propriate word, 1° Circle or underline the ap- propriate word. Of the two parts that contac spindle) moves, t the object, only the (anvil/ spindle A Program is a series of frames that work like the ones you have just done: Read the frame, Use the information to Allin the blanks or make a choice Move the mask doyn and check the response column, Go on to the next frame, Remember to cover the r ‘esponse column with a mas! you begin each page, k beforeSTRUCTIONS ‘This is a programed learning course. Programed learning gives information in a series of steps “called frames. Exch frame gives some information and asks you to make use of it. Here is how it works. First, cover the response column at the right with a mask. Read this frame and use the information it gives to fill in the blank. 2 A micrometer is an instrument designed to measure in thousandths of an inch, A micrometer is a good tool for measuring very differences in size. Move the mask down to uncover thé word at the right of the frame. If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. The drawing of a micrometer provides information that will help you fill in the next blanks. OBJECT TO BE MEASURED. ANVIL THIMBLE SPINDLE 1 RATCHET CAP FRAME Seven major parts are shown in the drawing, but only the and the —_ contact the object to be measured. small anvil; spindlePositive displacement pumps are reciprocating and rotary pumps that move liquid by the positive displacement of liquid volume. In Section 1 of Positive Displacement Pumps you learned the operating principles of these pumps; what determines their capacity, pressure, horsepower and efficiency: how NPSH is calculated; and the performance characteristies of positive displacement pumps. In Section 2, you learned the baste types of reciprocating and rotary pumps, including piston pumps, plunger pumps, di- aphragm pumps, direct-acting steam and sir pumps, ‘and rotary lobe, vane, gear, and screw pumps, You learned how these pumps differ from each other in design and perform, ance, In Section 3, you will learn the construction and operation of pump valves, pulsation dampeners and suction stabilizers, Yarlable displacement devices, bypasses and relief valves, {ou will learn about packing, lubrication, and cooling ays, tems, In Section 4, you will learn startup and shutdown proce- dures; how to recognize and solve common pumping prok lems; and proper operating maintenance.POSITIVE DISPLACEMENT PUMPS Section 3 Construction Details“SECTION 3 CONSTRUCTION DETAILS CYLINDER VALVES 1. This is a commonly-used pump valve. BALL VALVE SEAT ‘The part that moves during opening and closing of the valve is a metal alt 2. To close the valve, the ball must fit closely into the valve Poet seat To open the valve, liquid pressure below the seat must be more than (the pressure of the weight of the ball/ total pressure above the seat). total pressure above the seat, 4. This is another commonly-used pump valve. } | STEM GUIDE VALVE SEAT In this case, the part that moves during opening and closing of the valve is a flat, metal —___. dise 15. ‘The dise 4s fitted with a spring. ‘The spring provides some of the foree that causes the disc to ________ when suction pressure drops. seal 6, The tension of the spring also increases the suction pressure required to___-__ the valve. open, 7. Every valve must be constructed so that the ball or disc can make a complete seal across the valve seat every time. WING GUIDES In the ball valve, the ball is guided into the seat by the walls of a______ surrounding the ball cage 8. In the dise valve, the dise must be guided into the seat by some sort of sie oF stem; wings 9, Stem-guided valves are satisfactory for service involving relatively low pressures, The wing guide is sturdier in construction, so it can be used where the pressures are moderately gf high10, u For very high-pressure service, a wing guide may be beveled, ‘The beveled surface causes the guide to slightly as the liquid flows through it This turning ac valve. ion evens out the ____. on the A bowel valve is almost like a dise valve. ‘The bow! shape helps the valve make a tight —____— against the valve seat. turn, or rotate seat, or seal, or fit13. Some valves are dual-seated, One part of this valve seats metal-to-metal RUBBER ‘The other part seats metal-to- rubber j U4. Here ave two valves designed for use in pumping thick bands. | | | | Valve A is used where the pressure is low. Valve B, be- cause it has wing guides, can be used where pressure is ae highhese views show the seat area of both a dise valve and “4 bow! valve. DISC VALVE SEAT BOWL VALVE SEAT Im this case, the seat of the (dise bowl) valve offers less obstruction to flow Suppose a highly viscous liquid is to be pumped. Based on the difference in seat area, the (dise/bowl) valve just shown would be a better choice. ;, Suppose the liquid is abrasive. ‘The seat with (more less) obstruction to flow would be better. ‘The seats of the ball and bowl valves have the freest openings. be INCH: Of these two valves, the (ball/bowl) valve has a greater seat area. bowl bowl bowl"s0f the two, the (ball/bow!) valve is simpler in con- struction. Because of the spring, the action of the bowl valve is (amoother than/not as smooth as) the ball valve. 21. When clear flow is required but smooth valve action is not essential, the ________ valve is a better choice for easy maintenance. | Suppose a pump must handle a thick, gritty liquid. You would expect wear on the valve parts to be (rapid/ no different from other service) 28. These two valves show one way of compensating for such severe service conditions. Valve A has renewable rubber inserts for the —___ and part of the 24. Valve B is designed so the —___ can be replaced, __ of the valve ball smoother than ball rapid wings dise seat26. 21 &) SYNTHETIC INSERT ‘The synthetie insert is used for all ordinary services, ‘The construction is such that the insert could be re- placed (casily/only with difficulty) with a special corro- sion or abrasion-resistant insert for severe service. Usually, the same kind of valve is used for both the suetion and the discharge of a given pump. However, a pump’s discharge pressure may be (the same as/greater than, equal to) the suetion pressure, ‘Therefore, if there is a difference between suetion and discharge valves, it is likely that the (suetion/discharge) springs are heavier. ‘The major difference between suction and discharge valves is the way the valves are installed. Suction valves open into the (line/eylinder) Discharge valves open into the ae 7 easily greater than discharge eylinder line, or discharge suction,‘ikoush pumps vary, suction valves are usually in- Sfalled near the bottom of a pump. E pischarge valves are usually installed near the —__ ofthe pump. 2. ‘This is called a furret assembly. SPRING SUCTION CHAMBER ©) [fp VALVE SEAT pa The suction valve is mounted (on top of/beneath) the discharge valve, 88, The two valves share the same __ BA, Access to both valves for inspection or adjustment is through the pot cover. The discharge valve (must be removable/need not be removable) Summary 35. Pump valves work as check valves by allowing uid flow in (only one direction /two directions). . 