Practical work # 1

Subject: Inspection, overhaul, and repair of centrifugal pumps

Purpose: Study major failures and ways to fix them during overhauling and
repair of ship centrifugal pumps.

Task: To study the design and rules of maintenance and repair of the centrifugal
pumps (CP) and possible breakdown or damage to the parts of the CP.
All pumps are not equal! There are a wide range of pump types because some
designs are better; more efficient or more consistent or last longer; at handling
specific operating conditions or specific liquid properties. Each application should
be assessed individually, on merit, when considering: liquid properties, allowable
leakage, driver type, installation arrangement, operating efficiency required, duty
cycle, allowable noise level, operational safety, site facilities.
1. Theoretical information: Types of centrifugal pumps used at sea:
- centrifugal pump vertical (CPV) non-self-suction (purpose: maintenance of fire,
cooling, drainage or ballast systems);
- centrifugal pump vertical (CPVS) self-suction; (purpose: sea & fresh water-
cooling systems, brine or condensate systems);
- centrifugal pump vertical (CPVS) self-suction, two-stage (fire extinguishing &
foam system maintenance);
Pump classification:

1.1. General instructions for pump maintenance before pump start-up for ballast
or other pumping make sure that the appropriate suction and discharge are
prepared for these actions, then open the corresponding valves on the
distribution box, suction & discharge, check the bypass valve on the pump
discharge. For a smooth start of the pump, if pump equipped with bypass valve, it
is need to open bypass valve (partial) to the suction side of the pump, and as soon
discharge pressure stabilized, the bypass valve should be closed. During pump
operating it is necessary:
- to monitor the operation of both the pump and drive motor and according to
the readings of the pump gauges to maintain (change) operation;
- adjustment the pump capacity & discharge pressure, if it is provided
constructively, change in the frequency of rotation. Centrifugal pumps capacity or
pressure regulating by throttle suction or discharge valves.
For proper pump operation and designed performance of the pump, it is
necessary to carry out preventive maintenance and repairs of the pump
components in accordance with Maker pump recommendations, inspection or
repair isolating valves, clean filters or strainers or wells in accordance with PMS or
as required.
The pump should be stopped immediately:
- if the drive motor malfunction (vibrations, noises or knocks);
- if the pump pressure on the discharge pipe suddenly drop or increase;
-if any pump part is overheated.
The pumps of the service systems, which are operated periodically, should be
inspected every 3... 5 days, external visual check, turn pump drive or control start.
This operation should include to Preventive Maintenance System (PMS) of specific
ship. During ship drydocking or repair period or lay up in the autumn-winter
period, in order to avoid damage pump, measures should be implemented to
drain water from the pump casing and pipeline systems: the casing plugs of the
pumps should be unscrewed, divide pipeline flanges in the lowest places of the
systems , pipelines blown by compressed air.
1.2 Pump failures and corrective actions: the technical malfunctions that occur
during their operation (table.1.1).
Table 1.1 - Malfunctions and corrective actions to restore centrifugal pumps
Malfunction Reason & Corrective action
No pumping, low or zero discharge Suction and/or discharge valves are
pressure & pump capacity closed or partly open. OPEN valves
Suction filter or strainer, sea chest Clean suction filter or strainer of the
filters, etc. are dirty or chocked pump
System pipeline flanges, pump or valve Eliminate air suction to pump
packings are slack, air sucked in pump
Pump is not filled with liquid Fill up pump with liquid
Wrongly pump rotation Correct the pump rotation
Low / not enough pump rotation Increase speed of the pump rotation
speed
Boiling liquid at the pump suction Decrease temperature of the pumping
liquid or increase pressure on the
 pump suction.
Suction height is too HIGH Reduce pump suction height
Pump impeller is dirty Clean pump impeller
Leakages on the pump suction side Eliminate leakages
Pump wearing and/or casing rings are Renew wearing and/or casing rings,
worn out, clearances are above the restore clearances
limits
Pump impeller and/or casing are worn Renew pump impeller and/or casing
out
Continuation of the table. 1.1
Pump is not assembling correct / Assembly pump in acc.with Maker
properly (f.e. upside impeller) Manual / correct
Increased hydraulic resistance on the Restore defects on the pressure /
discharge pumping line, appear discharge line, clean heat exchanger,
cavitation mode. Safety (bypass) valve increase suction pressure or reduce
is partly open / leak speed (rpm) of the pump. Clean, repair
and adjust safety (bypass) valve in
order to eliminate passing through.
Pump vibration
Misalignment the pump connection Restore / adjust alignment (centering)
(coupling) of the drive motor with of the connections (coupling) of the
pump drive motor with pump
Unbalancing moving parts of the pump Balance moving parts (shaft, impeller,
due to worn out or partly clogging seal, coupling, etc.), clean pump.
(dirty) liquid flue part
Loose foundation bolts of the pump. Re-tight foundation bolts as per Maker
Manual
The pump bearings are worn out Renew bearings of the pump
(noise or abnormal sound)
The pump drive motor load is above limit (motor overloaded)
The pump impeller is not assembled or Assemly correct and adjust clearances,
adjusted in casing correct (touch then start pump.
casing)
Start pump with OPEN discharge valve Start pump at nominal speed (rpm)
or flap (non-return) valve is not with closed discharge valve or restore
installed / equipped or stuck. operation of the flap (non-return)
valve
The pump gland packing is overtough. The pump gland packing tightening to
be adjusted as per Maker Instruction
Axial pressure is too HIGH Adjust / ensure normal operation of
the unloading device
The pump flowing liquid parts is Clean pump flowing parts.
DIRTHY/ chocked
Viscosity of pumping liquid is above Raise the temperature of the pumping
the passport limit. liquid.
Mechanical damages of impeller, shaft Recondition or renew parts
running surface, mechanical seals
(scratches, dents)
Pump components temperature is above limit
Overtightening or unequal tightening Correct tightening as per Maker
of the pump shaft gland packing Instruction
Continuation of the table. 1.1
Gland packing material is in bad Renew packing material
condition (hardened due to age)
Gland packing material is not original / Restore / renew appropriate gland
wrongly quality or purpose packing
Cooling water to jacket (if available) is Provide / OPEN / clean water pipelines
not provided to cooling jacket
Closed or not enough opened the Completely open discharge valve
pump discharge valve
The temperature of pumped liquid is Decrease / reduce the temperature of
too HIGH pumped liquid.
Mechanical defects of the bearing Renew bearing
(broken separator, balls are worn out,
scratches, etc)
The bearing is wrongly / not correct Assembly / install bearing correctly
installed
Loose bearing on the shaft or in the Fix / eliminate turning (loose) of the
housing. bearing as per Maker Instruction
Dearty or aged (hardened) grease of Remove grease / clean bearing, refresh
the bearing with appropriate grease.
Misalignment coupling of drive motor Alignment / centering shaft coupling.
with pump
Mechanical defects of the running Recondition / repair mechanical
surface shells or shaft sleeves defects, machining or build up running
(scratches, dents, metal detachment, surfaces.
etc.)
Increased or reduced clearances / gaps Restore designed (as per Maker
in bearings, misalignment (not Manual) clearances, carry out
centered) of the pump and drive centering the pump and drive motor
motor coupling coupling.
Contamination or flooding with water Find reason and refresh or clean
of the bearings oil (purify) lubricating oil
 Low or High oil levels in the bearing
casing
Broken lubricating ring at bearing with
ring lubrication
Lubricating oil of the bearing with
circulating lubricants Pressure is
reduced.
Hydraulic shocks at the pump during operation
Suction of a significant amount of air
to the pump suction side due to
pipeline is not integrity
The appearance of vapor formation.
Correct and maintain lube oil level
limit
Repair or renew lubricating ring
Check Lubricating pump, integrity of
lube oil system (no leak), lube oil
quality, cleaning filters, inspect lube oil
pipes.
Find and eliminate defects / retight
connections, renew gaskets
Reduce / decrease the temperature of
the pumped liquid.

