a Centrifugal Pumps the pump is taken out.of service overnight, mall water from it and Aisconnect the airsupply and exhaust hoveh Zeer a small amount of cl into the live-ar inlet, connect the ai ha#6.amd allow the pump to {le for about » minute. Disconnect the Iie. Spare Part: ‘The number of spare parl# Wi should be kept on ‘hand varies with the pump application. ‘Thus sinard ship more parts ae generally carried than in a stationary am: Most manufacturers recommend that the minimum number of #4 sbould be one set of shaft bearings, one set of shaft sleeves, ont S62 wearing rings, and 4 supply of suitable packing for the sullg axes. On vital obs where a standby pump is nt iasalled, stk # Smplete spare rotating clement. When ordering spare parts, give the watiicturer the folowing informatio: serial number of pump, size aNd te of pump as given ‘on the pump nameplate, the numberof the PA listed inthe pump instruction manual, and the name of the \\tt. 1 listed. When pos- sible, give the complete symbols stamped wt tix old part, CHAPTER 3 Routine Maintenance of Centrifugal Pumps Categories. Maintenance operations for centrifugal pumps fall into two categories: (1) routine preventive maintenance, often performed as part of the operating schedule, and (2) overhaul or repair opera tions. Routine maintenance may be classed as work done primarily to rectify the effects of normal wear in the pump. Overhaul or repair ‘operations are performed to rectify the results of excessive wear, over, heating, damage from solids in the liquid, or injury or wear from any other cause. Routine maintenance is discussed in this chapter over hhauls and other major maintenance jobs are considered in Chap. 6 Maintenance Records. To ensure accurate recording of all the ‘maintenance operations performed on a given pump, secure oe pee ppare a record card (Figs, 9-1, 9-2, and 17-6) for it. The cards shown {in Figs. $1, 32, and 17-6 have space on the front for important facts sate [Peotone [ReFic. 32. Date thet for w Co.) Aeepwelltuthine pump. (Courteny of A. 0. Smith about the pump. These inchide the pump seral number, pump size and type, its builder, order number, date shipped, rated conditions, stofiog-box dat, construction materials, and type of drive used. ‘Keep this record card handy because it is extremely useful during male nance and when ordering spare parts. Figure 92 shows part of similar data card for a deepwell turbine pump, ‘The back of the card in Fig. 3-1 has spaces for entering details of the ‘maintenance performed on the unit. Or a separate ear resembling Fig. 17-6 may be used for this purpose. Essential data that the record should include are the date, condition or defect noted, its cause, who did the repair work, the cost of the repair, the number and cost of ‘any spare parts used, and any remarks concerning. the inaintenance work oF the trouble encountered in the pump, tn | ! f€ Routine Maintenance of Centrifugal Pumps 7. ©, Maintenance Intervals, Chapter 2 lists « number of the hourly | Sperating checks recommended by pump manufacturers. ‘These checks ensure a regular inspection ofthe pump while it runs, thereby prevent, {ng a major failure. In addition to these checks there are a number of routine preventive-maintenance operations that should be performed ot stated intervals, While there are slight variations in the recommends: tions of manufacturers as tothe work to be performed, there ts, in gen. ‘ral @ good degree of agreement, for both the intervals and the job to be done. ‘The usual intervals recommended for routine preventive mainte ppance are monthly, quarterly, semiannually, and annvally. These are satisfactory for all usual centrifugal pumps, provided the hourly cheeks recommended in Chap. 2 are regularly made. While these intevsals are accepted throughout the pump industry, it should be understood that it may be necessary or desirable to perform the stated tasks at more frequent intervals. Never neglect maintenance just to adhere oan arbitrary schedule. On the other hand, do not perform unneves sary maintenance operations because this defeats the purpose of the routine preventive prograin, Monthly. Use a thermometer to check the temperature of each beating in the pump. Where no thermometer well is provided, wee ball of putty to hold the thermometer bulb in place on the extesion surface