GEAR PUMPS

An outer gear is used to drive the inner gear
The inner which is smaller than the outer gear, rotates on a
stationary pin and operates inside the outer gear.
The gears create voids as they come out of mesh and liquid
flows into the pump.
As the gears come back into mesh, volumes are reduced and
liquid is forced out the discharge port.
Liquid can enter the expanding cavities through the gear
teeth or recessed areas.
The crescent is integral with the pump head and prevents
liquids from flowing to the suction port from the discharge
port.
The outer gear is driven by a shaft supported by bearings.

INTERNAL GEAR PUMPS

May run in pumped liquid (proper sealing arrangement).

Can wear out a support bearing when pump abrasive liquid
The speed of internal gear pumps is slow (1,150 rpm)
Ability to operate at low speeds, internal gear pumps are well
suited for high-viscosity applications.
Internal gear pump, the gears have a long time to come out of
mesh allowing the spaces between gear teeth to completely fill
(in every revolution).
Internal gear pumps have successfully pumped liquids (very
low viscosity liquids - propane and ammonia).
Internal gear pumps are made to close tolerances and are
damaged when pumping large solids.

Internal gear pump

EXTERNAL GEAR PUMPS

External gear pumps - are similar in pumping action to internal
gear pumps .
However, the external gear pump uses two gears rotating
against each other.
Each gear is supported by a shaft with bearings.
Because the gears are supported on both sides, external gear
pumps are used for high pressure applications such as
hydraulics.
Operate at 1,750 or 3,450 rpm.
Made to closer tolerances than internal gear pumps (not allow
any particulate in the pumped liquid.

EXTERNAL GEAR PUMPS

Since there are clearances at both ends of the gears,
there is no end clearance adjustment for wear.
When an external gear pump wears, it must be
replaced.
External gear pumps - viscous and watery-type
liquids (at proper speed).
Gear teeth come out of mesh a short time, and viscous
liquids need time to fill the spaces between gear teeth
(pump speed must be slowed down)

External gear pump

LOBE PUMPS
Lobe pumps are similar to external gear pumps in operation,
except the pumping elements (lobe) do not make contact.
Lobe contact is prevented by external timing gears.
Pump shaft supported by bearings (in the timing gear case).
Not metal-to-metal contact and wear in abrasive applications is
minimal.
Used in food applications, because they handle solids without
damaging the pump.
Since the lobes do not make contact, and clearances are not as
close as in other PD pumps
Design handles low viscosity liquids.

Lobe pump

VANE PUMPS
A rotor with radial slots, is positioned off-center in a housing
bore.
Vanes that fit closely in rotor slots slide in and out as the rotor
turns.
Vane action is aided by centrifugal force or hydraulic pressure.
Pumping action is caused by the expanding and contracting
volumes contained by the rotor, vanes, and housing.
Vanes are the main sealing element between the suction and
discharge ports.
The speed of vane pumps - 1,000 rpm, but also run at 1,750 rpm.

VANE PUMPS
The pumps work well with low-viscosity liquids.
Speeds must be reduced dramatically for highviscosity applications.
No metal-to-metal contact frequently used with
low-viscosity (propane or solvent).
Not well suited to handling abrasive applications.
Vane pumps have fixed end clearances on both
sides of the rotor and vanes.

Vane pump

Failure
Pumping machinery and pumping station are very
important components in a water supply system.
Pumping machinery is subjected to wear, tear, erosion
and corrosion due to their nature of functioning and
therefore are vulnerable for failures.
Sudden failures can be avoided by timely inspection,
follow up actions on observations of inspection and
planned periodical maintenance.

Common Failures

Cavitations
Air in fluid
Coupling misaligned
Pump worn or damaged
Excessive load
Damage caused by metal object
Excessive heat
Overpressure
Incorrect installation

MaintenancePreventive Maintenance

Change the return or pressure hydraulic filter

Obtain a hydraulic fluid sample
Filter hydraulic fluid
Clean the inside of a hydraulic reservoir
Check and record hydraulic pressures
Check and record pump flow
Check hydraulic hoses, tubing, and fittings
Check and record vacuum on the suction side of the
pump
Overhaul and replace

Daily observation and

maintenance
(a) Daily Maintenance
Clean the pump, motor and other accessories.
Check coupling bushes/rubber spider.
Check stuffing box, gland etc.
(b) Routine observations of irregularities
Changes in sound of running pump and motor
Abrupt changes in bearing temperature.
Oil leakage from bearings

Contd.
(c) Record of operations and observations
A log book should be maintained to record the hourly
observations, which should cover the following items.
Timings when the pumps are started, operated and
stopped during 24 hours.
Readings of vacuum and pressure gauges.
Motor winding temperature.
Bearing temperature for pump and motor.
Water level in intake/sump.

Monthly maintenance
1. Check free movement of the gland of the stuffing
box; check gland packing and replace if necessary.
2. Clean and apply oil to the gland bolts.
3. Inspect the mechanical seal for wear and
replacement if necessary.
4. Check condition of bearing oil and replace or top up
if necessary.

Quarterly Maintenance
1. Check alignment of the pump and the drive. The pump and
motor shall be decoupled while correcting alignment.
2. Clean oil lubricated bearings and replenish with fresh oil. If
bearings are grease lubricated, the condition of the grease
should be checked and replaced/replenished to the correct
quantity.
3. Tighten the foundation bolts and holding down bolts of pump
and motor mounting on base plate or frame.
4. Check vibration level with instruments if available; otherwise
by observation.
5. Clean flow indicator, other instruments in the pump house.

Annual Maintenance
1. Clean and flush bearings with kerosene and examine for flaws
developed, if any, e.g. corrosion, wear and scratches. Check
end play. Immediately after cleaning, the bearings should be
coated with oil or grease to prevent ingress of dirt or moisture.
2. Clean bearing housing and examine for flaws, e.g. wear,
grooving etc. Change oil or grease in bearing housing.
3. Examine shaft sleeves for wear or scour and necessary
rectification. If shaft sleeves are not used, shaft at gland
packings should be examined for wear.
4. Check stuffing box, glands, lantern ring, mechanical seal and
rectify if necessary.
5. Check clearances in wearing ring.