Mechanical seals. Operating principles

The sealing of a rotating shaft passing through a pump casing is achieved by
means of a rotating, optically flat seat, rubbing against a stationary, optically flat,
seat with a fluid film in between them, see Figure 8.16.

Figure 8.16 A simple unbalanced seal arrangement for a pump

Sealing between the rotating seat and shaft or sleeve, and the stationary seat and
gland, is usually performed by means of an elastomer such as an "O" ring, "V"
ring, etc. The primary purpose of the spring is to provide an initial pressure
between the sealing seats. One of the great advantages of this type of sealing is
that it does not cause wear to the shaft or the sleeve. The theory as to what
happens between the seat faces is explained schematically in Figure 8.17.

Figure 8.17 Fluid distribution across seat faces and operating pressures
The seal should be considered as drip-free but not leak-free. The very low leakage
rate, known as diffusion, will escape in the form of vapour on the atmospheric
side of the seal. The very low leakage rate, known as diffusion, will escape in the
form of vapour on the atmospheric side of the seal.
A general and very important rule is that a mechanical seal should never be run
dry, there must always be a fluid film between the faces. Dry running can occur
even when the pump is full of liquid if the temperature is so high that the liquid
vaporizes in the stuffing box. Only specially designed seals can be run on the
vapour phase of a liquid. Dry running seals are available for specific applications.
The seal operating conditions must be fully described and include details of the
vapour properties and the length of time the seal will operate without liquid
lubrication or cooling. At high pressures and high speeds the sliding surfaces must
be relieved so that the fluid film is kept stable. The frictional heat must be limited
at temperatures approaching the vapour temperature. In such cases, the face
pressure is reduced hydraulically. This is done by balancing the ratio between the
sealing diameter "S" and the inner diameter of the stationary seat. The pressure
between the seal faces is thus varied according to the liquid pressure. Dependent
upon the relationship between the two surfaces "A" and "B" in Figure 8.18, the
seal is termed, balanced or unbalanced.