of the bearing, In general, the temperature of any bearing in a centrifugal pump should not exceed 160 F. Before allowing bearing to operate at any temperature above that recommenced! check ith the pump manufacturer. Much depends on the type of beating, ft lubricant, and the duty the bearing performs in the pump, If any bearing is running hot, check for the cause. Ball or roller bearings may be overlubricated. Remove some grease and test wader + load. “Hot sleeve bearings may not have enough oi, the oil sings may bo stuck or broken, or the lubricant may be ton thick for ite job, If the oll is thought to be too thick, change it. Run the pump. again 1f the bearing still runs hot, disassemble, wash, anud inspect the Kea ing. Replace worn or damaged parts, Check the alignment of the pump and its driver. Readjust i neces. sary. Be sure to check hot liquid pumps in hot condition Quarterly. Once every 3 months, drain the ll from sleve-type bearings. Wash out the oil wells and bearing interior parts with cles Kerosene. Check the oil rings~they should be clean, completely cir, ular, and must tur freely when the pump shaft is rotated. Repals or replace any defective oil rings. Refill the bearing with the rorrectInspect: grease-lubricated’ rolling-contact and sleeve bearings for saponification—a condition revealed by a whitish color of the grease. Seponifcation {s usually caused by leakage of water or other liquids past thie Bearing-shaft seals. To relieve this condition, fush all grease from the bearing. Use clean warm kerosene to do this. When the bearing is clean and dry, repack it with new clean grease of the recom mended grade. Measure the pump sleeve bearings for wear. Most manufacturers ‘recommend a clearance of 0.002 in. for each inch or fraction of an Inch of shaft diameter, plus 0.001 in, Exemple: A pump has a shaft 5.5 in. in diameter, What clearance should exis inthe sleeve bearings for this shaft ifthe above rule apnlics to? Solution: Clearance shoul be 6(0.002) + 0.001 = 0.018 in. for this Dearing, ifthe above rule applis to it Measure bearing clearance by placing three lengths of soft lead ire, threads of metallic packing, or plastic wire on top of the journal ‘The wire should not be more than 0.010 in, thicker than the estimated bearing clearance. Replace the bearing cap and tighten its hold-down nuts. Remove the cap and measure the thickness of each Aattened wire with a micrometer. If all leads are the same thickness, the clear- ance is uniform throughout the bearing. The thickness of any wire tives the bearing clearance at the point at which the wire was located. If the bearing clearance exceeds the recommended value, replace the upper and lower halves. Check the clearance and enter it on the pump record card, along with the date of the replacement. Semiannually. Check the shaft packing by observing the leakage from it. Some pump engineers recommend that the box leak 40 to 60 drops of liquid per minute for adequate cooling, but this varies widely with the pump, its service conditions, liquid handled, and the type of packing used. If leakage from the stuffing box is excessive, or the packing is badly worn, replace all the packing in the box. Never replace just one o wo rings—they will not seal effectively, Be certain to use only the grade of packing recommended by the pump builder. Remove the packing gland (Fig. 33) firt. Then use a packing nook (Fig. 3-4) to remove all the old packing Aim the hook at the ore of the box (Fig. $50) to prevent teratching the shaft. Note the Frc. 93 lod (Courtery of All-Chalmers hook Mie: co.) Removing, packing-bor Fic. 4, Removing packing with a “courte of Als Chalmers Mie. Co.) io. 88. Steps tn repacking «pump, (Courter of Power)% Centrifugal Pumpe location of the seal cage, if used (Fig. 2-10), soit can be replaced fn its correct position, Clean the interior of the box thoroughly 30 the packing tan move easly inside it ‘Check the shaft sleeves for wear. If the sleeve is badly scored or ‘worn, replace it. Use a sleeve puller (Fig. 8-6) to slip the sleeve from the shaft. Worn or scored shaft sleeves accelerate packing. wear and Increase the maintenance cost of a pump. If packing wear is excessive, but the shaft sleeves are in good con- is capacity i at the rated value, ump produces the required press it may have dropped ta neatly zero