Very Usefully Course

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The key takeaways are the different types of pumps, their components and applications that are discussed in the presentation.

The main types of pumps discussed are reciprocating pumps and rotary pumps. Reciprocating pumps include piston pumps and plunger pumps. Rotary pumps include gear pumps, vane pumps, screw pumps and centrifugal pumps.

The main components of a reciprocating pump are the cylinder, piston, valves, packing and gland follower.

PUMPS

Performance, Maintenance and Troubleshooting


FOR ENGINEERS

Presented By
Hesham M. Abdelgayed, MSc.

Rotating Equipment Section Head


Egyptian Natural Gas Company, Gasco

PhD Student,
Mechanical Engineering Department
University Of Alexandria
Pump or Compressor ?

Pumps

A mechanical device used to move


incompressible fluids through piping
system from one point to another.
Pump or Compressor ?

Pumps
Pumps or Compressor ?

Compressors
Applications of Pumps

1- Gas Facilities/Oil Refineries (Recirculation Pumps)


Applications of Pumps

2- Oil Transmission
(Transmission Pumps)
Applications of Pumps

3- High Pressure Injection (Hydraulic, Lubrication and Odorization


Pumps)
Introduction

One of the first pieces of powered machinery to be invented at the dawn of the
industrial age was a crude form of pump. The pump has since evolved into an
endless variety of types, sizes, and applications.

Operators should become familiar with the diversity of pumps that are in existence
as they may be required to safely operate pumps in the normal course of their daily
routines. A functional understanding of pumps, their use, and application, is
essential to understanding how most processes are handled in plants today.
Theory of Pumping
Important Definitions
Theory of Pumping

Friction Head
When the pump puts the water in motion, this water will meet resistance in the pipes,
valves and fittings. To overcome this resistance a certain amount of pressure is
required. This pressure is called the friction head and is also expressed in metres or
feet of water.

Velocity Head
A force is required to put the water in motion. This is called the velocity head.

Pressure or Equivalent Head


When the pump discharges the water into a vessel under pressure, such as a boiler, it
has to impart additional pressure to the water in order to overcome the boiler pressure.
This extra pressure is called the pressure or equivalent head.
Theory of Pumping

Dynamic Head
Friction, and velocity head are required to move the water from the source of supply
into the discharge vessel. For this reason we call the sum of these heads the dynamic
(force in motion) head.

Total Head
The total head required to move the water from the source of supply to the point of
discharge is the sum of static and dynamic head.

The power required to drive a pump is determined by the amount of liquid pumped and
the total head against which the pump operates.
Theory of Pumping

Dynamic Pumping Positive Pumping


Theory of Pumping

Dynamic Pumping
Theory of Pumping
Dynamic Pumping
1- WITHOUT DIFFUSER

Volute function is to
convert most of the
Velocity energy (v2/2g)
to pressure P

Volute
Theory of Pumping
Dynamic Pumping
2- WITH DIFFUSER

Diffuser function is to
decrease the turbulence
losses and unify the
direction of the outlet fluid

Volute

Diffuser
Theory of Pumping
Dynamic Pumping
Impeller velocity diagrams Velocity of liquid
Result

Velocity of liquid
(effect of flow tangential to
the blade trim)

Velocity of liquid
(effect of impeller rotation)
Theory of Pumping

Positive Displacement Pumping


Types of Pumps
Types of Pumps
10,000 Multi cylinder plunger 10,000

5000 5000
Centrifugal multistage

2000 Gear 2000

Ft of Liquid
1000 1000
Screw Centrifugal
double suct.
500 500

psig
Centrifugal single stage

200 200

100 100

50 50

20 20
GPM Axial flow

10 100 1000 10000


2 5 20 50 200 500 2000 5000
Types of Pumps

Axial Pump
Bearing
House

Packing or
Mechanical
Seal Propeller
Types of Pumps

Centrifugal
Pump
Types of Pumps Centrifugal Pumps
Single Stage
Overhung Pump
• Most common type.
• Used for medium head
range < 500 ft
Types of Pumps Centrifugal Pumps

