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Centrifugal-Pump Operation: Mygazee 99
Centrifugal-Pump Operation: Mygazee 99
MYGAZEE 99
CENTRIFUGAL-PUMP OPERATION
MYGAZEE 99
Initial Start.
Starting a centrifugal pump for the first time can be a troublesome
experience unless our plant crew has made a thorough check of the unit during and
after installation. There are probably more unusual accidents and troubles during
initial starting of a pump than at almost any other time. Factors to be considered
in starting any centrifugal pump include pipe cleanliness, pump alignment, rotation,
lubrication, position of valves, stuffing-box and mechanical seals leakage, effect of
changes, bypass quantities, throttling of the discharge, and performance checks.
Pipe Cleanliness.
Multistage pumps, and many single-stage units, have close-clearance running
parts which must be protected from Abrasive particles often found in new piping
systems. In one subsidiary, Rust particles which lodge in the running clearance of a
large barrel type feed pump caused the unit to seize, requiring expensive repairs and
loss of pumping capacity during the ensuing shutdown.
This is but one example of damage caused by materials lodged in new piping.
Many others could be cited because this problem is rather common. To reduce the
possibility of larger abrasive particles from reaching the pump, install a flat or conical
strainer made up of No. 20 or 30 mesh window screen backed with inch mesh
screen. Place the screen in the suction line as close as possible to the pump suction
nozzle. Install pressure gauges on each side of the screen so the pressure drop across
it can be measured.
When starting the pump for the first time, watch both gages and when
a pressure difference occurs between the two, indicating the screen is clogged, stop
the pump and remove the dirt and scale from it. When the screen is clean, replace it.
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Continue cleaning and replacing, as necessary, until no further pressure drop occurs.
For most installations, the screen should be used for at least 24 hrs before being
removed.
Alignment.
Bring the pump to operating temperature by admitting liquid to the casing.
Check the alignment,. Turn the pump over by hand. It should turn freely , without
binding, scraping, or making any noise. Inspect the pump footings to see that any
device for expension of the casing are free and in good working condition.
Rotation.
Check the driver and pump rotation. When a polyphase driving motor is
used, touch the starter button just long enough to make the motor turn a few
revolutions. The pump shaft should turn in the direction of the arrow on the casing.
Figure 2a shows how to determine the direction of rotation of a horizontal
centrifugal pump. Stand at the driver end facing the pump. If the top of the shaft
revolves from left to right when viewed from this position the pump is said to rotate
clockwise. A counter-clockwise pump turns in the opposite direction when viewed
from the same point. For a vertical pump (Fig. 2b) look down at the top of the
pump. If a point on the shaft revolves from left to right, when viewed from this
position, the rotation is clockwise. When the shaft turns in the opposite direction its
rotation is counterclockwise.
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Pump Bearings.
Before any pump is started its bearings must be carefully inspected, cleaned
and lubricated. With Oil-lubricated shoes sleeve bearings, thrust shoes (if used),
and drain plug. Flush out the housing, oil piping, cooler, pump, and sump tank with
kerosene, carbon-tetrachloride or safety solvent such as Klenco. Wash the bearing
parts throughly and reassemble them the housing. Flush entire system with
lubricating oil and allow it to drain to waste. This will ensure removal of any dirt,
metallic, or waste particles present in the bearings or lube sysem. Replace the drain
plug, caps, and other parts and fill the bearing as directed by the manufacturer or as
given later in this article.
Grease-lubricated ball, roller, and needle bearings are usually packed with
grease at the factory before the pump is shipped. So no lubrication may be
necessary before starting the pump. Check the condition of the grease by removing
the bearing housing cover. See that there is grease in the bearing. In general, do not
add any grease unless the pump manufacturer gives specific direction to do so. An
over-greased bearing may overheat soon after the pump is started. If it has,
replace as directed later in this article.
Never start a pump equipped with Kingsbury-type thrust bearings without
first pouring enough oil into the bushing to protect the thrust shoes. Extreme care
must be exercised with all types of bearings on pumps to see that they have enough
clean lubricant, Watch for contamination and for dirt picked up during shipment.
Thrust Bearings.