fa.an [uample wssume that the pump én Fig. 81 was designed to iriver 18 xp at 300 ps to an oil burner. When new Ht supplice oe {lan expected, tay svar increases to O06 in, it haeely delivers ae rr aianbiy, | Wear beyonal this point reduces the capacity of {ht Dump Ielow that eequite for elfcient Durer uperation san Sneed Operating a rotary pump well below rated speed ‘when Hauling Jow-wiscsity liquids enuses its volumetric elfcleny aa Mlectease to where the putip ne longer delivers its rated capacity and Dressure. Figure 8:2 shows what to expect of a pump havin 100sgpm displacement at 100 per cent speed, This pump has zero displacement at sere spl Fak ‘As the speed inereses, displace: iment ineresses any the diel Iment cure ntl at 100 pe coe speed ite displacement te 100 gor Point B. Because of high preset 84,20 pert of sneer of pat aad ee Sn RPO pew wih 8 oe ae hac eh ee 1S a Wiican is (Se and dete rh ay 22 et pe omtspead pant 4 the sped decreas, pump dang deren doth eat ne wot at 20 per cnt rated speed delvey ae 6 ey D._ For lest eliciency. dot operate rater, ao okt speed, prticulrs when handing lesa We170 ramgrenent it as eo St etn ar jmp are to be chee joing, through the bypass and multiply this by the number of holes in the two plates to obtain the total discharge of the pump. Fic, $5, Ifthe pump capacity isto large for meter, we orifice pats with fall mets. Mcp the teadig” by the number of wnbres.” (Couey Warthington Corp.) Where Troubles Occur. Rotary pumps can develop a number diferent woubet, The most common at allure to ihe, sive noise, rapid wear, reduced capacity, excessive power consi and loss of suetion. ‘The causes and cures of these troubles are cussed in detail below. PUMP DOES NOT DISCHARGE Suction-Line Troubles: Check for air leaks at the joints in the s line, a closed valve, obstruction in the pipe, clogged strainer, Rotary-pump Trouble Shooting m level too low in the supply tank, or a clogged or stuck foot valve, To tliminate air leaks in the suction piping, tighten the bolts in Banged joints and the couplings or nipples in threaded joints, Paint the ex terior of the piping, applying at least two coats, Always open the surtion valve wide before starting a rotary pump. Using the suction 1-10 thot tw into the pump cat lead to excessive noise, eavita Attach a vacunm gage to the suction bine, close to the pomp. Fe vaill show if leaks are present, and if the suetion valve i shes Srake ont cloguve! suction pipes. Carefully check the gaskets in {ange joints to sce that the enter portion has been eut gute Tt not sncommon to Bind aset lft in ve pipe, abstracting flow, Remove ail obstructions from the pipe before atempting to sar the pnp nga. Clean the suction strainer by removing. i and. washing. 1 Shnonghly ithe Hui handled. Cheek to se that the strainer has an open fre area at least four times the cross-sectional area of the , Where the liquid level is too low in the supply tank, either extend. the end ofthe suction pipe lower or raise the level by feeding more liguid into the system or tank.” Remove clogged or stuck foot valves and clean them, Be careful not to Insert the suction pipe so far Into the foot valve that st prevents the disk from lifting tor adit quid svhon the pump is started Pump Not Primed: Fill the pump casing ful of the lguid handled He sre a small amount of liquid everlows from the easing. ‘Then the air in the easing has been displaced by the guid Pump Worm Excesicely: Take the pump out of service and place the worn parts with new ones obtatned from the pump manufactures, kis often beter to take the pomp tothe maintenance shop to work ox it Instead of trying to make repairs in the plant working area, Keep several spare pumps on band to replace worn pumps if sorvce cone tnt erica Driver Troubles: Check fo se thatthe pamp turns inthe correct die ssstion and that the motor or engine tums it at rated speed. ‘These troubles are most common with new and overhauled pampe Open or Leaking Relief Valee or Bypass: Check to see that mana Spas valves are closed and thatthe relie-valve spring is adjusted tothe corect pressure setting, Disconnect the reli line and watch ‘he fow through it while the pump operates. "At normal dl resure there should be no flow from the relief valve trough the te172 Rotary Pumps lief liné. If there is fow, check for a stuck relief valve, broken. or valve disk. Replace the damaged parts : Excessive Suction Lift: Use a vacuum gage to check the pressure ia the suction pipe. For all usual rotary pumps the suction lift should be - ut least 2.5 psi greater than the vapor pressure of the liquid at its | Pomping temperature. 