36. In order for the valve to operate, there (must be/need not be) a pressure difference across the valve. 37. Springs are put into many valves to {increase/deerease) the speed of seating and also to increase the amount of pressure required to the valve. 238, type of guide used depends in part on (pump speed the pressure difference across the valve) 8 ‘top beneath, stem, or guide must be removable only one direction must be increase open. the pressure difference across the valveFrentity these three kinds of valve guides. OR se pute 40. Name the lettered parts of this valve. wing stem. beveled wing power spring disc, or valve valve seat stem, or valve guideFos (he valve shown in frame 40 is a ___-guided ane valve. ja, Tt would be used when the pumping liquid (is/is not) highly viscous, corrosive, or abrasive. BULSATION DAMPENERS AND SUCTION STABILIZERS |. The flow of liquid from a reciprocating pump is (con- tinuous’ pulsating) ‘The flow is more even from a (single-acting/double- acting) pump. . Flow is also more even if the pump is (simplex/multi- plex). = 47, A pulsation dampener evens out the flow from a recipro- cating pump. an PULSATION DAMPNER ‘The pulsation dampener is a sealed chamber containing 48, The gas used may be air or nitrogen. Since hydrocarbons mixed with air can ignite and burn, (air/nitrogen) is preferred when hydrocarbons are being pumped. 10 stem dise high is not pulsating double-acting multiplex gas nitrogenpumping water, the pulsation dampener would nor- ally be filled with —.——.——— While the pump is discharging, liquid is foreed (into/ out of) the dampener chamber ‘The liquid compresses the in the chamber. As the piston moves back, the gas expands against the iquidl Now the ——- Forces .-— into the discharge line, |. Because the gas in the chamber compresses, the damp- ener ean minimize any sudden (increase/decrease) in discharge line pressure, Because the gas onee compressed can provide enough pressure to force liquid out of the chamber, the damp- ener can minimize any sudden __——- in dis- charge line pressure, ‘The pulsation dampener functions to minimize the effect of sudden changes in flowline ————— uw air into gas, or air gas; liquid inerease decrease pressureBe earrcagh tre ln ischarges "A single-acting simplex pump ives a gas chamber th displacement, a double equal in volume to the pump's Liquids under pre The greater the Pp fas pwer) th absorbs the Pumps in pressure service require proportionate 13. 67. Bren there is no bladder, the gas in the chamber is gradually absorbed by the. ——— When a bludder is not used, some means must be sup plied to periodically replenish the supply of _ If air at atmospheric pressure is used, the chamber may be replenished by isolating the chamber and opening a dyain valve at the bottom, Opening the valve drains the chamber of a and admits fresh ___ into the chamber Or the chamber may be replenished by foreing com- pressed into the top of the chamber In low-pressure pumps, a suifter may be used to autor mativally recharge Ue air chamber. [< SNIFTER valve ‘he snifter is a partially-filed liquid cylinder that is connected between the air chamber and the wall of the ‘Two check valves above the snifter allow flow from the snifter and the atmosphere (into the air chamber only/ both into and out of the air chamber). 13 Tiguia gas liquid gas, or air pump, or cylinder into the air chamber only68. On the backstroke, the pump draws some liquid from the snifter ‘The snifter in turn draws air from the ————__ 69. On the forward stroke, the pump forces liquid into the snifter. ‘The rising level in the snifter closes the check valve from the atmosphere, forcing — into the chamber. u atmosphere airFrye viquid in the anifter acts as piston to draw in air from the ——— atmosphere ‘after dvavwing it in, the Hquid foress the air from the air chamber, or pulsation dampener For proper operation, the snifter cylinder should never tbe completely empty of liquid. ‘yhen the system is properly adjusted, te Yiquid level Wine shifter sight gage should rise a4 fall practically the {ull length of the glass, in Hime with the strokes of pump, or piston the ——— need to drain and replenish the snifter qa. The operator does nots BP “Parse, it a: properly obertting is installed. vd only for (high-pressure/Low- an be use 74, But snitters low-pressure pressure) PUMPS. ction stabilizer works like « pulsation dampener 1" to the pump's suction, ‘The stabilizer is connected Tine. 1676. This drawing shows the suction stroke, SUCTION STABILIZER While the pump is drawing liquid, liquid flows (into/ out of) the stabilizer, 77, When the suction valve closes, liquid flows from the suction line into the 78. This prevents the suetion liquid trom hi ammering at the cylinder valve and piping, Then, on the suction stroke, liq uid is again drawn from the stabilizer into the sling, 79. Suction stabilizers are especially needed on high-pressure or high-speed pumps, where the suction liquid eould develop a strong hammer when it is not heing drawn into the pump, The stabilizer should be large enough to hold a volume of liquid at least equal to the pump's 16 out of stabilizer suction displacementpulsation dampener, or gas chamber suction stabilizer qTGeese {> BI. A snifter is used to replenish the supply of —— 82, The pulsation dampener and suction stabilizer act as hock absorbers to prevent the — from hammering at the pump or piping. BYPASSES AND RELIEF VALVES 83. This pump is equipped with a discharge-to-suction by- pass. Opening the bypass sends liquid from the discharge line back to the ______ line. 18 snifter air chamber, oy pulsation chamber iguia suetiona. a Engines and turbines must be started with no load. A bypass (can/eannot) remove the load from the pump hes during startup, If less liquid is needed for a process, the bypass can ——__ the volume of liquid flowing through the decrease, or reduce discharge line. pass valve can be installed to be operated man- wally ors antomatically A positive displacement pump must discharge liquid in order to complete its pumping cycle. |_-VALVE aan t) vischarce (a) os asa _| d st a ue f SUCTION Here, a valve in the discharge line is accidentally closed. The pump (can/eannot) discharge, cannot 88. The piston (can/cannot) displace the liquid down the cannot: Sowing, 89. As the piston continues to transmit force, liquid pressure mie Inereases, or rises i 90. Tf the pump fs direct-aeting, the pistons will cee stall, or stop 91. If the pump is a power pump, a pressure relief valve must open, i Otherwise, the prime mover will overload or some part of the pump or piping will _ break, or rupture 82. A (power/direct-acting) pump will be damaged if it power cannot discharge liquid. 