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R E L I A B I L I T Y- D R I V E N P U M P M A I N T E N A N C E H A N D B O O K

Table of Contents
A Systems Approach to Pump Reliability...................................................................1
Improving Pump Reliability at Thermal Power Plants .............................................3
Improving Performance of a Water Transport Pump................................................6
Early Maintenance Staff Involvement ......................................................................10
Team Approach Produces Winning O&M Formula - Part 1....................................12
Team Approach Produces Winning O&M Formula - Part 2....................................15
Team Approach Produces Winning O&M Formula - Part 3....................................18
Reducing Acoustic Emissions ....................................................................................22
Addressing Pump Vibrations - Part 1 .......................................................................25
Addressing Pump Vibrations - Part 2 .......................................................................27
Lubrication Systems for Rotating Equipment ..........................................................29
Lubrication Oil Viscosity Classification… Don’t Get Confused...............................34
Probe Installation Tips ..............................................................................................35
Bearing Basics ............................................................................................................38
Troubleshooting Boiler Feed Pumps.........................................................................42
Torsional Analysis in Couplings Selection ................................................................43
Not All Grouts are Created Equal .............................................................................47
Bearing Lubrication Trends and Tips .......................................................................49
A Multistage Vertical Pump in Light Hydrocarbon Service - Part 1........................53
A Multistage Vertical Pump in Light Hydrocarbon Service - Part 2........................56
What Does It Cost? ....................................................................................................60
Keys to Improve Pump Record-Keeping ...................................................................63
Reliability Improvements to a 13 Stage Charge Pump ............................................68
Reliability Improvements to a High Pressure Charge Pump...................................71
Reliability-Driven Pump Maintenance .....................................................................76
Fluid and Material Basics..........................................................................................85
Baseplate Design Affects Reliability .........................................................................87
Exploring Bearing Lubrication Options....................................................................90
How to Extend Pump Bearing Life...........................................................................95
Mounting and Clearances for Casing Wear Rings....................................................99
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R E L I A B I L I T Y- D R I V E N P U M P M A I N T E N A N C E H A N D B O O K

Table of Contents
Factors in Pump Suction Piping .............................................................................102
Alignment Movement Methods...............................................................................105
Foundation Tips.......................................................................................................109
Evaluating Pump Monitoring Options....................................................................110
Applying Predictive Maintenance Measures...........................................................112
Vibration Analysis Yields Good Vibes ....................................................................116
Getting the Full Benefit from High-Efficiency Motors ...........................................121
Coupling Strategies ..................................................................................................127
Adjustable Speed Drive Offers Pump Flexibility ...................................................132
Solid State Controls Tune Pump Operation ...........................................................135

Pumps for Haz/Rad Wastewater Service ................................................................138

Alignment Tolerances for Spacer Couplings...........................................................143
Couplings Alignment - Let’s Talk Tolerances .........................................................147
Machinery Alignment vs. Coupling Alignment......................................................149
Build a Better Foundation to Reduce Costly Downtime .......................................151
Flow Sensing For Pump Protection ........................................................................154
Reliability Profile: Champion International ..........................................................157
Tips and Trends in Sanitary Pumping....................................................................160
Computer-Based Pump Reliability.........................................................................164
Proper Repairs Avert Failures:
Part 1 - Centrifugal Pump Gasket & Impeller .......................................................176
Part 2 - Single Stage Horizontal Pumps ..................................................................181
Part 3 - Multistage Horizontal Pumps ....................................................................183
Part 4 - Vertical Pumps ...........................................................................................187
Evaluating Motor and Drive Solutions....................................................................191

Slurry Pump Wear Factors ......................................................................................194

Tools That Do Our Work for Us - Or Do They? ............................................204

Users Q&A: Canned Motor Pumps ...............................................................206
Winning Maintenance Strategies at Thorn Creek.........................................209
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R E L I A B I L I T Y- D R I V E N P U M P M A I N T E N A N C E H A N D B O O K

Table of Contents
Innovations in Multiphase Hydrocarbon Operations ...................................211
Key Indicators - The Measure of Reliability .................................................217
New Coatings Make Their Mark ..................................................................220
Rim and Face Alignment Procedures for Direct Motor Driven Equipment..224
“Best-of-Class” Lubrication for Pumps and Drivers .....................................227
Universal Drive Shaft Maintenance..............................................................230
Optimizing High Energy Pump Operation ...................................................232
Managing Vertical Pumps in a Changing World...........................................236
Improving Progressing Cavity Pump Reliability...........................................241
Water-Lubricated Fluid Film Bearings Can Be Trouble-Free........................244
Oil Lubrication for Process Pumps and Related Equipment........................248
Injectable Packing Compounds - An Alternative Sealing Technology ..........260
Multistage Pumps in the CPI .......................................................................263
The Role of Grouting in Standardized Installation Practices .......................270
Variable Frequency Drives for a Vacuum Pump System ..............................274
Turnaround Time! ........................................................................................276
The Critical “First Hour” Startup of a Turbine-Driven Boiler Feed Pump ..278
Methodologies for Calculating MTBF Part I ................................................282
Methodologies for Calculating MTBF Part II ..............................................287
Packing & Rotating Equipment ....................................................................291
Which Alignment Method Is Right for You? ................................................294
Troubleshooting Liquid Ring Pumps ............................................................296
Replacement of the Boiler Feedpumps at Janschwalde Power Station ........298
The Nuts and Bolts of Vibration Signature Analysis ....................................305
Energy Savings Pay for Reliability Improvements at Chevron......................311
Teamwork Key to Pump Reliability Upgrades at Conoco ............................315
Maximizing Reliability in Sealless Pump Operation ....................................318
Laser Shaft Alignment of a “Bark Hog” ......................................................323
Balancing Pump Impellers ..........................................................................325

All materials ® 1998 AES Marketing, Inc. No part of this publication may be reproduced without the written consent of the publisher. The publisher does
not warrant, either expressly or by implication, the factual accuracy of the articles or descriptions herein, nor does the publisher warrant the accuracy of
any views or opinions offered by the authors of said articles or descriptions.
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R E L I A B I L I T Y- D R I V E N P U M P M A I N T E N A N C E H A N D B O O K

Revitalizing Vertical Lineshaft Turbines ......................................................329

Sealing Lime Slurry at Alberta-Pacific..........................................................333
AlliedSignal GeismarWorks ..........................................................................334
Well Pump Applications for Mine Dewatering ............................................337
Hazardous Fluid Pump and Sealing Systems: Reliability Driven Improvements ........341
Classifying Chemicals to Ensure Effective Sealing ......................................344
Reliability: Big Opportunity or Big Distraction? ..........................................347
Controlling the Seal Environment—A Key to Seal Reliability ......................353