Double Suction Pump


• Jockey Pumps for Fire
Fighting Applications
Types of Pumps Centrifugal Pumps

Multistage Centrifugal Pump


• Up to 13 impeller for higher head
• 13000 gpm
• 7000 ft

Side Suction – Side Discharge


Types of Pumps Centrifugal Pumps

Multistage Centrifugal Pump

Top Suction – Top Discharge


Types of Pumps Centrifugal Pumps

Vertical Can Pump

Typically used for condensate service


Low NPSH Application (specify to inlet flange)
60,000 gpm
700 ft head
Types of Pumps Centrifugal Pumps

Vertical Inline Pump

• Supported by piping or small foundations


• Motor supported by the pump, Piping forces
do not affect alignment.
• Lower cost – simpler maintenance
• Slightly higher NPSHreq
Types of Pumps

Centrifugal Pumps
API 610
ASME B73.1 & B73.2 Most common pumps
API 685 Seal less Pumps

Liquid Ring Vacuum Pumps


API 681

Positive Displacement Pumps


API 674 Reciprocating
API 675 Controlled volume
API 676 Rotary

Firewater Pumps
NFPA 20
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps
API Centrifugal Pump Configurations
Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction 1- Impeller
Types of Pumps Centrifugal Pumps

Construction 1- Impeller

• It converts the mechanical rotation to the velocity of


the liquid.
• It has an inlet eye through which the liquid suction
occurs. The liquid is then guided from the inlet to the
outlet of the impeller by vanes. The angle and shape
of the vanes are designed based on flow rate.
• The guide vanes are usually cast with a back plate,
termed shroud or back cover, and a front plate,
termed front cover.
• Impellers are generally made in castings and very
rarely do come across fabricated and welded
impellers. Impellers can have many features on them
like balancing holes and back vanes. These help in
reducing the axial thrust generated by the hydraulic
pressure.
Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction

Closed Impellers

The closed impeller consists of radial vanes


(typically 3–7 in number), which are enclosed
from both sides by two discs termed ‘shrouds’.
These have a wear ring on the suction eye and
may or may not have one on the back shroud.
Impellers that do not have a wear ring at the
back typically have back vanes. Pumps with
closed type impellers and wear rings on both
sides have a higher efficiency.
Types of Pumps Centrifugal Pumps

Construction

Semi-Open Impellers

The semi-open type impellers are more


efficient due to the elimination of disk friction
from the front shroud and are preferred when
the liquid used may contain suspended
particles or fibers. The axial thrust generated
in semi-open impellers is usually higher than
closed impellers.
Types of Pumps Centrifugal Pumps

Construction

Open Impellers

These are used in applications where the


suspended solid’s size maybe large or the
solid’s maybe of crystals and fibers type.
Types of Pumps Centrifugal Pumps

Construction Impeller Arrangements

Single Suction Double Suction


Types of Pumps Centrifugal Pumps

Construction Impeller Arrangements

Double Suction Impeller


Types of Pumps Centrifugal Pumps

Construction Impeller Arrangements

Multistage Pump
Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction 2- Pump Casing

Volute Casing
Types of Pumps Centrifugal Pumps

Construction

Volute Casing
Types of Pumps Centrifugal Pumps

Construction 2- Pump Casing

Diffuser Casing
Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction 3- Wear Rings


• In order to prevent leakage between the rotating impeller
and pump casing wear rings are used.
• They are installed on impeller or casing or both. They
reduced the clearance between the impeller and the
casing to a very small amount.
• The smaller the clearance the smaller amount of liquid
transferred from the high pressure discharge side to the
low pressure suction side and the higher the efficiency will
be.
• They also prevent the wear of pump impeller and/or the
casing, hence their name. They are made of soft material
that can be sacrificed like bronze or cast iron.
Types of Pumps Centrifugal Pumps