7 EXCESSIVE NOISE, Liquid Troubles: These can be caused by air or gas trapped in the Jiquid handled, suction-line leaks, insulficient flow into the suction pipe, and chattering ofthe relief valve. If air leaks are found in the suction line, check and paint the pipe as described above. A crackling note ‘occurring while the pump operates is caused by the collapse of aie bubbles in the liquid as it moves from the suction to the discharge side. of the pump. If the crackling continues after air leaks are eliminated, from the suction pipe, replace the stulfing-box packing to eliminate the entrance of air. When a mechanical seal is used in the pump it may be} necessary to replace it completely while it is being repaired When enough liquid does not enter the pump, check for clogging. the suction pipe, strainer, or foot valve. If these are free and inspect the pipe to see that iti at least the sume size of the pump inl and preferably one pipe size larger. If the suetion lift is excessiv lower the pump so it is closer to the liquid level, or increase the level of the liquid in the suction tank Cure a chattering relief valve by resetting it to a higher pressure or fitting it with a dashpot to even out the pressure impulses mitted to it from the pump discharge. Misalignment: Check the pump alignment as described in Chap. If the pump handles hot liquid, check the alignment both before pump is started and after it reaches its operating temperature. If piping transmits strains to the pump easing, loosen the conn and move the piping to a position where it places no strain on ump. If this is not possible, insert expansion joints in the pipe, to the pump. Bent pump or driver shafts also lead to noise. Using a strain rotate the pump and driver shafts and check their runouts. should not exceed the limits recommended by the pump builder. bent shaft often produces grinding type of noise. If the found to be bent, check the pump rotating elements for high Rotary-pump. Trouble Shooting 18 Grind fle these level with the surrounding surfaces. Though itis possible to straighten a bent pump shaft, it is usually more economical to replace it with a new one. Discharge Presrure Too High: This leads to a crackling or grinding noise. Check the dischargespressure gaze to see that it gives the exe rect reading, Reduce the pressure setting on the reli valve if the lvcharge pressure is higher than the rated value. “When the pump is not equipped with a reliet valve, ft one. EXCESSIVE WEAR Liguid Troubles: These can be traced to corrosion of the pump working parts, no liquid supply, and abrasive dirt in the liquid, "Row tine wear of rotary pumps is generally extremely low; excessive weer should not be tolerated because it increases the pump slip, reducing the capacity and leading to early replacement of the uni, Corrosion or erosion of the pump parts by the liquid handled is usually a result of incorrect selection of pump materials. If these con. ditions occur, replace the pump by one made of suitable materials fog the liquid handled. Insufficient oF no liquid supply causes the pump to run without its required lubrication. If possible, provide a suetion head on the pump Keep suficient liquid in reserve at all times to operate the pump for several minutes, should the liquid supply fail. Never operate a rotary pump dry. Abrasives inthe liquid handled can be extremely harmful to a rotary ump because the clearances are so small. The most common way of Preventing abrasives from entering the pump is by using « fine mesh strainer. If one is fitted to a rotary pump, be sure that it docs aot increase the suction-line friction to the point where cavitation cocue Clean the strainer often. When handling heavy thick liquids that will not flow readily, itis often advisable to steam-trace or electrically heat the suction pipe or pump casing, Or a stearm jacketed pump nay be used, if the solids can be melted at the steam temperature evailsble, Casing Distortion: This can be caused by excessive strainem4 Rotary Pumps desired pressure. If this does