The limit between balanced and unbalanced seals is determined by the pv factor
and the operating temperature. Balanced standard seals can be used for
pressures up to about 16 bar at speeds of 20 m/s. In the case of higher pv values,
hydrodynamic seals having a controlled leakage must be used.
Surface flatness. The flatness of the seat faces must be of a very high accuracy.
The leakage is approximately proportional to the third power of the thickness of
the fluid film which normally is in the order of 0.001 mm. Flatness is normally
expressed in light bands, since checking normally takes place using an optical flat
and monochromatic light, usually sodium light. A deviation of one light band
corresponds to an out of flatness of 0.25 pm. Normal standards of flatness are
better than 1 to 2 light bands with variations up to approximately 5 light bands in
the case of shaft diameters over 100 mm or in the case of special face materials.
In addition to the number of light bands the light pattern must also be
considered, see Figure 8.19.
Large differences in seal tightness occur, for example, between a spherical
surface, light pattern 3, and a wavy surface, light pattern 5. A check of seat faces
is recommended as a standard measure prior to the installation of a mechanical
seal. Because of the accuracy of mechanical seal components, any work done on
seals must be carried out in clean conditions. All components must be thoroughly
cleaned prior to assembly.
Design principles. The generation of the initial sealing pressure, i.e. the initial face
load is provided by using different types of springs. Single springs, multiple
springs, Bellville washers and wave springs are the most common, see Figure
8.20. The drive, i.e. transmission of the torque to the rotating seat, can when
single springs are being used, be carried out by the spring itself, separate driving
elements used with other spring types. At least two driving points are necessary
in order to guarantee a satisfactory loading of the seal faces. The top illustration
in Figure 8.20 shows a seal utilising two Bellville washers to provide the axial load.
The rotating seat is positively driven by the shroud extending from the drive
collar. The next picture shows the same type of seal but the axial load. Single
springs should generally be chosen in preference to multiple spring types. The
reasons for this are that driving and face loading can be combined in one
element, that the single spring is robust and withstands corrosion, as well as the
fact that the risk for blocking is less than in the case of small springs. In addition,
the single spring is easier to handle. The single helical spring has one major
disadvantage; the spring handing must be changed if the direction of rotation is
changed. For example, a double suction between bearings on a pump, with two
stuffing boxes, would have a different seal at each end, i.e. different springs. To
overcome this problem, many standard mechanical seals are fitted with Bellville
washers. The springs are usually inside the stuffing box in the process liquid.
Special mechanical seals can have the springs outside the liquid on the
atmospheric side.
The shape of the rotating seat varies with the method of driving, engagement and
the loading, as well as the materials of which the seal faces are made. In order to
take up any vibration in the shaft, parallel deviations in the "O" ring grooves as
well as any effects of the driving arrangement, the stationary seat should be
mounted as flexible as possible. Figure 8.21 shows various methods of
attachment. "a" is DIN standard construction and provides the greatest flexibility.
Figure 8.20 Examples of face loading and drive
Figure 8.21 Examples of how a stationary seat can be fitted and sealed
Temperature considerations. To achieve acceptable temperature conditions at
the seal faces, frictional heat must be dissipated to avoid dry running due to loss
of liquid between the faces. Heat dissipation takes place by means of heat
transfer through the seats and by convection to the surrounding medium. See
Figure 8.23.

