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Maintenance of Pumps

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Hammad Akber
Hammad Akber

Following presentation consist of a fundamental steps that took place during a pump overhaul. this presentation will give you the basic idea about maintenance .

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Maintenance Of Pumps Hammad Akber GTE
Introduction: • Pump: is a machine that converts mechanical energy into fluid energy, the fluid being incompressible. • Types: Following are the 2 basic types. • Dynamic: Centrifugal , Axial. • Displacement: Reciprocating & Rotary.
MAINTENANCE PHOILOSOPHY: • Maintenance is done on to the machine in order to improve system reliability. Maintenance may be : • Preventive Predictive (Conditional Monitoring) Periodic • Break down • RCM
PUMP MAJOR COMPONENTS: • Shaft • Impeller • Wear Rings • Stuffing Box • Diffuser Casing • Bearings
Shaft Run Out • Runout checks are made to determine out of roundness conditions (eccentricity) in a shaft. Whether shaft is concentric or not ? • Runout occurs due to: a) Machining Process b) Dents from handling. c) Rust patches. d) Rotor bow / sag due to thermal effects, gravity, or other influences/loads. e) Defective or worn bearings in the machine or lathe supports
Cont’d • Moderate to excessive run out will create moderate to excessive vibration within a pump (may cause rubbing). • Firstly shaft itself is checked and then along with its attached components (wear ring , impeller etc.) • Dial Indicator is attached on axially given points. Variation in readings indicates:
Balancing & Float Check • Balancing of a rotor is carried out to eliminate the vibration. • Balancing correction weights may eliminate the dynamic forces but they will not resolve the eccentricity issue. • Correction weights may added or material may remove for the balancing. • FLOAT
Cont’d BACK
Wear Ring Clearances: • Wear ring provides close clearances to minimize leakage from the discharge to the suction of the impeller. • As the wear ring wears with use , leakage will gradually increases , effecting the pump efficiency. • The gap is destroyed if there is misalignment or shaft deflection. • Clearances is taken through the Feeler Gauge. • Material : SS or Bronze
Cont’d BACK
BEARING • Providing Support to a shaft for smooth Running. • Lubrication prevents metal-metal contact. • Thrust Bearings are used to compensate/bear axial load. Bearing inspection is very important during Pump maintenance. Causes of Bearing Failure: Flaking , Spalling , Rust & Corrosion, wear , Babbit metal remove , loss of lubrication etc.
Shaft Alignment • Shaft alignment is the process to align two or more shafts with each other to within a tolerated margin. It is an absolute requirement for machinery before the machinery is put in service. Therefore pump and motor shafts are aligned before they put into service. • Misalignment between the pump and drive can result in premature bearing failure or other damage.
Cont’d
Shaft Alignment
Inspection During Maintenance: • Pump Impeller. • Mechanical Seal. • Gland Packing. • Shaft Sleeve. • Relieve Valve. • Pump Element (PD).
Mechanical Seal  Seal may fail due to lack of lubrication. Due to which temperature rises at the sealing faces that will damage the elastomer part of the mechanical seal.  Pump Vibration. Vibration imparts forces on each part of the seal components. Vibrations may be due to worn bearings.
Cont’d
Gland Packing
Relieve Valve • During Pump Maintenance relief valve is overhaul for cleaning and inspection purpose. • Checking spring stiffness etc.
Pump Element Inspection
Maintenance of Pumps
QUESTIONS

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Maintenance of Pumps

  • 2. Introduction: • Pump: is a machine that converts mechanical energy into fluid energy, the fluid being incompressible. • Types: Following are the 2 basic types. • Dynamic: Centrifugal , Axial. • Displacement: Reciprocating & Rotary.
  • 3. MAINTENANCE PHOILOSOPHY: • Maintenance is done on to the machine in order to improve system reliability. Maintenance may be : • Preventive Predictive (Conditional Monitoring) Periodic • Break down • RCM
  • 4. PUMP MAJOR COMPONENTS: • Shaft • Impeller • Wear Rings • Stuffing Box • Diffuser Casing • Bearings
  • 5. Shaft Run Out • Runout checks are made to determine out of roundness conditions (eccentricity) in a shaft. Whether shaft is concentric or not ? • Runout occurs due to: a) Machining Process b) Dents from handling. c) Rust patches. d) Rotor bow / sag due to thermal effects, gravity, or other influences/loads. e) Defective or worn bearings in the machine or lathe supports
  • 6. Cont’d • Moderate to excessive run out will create moderate to excessive vibration within a pump (may cause rubbing). • Firstly shaft itself is checked and then along with its attached components (wear ring , impeller etc.) • Dial Indicator is attached on axially given points. Variation in readings indicates:
  • 7. Balancing & Float Check • Balancing of a rotor is carried out to eliminate the vibration. • Balancing correction weights may eliminate the dynamic forces but they will not resolve the eccentricity issue. • Correction weights may added or material may remove for the balancing. • FLOAT
  • 9. Wear Ring Clearances: • Wear ring provides close clearances to minimize leakage from the discharge to the suction of the impeller. • As the wear ring wears with use , leakage will gradually increases , effecting the pump efficiency. • The gap is destroyed if there is misalignment or shaft deflection. • Clearances is taken through the Feeler Gauge. • Material : SS or Bronze
  • 11. BEARING • Providing Support to a shaft for smooth Running. • Lubrication prevents metal-metal contact. • Thrust Bearings are used to compensate/bear axial load. Bearing inspection is very important during Pump maintenance. Causes of Bearing Failure: Flaking , Spalling , Rust & Corrosion, wear , Babbit metal remove , loss of lubrication etc.
  • 12. Shaft Alignment • Shaft alignment is the process to align two or more shafts with each other to within a tolerated margin. It is an absolute requirement for machinery before the machinery is put in service. Therefore pump and motor shafts are aligned before they put into service. • Misalignment between the pump and drive can result in premature bearing failure or other damage.
  • 15. Inspection During Maintenance: • Pump Impeller. • Mechanical Seal. • Gland Packing. • Shaft Sleeve. • Relieve Valve. • Pump Element (PD).
  • 16. Mechanical Seal  Seal may fail due to lack of lubrication. Due to which temperature rises at the sealing faces that will damage the elastomer part of the mechanical seal.  Pump Vibration. Vibration imparts forces on each part of the seal components. Vibrations may be due to worn bearings.
  • 19. Relieve Valve • During Pump Maintenance relief valve is overhaul for cleaning and inspection purpose. • Checking spring stiffness etc.