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Centrifugal Pump Maintenance
MAINTENACE
Practices
&
techniques
to
keep
the
Maintenance Philosophy
Reliability of work
Improvement in MTBF
Reduction MTTR
Reduction of Maintenance Cost
Constructional Improvement
Training of Personnel
Tools & Equipment.
Replacement parts (Spares)
Type of Maintenance
Preventive - Based on Time
Predictive
Based
on
condition
monitoring
Corrective - After occurrence of failure
operation.
It should be a combination of preventive,
predictive & corrective maintenance.
A good maintenance program starts well
before installation and continues through the
start-up phase until a plant is on-stream then
continuing it with special emphasis on
reliability improvement.
Maintenance Strategies
Categorization
of machines according to
criticality of applications.
Categorization of machines / parts of
machines according to maintenance types.
Preparation
of preventive & predictive
maintenance plans.
Effective implementation of these plans
Use of PDCA-cycle & Cost-Analysis techniques
to identify areas of improvement.
Continual improvement to enhance reliability.
Maintenance Approach
Centrifugal Pumps
2. Predictive Maintenance
Monitor
operating
parameters
including
motor
amperage to check consistency of operation and/or any
change in the system.
Develop Condition Monitoring plans i.e, measurement
of vibrations at a particular interval.
Build your own database of pumps noise and
vibrations by simply feeling with hands on regular
basis.
Trending the data of parameters; vibration, noise, etc.
helps in depicting clear picture of pumps behaviour.
Maintenance Approach
Centrifugal Pumps
3. Reliability Enhancement.
In other words, it is also called Continual
Improvement.
Problematic areas should be identified.
Try the option of modifying pump parts and/or
auxiliary systems to rectify persistent problems.
Keep in mind: Drastic changes can lead to drastic
results.
After modification, compare results with previous
history for continual improvement & keep the
machine under observation till next outage.
General Troubleshooting
Troubleshooting procedure requires some basic
Application
- New or Old
Failed Item - New Design or same model
Failure
Time
-Start-up,
seasonal
(temp.
related) or activity related.
Failure Frequency
- First time or repeated.
Develop habit of asking why questions.
Newer approach - Nothing can be solved until the
question why? has bee asked at least five times &
each question is supported by a sensible answer .
of
involves the following:
any
problem
Troubleshooting Bearings
Bearing Contamination
Major cause of premature bearing failure is Contamination.
0.002% water in the lubricant reduce bearing life by 48%.
Symptoms
Troubleshooting Bearings
Bearing Contamination
Remedial Actions:
Replace grease or labyrinth seals with positive
seals.
Alignment
Bringing the rotating members of driver and
driven machine in line / desired line is referred
as Alignment
Radial alignment
Radial Vertical Alignment
Radial Horizontal Alignment
Axial Alignment
Axial Vertical Alignment
Axial Horizontal Alignment
unsymmetrical machines.
If the machine to be aligned has six feet, it
Maintenance Tips
Arrange all tools necessary for service in a
Maintenance Tips
Rest the rotor on wooden V-notch stand. Cover
Maintenance Tips
If
Maintenance Tips
When hoisting system are used, ensure
Maintenance Tips
During assembling, apply equal amount
Coupling
Couplings are the connecting elements between the
compressor and its prime mover or between
compressors different stages.
Construction
In a particular flexible Shim Pack Coupling, there are two
hubs, one installed to each shaft end, a spacer and the
flexible elements located between the spacer and hubs.
Coupling
Efficient transmission of mechanical power from one
shaft to the other.
To compensate all types of misalignment without
inducing abnormal stresses and load on connected
equipment and without significant loss of power.
To compensate the axial movement of the coupled
shafts,
preventing
either
shaft
from
exerting
1.
Causes
Remedial Actions
Vibrations
Vibrations are measured by instruments
Remedial Actions
rotating
Balance them
Straighten it or replace it.
Proper
alignment
is
tightening
&
required.
Proper
interference to be ensured.
.
Add
mass
stiffness.
or
increase