Construction 3- Wear Rings


Types of Pumps Centrifugal Pumps

Construction 3- Wear Rings

Wearing rings are installed on the hub of


the impeller by either threading or
shrinking.
Casing wearing rings consist of either a
continuous ring or two half rings which
are pressed into place.
The continuous ring is used with
vertically split casings while
horizontally split casings are equipped
with wearing rings consisting of two
halves.
Split rings can be fitted onto a ridge or
into a groove of the casing which will
prevent any axial movement should the
rings work loose.
Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
• Packing is made from a wide variety
of materials, some of which are
asbestos, nylon, flax, Teflon, lead,
copper and aluminum.
• Frequently a lubricating material,
called the saturant, such as graphite or
grease, is incorporated into the
packing material.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
Packing in the stuffing boxes of a
centrifugal pump is not supposed to stop
leakage entirely, it only should throttle the
fluid. The reason for this is that the
packing acts as a bearing and must be
lubricated as such. Lubrication comes
from slight leakage of fluid from the
pump or, in emergency, from a lubricant
in the packing. It is sometimes necessary
to provide lubricant from an outside
source.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
The lantern ring (also called the seal cage) is a
metal ring having radial holes and it serves to
distribute the sealing water to the packing. The
sealing water not only helps to prevent air leakage
but also lubricates the packing and this water is
usually supplied from a higher pressure section of
the pump. In cases where the pump is pumping
water containing sand or grit or other abrasives,
then clean sealing water may be supplied from a
separate source.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression
Packing
Pump packing has to be replaced periodically
due to its deterioration from being compressed
and from loss of saturant. How often this has to
be done will depend upon the operating
conditions of the pump, the quality of the
packing used, and the care with which the
packing was installed and adjusted. The
frequency of replacement of the packing may
vary between a matter of months in the case of
severe operating conditions, to several years
under more moderate conditions.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression Packing Replacement


The recommended steps for replacing packing are as follows:
• Shut down, isolate and drain pump. Make sure pump motor switch is
locked open or fuses removed and switch tagged with a "Do Not Operate"
warning tag.
• Remove gland adjusting nuts and slide gland away from the stuffing box. Then remove all the old packing using some
type of packing hook. Make sure the stuffing box is thoroughly clean and free from any small pieces of old packing.
Check that the sealing water connection to stuffing box is clear.
• Check the conditions of the shaft or the shaft sleeve if a sleeve is installed over the shaft. If the surface is grooved or
scored, then it should be replaced as any rough surface will damage the packing.
• To determine the correct size (thickness) of packing to use, measure the bore of the stuffing box and subtract the
diameter of the pump shaft and divide the difference by two.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression Packing Replacement


• Then wrap a coil of the correct size packing around a rod (same diameter as
shaft and held in a vise) and cut through each turn. If the packing is slightly
too large, never flatten it with a hammer. Place each turn on a clean surface
and roll it out with a piece of pipe.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression Packing Replacement


• Install the packing rings one at a time
after putting a light coating of oil or
grease on the inner diameter of each
ring. Slide each ring sideways over the
shaft. to prevent breaking of the ring.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression Packing Replacement


• Tamp the rings into place
one at a time using a split
wooden bushing or metal
ring to push each ring into
the stuffing box.
• Make sure the ring joints
are staggered and the
lantern ring lines up
properly with the sealing
water inlet.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Compression Packing Replacement

• Put packing follower in place and compress the packing slightly by tightening the gland nuts. Then
slacken off to just finger tight to allow for packing expansion. In the case of small pumps the shaft
should turn freely by hand.
• The packing should be allowed to leak freely when the pump is first started. After about twenty minutes
of running the follower should be gradually tightened until only the necessary operating leakage is
apparent.
• The above method of installation of packing in stuffing boxes is essentially the same for centrifugal,
rotary and reciprocating pumps.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Instead of employing a stuffing box with packing, many pumps use mechanical seals to prevent leakage along the shaft.
Mechanical seals have the following advantages over packing.
1. They require much less maintenance.
2. They do not produce wear of shafts or shaft sleeves as do packing rings.
3. They reduce leakage to a minimum.
4. They can be designed to work under very high temperatures and pressures.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal

Stationary Seal Rotating Seal


Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
On the other hand, mechanical seals have a greater first cost than packing, and when they fail, the pump must be taken
out of service for a longer period to replace the seal than would be necessary with the simple stuffing box and packing
method.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal

• The materials chosen for the sealing and mating rings depend
upon such things as the type of liquid being pumped, its
temperature, its pressure, pump speed and seal design.

• Materials frequently used by various seal manufacturers are


bronze, carbon graphite, ceramics, stellite, and tungsten
carbide.
Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal

Tandem Type
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal

Dry Running ?
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal

Heat Generation
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal
Care of Mechanical Seals

It is extremely important that the seals never run in a dry condition, otherwise the faces will become
grooved and scored. The following precautions should therefore be followed:

1. Never run the pump in a dry condition even for a few minutes.

2. Vent any air present from the seal housing before start up.

3. Make sure an adequate flow of quenching or cooling liquid is flowing to the seal.

A squealing sound is an indication of a dry seal but this sound is not always present if the seal runs dry.
Types of Pumps Centrifugal Pumps

Construction 4- Shaft Sealing

Mechanical Seal

A leaking seal may be caused by the following:

1. Seal faces scored or grooved.

2. Seal housing bolts too tight, causing distortion of rings.

3. "O" ring gaskets cut or nicked during installation.

