Pump and Valve Components and Maintenance

Pump and Valve Components and

Maintenance

Outline:

1. Split case and End Suction pumps, industry in the 21st _{century, cost of ownership, and performance}

tips

2. Split case Pumps features, maintenance, and start up

3. End Suction Pumps features, maintenance, and start up

4. Methods of Pump Alignment

Split Case Pumps

&

End Suction Pumps

Pump industry in the 21

_century

Trends Implications for pump industry

Information age

Easier access to data on pumps, pump accessories and pumping systems. Use of world wide web.

Service economy

a) Increasing relevance of pre and post

purchase services, “software” associated with the product.

b) Emergence of a variety of new services – design & development, retrofit & energy audit, specialized maintenance, condition monitoring etc.

Rise of the knowledge worker

a) Sales engineers act as consultant to clients. b) Value addition by knowledge workers in system engineering, equipment selection, pump installation and commissioning,

Pump industry in the 21

_century

Trends Implications for pump industry

Age of the smart machines

a)Pumps that learn on the job.

b)Pump selection, application & training

program.

c)Availability of condition monitoring tools

and satellite communication.

Increase in trust and alliances

a)Collaborative efforts between users and

manufacturers of pumps.

b)Increasing use of single source

procurement by major pump users.

Age of mass customization

Domestic

pumps Agricultural close coupled pumps DIN 24255 End Suction pumps ISO 2858 End Suction Pumps Standard split case pumps Standard vertical wet pit pumps Engineered split case & Wet pit pumps. Boiler feed & extraction pumps

Product range optimization --- Tender optimization Integrated excellence --- Task Group excellence

Little or no interaction with user --- Protracted Interaction Design & development skills --- Application engineering skill Large batch manufacturing --- Customized manufacturing

Advantages

Split Case & End Suction Pumps

• Inspection of internals without disturbing

the pipework and the bearings.

• Simpler maintenance – lower maintenance

downtime

Importance of efficiency

a. Life cycle cost

Capitalized cost of one unit difference in

efficiency is equal to the price of the

Reasons for sub-optimal performance

Specification

related Inaccurate capacity, head , NPSHA & range of operation specified. System

related

Change in demand

Change in system components

Change in sump/suction condition Change in application

1. Increased power consumption.

2. Increased level of noise and vibration. 3. Cavitation erosion.

4. Shaft / bearing failure.

LOCATION MODIFICATION EFFECT

Volute throat Cut back Improves capacity and _efficiency Impeller outlet Undefiled vanes Improves head at BEP

Impeller inlet Cut back vanes Improves NPSHR

Impeller diameter Reduce Change in performance as _{per affinity law} Wear rings Restore clearance particularly in low NS Improves efficiency

pumps

Vane passages Clean/Polish/Coat Improves efficiency in low _{NS pumps} Impeller width Increase Flattens curve and _{increases capacity}

No. of vanes Decreases Steepens curve and moves

Split Case Base Mount Pumps

Features and Benefits - SCP

• Horizontal Split Case, Double Suction Design

• Simple access to rotating assembly • Hydraulically balanced

• Highest efficiency of any pump type

•Uses NEMA Frame Foot Mount Motors (Any Mfg’s OK)

• All voltages and enclosures available.

• Various efficiency types and VFD compatible versions available

• “Metric Free”????

• All tappings NPT (gauge and gland drain)

•Know what your buying, metric is OK if your prepared for it

• ¼” Pressure Gauge Tappings Standard

Detailed Technical Features

Tongue & groove case ring design eliminates axial displacement and seizure of rotating

assembly

Impeller double suction (hydraulically balanced), minimizes axial thrust Horizontally split casing - enables

replacement of bearings and mechanical seals without disturbing system piping

Internal flush water insures maximum seal life (Copper or SS tubing for Long Life)

Double lock nut and key arrangement ensures reverse rotation of shaft sleeve

Short shaft sleeve

Nut

Keyed Impeller

Features & Benefits

Easy maintenance

Reduced maintenance downtime

Split case concept :

- The top casing can be removed, in order to have

direct access to the rotating

parts.

Casing :

- Standard construction in Cast iron

- Alternative materials

available (Bronze, Stainless Steel…).

Material information Wear rings : - Standard construction in Bronze. - Alternative materials available

 Longer seal lifetime Controls cavitation

Tong & groove wear rings.

- To guarantee a correct location on reassembly. - To avoid wear on the casing. -Minimise bypass from suction

to discharge

Easy maintenance

Axial thrust

Axial thrust

More reliable

Double suction concept.

- The impeller are hydraulically balanced so axial thrust is

minimised. - To minimised the NPSHr More reliable Impeller : - Standard construction in Bronze.

- Alternative materials available (Cast iron, Stainless Steel…).

Material information

 Longer bearing and

seal lifetime

Between bearing concept.

- To reduced shaft deflection. - To minimised vibration. - Bearings can also be removed

without disturbing top casing. Lifetime extended Material information Shaft : - Standard construction in Stainless Steel. - Alternative materials available 316 SS, Duplex SS

Material information

Seal return pipes :

- Standard construction in

Copper.

- Alternative materials available

 Longer seal lifetime

Seal return pipes.

- To avoid premature wear of the mechanical seal or packing.

- For abrasive fluid use a cyclone separator in the

stuffing box.

Lifetime extended

There is always an uneven turbulent

flow round an elbow and when it is in a

position other than vertical it causes

more liquid to enter one side of the

impeller than the other. This results in

high un equal thrust loads that will

overheat the bearings and cause rapid

wear in addition to affecting hydraulic

performance.

