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    Centrifugal Pump Health Check Up 1691257011

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    Luis Marsh
    The document discusses centrifugal pumps and provides information on five common problems with pumps: performance issues, high vibration, abnormal sound, abnormal temperature, and excessive leakages. It describes the causes and possible solutions for each problem. The document also provides details on pump components and operation.

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    © All Rights Reserved
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    Centrifugal Pump Health Check Up 1691257011

    Uploaded by

    Luis Marsh
    82 views35 pages
    The document discusses centrifugal pumps and provides information on five common problems with pumps: performance issues, high vibration, abnormal sound, abnormal temperature, and excessive leakages. It describes the causes and possible solutions for each problem. The document also provides details on pump components and operation.

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    © © All Rights Reserved

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    The document discusses centrifugal pumps and provides information on five common problems with pumps: performance issues, high vibration, abnormal sound, abnormal temperature, and excessive leakages. It describes the causes and possible solutions for each problem. The document also provides details on pump components and operation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    82 views35 pages

    Centrifugal Pump Health Check Up 1691257011

    Uploaded by

    Luis Marsh
    The document discusses centrifugal pumps and provides information on five common problems with pumps: performance issues, high vibration, abnormal sound, abnormal temperature, and excessive leakages. It describes the causes and possible solutions for each problem. The document also provides details on pump components and operation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 35

    Centrifugal Pumps

    Five Symptoms Or problems


    and Possible solutions
    By Kirit Domadiya
    Why Pump ?
    • Moving fluids plays a major role in every aspect of our life,
    whether it is about pumping water for our daily usage or
    transferring hazardous chemicals in any Industry.
    • Pump systems consume almost 22% of all electric energy
    generated throughout the world. Predominant addressable
    segment for energy saving and reduce carbon footprint.
    • Coming back to Industry, Pump consumes 25% to 50% of the
    total energy usage in industrial plant operations.

    Why Centrifugal Pump ?


    • Next to electric motors, centrifugal pump is the most frequently
    utilized machine on earth. It has been estimated that over
    10,000,000,000 of them are in use worldwide.
    • More than 80% pumps in Industry are Centrifugal pumps among Source : LEWA Pump
    all types of pump.
    • Simplicity, Wide operating range, Smooth flow rate, Reliability,
    ease of O&M, Safety are some of the reason behind dominance
    Source : Pump Handbook - BHGE
    Close look at the major parts…..
    Head vs. Pressure
    Diesel Fuel Water Sulfuric Acid

    SG = 0.8 SG = 1.0 SG = 1.8 100 m

    8.0 10 18
    Kg/Cm2 Kg/Cm2 Kg/Cm2
    Pump is not only about Pump………..

    Fluid Characteristics,
    Viscosity
    Specific gravity
    Vapor pressure at op. temp
    Presence of solid
    Corrosiveness
    Top 5 Problems with pumps
    1. Performance issue
    2. High Vibration Sometimes the problem,
    3. Unusual sound We think problem,
    4. Abnormal temperature may not be the problem
    5. Excessive Leakages

     Essential to dig out the exact underlying problem to eliminate


    unplanned shut down or risk of breakdown, expensive repair,
    production loss or sometimes HSE incident
    • Problems are valuable inputs or indicators of presence of big
    problems.
    • If any of these are real problems, how to protect the pump
    from it’s consequence ?
    Centrifugal Pump Classification / Types

    Each Pump types will


    have Impeller, Casing,
    Suction / Discharge
    Nozzle, Shaft,
    Mechanical Seal,
    Bearings etc.

    Source : Sundyne LLC


    Problem 1 : Performance Issues

    Major Issues
    • Low Flow
    • No Flow
    • Erratic flow
    • Inadequate dis. pressure
    • Motor tripping at FLC

    Available Field parameters


    • Flow
    • Suction Pressure
    • Discharge pressure ‘I interact well with the people who comes to
    • Input Currant me with the datasheet and performance curve’
    – By Anonymous pump
    Performance Issue and possible causes
    Operating away from BEP On the Curve
    • System resistance
    • Control Valve opening
    • Modification in downstream pipe work

    Operating point off the curve


    • Undue wear and tear of pump component
    • Impeller diameter or DOR is different
    • Change in viscosity or specific gravity
    • Suction strainer or impeller clogged
    • Suction starvation or air / vapor ingestion
    • Hidden flow before flow meter (Possibly, recirculation line or valve passing)
    Focus on pump’s designed hydraulics, instead of only desired hydraulics
    Consequences of Off-design pump operation

    Unstable operating condition or running pump far off


    BEP is the major cause of many reliability issues like
    • High Vibrations
    • Excessive Temperatures
    • Abnormal Sound
    • Seal failures
    Problem 2 High Vibrations

    Vibration is a normal,
    unwanted but typically
    unavoidable outcome of any
    rotating machine.

    Source of Vibrations
    • Fault within pump
    • Flow Induced vibration
    • Resonance
    Vibration Causes and process
    Category Source / cause of vibration
    Fault or anomalies within Bent shaft, imbalance, Looseness,
    pump Bearing fault, Excessive wear
    Fluid dynamics Or Cavitation, Internal recirculation,
    instability Pressure pulsation, Oil whirl
    Resonance It is a phenomenon that amplifies a vibration. Due to
    operating speed is at natural frequency.