4. Misalignment of piping, causing distortion of pump parts.

5. Excessive pump shaft vibration.


Types of Pumps Centrifugal Pumps

Construction
Types of Pumps Centrifugal Pumps

Construction 5- Bearings

NON DRIVE END DRIVE END


PUMP SIDE MOTOR SIDE
Thrust Load
DRIVE END NON DRIVE END
MOTOR SIDE PUMP SIDE

Radial Load Radial Load Radial Load


Deep Groove Ball Bearings
Angular Contact Ball Bearings
Types of Pumps Centrifugal Pumps

Construction 6- BEARING LUBRICATION METHOD

Oil Bath Method Oil Slinger Method


Types of Pumps Centrifugal Pumps

Construction 7- Pump Coupling


Types of Pumps Centrifugal Pumps

Construction 7- Pump Coupling

Grid Type Coupling Jaw Coupling


Types of Pumps Centrifugal Pumps

Construction 7- Pump Coupling

Disc Type Coupling


Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation CAUTION:

1. Never run a centrifugal pump continuously with the discharge valve completely
closed. The mechanical power applied to the impeller is dispelled as friction to the
water trapped and churned about in the casing. This friction causes overheating of
the water to the point where it turns into steam which may result in damage to the
pump.

2. Always operate a centrifugal pump with its suction valve wide open. Never use it
for flow control. Throttling or closing of this valve starves the impeller of its water
supply and the casing becomes partially empty resulting in excessive vibration
which may ruin the bearings. The lack of liquid also affects stuffing boxes and seals
which require a certain amount of liquid for lubrication and cooling.
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation

Start-Up
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation Cavitation

General Symptoms of Cavitation and its Affects Pump Performance and Pump Parts

• Reduction in capacity of the pump

• Decrease in the head developed

• Abnormal sound and vibrations

Cavitation implies a dynamic process of formation of bubbles inside the liquid, their growth and
subsequent collapse as the liquid flows through the pump.
Types of Pumps Centrifugal Pumps

Operation Cavitation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Operation
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance 1- Wear Rings
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance 2- Packing
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance 3- Mechanical Seal
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance 4- Bearing House
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance 4- Pump Strainer
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance THE PROBLEM

CAN NOT DO ALIGNMENT


MECH SEAL FAILURE
WATER IN LUBE OIL
LOSS OF P DISH.
HIGH VIBRATION

HI BEARING OIL T

START
HIGH NOISE

MOTOR TRIP
TRIP
FAIL TO
MOTOR
THE CAUSE

Insufficient inlet quantity ( Cavity) 0


Lube Oil heat exch. Tubes leak 0
Operating in critical speed range” 0
Piping strain 0 0
Poor oil condition 0
Rotor imbalance 0 0 0
Misalignment 0 0 0
Journal/thrust bearing damaged 0 0 0
Oil reservoir low temperature 0
Types of Pumps Centrifugal Pumps

Troubleshooting
and Maintenance THE PROBLEM

CAN NOT DO ALIGNMENT


MECH SEAL FAILURE
WATER IN LUBE OIL
LOSS OF P DISH.
HIGH VIBRATION

HI BEARING OIL T
HIGH NOISE

START
LOW OIL PR

MOTOR TRIP
TRIP
CAN NOT
MOTOR
THE CAUSE

Clogging lube oil strainer/ filter 0 0


Condensate in oil reservoir 0
Damaged rotor 0
Excessive bearing clearance 0
Excessive Inlet temperature 0

Faulty temperature switch 0 0 0


Improper assembled parts 0 0 0
Types of Pumps Centrifugal Pumps

Troubleshooting THE PROBLEM


and Maintenance

SHORT BEARING LIFE


EXCESSIVE WEAR

EXCESSIVE HEAT

HIGH VIBRATION
LOW Q DISH.
LOW P DISH.
NO Q DISH.