not correct the condition it may: necessary to replace the pump with one designed for the higher pressure met in the system, REDUCED CaPactry Suction-tine Troubles: Follow the same procedures listed under this hoeading above. Inspect anel check for excessive friction in the suction Pipe caused by too small a suetion pipe, too many fitings in the pipe, ‘logged strainer, excessive suction lift, insufficient submergence of the suction-pipe inlet, too high a lft, and air leaks in the suction pipe, its flanges or serewed connections Aur in Pump Casing: Check for air leaks in the suction pipe and its fitting. Eliminate these by tightening the connections and painting the exterior of the pipe. Examine the shaft packing. Repack with new packing of the grade recommended by the pump manufacturer, Tighten the gland until there is only a slow leak, Be careful not to overtighten the gland because this can lead to rapid wear of the pack. ing and overheating of the shaft, Driver Troubles: See the procedures under this heading above. Excessive Wear: See the procedures under this heading above. Discharge Misdirected: Check the pump for too low a relief setting, open bypass valve, and discharge-line leaks. Reset the reli valve grinding its seat, if necessary. Close the bypass valve, unleat some bypass flow is desired, Check the valve for leaks. A pivce dirt or scale may be lodged under the disk EXCESS! POWER CONSUMPTION Excessive Discharge Pressure: Inspect all valves in the discharg line to see that they are open and permit free flow. Snake out ischarge pipe to remove any obstructions from the line. IF the 's being operated for the first time, compute the discharge head f the actual piping system, using the pipe sizes, lengths, types, number of fittings installed. The discharge head loss should be than the rated head of the pump. If necessary, the power input uired can be prevented from overloading the motor er driver by stalling a larger driver or reducing the speed of thie pump. Shaft Troubles: Check for misalignment, bending of the shaft, ‘excessively tight stuffing-box packing. All these conditions. act Rotary-pump Trouble Shooting * 15 overload the driver, increasing the required power input for a given flow rate and discharge pressure, Correct as discussed earlier. Liquid Too Thick: Rotary pumps are rated to deliver a certain capacity and head when handling a liquid of a specified viscosity. In creasing the viscosity of the liquid raises the power input required to Aliver the same capacity and head. To reduce the viscosity of the Tiquid before it reaches the pump suction, heat the pipe with steam fr eleetrie heaters. Keep the viscosity within the range recommended by the pump manufacturer. Pump Speed Higher Than Rated: Reduce speed to the rated value Internal Wear: Check for casing distortion by disconnecting, the pump suction and discharge piping, It should not be necessary to force the piping or fanges to align with the pump flanges. Measure the clearances between the rotating parts to see that they have not been reduced to too low a value. If the pump casing supports the piping, rearrange the connections so hangers take the load instead. PUMP LOSES ITS SUCTION Suction-line Troubles: Check for the following conditions: air or sas leaks in the suction pipe, air pockets in the pipe, vaporization of liquid in the suction line, and insuficient submergence of the line int. Correct as detailed earlier For complete details of recommended selection methods for rotary pumps, their suction and discharge piping, and drivers, see “Pump Selection and Application,” by Tyler G. Hicks (McGraw-Hill Book Company, Inc., New York, 1957).152 Centrifugal Pumps fends that are scuffed or dented. Rechase damaged threads and renew shaft couplings if they are in poor condition. Bearing Wear. Check metal-bearing wear with micrometers. Make ‘measurements at both ends of the bearing and in two planes, as wear is often bell-mouthed or elliptical. Replace bearings if wear is more than 2 oF 3 mils, ‘Rubber Bearings. Because of the uted surface and their resiliency, rubber bearings cannot be checked with micrometers. A shaft-size plug gage or a test on an undamaged section of the shaft will indicate the amount of wear. Loose Bearings. A whipping shaft hammering rubber bearings may loosen the bond between the rubber and