19RELIEF VALVE SN jl I ‘The relief valve is installed in the discharge-to-suction bypass As long as discharge pressure is normal, the relief valve t is closed. i If discharge pressure gets too high, the relief valve i : opens 95. With the relief valve open, liquid is bypassed into the sae suction 96, The relief valve is a safety device that protects against excessive discharge pressure or a dis- blocked, or plugged, charge line or closed 97. With a discharge line blockage, a direct-acting pump is more likely to (stall/rupture). stall 98. A power pump (will/will not) develop dangerously high will pressure with a discharge line blockage. For safety, any positive displacement pump should have a pressure —_____ between the pump relief valve discharge valves or port and the first block valye in the discharge line. 20LE DISPLACEMENT DEVICES THREADED CONNECTING SLEEVE ROD PLUNGER ROD }—-|~LOST MOTION ‘The plunger rod is coupled to a connecting rod by a threaded — 101. As shown above, the plunger rod is almost touching the connecting rod. Suppose the conneeting vod moves to the right. For some distance the plunger vod (will also move/will not move). 102, Depending on the setting of the threaded sleeve, a cer- tain amount of the connecting rod travel is lost mation, In this arrangement, the lost mation is (always the same/variable). 103, Look at the positions of the plunger and connecting rods here. If the connecting rod moves to the left, there will be (ost motion/no lost motion). 104. Changing the lost motion distance (changes/does not change) the length of stroke of the plunger | 21 sleeve will not move variable lost motion changes109. 10. an. Changing the length of stroke of the plunger changes the volume of liquid that is ________by the pump. If the stroke is increased for a given speed, the pump moves (more/less) liquid. In order to increase the stroke of the plunger pump by a lost motion device, the lost motion must be (increased decreased) Direct-acting pumps also have lost motion mechanisms. LINKAGE ioL ADJUSTABLE STOPS ‘To provide lost motion, one part of a linkage assembly slides back and forth between two — stops. In this case, the lost motion effect is opposite to that in the plunger pump, As lost motion decreases, the piston stroke (also de- ereases/ increases) Whether the pump is power or direct-acting, plunger or piston, decreasing the stroke for a given speed causes (more/less) liquid to be displaced. For plunger pumps, another way to change displace- ‘ment is to change the size of the plunger. ‘The pump displaces more liquid with a (larger/smaller) plunger. 22 displaced more decreased adjustable also decreases less largerChanging the crank length affects displacement. Com- pare these two cranks. STROKE x B Crank (A/B) is longer. A 113. Pump (A/B) has the longer stroke. A 114. Inereasing the length of the crank _ the increases pump’s displacement. 115, ‘The crank for this pump is slotted. | | "Phe connecting rod is attached to the crank through a crank. pin 23Moving the erank pin toward the shaft has the effect of (engthening/shortening) the crank. 17. The pump's displacement increases as the erank pin is moved (toward /away from) the shaft. ‘This crank pin can be centered with the shaft. With the crank pin in the center position, the pumps Ep displacement is (maximum/zero) [) 119. This device is called a stroke transformer | gaa foe PLunoen LINKAGE cuipe BLOCK, HYDRAULIC PISTON ‘The connecting vod is replaced by a two-part mechanical 2 shortening away from zero linkagef The linkage pivots on a track in the |. When the guide block is level, there is no displacement at the pump, NO DISPLACEMENT DISPLACEMENT Ti ‘The rods move when the guide block is (level/at an angle) The stroke length is controlled by controlling the ____ of the guide block. 123. ‘The guide blo may be controlled by a hydraulic piston. GUIDE BLOCK PISTON Hydraulic fluid fed wer this piston (ineveases/de- creases) the angle of the guide block. Fluid fed in above the piston (ineveases/decreases) the angle at the stroke transformer 25 guide block at an angle angle, or position increases decreasesi Fe 129. i The hydraulic piston can be controlled by pump dis- charge pressure. This arvangement varies the displacement of the pump to adjust to changes in the ——__ of the liquid in the discharge line, A. reciprocating variable displacement pump may be matched to the stroke of some other pump in a process. Both pumps then make the same number of —___ per minute. A pump used this way is usually called a proportioning pump, The volume of flow from one pump is proportioned to the — of flow from the other pump. Suppose one pump is moving water and another pump is moving chemicals to treat the water, The flow of chemical may be of water to the Row Variable displacement and proportioning pumps permit fine control of pump capacity without changing pump Summary 130, 133. 134 138, 136 From time to time, the capacity of a pump may need to be changed. One way to change capacity is to change the operating Another way to change capacity is to — the displacement of the pump. Variable displacement pumps are built to permit changes in _____ without changing operating speed. For a plinger pump, displacement can be varied by changing the setting of the connecting — in an adjustable For a divect: changed. cting pump, the travel of a linkage can be In both cases, changing the amount of lost: motion (changes does not change) the stroke. Where an adjustable sleeve is used, inereasing the lost motion (increases /decreases) the stroke. Where the linkage to a steam valve is used, increasing the lost motion _— the stroke, 26. pressure strokes volume proportioned, or adjusted RPM, or specd speed, or RPM vary, or change capacity, or displacement rod sleeve | changes decreases increases.