Figure 8.23 Heat dissipation in a mechanical seal

Each seal and combination of materials has what is called a minimum AT in order
to be able to function, see Figure 8.24. AT is the difference in temperature
between the boiling point of the liquid at the seal cavity pressure and the actual
temperature of the liquid. Usually AT should be at least 20 ~ The seal
manufacturer can provide information for each type of duty and seal
arrangement. By means of various installation options, internal and external
circulation or cooling, the available AT can be increased., see the definitions at the
beginning of Section 8.3.1.2. The required AT of a seal can also be reduced by
using materials with good thermal conductivity or with low friction, etc. In such
special cases the AT required can be reduced to approximately 5 ~ In Figure 8.24,
the operation range of the seal is to the left of each respective speed boundary.
The liquid is water. The distance between the vapour curve and the seal's limit is
the required AT for each speed.ness
The flatness of the seat faces must be of a very high accuracy.
1.3 Damages of the pump shaft seals
Leakage pump due to damage of the shaft mechanical seal is the most common
reason out of operation order of the pump. The condition of the shaft seal
depends on factors of operating conditions, pumping media (temperature,
density, viscosity, etc.). Damage sealing the shaft is the most common cause
failure of the pump. The damage to the shaft seal depends on the structure (type)
of the seal and a pair of surface materials. The ring seals of the shaft with a
dynamic sealing ring and one surface of the seal from the coal graphite
characteristic damages are the wear and stick of seal surfaces and the seating
seals that prevent the axial movement of the dynamic sealing ring and seal static
(cover) ring. For the end seals with surfaces of solid materials with characteristic
damage are damage caused by working without lubricant. To analyse the causes
of damage to the shaft seal and further warning of new damage is required
information about the work of the seal. On the damaged seal of the shaft you can
see what exactly was damaged, but the cause of the damage is based on
information about the pump and operation conditions.
1.3.1 Damage due to lack of lubricant
The running of shaft seals with surfaces of solid materials depends on the
lubricant of the pumping liquid. Operating pump without lubricant and lack of
lubricant can lead to damage described below. Work without lubricant occurs
when there is no liquid in the seal area, either in the pump as a whole, or because
of insufficient ventilation, leading to a build-up of air around the seal. Lack of a
lubricating film leads to increased friction of seal surfaces and, accordingly, quick
raise temperature. Lack of liquid, heat is exchanged through the seal - with the
temperature of many solid seal surfaces reaching few hundred degr.C very quick.
Therefore, the typical damage caused by working without lubricant is the burning
of parts, from ERDM (ethylene propylene) and FCM (fluorocarbon) material. The
damage occurs when the sealing ring comes into contact with the hot seal surface
(Figure 1.1).
Figure 1.1 - Surface damage caused by exposure to high temperature on
secondary seals from ERDM (ethylene propylene) and FCM (fluorocarbon).
Pump shaft seal run without lubricant, the heat released during friction can cause
damage. Lack of lubricant occurs if the pumped liquid has a very low viscosity or if
the temperature of the liquid is much higher than its boiling point at atmospheric
pressure. Under such conditions, the heat released during friction can create a
very high temperature. Quick change local heating and cooling of seal surfaces
can lead to small radial thermal cracks on seal surfaces (Figure 1.2).

Figure 1.2 - Thermal destruction of the seal surface from WC, due to insufficient
lubrication
Noise. If there is lack of lubricant or no lubricant, the sealing of the shaft with
solid surfaces can create a loud noise when pump running. Depending on the seal
design, the solid materials used and the pump mode, the noise can be constant or
periodic. When the shaft seal makes noise, some parts of it vibrate. This can
reduce the seal life / running period due to fatigue caused by vibrations.
1.3.2 Damage due to pollution Pumped environment is often a mixture of liquids
and solids, as well as small suspended insoluble particles. The lubricant in the seal
gap is subject to large changes in temperature, pressure and velocity. This
increases the risk of accumulation sediment in or near the seal gap / contact
surface. The wedge / jam of the shaft seal means that the axial movement of the
rotating part of the shaft seal is blocked. Mostly, the wedge occurs in ring seals,
but is also observed in the bellow seals, although the basis is a different
mechanism. In the ring seal sediment can accumulate on the shaft next to the
sealing ring, preventing its free sliding. When the temperature or pressure
changes in the system, the size of the pump parts changes, so for continuous
operation the seal must slide freely on the shaft or clutch (Figure 1.3).

Figure 1.3 - Scheme to block the axial motion of the rotating seal surface
If the rubber bellow seal is operated at temperatures close to the allowable
maximum for the seal, the inner surfaces of the compensator begin to stick to the
shaft, which leads to a wedge. This also applies to elastomers seals, such as FCM,
have properties to stick to stainless steel. The wedge cannot always be detected
during the damage inspection, as the seal has often already been disassembled.
Expanding the seal gap. Some suspensions and solutions can cause growths from
sediments on seal surfaces. Since these sediments cover only part of the seal
surfaces, the seal gap is opened, leading to a leak through the seal of the shaft,
started the small leak, but the more liquid gets into the seal gap, the more
intense the leakage becomes. At the same time, the formation of precipitation
will accelerate, as the temperature on the surface of already fixed sediments will
increase (see Figure 1.4).

