Very Usefully Course
Very Usefully Course
Very Usefully Course
Presented By
Hesham M. Abdelgayed, MSc.
PhD Student,
Mechanical Engineering Department
University Of Alexandria
Pump or Compressor ?
Pumps
Pumps
Pumps or Compressor ?
Compressors
Applications of Pumps
2- Oil Transmission
(Transmission Pumps)
Applications of Pumps
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.
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
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
5000 5000
Centrifugal multistage
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
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
Centrifugal Pumps
API 610
ASME B73.1 & B73.2 Most common pumps
API 685 Seal less Pumps
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
Construction
Types of Pumps Centrifugal Pumps
Construction
Closed Impellers
Construction
Semi-Open Impellers
Construction
Open Impellers
Multistage Pump
Types of Pumps Centrifugal Pumps
Construction
Types of Pumps Centrifugal Pumps
Volute Casing
Types of Pumps Centrifugal Pumps
Construction
Volute Casing
Types of Pumps Centrifugal Pumps
Diffuser Casing
Types of Pumps Centrifugal Pumps
Construction
Types of Pumps Centrifugal Pumps
Construction
Types of Pumps Centrifugal Pumps
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
Compression
Packing
Types of Pumps Centrifugal Pumps
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
Compression
Packing
Types of Pumps Centrifugal Pumps
Compression
Packing
Types of Pumps Centrifugal Pumps
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
Compression
Packing
Types of Pumps Centrifugal Pumps
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
• 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
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
Mechanical Seal
Types of Pumps Centrifugal Pumps
Mechanical Seal
Types of Pumps Centrifugal Pumps
Mechanical Seal
Types of Pumps Centrifugal Pumps
Mechanical Seal
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
Mechanical Seal
Types of Pumps Centrifugal Pumps
Mechanical Seal
Types of Pumps Centrifugal Pumps
Mechanical Seal
Types of Pumps Centrifugal Pumps
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.
Construction
Types of Pumps Centrifugal Pumps
Mechanical Seal
Tandem Type
Types of Pumps Centrifugal Pumps
Mechanical Seal
Types of Pumps Centrifugal Pumps
Mechanical Seal
Dry Running ?
Types of Pumps Centrifugal Pumps
Mechanical Seal
Heat Generation
Types of Pumps Centrifugal Pumps
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
Mechanical Seal
Construction
Types of Pumps Centrifugal Pumps
Construction 5- Bearings
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
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
HI BEARING OIL T
START
HIGH NOISE
MOTOR TRIP
TRIP
FAIL TO
MOTOR
THE CAUSE
Troubleshooting
and Maintenance THE PROBLEM
HI BEARING OIL T
HIGH NOISE
START
LOW OIL PR
MOTOR TRIP
TRIP
CAN NOT
MOTOR
THE CAUSE
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
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
• 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.).
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
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
Piping Tolerances
Piping Misalignment Check
API 686
Verifying Piping
Strain
Piping Misalignment Check
API 686
Piping Alignment
Requirements
Couplings
Installation
Alignment Tools
regularly
Alignment Techniques
Laser Alignment
M R
International Standards
Organization (ISO)
Single Plane Balancing
Trial + Original
Readings (O+T)
Single Plane Balancing
Correction weigℎ𝑡
𝑂
= 𝑇𝑟𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑥
𝑇
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.
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
Pump
Piston Pump
• Cylinder liner is used.
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
Rotary
Pumps
Suction
Types of Pumps
Rotary
Pumps
Rotary
Pumps
Gear Pump
Types of Pumps
Rotary
Pumps
Internal Gear
Pump
Types of Pumps
Rotary
Pumps
Gear Pump
clearance
Types of Pumps
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
Hesham AbdelGayed
Tel: 01002729088