| Where a guide block is used, the adjustment in stroke is made by changing the — of the guidle block. fg. If one pump is being matched or related to the stroke of another, the pump is ustally ealled a — pump. 39. Some clearance space is required between stationary and moving pump parts. If a pump were not packed, liquid could through pump clearances 140, Besicles being used to control leakage, packing is used to reduce between stationary and moving pump parts. Lut. To reduce wea, packing mlist be made of low-frietion material It also must be flexible enough to provide a tight 142, Some materials soften and break at high temperatures; ‘others swell and become too tight. Packing is chosen for the nature and — of the pumping liquid. 143. In piston pumps, some packing is carried on the piston. ‘That is, the packing is on and moves with the —_ itself. 144. ‘This drawing shows one form of piston packing. ‘The packing is actually a set of rings fitted into grooves on the 21 angle proportioning leak wear seal, or fit temperature piston pistonEon packing rings are usually made of east iron, with ms for expansion. A Ji \ ne rings may be made in one piece or in —__ The pieces, or segments, three "> phe gaps allow the rings to _________ against the expand, or swell eylinder as the pump reaches operating temperatures. | set of metal rings is installed so that the gaps (line uup/do not line up) with each other do not tine up Metal rings ave corroded or abraded easily. Where corrosive or abrasive liquids are being pumped, it is probably (desirable/undesirable) to use metal piston undesirable rings. ‘This piston is also packed, but is fitted with eup leathers instead of rings. CUP LEATHERS Contact with the pumping liguid causes the cup leathers to swell out against the wall or lining of the —____ cylinder 28 Now ten th low turn the page, turn the book over, and go on.Jrstead of cup leathers, hard rubber or fiber rings may fe used for pumping liquids that are — on. caclne abrasive. By, All piston pumps are inside packed. PACKING Notice the location of the plunger packing in this lunger pump. It is (also inside packed/not inside packed) also inside packed 152, In most plunger and rotary pumps, however, the packing. is usually located ouside or at one end of the cylinder. PLUNGER PACKING Although the plunger packing here is in the center of the entire pump unit, each packing gland is located (outside/inside) of the cylinders, outside 29“FLook at these two pumps. SEZ, E 4 DIAPHRAGM PACKING / “On the outside-packed plunger pump, tionary prevents lea ie plunger’s sta- age from the eyl- packing gm pump, the diaphragm g liquid and the reds, (so no packing if is still needed) 80 no packing is 1 dedtained in a packing box. PACKING RINGS PACKING GLAND PACKING GLAND NUT STUFFING BOX The packing itself is usu: metal or fiber 156. The packing can be tighte each —on the packing gland, nut If the packing is too tight, there is too much feiction and the rings - —— too quickly. wear 108,41 the packing is too loose, there is too much leakage of the pumping liquid a HY most pamps, some leakage is permitted for Iubrica- tion of the packing, Bul if the liquid is corrosive or abrasive, then it is (esivable/undesivable) to allow leakage for lubrication undesirable 16N_Mhen corrosive or abrasive liquids are being pumped, an outside source may be used to the lubricate packing. 31 EE The packing used on rotary and plunger pumps is con- ally soft packing or a set of packing rings ned or loosened by adjusting182, 164. 165, 166. 161 Instead of a packing box, a rotary pump may have a mechanical seal. SPRING SEAL OIL STATIONARY HOLDER OUTLET SEAL RING (Cerbon) ye o-RING COMPRESSION | RING \e aS forarite EAL Oh Seat SEAL RING iS (Hord-Surface Meral) The stationary seal ring is held by the — The rotating seal ring —___ — with the shaft, ‘The compression ring is foreed into the rotating seal ving by a ‘The compression ving compresses a flexible O-ring. The O-ring prevents ——__ around the shatt. A thin film of seal oil lubricates and cools the rings The seal oil also helps to _ the space be- tween the rings Mechanical seals may be used for pumping liquids at temperatures below 500°P, They provide sealing with very little —_ of the pumping liquid. seal flange rotates, or turns spring leakage seal, or fill leakage, or lossvo f Packing does two things in a pump it. seals spaces between moving parts to keep toa minimum; it also provides a low-friction surface to reduce 168. Piston pumps are always {inside/outside) packed, 169. In a few cases, the packing of a plunger pump is inside, but in most eases, plunger and rotary pumps are _—— packed, 170. A certain amount of leakage past the packing ean be al- lowed to provide for other parts of a pump. LUBRICATION 171, Many moving pump parts are lubricated by the pumping ~Tiquid. However, some parts never come in contact with the an being pumped. 172. Oil and grease are used to — —— these parts. | Even the packing may be lubricated from an outside ‘source if the pumping has poor lubrieat- ings qualities. TL. This drawing shows a grease cup. As the shaft rotates under the cup, it picks up 83. leakage wear inside outside lubrication liquid lubrieate Hiquia grease115. The cap must be periodically turned down, and the eup must be —__ with grease as needed. filled 6. This is a drip oi] lubricator, om, Pe TE supplies oil (in a stondy stream/a drop at a time) a drop at a time Like the grease cup, the drip lubvieator must be periodi- aly Sener sited WS. This drawing shows a splash system of lubrication, ‘There is a veservoir of lubricating oil at the bottom of the crankcase, or casing 178, The gears pick up the oil and —__. it on the splash, or carry bearings, gears, and vankshatt, 34Then the oil drips down into the again. BI. The level of oil in the crankease must be —___ periodically, © 182. In large or slow spe ed pumps, a forced lubrication sys- tem is used, a EAR PUMP RESERVOIR STRAINER Oil is toreed from the ev ‘aukease to the bearings by a small 188. The oil trom the reservoir flows through a __ before it enters the oil pump. 181. This foree-feed tubvicator uses a small plunger pump. OIL FORCE FEED ee RESERVOIR ‘The lubyieator 'S powered by a linkage to the pump 185. ‘The forced-feed Iubvicator does not begin operating un- til the pump is started. A hand er rank may be used to operate the forced-fecd lubricator (before/after) the pump is started. 