Figure 3 shows the steps in priming two designs of Kingsbury thrust
bearings commonly used in centrifugal pumps. In the bearing in Fig.3a, fill the
housing with the correct. grade of oil until the level reaches the ring on the oil-level
gage. This resembles the gage shown in Fig. 4a. Remove the locking screw in the
top of the thrust-bearing cap and pour a liberal amount of oil into the bushing
(Fig.3a). Replace the locking screw, making sure it fits into the bushing, to prevent it
from rotating. Remove the vent plug at the top of the oil-pump body and pour in
enough oil to wet the parts of the oil pump. Watch the oil level in the gage glass after
the main pump starts. If the level stabilises too far below the marker, add oil until the
level is (12.5mm) to in. (6.5mm) below the ring.
The bearing in Fig. 3b and 3c does not have an integral oil pump. It is,
however, filled in a manner similar to that described above for Fig. 3a. Be sure to
replace the locking screw tightly, to prevent the bushing from rotating. The
procedures given here apply to one make of Kingsbury thrust bearing. To be
completely safe, check the pump instruction manual before flushing and filling thrust
bearings of this type. The exact procedure may differ from that given here.
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Lube-oil Systems.
Figure 5 shows a typical forced-feed lube-oil system for a horizontal
multistage centrifugal pump. It consists of an integral gear-type oil pump mounted
within the thrust-bearing housing and taking its suction from an oil reservoir mounted
below the pump shaft, as shown, a tubular oil cooler, piping, and pressure and level
gages. With this type of system, which is often used with large pumps having sleeve
bearings for the main shaft, clean and flush the bearings as outlined above, including
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the sump-tank reservoir and the oil cooler. Pour oil into each bearing bushing and fill
the sump tank until it is full, or more. Important: Fill the supply line to the
bearings so it will be full when the pump starts and there will be no delay in the oil
reaching the bearings. The system supplies oil to both the bearings of the main pump
and its driver. Some pumps have a centrifugal-type impeller on the end of their
shaft, instead of a gear pump.
Ball Bearings.
Almost all modern pumps use ball bearings to carry radial or thrust loads, or
both. (These are usually lubricated by an advanced pure or purge mist
systems- (fig.5b). The types of ball bearings used for centrifugal pumps include
single-row deep-groove, double-row deep groove, double-row self-aligning, and
angular contact types made in double-and single-row designs. They may be greaseor oil-lubricated, with oil being popular for the al rger sizes. Figure 6a shows a
typical double-type out-board bearing designed to take small axial thrust loads
during pump starts and stops. It consists of two angular-contract ball thrust bearings
mounted back to back. A locknut and washer hold this bearing and the rotor
assembly in correct position with respect to the rest of the pump.
Cooled Ball Bearings.
Where high temperatures are expected in bearing operation the race may be
surrounded by a cooling jacket (Fig.6b). Water or another suitable liquid is
circulated through the jackets during pump operation.
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Sleeve Bearings.
In horizontal pumps these resemble the bearing shown in Fig. 3b, except
that a thrust collar is not fitted. A spherical seat permits the bearing bushing to align
itself with the shaft journal. Bearing linings are removable.
Vertical deepwell turbine pumps use either water-lubricated bearings
(Fig.6b) or oil-lubricated bearings (Fig. 6d). With the first type the liquid pumped
serves as the lubricant and no supply from the surface is needed. Oil-lubricated
bearings are inside a shaft-enclosing tube and are fed oil from the ground surface by
a lubricator mounted on or near the pump drive.
Lubricants.
Many manufacturers recommend a straight correctly refined turbine-type
Petronas Jentram type neutral mineral oil for centrifugal pumps. Normally it should
not contain any free acid, chlorine, sulfur, or more than a trace of free alkali. Based
on tests by ASTM standard methods, the oil should at least have the physical
characteristics given in Table 2-1.
Oil characteristics
Napthene-base oil
Paraffin-base oil
165.5 min
65.5 SSU min
-15 max
75 sec max
182.2 min
60 SSU min
1.6 max
75 sec max
Ambient Temp. C
Greasing Interval
8 hour day:
7-day week
7-day week
Pump Service
Low
High
6 months
3 months
24 hour day:
7-day week
7-day week
Low
High
6 weeks
3 weeks
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Fig.6. (a) Double type outboard bearing. (b) Water lubricated bearing for deepwell turbine pump
(c) ball bearing with cooling jacket (d) Oil lubricated bearing for deepwell turbine pump.