HIGH NOISE
HIGH A mps

MOTOR TRIP
THE CAUSE
INSUFFICIENT LUBE OIL (Lubricators) 0* 0 0 0 0
Misalignment 0 0 0

Internal parts wear fluid end 0 0 0


Strainer partially clogged 0 0 0
Internal parts wear Power end 0 0 0
P.R.V. problem 0 0
Insufficient lube oil cooling 0 0 0
WRONG DIRECTION OF ROTATION 0 0
Types of Pumps Centrifugal Pumps

Troubleshooting THE PROBLEM


and Maintenance

SHORT BEARING LIFE


EXCESSIVE WEAR

EXCESSIVE HEAT

HIGH VIBRATION
LOW Q DISH.
LOW P DISH.

HIGH NOISE
NO Q DISH.

HIGH A mps

MOTOR TRIP
THE CAUSE
INSUFFICIENT LUBE OIL 0 0 0 0 0 0
Misalignment 0 0 0 0
EXCESSIVE SYSTEM PRESSURE 0 0 0 0 0 0
EXCESSIVE INLET TEMPERATURE 0 0
INSUFFICIENT LIQUID IN SUCTION 0 0 0 0
INTERNAL COMPONENT WEAR 0 0 0
STRAINER PARTIALLY CLOGGED 0 0 0 0
SPEED TOO LOW 0 0
P.R. VALVE LEAKS OR WRONG SET 0 0
ROTARY ELEMENTS BINDING 0 0 0 0 0 0
PIPING STRAIN 0 0 0 0
WRONG DIRECTION OF ROTATION 0 0
Types of Pumps Centrifugal Pumps

Case Studies Case Study

• Very high temperature of pump 20-P-01A bearing house was noticed with severe
bearing noise.
• Flow rate : 123-140 m3/hr (till 48 hours before the failure), 180 m3/hr within the
moment of failure and 48 hours before.
• Thrust Bearings found overheated and damaged, Radial Bearing found normal.
• Oil thrower of radial bearing side was found lose while the another one was found
fixed in place.
• Impeller and casing wear rings were found worn and out of tolerance. They were
replaced.
• Mechanical Seal was in good condition.
Alignment ?

The process of reducing the misalignment of two adjacent shafts so that the
Definition center line for each shaft is as near collinear as practical.
Parallel (Offset) Misalignment?

The distance between two adjacent and parallel shaft centerlines. This offset is
Definition normally described in a unit (millimeters or mils) at the flex element location.
Angular Misalignment ?

The angle between the shaft centerline of two adjacent shafts. This angle is
Definition normally reported in slope of millimeter of change per meter of linear distance
(mils per in.) (1 mil = 0.001 in.).

Millimeters of change per meter of linear


distance
Combination Misalignment ?

When the centerlines of two adjacent shafts are neither parallel nor intersect.
Definition This misalignment is normally described in both angular and offset terms.
Locations of Potential Misalignment

3
Consequences of Misalignment
Sources of Misalignment
Piping Strain
Deviation of Operating Conditions than
Ambient Conditions

80 % of Chronic Failures

Improper
Alignment

Improper Foundation Design


Sources of Misalignment

Improper Base Plate /Foundation Design

Pump Base
Plate
A fabricated (or cast)
metal structure used to
mount, support, and
align, machinery and its
auxiliary components.
Base Plate /Foundation
Design
Sources of Misalignment

Improper Base Plate /Foundation Design


Sources of Misalignment

Improper Base Plate /Foundation Design


Sources of Misalignment

Improper Base Plate /Foundation Design


Piping Misalignment Check
API 686

Piping Tolerances
Piping Misalignment Check
API 686

Verifying Piping
Strain
Piping Misalignment Check
API 686

Piping Alignment
Requirements
Couplings

Installation
Alignment Tools

Dial Indicator Clamps Shims Feeler Guage

Straight Edge Taper Guage


Alignment Tools

Vernier Caliper Laser Alignment Kit Torque Wrenches

Open/Closed Wrenches Mirror Level Bar


Alignment Tools
Dial Guage/Indicator
Alignment Tools
Dial Guage/Indicator
Alignment Tools
Dial Guage/Indicator

Various Styles, Sizes and Ranges

Metric Dial Indicator


Alignment Tools
Shims
Alignment Techniques
Laser Alignment
Alignment Techniques
Laser Alignment