85 Yeservoir, or crankcase, or casing checked pump strainer rod, or shaft before189, 190. }, The oil fow from a forced-feed system is usuaily ob- served through a drip glass. Proper lubrication is maintained only when the oil is through the system. A lantern ring is a metal cage about the size of a pack- ing ring. LUBRICATING. OR SEAL OIL, 2 ot | Eo LANTERN RING It fits near the eenter of the The lantern ring makes a space between the packing rings. This space is used to provide lubricating or seal ___ to the packing The lubricant may be the pumping liquid or another liquid, When corrosive liquids are being pumped, liquid from (the pump/another source) is used to lubricate the lan- tern ring, When the pumping liquid is noé used, lantern ring lubri- cation must be pumped in at a higher pressure than the pressure in the pump. This higher pressure prevents pumping liquid from entering ths. SSS Lantern rings are also used when the pump is operating under vacuum. ‘To Keep air from entering a vacuum pump, the sealing oil or other sealant at the lantern ring must be kept at a pressure that is (higher/lower) than atmospheric pressure. 36 flowing packing box, or packing rings f oil another source packing box higherThe shaft of a rotary pump may tend to move in three different ways. (TURNING) (THRUST) cass Cat (VIBRATION) ‘Pheust, or movement in a straight-line direction, is movement. axial 193. A long, unsupported shaft can’ also vibrate up and down. This is (axial/radial) movement. radial 194. Bearings are used to control axial and radial movement in shafts. A thrust bearing limits the amount of (asial/radial) axial movement. 195. A radial (journal) bearing controls _______ move- radial ment, is rotary pump uses ball bearings. RADIAL BALL BEARING gen THRUST BALL BEARING ‘The ball bearings control (axial/radial/both axial and radial) motion. both axial and radial 31‘The ball bearings turn freely as the shaft rotates, The bearing ubricant provides a fluid film that reduces —.. between the bearing and the shaft, friction, or wear 198. Balll bearings may be grease- or oil-lubricated, Where the load on the bearing is great and considerable heat is generated, oil is used as the lubricant because it can also _ the shaft and bearing, cool 199. Grease-packed bearings can be over-greased, Overgreasing causes the bearing to — ea ae, overheat, or fail 200. Some pumps use sleeve bearings instead of ball bearings. BEARING CONTAINER eel on FILM BABBITT BEARING — BEARING BRACKET Sleeve bearings control (axial/radial) movement, radial 201. There is no contact between the shaft and bearing. ‘The shaft rotates on a film of —__ oil 202, The oil is supplied through grooves on the bearing sur- face. SHAFT ae BEARING OIL RING oiL, RESERVOIR An oil ring picks up oil from a____ _ and car- reservoir ries it up to the bearing. 38ump couplings may be lubricated with heavy oil or grease. Before the pump is started and during operation, the ‘couplings should be checked for —____. |. ‘The operating manual or the supervisor specifies the = and amount of oil to be used for lubri- cating the coupling. Oil must be free of dirt and water Water breaks down the film between the shaft and bear- ing, and — is abrasive. Summary 206. ‘The main purpose of lubrication is to prevent 5 between moving parts, 207. If the liquid being pumped cannot provide Tubrication, outside sources of __— and oe aT used. = 208. The drawing shows one device for lubricating moving parts. ‘This is a grease _________. Grease is forced in by tightening the —________. 39 leakage, or lubrication grade, or type airt contact, or wear oil grease cup capF909. This device supplies oil, Mila ty ae nti oriuatne 210. This arrangement also supplies oil, This is a system, 211, If a splash system is not adequate, oil can be brought to the desired points by way of a gear or plunger 40 drip splash pump —__tern ring is designed to provide space between king rings so that lubricating —_—______ean ‘h moving parts. Bearings provide low friction contaet points. Regardless of type, bearings normally (should/should not) be lubricated. COOLING © 214, When the temperature is not too high, the heat at the packing box can be carried away by the surrounding F215, Sometimes air cooling i not enough, F / PACKING WATER JACKET ' ‘ ‘This packing box is cooled by water circulating through a —_____ 216, ‘The water ___ the packing and rod or shaft. 217, When the bearing must be cooled, the bearing and reservoirs may be surrounded with 218. High-temperature pumps usually have water-jacketed bases (pedestals). ‘The more heat the pump has to handle, the more thor- oughly it is _____ 2 4a oil should air, or atmosphere water jacket cools, water jackets water-jacketed, or water-cooled1 8 10 1. ‘OPERATION PRESTART Before startup, be sure the pump and its driver are ready for operation, Check the crankease and other —__ systems and fill with oil or lubricants if necessary. Bearings and fittings are usually greased on a regular schedule, rather than before every startup. Overgreasing may cause a bearing to —— and fail during operation, Steam eylinders are ally lubricated with a quill ‘The quill is used to inject a spray of —_ into the steam supply line If the pump or its driver has a cooling system, fill with and begin eireulation, If a pump is put under load when it is cold, some of the parts heat up faster than other parts, When parts heat up unevenly, they expand at (equal/ unequal) rates, Expansion at unequal rates can cause the parts to seize and the entive pump unit, When the pump is not running, heating the parts un- evenly is (ikely/not likely) to cause damage. If hot Liquid is civculated through the cylinders o casing for a long enough time, (all/only some) of the pump will come up to the same temperature, Circulate the hot liquid long enough before the pump is started so the pump is at a sage operating when you start it up. A spare pump in hot service is usually kept warm by a circulating line from the operating pump's discharge line. The circulating line moves _________ through the spare pump and back into the suetion line. If electrical work has been done on a motor-driven pump, check to be sure the — ____ of the pump and the motor shaft is in the proper direction, 42 lubrication overheat oil water, or coolant unequal stop, or damage not likely’ all temperature liquid rotationDrain any condensate or liquid water in steam engine cylinders. Condensate is not compressible and may cylinder heads, Check the condition and tension of V-belts. ‘The span of this V-belt drive ig __ feet. Generally, a V-belt is properly adjusted when it gives its own thickness or width for every 4 fest of span, A ¥h-inch belt should give ________ineh for every 4 Teet of span. Tighten any slack belts and replace ____ elt. In a piston pump, replace worn piston ___or cylinder liners, Check the packing box for leaks, and _______as needed Check to make sure that valve covers are in place and that all bolts are _____ enough. Relief valves should be routinely checked and so that they operate properly. There are block valves in the piping leading to and from the pump. Refore startup, the suction and discharge line valves must be (open/closed). Double-check the discharge line valves. ‘Trying to start a pump with a closed discharge line valve can stall the driver or — the pump or piping. 