Figure 1.4 - Sediments on the surface of the seal, material coal graphite
Clogged. If the pumped liquid contains a large number of suspended particles and
fibers, the seal may be damaged due to deposits or accumulations of particles and
fibers on springs, compensators, seal frames or seal rings. The rate of subsidence
is affected by the type of fluid being pumped and the flow parameters around the
seal.
Particles and sediments. Small amounts of particles on seal surfaces cause
increased wear and tear, especially when a pair of materials are used to combine
hard/soft surfaces. In such cases, small particles can penetrate into a softer seal
surface and then work on a hard surface as a grinding tool.
Getting an outsider particle into the gap between seal surfaces causes an increase
in the degree of leakage until the particle is ground and washed away. For
example: - human hair has a thickness of 50... 100 microns, while the seal gap
operating under normal operating conditions is only 0.3 microns thick. Thus,
human hair 60 microns thick is 200 times thicker than a normal seal gap. The
degree of leakage is proportional to the thickness of the seal gap erected in the
third degree. That is, if human hair gets stuck between the seal surfaces, the
degree of leakage will be in 2003 to 8,000,000 times the degree of leakage
through the seal of the shaft with clean seal surfaces (without hair).
The seizing occurs when two seal surfaces are stuck or partially stuck to each
other. The grip damage causes the seal to damage if the seizing is higher than the
engine turning torque. It can also cause mechanical damage to seal parts. The
seizing can be caused by some of reasons. The tendency to seize have seals with a
combination of two solid materials in the surfaces. The main causes of seizing are
sediments on the surfaces of the seal from the pumped liquid or corrosion of seal
surfaces. The seizing is possible only in the seals of the pump shaft with the
start/stop mode. The period during which seal rings are glued can be from a few
hours, depending on the fluid being pumped. At high temperatures, the process is
accelerated.
1.3.3 Damage due to chemical and physical impact. All parts of the shaft seal
material to be sufficiently resistant to the chemical and physical factors of the
affecting environment to work throughout the service life as designed. Increased
temperatures and excessive chemical or mechanical loads shorten the life of the
seal. The proper sealing is provided in certain ranges of temperature and loads; if
the limits are exceeded, there is damage and quick destruction. In this case, parts
of elastomers can have many different damages, such as gas sinks, cracks, cavities
or discoloration. In some cases, destruction can only be determined by measuring
physical properties. Unacceptable chemical and/or temperature exposure lead to
the complete destruction of the seal.
Swelling is an increase in volume and a decrease in stiffness due to the absorption
of solvent. The increase in volume depends on the type of sealing ring material,
type and concentration of the solvent, as well as the temperature and duration of
exposure. In some cases, the swollen rubber part can double in volume. The work
of many types of shaft seals largely depends on the geometry of rubber parts.
Therefore, even minor changes in size can be critical. The decrease in hardness is
due to changes in the mechanical properties of rubber. The most common
material of THE EROM demonstrates a high degree of swelling when exposed to
mineral oil, and the swelling occurs regardless of the concentration of oil in the
water. However, the lower the concentration, the longer the seal will work.
Other types of sealing ring material also swell under the influence of some fluids.
As stated above, swelling is only one sign of incompatibility with the pumped
liquid. Also, the effect of pumped liquid on the sealing ring can be determinate as
changes in physical properties such as strength on rupture, relative lengthening
and hardness. Increased temperatures and duration of exposure create more
aggressive conditions. The physical properties of the end seal may change as a
result of aging. Typically, aging affects characteristics such as strength on rupture
and hardness. Divides two main categories of aging:
- aging in storage;
- atmospheric aging.
Aging in storage is essentially a decomposition of the material as a result of
oxidation. Sources of oxidation, in addition to the most obvious - oxygen, are
heat, light, internal and external mechanical load or voltage, and actively oxidizing
metals.
In contrast to aging in storage, atmospheric aging occurs as a result of ozone
exposure. At the same time, the mechanism of influence is significantly different.
If the rubber is exposed to any load, then the result is atmospheric cracking, in
which cracks appear on the rubber, located perpendicular to the direction of
elongation. This is clearly seen on the surface of old bicycle or car tires - deep
concentric cracks are formed in places where the tire is most deformed during
operation.
Explosive decompression is appeared on the surface of polymeric parts in the
form of bloating, surface pit or potholes. When the pumped liquid has high gas
phase partial pressure, the gas can penetrate the rubber. If the pressure drops
and the rubber-absorbed gas cannot release at the same rate at which the
pressure is lowered, the internal pressure becomes excessive. If this pressure
exceeds the strength of the material, there is an explosion caused by
decompression. Therefore, elastomers with high gas solubility and low
mechanical strength are affected to explosive decompression.
Corrosion. As a rule, the surfaces of the end seal are made of composite
materials. To prevent selective corrosion, all components of the material must be
resistant to the pumped liquid. For example, corrosion of cemented tungsten
carbide is due to the effect on the metal binder. As a result of this impact,
mechanical properties, including wear resistance, deteriorate. When the metal
binder disappears, the surface will become matte. In addition, selective corrosion
of the binder can cause tensions that lead to cracks in the seal rings (Figure 1.5).

Figure 1.5 - Selective corrosion of cemented tungsten carbide. The phase of the
metal binder is corrosion, which has reduced resistance to wear
On the surfaces of seals from other materials in places where the phase of the
binder was treated to corrosion, there may be severe erosion. For example, in
stainless steel pumps, tungsten with a cobalt binder corrodes in running water.
Corrosion sometime occurs on the metal seal parts in stainless steel pumps, as
the metal seal parts are usually made of a higher stainless-steel grade than other
metal parts of the pump.
Wear. Since the thickness of the lubricant is comparable to the roughness of the
surface, the seal surfaces will always wear out a little. Normal wear is so small
that the seal can work for many years (Figure 1.6). In some cases, wear can cause
problems, but often seals function perfectly when worn up to 0.5... 1.0 mm if the
axial flexibility of the seal ring still exists. Deep scratches on the surface of the seal
from the pumping liquid indicate that the particles from the pumped liquid has
penetrate into the seal gap. Deep scratches from the atmosphere indicate that
solid deposits have formed in the places where the lubricants evaporate.