• With the advent of laser technology, alignments can


be achieved to high degrees of accuracy.
• A laser alignment system uses a laser diode to
produce a straight laser beam.
• These beams can be either visible or invisible to
the naked eye.
• The laser beams may be Class 1 (invisible) or Class
2 (visible).
• Looking directly into the laser beam without
protection is not recommended.
Alignment Techniques
Laser Alignment

Advantages of Laser Alignment

• Good for long spans

• Gives consistent, accurate results

• Avoids mistakes in calculation

• Has fast set-up and most system brackets are

easily attached to the machine

• Avoids the problem of bracket sag


Alignment Techniques
Laser Alignment

Disadvantages of Laser Alignment

• The equipment has high initial cost

• Heat sources can have a negative effect on the

accuracy of the beam

• Equipment calibration must be checked

regularly
Alignment Techniques
Laser Alignment

Aligning Motor to Pump

Reading Shows Angular & Parallel Deviation

LASER Aligning Display Unit


Unbalance ?

‘That condition which


exists in a rotor when Mass Eccentricity
vibratory force or motion e
is imparted to its bearings
as a result of centrifugal
forces’ Center of Gravity Center of Rotation

M R
International Standards
Organization (ISO)
Single Plane Balancing

Original Readings (O)


Single Plane Balancing

After putting a trial


weight

Trial + Original
Readings (O+T)
Single Plane Balancing

Using Vector Summation


to determine the trial
weight effect.
To determine amount of
correction weight:

Correction weigℎ𝑡
𝑂
= 𝑇𝑟𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑥
𝑇
Residual Unbalance

ISO 1940 G2.5


Example for Turbine Rotor

Rotor weight = 400 kg


Maximum speed = 10000 rpm

ISO 1940 G2.5

Umax = 2.4 μm x 400 kg


= 960 g.mm
Residual Unbalance

ISO 1940
Selection of Trial Weights
There are numerous ways to add trial weights to a rotor, and a close inspection of the exact application
will reveal the most appropriate method.

Modelling Clay Flat Washers Lead Weights

Hose Clips Reinforced Tape Epoxy


Attachment of Trial Weights
There are numerous ways to attach trial weights to a rotor,

Soldering Brazing Welding

Adding Washers To Bolts Drilling or Tapping New Bolts


Attachment of Trial Weights
There are numerous ways to attach trial weights to a rotor,

Balancing Ring
Types of Pumps

Reciprocating
Pump Pulsation Dampener P

REDUCE PRESSURE
FLUCTUATION

Relief
Accumulator Valve
Q

KEEP ENOUGH
QUANTITY IN SUCTION
Types of Pumps

Reciprocating THROAT BUSH


Pump PACKING
LANTERN RING

Plunger Pump FOLLOWER


GLAND

• Displaces only part of


the liquid inside the
cylinder as it does not
touch the cylinder
walls.
• No cylinder liner is
used.
Types of Pumps

Reciprocating
Pump

Piston Pump
• Cylinder liner is used.

• The movement of the


piston in the cylinder
in one direction is
called the stroke of the
plunger. The distance
the piston moves in
and out of the cylinder
is called the length of
the stroke.
Types of Pumps

Reciprocating
Pump

Piston Pump

Single Acting
Types of Pumps

Reciprocating
Pump

Piston Pump

Double Acting
Types of Pumps

Reciprocating
Pump

Duplex Pump
Types of Pumps

Rotary
Pumps

Twin Lube Pump


Types of Pumps

Rotary
Pumps

Sliding Vane Pump Discharge

Suction
Types of Pumps

Rotary
Pumps

Sliding Vane Pump


Types of Pumps

Rotary
Pumps

Gear Pump
Types of Pumps

Rotary
Pumps

Internal Gear
Pump
Types of Pumps

Rotary
Pumps

Gear Pump

clearance
Types of Pumps

Rotary TIMING GEAR FUNCTION


Pumps

Gear Pump 1- TRANSMIT MOTION


TO OTHER ROTOR

2- KEEPS NO CONTACT
BETWEEN ROTORS

3- PREVENT WEAR
BETWEEN ROTORS
Types of Pumps

Rotary
Pumps

Multiple-Screw
Double-End Pump
Types of Pumps

Rotary
Pumps
Centrifugal Rotary

Differential Head Ft

Flow rate GPM


0 50 100 150 200 250 300 350 400 450 500
Thank you for
your attention!
Any Questions?
Contact Details

Hesham AbdelGayed
Tel: 01002729088

[email protected]

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