2. Before startup, fll the suction line completely with liquid, so that there is a liquid seal at the suction ee ar port 28. Bleed or vent vapor pockets in the suction liquid ____ they reach the pump, 43, damage % worn rings tighten, or adjust, or repack tight set, or adjusted open rupture, or break, or damage valve beforeise vapors rise, vapor pockets are likely to occur at _— points in the suetion line. Jeeder valves are set at high points in the line to vent vapor or gas before it reaches the —_ If the vapor from the pumping liquid is valuable or hazardous, the vapor is vented into (the atmosphere/a disposal system). On a reciprocating pump, the pulsation dampener must be filled with —__ before startup. Fill the suction stabilizer with Itquid If vapor pockets have formed in the stabilizer, these pockets must be —_ off. 29, With vapor bled from the stabilizer, suction or flowline pressure will fill it with 30, Most rotary pump manufacturers recommend priming or bleeding the pump before startup. Filling the pump with liquid reduces between the close-fitting parts of the pump, BL. This drawing shows two types of priming systems, LIQUID FROM OUTSIDE SOURCE ‘The pump may be primed by admitting liquid directly into the 82. Or, a priming tank may be used to force liquid into the pump through the - __ line, 44 high pump a disposal system gas bled Tiguid wear, or friction casing, or-pump suction# 34, 36. 36, 38, 39, 4 ae STARTUP Some drivers can be damaged by low-speed operation at full load Before startup, the operator must make sure that the pump will not put too great a on the prime mover, ‘The bypass connects the discharge line to the suction line. With the discharge block or check valve closed and the bypass open, the pump takes in liquid from. the 7 line and discharges it back at essentially (the same/a different) pressure, Opening the —— valve removes most of the load from the prime mover. Internal combustion engines generate intense heat in their cylinders as soon as they start, Just after a cold engine has been started, the different parts will be at (equal/unequal) temperatures, Just after a cold start, the parts of the engine have ex: panded (equally /unequally). With unequal expansion, it is likely that operating condi- tions (are correct/are not correct). Under these circumstances, running a cold engine under full load may cause ____"__to the parts, Internal combustion engines, therefore, should be started under no load, Full load can be applied safely to the engine (as soon as it is running/only when operating temperature has been reached). Electric motors, on the ‘other hand, heat up equally throughout the parts. Expansion of motor parts is, therefore, (equal/unequal). 45, load, or strain suction the same bypass unequal unequally | are not correct damage i only when operating temperature has been reached equal46, 'To apply full load to a motor just after it has reached running speed is (likely/not likely) to cause damage. 3. Electric motors (require/do not require) a long warmup period after starting, A pump powered by an (electri motor/internal combus- tion engine) requires a longer warm up. When the prime mover has reached full operating tem- perature and speed, the bypass valve can be again as the discharge block valve is —_——___. ‘This is a direct-acting steam pump. DRAIN COCKS ‘The steam eylinder has been prepared during prestart by draining out —__ ‘To start, open the exhaust line and crack open the high- pressure __valve. Allow time for _ Close the _____ drain valves. If the pump is moving hot liquid, the pump itself should have a chance to up. . Prime the pump if possible and bleed off —___ from the suction piping. Open steam to the pumping rate. ___, and adjust for proper Once the pump is operating, it should be checked for in the casing, packing, or piping. Packing should be checked for temperature as well ax for leakage. Excessive temperature may mean that the packing is too 46 not likely do not require internal combustion engine closed opened water, or condensate steam, warm-up, or heating-up condensate, or cylinder warm, or heat vapor, or gas cylinder Teaks tight.Loose packing must be tightened, To permit the amount of leakage desired for lubrication, Packing that is too tight should be. loosened 58. Continue to check the pump during operation, 1 jtinusual noises develop, determine the source and probable cause, The pump should be _ —— to correct shut down the trouble, SHUTDOWN °F A power pump is shut down by shutting down the ea oes prime mover An electric motor is simply switched off An internal combustion engine should be run at low load OF Bo Toad for 10 to 15 minutes to allow the engine to before it is shut down, cool After the prime mover is shut down, close all the pump a Eee valves Ih a divect-acting steam pump, the Power is steam, supplied by To shut this pump down, the (steam inlet/exhaust valves) should be closed first, steam inlet The next steps are to close the exhaust valves, then drain the steam cylinder to remave Ve freeing ‘is italy “dvain Water from the pump’s ~ system, cooling Vent the pump if theve is any poss bility that heat will cause excess or vapor Tf a pump is to be taken out of service, shut down the fitiver and lock it out to be sure that itis not started by accident, When a pump is shut down to work on it, either in place OF In the shop, close off the process, lines by installing eos, blinds, or blanks To take the pump to the shop, urge or flush it out and slings "°*t i from its base (before/after) installing the after olinds, 47 or pump driver condensate, or water to build up, Pressure, or gas,68. 69, To remove hazardous vapor or liquid, purge the pump with steam or wash it with 5 If a pump is going to be set as an operating spare, leave the cooling systems operating and the suction and dis charge valves open in the line, With this done, the pump is ready to — Usually, a check valve in the discharge line prevents liquid in the line from backing up through the spare During shutdown, the check valve should close auto- matically If liquid should leak back through the spare, the pump- ing system loses Summary m1. 