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Regreasing.
To replace the grease in a new or used antifriction bearing, remove the
bearing from the shaft. Using a brush, wash the race, balls, and other parts with
warm kerosene or carbon tetrachloride. Soak the bearing in one of these solvents
until the grease on it starts to dissolve. Use an innert-air hose to blow the grease off
the bearing parts.
Wash the bearing housing out with the same solvent. When both it and the
bearing are clean, flusih both with clean mineral oil. Allow the oil to drain to waste.
Check the cleanliness of the bearing by rotating it slowly. If it turns smoothly, you
can assume it is clean. Do not use kerosene or carbon tetrachloride at a
temperature higher fhan 50 C when cleaning the housing and bearing.
Pump Exterior.
Clean all external surfaces of The pump and its driver. Use rags or waste to remove
dirt, dust, oil drippings, globs of grease, and similar matter. It is important to have
the pump spotless if accidents and other operating troubles are to be avoided.
Check the suction and discharge piping to see that flanges and screwed
joints are tightly made up and will not leak. Where automatic valve operators are
used, check their operation by opening and closing the valves several times. To be
sure that the valve operating mechanism is working satisfactorily, use the manual
controls to open and close the valves.
Auxiliary Piping.
Check the auxiliary piping and liquid supply by opening the cooling-water
supply and discharge valves (Fig. 9) and observing the liquid flow. Where an
independent oil pump is used, start it and check the pressure and flow in the various
lube-oil lines. Check the cooling-water and oil flow at the pump bearings. See that
the stuffing-box jackets and smothering glands, if used, have a sufficient supply of
clear cool water.
Pump Drive.
Check the motor, turbine, engine, or other drive to see that it is lubricated
and ready to operate. Whenever possible, solo-run the drive independently of the
pump to see that it is in good operating order. Follow the manufacturers
instructions for drive operation. Remember, the drive generally is not supplied by
the pump manufacturer. So directions for drive operation may, or may not, be
included with the pump instruction manual.
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Priming.
Prime the pump by one of the methods given by the manufacturers
recomendation. Take care to see that the suction pipe is full of liquid and that there
is enough reserve in the supply system to keep the line full while the pump operates.
Reduced flow into the suction pipe of a centrifugal pump can lead to
overheating and extensive damage to the pump.
Standard Motors.
General-purpose synchronous motors of ratings up to 500 hp (372.8 Kw)
at 80 per cent power factor, and those having speeds of 500 rpm or higher at unity
power factor, have sufficient pull-in torque to start centrifugal pumps with the
discharge gate valve closed. At higher ratings and speeds below 500 rpm, standard
synchronous motors do not have enough pull-in torque to start a pump when its
discharge gate valve is open. Specially built motors can, however, be obtained to
start under these conditions. The remarks above on the starting methods for
induction motors also apply to synchronous motors.
Where a centrifugal pump must be started with the discharge gate valve
open and the starting current must be held to a minimum, use a wound-rotor
induction motor where alternating current is available. This type of motor develops
full-load torque without taking an excessive line current. A d-c motor can also be
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used, if a suitable power supply is available. It will develop full-load torque without
the line currents exceeding 125 to 200 per cent of the normal full-load current.
Pump Warmup.
With pumps handling hot water or other hot liquids, the casing, rotor, and
other parts must be brought to within a temperature of 10 to 38 C of the liquid
before the unit is started. This prevents unequal expansion, with the possibility of
contact between the moving and stationary parts. Some long pumps actually bow
or arch when the top half is hot while the bottom half is cold.
Open the vent valve on top of the casing and admit warm liquid to the
pump. Use one or more casing drains to increase the liquid flow from the pump,
thereby reducing the time required for warm-up. Boiler-feed pumps, and units
handling valuable or toxic liquids, cannot economically be warmed up in this
manner. Instead, a jumper line around the discharge check valve is used. Hot liquid
flows through this line, into the pump, and out the suction pipe. In a 4.542 Cubic
meter/minute feed pump, a warmup flow of 37.8 liter/minute is enough to bring
the pump temperature to within 38 C of the liquid handled.