End Suction Base Mount Pumps

Features and Benefits - NL

• Radically Split, Back Pullout Design

• Repair “wet end” without disturbing piping

•Uses NEMA Frame Foot Mount Motors (other Mfg’s OK)

• All voltages and enclosures available.

• Various efficiency types and VFD compatible versions available

• “Metric Free”

• All tappings NPT (gauge and gland drain)

•Know what your buying, Metric is OK if your prepared for it.

• ¼” Pressure Gauge Tappings Standard

Shaft Sealing : Mechanical Seal For temperature (-4°F to 250°F)

List Of Components 10.20 Volute Casing 16.10 Casing Cover 18.30 Support Foot 21.00 Shaft 23.00 Impeller 32.10 Ball Bearing 33.00 Bearing Bkt 43.30 Mech. Seal 46.10 Stuffing Box 52.40 Shaft Sleeve (Stuffing Box)

Anti-Rotation rib Conical seal chamber Reduces the possibility of pressure drop in Mech seal area

Avoids vortex formation

Eccentric reducers should be

installed directly at the suction

nozzle, with the taper at the bottom

to prevent air pockets from forming.

Straight taper reducers should never

be used in a horizontal suction line

because of the air pocket that is

formed at the leg of the reducer and

the pipe.

Split Case Pumps

&

End Suction Pumps

To check angular alignment:

• Insert a feeler gauge or taper gage at any four places 90° apart around the coupling halves.

• Insert shims under the driver feet until the same reading is obtained at all four check

points.

• The pump and driver will then be in angular alignment.

To check parallel alignment:

• A straight edge should be held against the edges of the coupling halves at any four

places 90° apart around the coupling.

• The straight edge should be parallel to the pump and driver shafts at all times.

• Insert shims until the straight edge lies flat against both coupling halves at all four

checkpoints.

• The pump and driver will then be in proper parallel alignment

To check angular misalignment:

• Mount the dial indicator base to the coupling half, and position the dial indicator button on the front or rear face of the opposite coupling half.

• Set the dial to zero, rotate both coupling halves together, making sure the indicator button always indicates off the same spot.

• Misalignment values within 0.004 inches TIR per inch of coupler radius is permissible.

To check parallel misalignment:

• Mount the dial indicator base to one coupling half, or shaft and position the dial indicator

button on the outside diameter of the opposite coupling half.

• Set the dial to zero, rotate both coupling halves together, making sure the indicator button always indicates off the same spot. • Misalignment within 0.004 inches TIR is permissible

General Recommended Safety Precautions of both Split Case & End Suction Pumps

 Do not throttle the suction line to adjust the pump output.

 Do not operate pump without all guards in place.  Do not run pump dry, seal and packing damage may

occur.

 Do not let heated pump temperature rise above 150°F taken on external surfaces.

 Disconnect and lockout power before servicing.

• Check alignment between pump and motor.

• Check all connections to motor and starting device with the wiring diagram. Check voltage, phase, and frequency on motor nameplate with line circuit.

• Check suction and discharge piping and pressure gauges for proper operation.

• Turn pump shaft by hand to assure that it rotates freely. • Check driver lubrication.

• Assure that pump bearings are properly lubricated.

• Assure that coupling is properly lubricated, if required.

• Assure that pump is full of liquid (‘PRIMING’) and all valves are properly set and operational, with the discharge valve closed, and the suction valve open.

• Check rotation. Be sure that the drive operates in the direction indicated by the arrow on the pump casing as serious damage can result if the pump is operated with incorrect rotation.

• Check rotation each time the motor leads have been disconnected.

Vertical Turbine Pumps

Small Diameter Units

Impeller Running Clearance Adjustment

 Running clearance of an “Open” style impeller is critical, the entire performance of the pump and its ability to run at its

Best Efficiency Point [BP] depends on it. Refer to the OEM for this clearance dimensions.

 Running clearance of a closed or shrouded impeller is also

important, however its BP is based on the Diametric clearance between the impeller ring and the bowl ring.

 All settings must allow for shaft elongation based on the length and weight of shaft and the temperature of the water being

pumped. Refer to the OEM for this calculation.

 After setting the Running Clearance you should be able to turn the pump with relative ease to verify there is no rubbing.

Impeller Running Clearance continued

Pump Pre-Start Check List

 Check wiring connections to driver.

 Check voltage, phase, and frequency of circuit with name plate on driver

 Check for proper lubrication on Driver, reference the OEM  Check Impeller adjustment

 Inspect packing gland for adjustment. Check flush piping & validate water flow.

 Check for proper rotation efore connecting driver coupling. Reference OEM for direction of rotation.

 Inspect all piping connections and piping supports.  Install pressure gauge on discharge.

 Check water level in sump for proper submergence of the suction end. Not enough water could cause vortex or

Complexities of Valve Maintenance

How Hard Is It???

The majority of water

plant valve failures is

caused by 1 or more of

Step 1: Lubricate all moving components to OEM

recommended intervals

Step 2: Replace packing and soft goods when they

start to leak, NOT years later.

Step 3:

EXERSISE ! EXERSISE ! EXERSISE ! EXERSISE !

I thank you very much for your attention. If you have any further questions please don’t hesitate to contact me.

Matt Glova:

Industrial Pump & Valve Repair 440.269.8991

ANY QUESTIONS??