3, 4, The pump has heen checked through prestart and is ready to start when: all valves in the suction and discharge lines are ______ and the lines of ob- structions; all bleeders, vents, and drains are all cooling and lubrication systems are rotary pumps are with liqui is a liquid seal in the line; and relief valves are ___ properly, start a pump: first unload the pump by setting the bypass valve (open/etosed) ; start the driver and, if it is an internal combustion engine, let it idle under (no load/full load) ; load the engine only after it is up to — temperature. ‘To start when the driver is an electric motor, be con- cerned about reaching (operating temperature/running speed.) For a power driver, after speed and/or temperature are at the desired levels, (leave the bypass valve open/ close the bypass valve). At the same time, open the _ block valve. 48 water start, or operate pump ‘capacity, or pressure, or efficiency ‘open; free, or clear closed checked, or filled filled, or primed suction set, or operating open no load operating running speed close the bypass valve dischargeTerre ee ee ee ae ne 75. To start a direct-acting steam pump: set the exhaust line (open/elosed) ; open crack the high-pressure —— valve; steam let the unit = warm up set the cylinder drain valves (open/closed) ; closed prime the pump and bleed off ___; vapor let steam into the —, and adjust the cylinder of pumping. rate 76. To shut down a power pump: if an electric motor, (switch if offflet it idle under no load) ; switch it off if an internal combustion engine, run it for 10 or 15 4 minutes at low or no load to allow it to ool | | 77. To shut down a direct-acting steam pump, set the: live steam valve (off/on) ; off j exhaust steam valve (off/on); off | steam cylinder drains (open/elosed) ; open | pump suction valve (open/elosed) ; closed pump discharge valve (open/closed) ; closed cooling water (off/on). off | COMMON PUMPING PROBLEMS i Gradual Loss of Capacity 1 78. Wear and leakage in the pump cause a gradual loss of | eae capacity 79. Pump packing should be replaced or renewed when it no longer prevents excessive leakage | 80. Dirt, coke, or grit in the liquid can clog or wear cylinder valves, j Clogged valves should be cleaned | 81. Worn or broken valves must be repaired or replaced, Failure of eylinder valves to __ — properly is seat, or operate, common cause of loss of eapacity or close 49eae Teaking valve in the bypass line can also cause a loss capacity. Por operation at full capacity, the bypass valve should be tightly At a constant steam. or air pressure, the capacity of a direet-acting pump changes when’ liquid pressures change, Loss of capacity in direct-acting pumps may mean a rising pressure in the —____ line. Loss of Suction 84. Loss of suction pressure may prevent the pump from filling properly with liquid, If suction pressure falls below the required NPSH, the pump loses rapidly, 85. An increase in suction lift or a decrease in suction head causes a of suction pressure. 86. Obstructions or excessive pressure loss in the suetion piping can also cause the pump to lose —_____ 87. If a pump is losing suction, check the liquid level or pressure at the suction and the condition of the suetion Vapor-to 88. Gases are compressible, When force is applied to a gas, the gas is squeezed into asmaller closed discharge capacity, or suction loss, or decrease suction piping, or line volume, or spaceios 90, 1 92. ONS piston pump is filled with high-pressure gas, 8 the piston moves forward, it — the gas into a smaller volume, pute Pressure of the gas in the eylinder may not rise as high as discharge line pressure, Then the discharge valve does not forward stroke, on the When the discharge valve does not open, no ___ leaves the cylinder, As the piston moves back, the compressed #48 expands in the cylinder, ‘The Pressure of the gas in the cylinder Prevents the ————— Valve from opening, 51 compresses open Nquid, or vapor, or gas suction98, 99 100, 101. 103. 104. liquid (canfeannot) enter the cylinder on flough the piston continues to move back and forth, thing enter’s or leaves the cylinder The valves cannot operate because of the pressure of the _________ in the cylinder. When this happens, the pump is vapor-locked. ‘A vapor-locked pump moves (some/no) liquid. YVapor-locking may be indicated if the pump fails to ‘A vapor-locked pump is noisy, and the pump housing may vibrate. Noisy operation, together with greatly reduced or zero capacity, may indicate a pump that is ———— locked. ‘Air may enter the pump through leaks in the (suetion/ discharge) line. Air may also enter the pump through loose around the shaft or rod, "Air or gas may enter through a suetion pipe that is too near the _ of the liquid Evaporation of the pumping liquid can also eause vapor~ lock and loss of suction. To prevent vaporization, NPSH available must be equal to or than NPSH required, PSH can be increased by either (inereasing/decreasing) the suetion pressure, or by {ineveasing/decreasing) the temperature of the suc- tion liquid. If there is not enough NPSH available, pump speed must be (inerensed/decreased) to obtain proper operation. 'A vapor-locked pump must be bled of vapors by closing the discharge block valve and _—____ the pump to the atmosphere or to a low-pressure system, ‘The suction source must be checked to correct the cause of vapor-locking. Or, the pumping rate may be (inereased/deereased) to increase the NPSH at the pump. 52 cannot gas, or vapors no discharge, or pump suction packing surface, or top more, or greater inereasing decreasing decreased venting, or bleeding decreasedSudden Loss of Capacity 106. A blocked discharge line prevents the pump trom Se iinwla In the direct-acting steam pump, the steam engine will if the discharge is blocked, 108. A blocked discharge will overload the Prime mover or driver of a power pump and cause the pump to 108. If the prime mover does not stall or fail, a blocked dis- charge without a relief valve will rupture gaskets, pi ing, or some part of the pump. When the discharge is blocked, pump capacity is sud- de reduced to __ ——. 110. Excessive frietion in the Piping can cause high discharge pressures If the piping is too small or too long, the effect is similar to that caused by a ———in the discharge line. 111. Excessive discharge Pressures will cause a sudden (in- crease-decvease) in pump capacity, 112. Loss of suction also causes the pump to suddenly ———_—— discharging liquid. Overloading 113. Suppose the packing of a pump is too tight. Packing that is too tight can set up excessive ——_. or rubbing. 114. Suppose there is not enough lubrication at several points, This condition (sets up excessive/does not affect) frie tion 115. Improper alignment (can/eannot) set up excessive fric- tion, 116. Excessive friction (inereases/does not affect) the chance that the driver will overload or stall. 