    Capture
    Monitoring Analyze the Find the
    vibrations
    the trends spectra fault
    data
    Flow induced vibration

    Radial load on the shaft

    Operating range Vs Vibrations


    Source : API 610 standard , 12th edition
    Shaft deflection
    Effect of High Vibrations
    • It accelerates rate of wear, create noise, consume power
    • In general, bearing lifetime (L10) decreases rapidly with even small
    increments of vibration value.
    • Taking an example mentioned in ANSI/HI 9.6.4 standard, assuming
    that a vibration intensity of 2.5 mm/sec corresponds to 100% of
    nominal bearing lifetime, simply increasing the vibration level to 5
    mm/sec could reduce bearing lifetime to 60-70% of nominal
    bearing lifetime.
    Standards for pump vibration limits
    - Hydraulic Institute (HI), namely with ANSI/HI 9.6.4 standard
    - American Petroleum Institute, API 610 standard
    - International Standards Organisation ISO 10816 standard
    Normal Vs Abnormal vibration, Setpoints

    Source : ISO 10817


    Problem 3 : Abnormal Sound
    • Noise is normally considered as
    unwanted sound, quite pumps are
    good, but not possible.
    • Very often noise is not a problem but
    indicator of bigger problem
    • Unlike vibration, sound is the language
    pump use to express its pain, pleasure,
    annoyance, anger etc.
    • Major source of abnormal sounds are
    excessive wear, excessive recirculation,
    turbulence, cavitation, bearings, Smart mother can decode kid’s
    coupling.
    noise better than the Doctor.
    • Condition monitoring stethoscope is
    handy and useful tool to detect some of Can same logic be applicable for
    the typical machine fault. Pump ?
    Sound, Best understood by listening rather
    than expressing in words

    Normal Cavitation Bearing fault


    ..\Desktop\ASME ..\Desktop\ASME ASME Webinar\bearing
    Webinar\normal.aac Webinar\Cavitation.aac noise.aac
    Problem 4 : Abnormal temperature

    • Process end
    • Mechanical Seal
    • Bearing housing
    Temperature rise in the pump

    Δ𝑡𝑡 = Temperature rise through the pump, in °C


    𝐻𝐻 = Total developed heat in m
    𝐶𝐶p = Sp. heat of pumping fluid, in kJ/kg K
    η = Efficiency at operating flow, expressed as a decimal

    Fluid Seal lube.


    Temp. rise Cavitation
    Vaporization failure

    Unless otherwise specified, Temp. rise should be < 8 °C, (HI 1.3)
    Temperature rise in Seal stuffing box

    Source : API 682 standard , 4th edition


    Bearing and Lube temperature : Normal Vs Abnormal

    • Oil life decreases by 50% for every 11°


    C rise in temp. above 60° C
    • The sump oil temperature rise < 39 °C
    above the ambient temp Or Bearing-
    temperature < 93 °C.
    • For oil sump temperatures higher
    than 77 °C, the additives in the oil will
    deteriorate and coke formation will
    accelerate.
    Problem 5 : Excessive leakages

    Static Sealing → Gasket, O ring

    Dynamic Sealing → Gland packing, Mechanical Seal

    Bearing housing sealing → Lip seal, Labyrinth, Bearing isolator


    Mechanical Seal is an integral part of pump
    Prevalent Dynamic Sealing methods

    Source
    :Sundyne
    HMD

    Gland packing, Normal leak 2-20 drops / minute Sealless pump – Zero leak

    Permissible
    leakage 6 cc/hr
    Or 1000 ppm
    vapor
    Pusher type Mechanical Seal Non-pusher type Mechanical Seal
    Seal face lubrication and Leakage Rate
    (rough estimate)
    Q →leakage rate in m3/sec
    b → Face contact width in mm
    h → gap height in μm
    ΔP → pressure differential in Pa
    η → dynamic viscosity in Pa·s
    Stable liquid lube film must
    be maintained between the
    seal faces at all the times.

    Source : Hydraulic Institute


    Major causes of seal leakage / Failure

    Shaft deflection – off BEP operation

    Recirculation - heat generation

    Bearing failure or high vibrations Seal API plan failure or not adequate
    Important check points for Seal installation
    Shaft runout 25 – 40 micron depending on flexibility factor, → Seal faces
    parallelism and concentricity

    Seal chamber squareness 0.5 μm / mm of seal bore


    dia. → it ensures Seal faces parallelism

    Seal chamber Register concentricity within 0.125 mm


    → it ensures Seal faces concentricity

    O-ring sealing surfaces, shall have a maximum surface roughness average value,
    Ra, 1.6 μm for static O-rings, 0.8 μm for the surface against which dynamic O-rings
    slide, and 6.4 μm at gasket sitting area
    Lube leakages / Contamination
    • Water breaks down lube directly
    reducing bearing life .003% water in
    oil reduces life of oil 50%.
    • Lip seal is outdated concept, now
    replaced by Labyrinth, bearing isolator,
    magnetic isolator etc.
    • Lack of lubrication and contaminations
    are the main cause of bearing failure.
    It doesn’t mean, Overfilling the bearing
    housing is a safer option. Perhaps it
    invites even more risk.
    Keep Learning…..
    Keep Sharing……
    Keep Growing……

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