Figure 1.6 - Normal wear on the surface of the seal from tungsten carbide
1.3.4 Damage due to incorrect installation Sometimes damage to end seals
occurs due to improper installation and operation. Examples are: not centered
shaft, the installation of the cover ring is not perpendicular to the shaft, incorrect
mounting length, etc. Position and width of traces of wear on the cover seal ring
showing the failure of centering the shaft and seal.
If the width of the worn-out area same on the slip surface of the opposite seal
ring, the shaft seal is well centered and has no deviations (Figure 1.7).
If the sliding footprint on the cover ring is wider than the rotating surface of the
slip, this indicates a strong deviation from the shaft axis (Figure 1.8). Another
possible cause is the unbalance of the rotating parts. The different depth of the
seal wear marks indicates that the seal is assembled tilted to shaft (Figure 1.9)

Figure 1.7 – Correctly centered shaft Figure 1.8 – Shaft seal with radial
seal deviation
If the "seat" of the seal is tilted, there is excessive wear and tear of the rotating
surface. The wear and tear of the rotating surface is accompanied by axial
scratches on the inside surface (Figure 1.10) if the cause is the movement of the
shaft or clutch relative to the seal. It can be axial movement of the shaft due to
vibration or not alighned of the stationary "seat" ("seat” or cover ring is not
perpendicular to the shaft).

Figure 1.9 – Not the same depth of Figure 1.10 - Wear of the rotating
wear marks on the "seat of cover surface at the point of contact with
ring" due to the wrong installation the shaft
Axial movement caused by the vibration or tilt of the "seat of cover ring" can
cause the shaft or clutch to wear under the rotating seal surface. Friction seals on
the shaft damage the shaft protective layer, leading to corrosion (Figure 1.11).

Figure 1.11 - Corrosion of the shaft under the rotating part of the seal as a result
of the axial movement of the shaft
Assembling. When the end seal is mounted on a rotating shaft, the axial motion
of the shaft should not exceed the flexibility of the shaft seal. The axial motion of
the shaft, exceeding the allowable flexibility of the rotating part of the end seal,
can cause an increase in seal wear or irreversible damage to individual parts of
the shaft seal.
Installation. Many of the shaft seals have a standard mounting length. This allows
you to replace one type of seal with another with improved performance for
these conditions. But even if the two seals have the same mounting length, the
sliding surfaces can be placed at different levels. Using the components of two
different seals, the compression of the seal may be insufficient or excessive as a
result.
Damage due to changes in working conditions. During pump operating
conditions may differ slightly from those for which the pump was designed.
Changing operating conditions can affect the performance of the seal. These are: -
pressure in the seal chamber; temperature in the seal chamber; pumped liquid;
rotation speed; size of the shaft seal. If these parameters do not meet the
operating conditions, this may result in the shaft seal being damaged. The
pressure on the side of the pumped liquid should be within the corresponding
seal design, seal materials and pumped liquid. When the pressure of the liquid on
the shaft seal exceeds the maximum for the seal, it can lead to increased friction
of the seal surfaces and damaging of secondary seals.