117, Suppose the discharge line is blocked. Discharge pressure then (goes up/drops), 53 discharging, or pumph stall, or stop fail, or stop, or stall “ero, or no capacity block, or plug | decrease { stop friction sets up excessive can inereases goes upIf the discharge pressure gets too high, the driver will ‘Suppose there is an increase in the viscosity or density of the liquid being pumped. Power requirements go (up/down) If the load increases for any of these reasons — friction, blockage, or higher viscosity—the driver is (more likely less likels) to overload or stall Overspeeding - Overload leads to somewhat the same results in either direet-acting or power pumps. Loss of load effects both kinds of units (the same way/ differently) 22. Suppose an AC motor is running under load at its rated speed. If the load is removed, the motor will (speed up/slow down/continue at rated speed). 123. Suppose the driver is an internal combustion engine. Removing load causes the engine to speed up (more and more/up to the limit of the throttle setting). 124. If the load is removed from a direet-acting unit, the driver speeds up (more and more/up to a given limit), Low intake of uid is (like/not like) removing load. 126. Given a low intake of fluid, the power pump is (likely/ not likely) to overspeed; the direct-acting pump is (likely/not likely) to overspeed, Short-Stroking 127. Jerky, short strokes may be caused by a piston rod pack- ing that is too _ 128, On direct-acting pumps equipped with cushion valves, long- or short-stroking may call for an adjustment of these valves, ‘Too much cushion causes short-stroking. ‘Too little cushion may permit the piston to the end of the cylinder. 54 overload, or stall up more likely differently continue at rated speed up to the limit of the throttle setting more and more like not likely likely tight strike, or hiten oeoees ne uations, a lost-motion adjustment may be necessary to produce the correct 130. Loss of power in a direct-aeting pump sometimes indi- cates valve trouble, Incorrectly set or worn steam valves slow the pump down or even cause it to __ Noise and Vibration 181. “Excessive noise and vibration are signs of faulty opera: tion, Vapor-locking ean cause excessive pump, eee aa 182. Improper alignment ean also cause excessive Any improperly balanced rotating assembly ean cause excessive vibration, A loud pounding or rattling noise may mean that a bear- ing has become so worn that it is loose enough to = avound, 134, A piston nut could have worked loose and the could be slipping back and forth on the rod. 185, Almost any worn part ean produce noise, Weak or broken valve springs lead to pounding of the valves Operating at a lower speed reduces the noise until the faulty springs can be mae 186. Operating at too-high speed is another cause of exces: sive 187, Or, excessive vibration may indicate that the pump or its driver is not bolted securely enough to its —_ 188. Discharge piping may be poorly designed and may am- ally eo 189. Sometimes the pressure surges will eause the discharge Tine to vibrate, This may indicate that the discharge piping is too ——___ in diameter, +40. Or, the pulsation dampener may be filled with liquid and need to be refilled with stroke stop, or stall noise, or vibration noise, or vibration move piston replaced, or repaired noise, or vibration foundation, or base vibration, or noise small gasimproper lubrication can also cause pump parts to grab and seize. Faulty — can cause noise and vibration, 'A divect-acting steam pump gets noisy when steam en- ters the cylinder too late to cushion the piston enough at the ends of the stroke. To give more cushioning, the cylinder steam inlet valves must be timed to open (sooner later.) A crackling noise indicates water in the cylinders, When this oceurs, the eylinde _____ should be partly opened to let out the water, and kept open until the noise stops HA. If the noise comes back after the drains ave closed again, water is probably coming into the cylinders from the steam line. Water in the steam line indieates that the boiler is making very wet steam, or that the steam traps are not removing the Peviodie checking should assure that operation stays smooth and continuots. If unusual noises develop, the —— should be determined 146, Tt may be necessary to correct pumping conditions. If the trouble is mechanical, the pump (need not be/ should be) shut down. OPERATING MAINTENANCE 447. A pump must be checked periodically to keep it oper: ing 2. 148. Oil levels are checked to be sure that there is enough oil to reach all lubrication points. The flow of the oil is checked periodically to assure that moving parts are properly —— and _over- 149, Proper Inbrication prevents. —— heating. 150. Cooling jacket temperatures show how well the pump is being cooled, ‘These temperatures should be checked frequently to see that the pump bearings or packings are not getting too 56 lubrication sooner drains water, or condensate cause should be efficiently, or properly lubricated friction, or wear hot1B. m ‘To best assure continuous operation without malfunc- tions, the operator should make the checks recommended by his supervisor Logging pump speed, flow, pressures, and temperatures helps to show what ——~ take place in pump performance, Water level in a cooling system and________ levels, in the oil reservoirs need to be checked daily, All lines in the system should be checked at least once every day to make sure there are no losses of fuel, oil, water, or air as a result of ________ in the lines. Unless pure water is used, or rust and seale inhibitors ave added to the cooling water, rust and scale form quickly iv an engine's water jacket When no inhibitors are used, the engine water jackets should be checked for______ and formation at least once a month. Pump packing gland leakage should be observed during regular inspection rounds, Worn packing should be tightened or Operating manuals from manufacturers usually outline general maintenance guides for their pumps, These general maintenance guides should be combined with the procedures of your company for efficient —______ of each pump. aT changes oil leaks, or holes, or obstructions rust; scale replaced. maintenance, or operationPILOT SEVEN - PUMPS UNIT TWO: POSITIVE DISPLACEMENT PUMPS Secti3 Consction Details, ylinder Valves ‘Summary Julsation Dampeners and Suction Stabilizers Summary... Bypass and Relief Valves - Summary Variable Displacement Devices Summary « \ Peooking. : wei Summary... +++ 1 Lubrication Summary Cooling Section 4 Operationss sss. css oeete= Prestart. San Coe Startup... ae Shutdown ‘Summary Common Pumping Problems. Gradual Loss of Capacity . Loss of Suction Vapor Locking Sudden Loss of Capacity Overloading .. Overspeeding Short Stroking wa Noise and Vibration oe Operating Maintenance. . 878-6