Pumps having labyrinth leakoffs in the stuffing box generally do not need a
jumper line. Drainage through the leakoff is usually of sufficient quantity to keep the
pump warm, if the leakage is made up with hot liquid from the suction line. At liquid
temperatures of 175 C or higher, a period of 3 to 4 hrs. should be allowed for
pump to warmup, when starting from a cold condition. Shorter intervals may be
used when the pump is warm before heating is begun.
Starting the Pump.
The following steps are usually suitable for starting a centrifugal pump in
good operating condition:
(1) Turn on the cooling-water system for the pump bearings,
stuffing boxes, and mechanical seals, if these parts are
liquid-cooled.
(2) Start the auxiliary lube-oil pump, if one is fitted, and check the
oil flow to the bear- ings and other parts of the pump.
(3) Open the suction gate valve, and close or open the discharge
gate valve, depending on the starting procedure to be followed.
(4) Close all the drains in the casing and suction and discharge
piping.
(5) Prime the pump.
(6) Open the warmup valve if the pump is not at the right
temperature.
(7) Open the recirculating valve.
(8) Start the driver and bring the pump up to speed.
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Stuffing Boxes.
On pumps using discharge liquid for the stuffing boxes (Fig. 10a) close the
sealing-liquid valves while the pump is being started on a suction lift. When liquid is
being discharged by the pump, open the sealing valves. Adjust until there is a slight
but constant leakage of liquid from the stuffing-box glands. With an external
seal-liquid supply (Fig. 10b) turn on the control valve before starting the pump.
Figures 10c and 10d show two other sealing arrangements.
Bypass Use.
The recirculation or bypass connections should be cut in whenever the
pump must run at shutoff or at 20 per cent or less of its rated capacity. Be sure the
recirculated or bypassed liquid flows to a lower-pressure area where it can release
some of its heat before returning to the pump. Then, there will be no danger of the
pumps overheating. The bypassed liquid is often returned to the source of suction
supply, but not directly to the pump suction.
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Fig 10 (c) External grease seal for non-lubricating liquid, or where water cannot be used.
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Fig. 10 (d) Seal cage next to impeller keeps abrasive liquid away from packing or mechanical seal.
Standby Pumps.
When keeping a standby pump hot by circulating hot liquid, use the
following operating methods:
(1) Circulate cooling
water through the bearings, packing boxes, and lantern rings.
(2)Circulate oil to the bearings.
(3) Start the pump once each 8-hr shift, bringing it up to full speed
and operating it for 3 or 4 minutes if they are not in the RCM
convention.
When the pump is on hot-oil or other service where the liquid handled may
coke or plug the passages, start the pump twice each 8-hr shift. Standby boiler-feed
pumps are generally held in readiness with the suction and discharge gate valves
open at all times. Be sure to have sufficient liquid in the suction well, tank, or pond
when keeping a pump on standby.
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Operating Checks.
While the pump runs, make the hourly checks listed below: bearing
temperature, suction and discharge pressure, lube-oil temperature and pressure,
leakoff flow, discharge flowmeter, stuffing-box leakage, cooling-water suction and
discharge temperature and pressure, input to the pump driver and the oil level in the
pump and driver bearings. Keep an hourly record of all these readings, using a log
sheet (Fig. 11) developed for the particular installation. When the pump is fitted
with water-quenched glands (Fig. 12) shut off the quenching-water supply before
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frying to determine the leakage from the stuffing box. Otherwise, the
quenching-gland flow may be mistaken for leakage from the stuffing box (Fig. 10).
The condition of the packing box can often be checked by feeling the gland while
the pump is running (Fig 13). When the pump handles cool liquids, the gland
handles cool liquids, the gland should not be too hot to touch. With hot liquids this
test cannot be used because heat is transmitted from the liquid pumped to the
gland.
Check ring-oiled or ball sleeve bearings every hour to see that the oil rings
(Figs. 3 and 4) are taming freely and supplying enough oil to the bearings and
shaft. With any pump having oil-lubricated bearings it is wise to rotate the shaft a
few times by hand before starting for the first time when the oil is cold and the
bearing surfaces dry. This starts a flow of lube oil to the bearing surfaces, reducing
the possibility of overheating of the bearings during starting.
When making the hourly round of a pump, listen to the sound it makes while
running. Any change in the sound should be carefully checked because it may be the
first sign of impending trouble. Increased vibration and sudden changes in the
bearing temperatures are other indicators of possible operating troubles.