1.12 – Damaged sealing rings by HIGH pressure

1.4 Centrifugal pump maintenance.
1.4.1. The dismantling and assembly of support mechanisms and equipment
should be carried out in time in accordance with Preventive Maintenance Plan
and in a technological sequence provided by the Manual instructions, technical
conditions for repair or guidance on the repair of this mechanism.
1.4.2. When inspecting the parts of the pumps, it is necessary: - to identify
possible defects of shaft necks in the area of seals and sliding bearings (scratches,
bullies, etc.), as well as to check the condition of the shafts of pumps, ball
bearings, their landing in the pump casing and on the shafts; check pump
foundations, and piping; check freeing rotation of shafts in bearings; check the
pump – drive motor coupling, the condition of the valves and gauges.
When assembling and overhauling of the pump should avoid excessive tension of
connecting pipelines and tightening foundation bolts. The may lead to
misalignment coupling, additional pump wearing or damaging.
1.4.3. When inspecting centrifugal pumps, it is necessary to check the condition
of surfaces and input edges of the blades of working wheels. - temperature
bearings, seals, al. Engine, noises and vibrations
1.4.4 Service during operation. During the pump, it is necessary to:
- to monitor the readings of the control gauges (the arrows of the gauges in the
normal operation condition of the pump and pipelines have small smooth
vibrations without throws; significant fluctuations the arrow of the gauge indicate
the presence in the air pump throws in the readings of the amperemeter at the
calm readings of the rest of the devices indicate problems inside the pump:
seizing in bearings, impeller-casing wearing ring, mechanical seal);
- monitor the grease of bearings and their temperature (max temperature less
than 70 degr.C);
- monitor the condition of the shaft seal (their heating should not exceed 60
degrees Celsius) and the flow of liquid to hydraulic shutters (if any) If in a healthy
condition, the slings must pass continuously separate drops of water;
- time by time depends of operation condition carry out de-aerating pump casing
through designed valve opening.
- if the pump run for a long time, additional grease or lube oil to the ball bearing
as per Maker Manual may be required.
1.4.6. Annual inspection and repair. (Inspection and overhaul / examination in
accordance with Preventive Maintenance Plan).
With intensive operation of centrifugal pumps (4500 - 60000 hours per year)
should be carried out an annual inspection / maintenance of the following perts
of the pump:
- rubber and plastic sleeves of bearings;
- the sleeves of sealing impellers in two-stage pumps;
- the shaft seals (as a rule, a change packings is required);
- pump & drive motor flexible coupling (usually, required renewal of rubber
inserts);
- Device to switch pump mode from parallel to sequentially water supply (two
stage pumps).
It is forbidden to perform maintenance operations during the pump, which can
lead to an accident.
1.5 Maintenance of centrifugal pumps of the Wartsila L20 engine (Fig 1.13)
1.5.1 Device. The centrifugal pump is driven by gear connection at the free end
of the engine. The shaft is made of acid-resistant steel, impeller 6 and the rest of
the parts are cast-iron. The shaft is set in two ball bearings 8 and 10, which are
lubricated by spray of oil coming through the holes in the bearing hull. Shaft 16
seal prevents oil from leaking and at the same time protects against dirt and
leaking water. The gear 12 is attached to the shaft by conical ring elements 13.
When the screws are 14 tightened, the rings create pressure between the gear
and the shaft. Due to friction, the force from the gear is transferred to the shaft of
the pump. The water side of the pump is equipped with a mechanical seal of the
shaft. Ring 4 rotates with the shaft and seals it together with the ring seal. The
spring presses the rotating ring to the stationary ring 3, which seals the hull by
means of ring seal 7. Probably leaks through seals water and oil can drain via hole
18.
1.5.2 Service. Routine maintenance work, such as dismantling the impeller or
renewal a mechanical seal, can be done without the entire pump being removed
from the engine.
Figure 1.13 - Wartsila L20 centrifugal pump: 1 - cover clamp; 2 - sealing ring; 3 -
ring; 4 – shaft seal; 5 - bolt; 6 - working wheel; 7 - sealing ring; 8 - bearing; 9 -
shaft; 10 - bearing; 11 - bearing cover; 12 - drive gear;13 - tapered rings; 14 - bolt;
15 - hard drive; 16 - seal; 17 - sealing ring; 18 - "control" hole
The pump is to be inspected or overhauled as per intervals according to the
engine maintenance manual or if the coolant or oil leaks immediately. Periodically
check that the control hole 18 clean.
a) Disassembly and assembly of the working wheel:
- remove the pump cover, unscrew the cover clamp 1 and the screws of
fastening;
- unscrew the screw 5 fixing the impeller;
- remove the working wheel with the help of a puller;
- when assembling a impeller tighten the screws with a moment, 85-5 nm;
- make sure that the ring seal 2 and the reverse valve ring seals on the cylinder
block are not damaged and are in their seats when the pump cover is installed.
Check correct assembling of pump;
- Install the cover clamp 1 and tighten the screws.
b) Disassembly and assembly of mechanical sealing of the shaft:
- remove the working wheel according to paragraph (a) above;
- carefully remove all the details of the seals. The sealing rings are very fragile /
delicate. Special care is required not to damage the sealing surfaces, as a small
scratch can loss the sealing;
- completely replace the seal if it leaks or its sealing surfaces are damaged by
corrosion, uneven or worn out. Avoid touching the sealing surfaces with your
fingers. Do not lubricate with mineral oil when installing a seal - use liquid soap or
water.
Some seal parts are made of rubber that is not suitable for use with hydrocarbon
oils. Any fading or alteration of the color of the rubber parts of this seal has no
effect on its functioning;
- pay attention to the fact that the seal does not depend on the direction of
rotation;
- assemble the parts in the appropriate order and install the impeller according to
the pos. (a) above. Do not forget to install a thin washer between the spring and
the ring seal.
c) Renewal bearings and sealing the shaft:
- remove the pump from the engine;
- disassemble the working wheel and mechanical seal according to the paragraphs
(a) and b) above;
- unscrew screws 14 and remove the pressure plate 15;
- remove the gear without using any tool. If removing the gear is difficult, you can
knock with a soft hammer (friction ring elements 13 are released along with the
gear). Using a puller may damage the shaft (longitudinal risks);
- release the stop ring bearing 11 and remove the shaft and bearing;
- check seal 16 and bearings for the wearing and damage. If the seal leaks,
disassemble seal with a suitable brass instrument;
- remove the bearings. Press the bearing acting to inner ring; - to inspect the shaft
wearing and damage;
- lubricate new seal and insert it, pressing to the edge;
- grease and press the bearing for its inner ring with a suitable pipe (fig.1.14 A);
- rotate the shaft according to figure 1.14 B;
- grease and press the bearing over its inner ring with a suitable pipe (fig. 1.14 B);
- rotate the casing according to fig.1.14C and grease the outer surfaces of
bearings with oil. Press the shaft into the case on the inner and outer rings of the
bearing with a suitable pipe or correction.
Figure 1.14 - Mounting bearings
Figure 1.14 - Mounting bearings