Steam-turbine-driven Pumps.
Warm the turbine before starting by opening the steam exhaust valve and all
drains on the steam inlet and exhaust, and the turbine casing. Rotate the shaft at
least once by hand to see that it is free. Heat the turbine casing by cracking the
steam-inlet throttle valve and allowing a small amount of steam to pass through to
the exhaust line. Allow steam to enter the casing until the unit reaches its operating
temperature. Open all drain valves wide to remove all condensate from the casing
and steam lines. When the lines and casing are dry, close all drains, open the throttle
valve, and quickly bring the turbine up to rated speed. The governor will then take
over control of the turbine speed. Prepare the pump driven by a turbine in the same
manner as described earlier for other centrifugal pumps.
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Balancing-chamber Leakoff.
Be sure that the leakoff from the balancing chamber of a multistage pump is
always open while the unit runs. Shutting off flow from the chamber may prevent the
drum from functioning, severely damaging the pump. When the pump is used in
boiler-feed service, connect the balancing-chamber leakoff to the nearest
convenient liquid tank on the suction side of the pump. Since this is at a lower
pressure than in the chamber, leakoff liquid will automatically flow while the pump
operates. In general, do not connect the leakoff line to the pump suction nozzle or
pipe.
Mechanical Seals.
These are now used instead of packing in every pumps. When applied to
high-pressure high-temperature service, some seals have a quench connection.
Others, known as double seals, are used where the liquid is corrosive or abrasive.
This type generally has an auxiliary pump and reservoir. The small auxiliary pump
circulates lube oil through the seals to lubricate and cool them. Start the auxiliary
pump and establish oil circulation before the main pump is started. Pumps handling
clean cool liquids sometimes bypass a small portion of the discharge to the
mechanical seals to cool and lubricate them. Be certain to open any valves in these
and the quench connections before starting the main pump.
Casing Gasket.
Before starting split-casing pumps for the first time, tighten the casing bolts.
If the manufacturer recommends using a torque wrench, do so. This will ensure that
sufficient pressure is obtained on the paper or asbestos flange gaskets. After
tightening flange bolts, tighten the shaft-sleeve nuts on packed pumps. Then the
sleeve will rotate properly with the shaft.
Couplings.
Some gear-type shaft couplings must be filled with oil or grease before the
pump is started for the first time. Do not over-fill oil-type couplings because the
pack-oil may leak out while the pump operates, damaging the pump room walls,
ceilings, lights, or other fixtures. Figure 15 shows the three steps to be followed in
filling grease-packed gear-type couplings.
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Fig. 15. Steps in packing a gear-type coupling. (a) Pack grease over grid and teeth. (b) Draw up cover and fasten with bolts. (c)
Lubricate at least once every 6 months, using a grease gun.
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Solution:
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Spare Parts.
The number of spare parts which should be kept on hand varies with the
pump application. Thus, aboard ship more parts are generally carried than in a
stationary plant. Most manufacturers recommend that the minimum number of
spares should be one set of shaft bearings, one set of shaft sleeves, one set of
wearing rings, and a supply of suitable set of packing or mechanical seals for the
stuffing boxes. On vital jobs where a standby pump is not installed, stock a
complete spare rotating element.
When ordering spare parts, always remember to give the manufacturer the
following information: serial number of pump, size and type of pump as given on the
pump name-plate, the exact number of the part as listed in the pump instruction and
parts manual, and the name of the part, as listed. Where possible, give the complete
symbols stamped on the old part. This is important information hence our pumps are
not purchased off-the shelve.
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References:
(1) Hydraulic Institute. (2) Ingersoll-Rand Co. (3) Peerless Pump Div. (4) Layne & Bowler, Inc. (5) Westinghouse Electric
Corp. (6) Allis-Chalmers Mfg. Co. (7) Power. (8) Worthington Corp. (9) Falk Coupling Div, Borg-Warner Corp. (10) Ebara
Corporation. (11) Pacific-Hiro pump Div, Shin Nippon Machinery (12) EKK Eagle Industry Co. Ltd. (13) Lubrication Systems
Company. (14) American Petroleum Institute. (15) Institution of Electrical and Electronic Engineers. (16) Institution of
Diagnostic Engineers.