Fig. 1.14 - Mounting bearings

- install a stop ring bearing 11 (Figure 1.15). Fix the screws with mastics;
- before installing the gears should be cleaned and smeared all contact
surfaces;
- set in place gear and friction rings 13. Friction rings should easily stand in
place and should not seize;
- install pressure plate 15 in place;
- tighten the screws and check the correct position of the gear;
- tighten the screws to the point of 35-3 nm;
 Figure 1.15 - Drive gear editing: 11 - bearing stopper; 12 - drive gear; 13 -
conical rings; 14 - bolt; 15 - hard drive
- install the impeller and mechanical seal according to the points (a) & b) above.
2. How to do the job
- 2.1. Prepare data during preparation: study the design features, the purpose and
principle of the blade pumps. Check design of seals.
- 2.2. Learn safety instructions when working with a plumbing tool.
- 2.3. Get acquainted with the workplace and find out the location, purpose and
device of equipment, appliances and tools, the contents of regulatory documents.
Prepare the tools for work.
- 2.4 Disassemble the centrifugal pump: before disassembling, the pump should
be disconnected or isolated from the suction and discharging sides. The electric
motor to be disconnected from the power supply. The pump liquid (water, oil,
etc.) to be drained through the lower drain hole. The coupling motor-pump to be
released depend in way depend of design. The pump lubricating systems, water
supply for cooling and seals to be disconnected. Disassembling sequence,
depending on the design of the pump, may differ.
For single-stage pumps, the cover of the suction side, the lid of bearings, to be
disassembled on the first. Depending on the type of the shaft seal removes the
seal cover or securing arrangement the end seal. After that, the working wheel is
removed and pull out the shaft with the bearings. All the removed parts are
washed and examined to detect defects. At once defective parts of the pump
have been repaired or renewed, balance check of shaft assembling is carried out,
the pump should be assembled in reverse sequence.
Assembled to foundation pump coupling to be centered to drive motor.
The dismantling of the pump with two-way suction is carried out in the
consistency. First disassembling coupling, then the seal parts depend of design
(packings or mechanical seal). Next to be dismounted the bearing cover is then
removed pump casing. Bearings to be removed as per design of the pump, and
clearances / gaps, condition to be checked. The next step is the impeller to be
disassembled.

Figure 1.16 - Central pump sketch:1 - wheel, 2 - shaft, 3 - front disc, 4 - rear disc,
5 - blades, 6 - bearings, 7 and 8 - seals, 9 - liner, 10 - spiral pull, 11 - pressure patch
2.5 The pump parts should be inspected & examined for defects and wearing. The
results of the inspection to be recorded and written to Overhaul report
accordingly. Depend of the technical condition parts of pump to be reused or
renewed, the pump to be assembled as per Maker Manual.
3. Report
3.1 The Centrifugal pump design to be described;
3.2 Using the pump instructions make Maintenance and Overhaul Plan.
3.3 Describe the sequence of operations to disassemble and assemble the
Centrifugal Pump. Indicate the tightening moments of the main threaded
connections.
3.4 Describe main faults of the Centrifugal Pump and how to fix them.
3.5 Complete Overhaul and Inspection Report of the Centrifugal Pump with
description defects, inventory renewed and reused parts.
3.6 Answer and be ready for self-control questions belowmentioned.
4. Self-control questions:
4.1 Typical damages of the Centrifugal Pumps.
4.2 Materials of the Centrifugal Pump parts.
4.3 Operation Instruction for Centrifugal Pump: before start preparation, start,
stop, and lay-up of the pump;
4.4 What action to be carried out by Watch Engineer during the Centrifugal Pump
operation.
4.5 Instruction for mounting rolling bearings (best experience practice)?
4.6 How to assemble the seals of Centrifugal Pump shafts?
4.7 Safety precaution during maintenance of the Centrifugal Pump.

Literature 1. Cherkassky V.M. Pumps. Fans. Compressors. - M., Energy, 1977, p.

143 - 151.
2. Ravens V.F., Artykov A.P. Ship hydraulic machines. - L., Shipbuilding, 1976, p.
24-25.
3. Blinov I.S. Handbook of the technologist of the mechanical assembly shop of
the ship repair plant. - M., Transport, 1979, p.593