metal backing. Discard bearings in this condition, Silt getting behind the lining may force it against the shaft. Or the lining may come loose from its metal backing and drop out of its holder, and this is serious. Metal Backings. Do not tack-weld metal backings of rubber be {ngs as the welding heat will separate the lining from the backing Press-fit the bearings in their housings or hold them with setscrews. Water Lubrication. Where parts of the rubber lining stick to the shaft journal and the liniog bore is torn, the bearing has run withou lubricating water, Water-lubricated column bearings require a con: tinuous supply of clean water at a pressure high enough to push ft down the column, Grease of Oil. On grease-packed suction-head bearings, run @ sup: ply line from the surface and regularly give the bearings a shot of srease. Once a day is not too often in dirty-water service, as the srease pushes out the abrasive dirt. Give oil-lubricated column bear- ings several drops a minute from the oiler. Turn on the oiler 15 min before starting the pump. Propeller Blades. Bent or damaged propeller blacles or pitted areas fon them cause unbalance and, as a result, rapid journal and beating wear. ‘The kind of wear on the journal above and below the propeller sives a clue to the amount of balance Propeller Balance. If the journals are worn evenly all around, the propeller isin good balance. Ifthe wear is eccentric, but both journals are worn in the same plane, the unbalance is mainly static. If the journals are worn out of round and the wear planes are 90 to 180 deg from each other, the unbalance is dynamic, ‘Wearing Rings. Where the propeller has a wearing ring on its hub, check the clearance between this ring and the stationary casing ring, Replace them when they are worn more than 0,010 in. Overhoul Procedures for Centrifugal Pumps 153 © Throttle Bushing. High-head multistage purmps may have a throttle bushing and bleed-off port above the last impeller. If this bushing replace it to prevent high-pressure water entering the column TF Suction Bell. When the bottom bearings and journals are badly “wor, the propeller-blade edges may contact and groove or seu the suction bell. This type of damage can be corrected by a light eut to restore the original bevel Pitting and Erosion. Cavitation may cause pitting of the suction | bell near the leading edges of the propeller blades. Erosion caused by abrasive action of solids in the pumped liquid is a third type of ‘wear. Figure 6-30b shows a suction bell which has been attack cavitation (deep grooves) and erosion (general scoring) Cast iron being a brite material, is most subject to this type of attack, and stainless steel have high resistance to the effect of cavitation he cause of their better fatigue qualities, Metal Spraying. Pitted arvas in cast-iron bells may be repaired by: smetal spray if cate is taken to ensure proper bonding, Replace suction bells that are badly eroded, Check Propeller. After the pomp is in operation and has been started and stopped several times, check the propeller setting because "# the turning effort of the motor may further tighten the shaft couplings I the propeller sets too high, it can cause turbulence at the blade ends + which will speedup suictiow-bell erasion, Pump Runs Roughly. If after overhauling a vestical pus, the unit is still onigh, purticaarly if this happens off and on, cheek the water suface for vurtes formation. Whe the hottam of the suction nay be pulled int the impeller hates attached ty the pits Dall isnot far enongh under water, Wood rafts on the water's sutfac may break up the whirls where air enters,cuarrer 9 Rotary-pump Maintenance General. There are probably more designs of rotary pumps than any class—reeiprocating or centrifugal. But the maintenanoe of rotary Pumps is usually somewhat simpler than that of reciprocating, oF centrifugal pumps because there are fewer moving parts and they caa This, of course, is a general statement and may. tice. develop less trouble. not hol in every case met in prac of Fic 6. Extemal view of Worthington Corp) ‘These are built ina variety of gear types-herringbone, spur, ind helical” Figure 9-1 shows an external view of «typical herring. bone-gear pump, while Fig. 92 shows a spurgear unit. Note thee Seartype rotary pumps are postive-dsplacement-they. tap. liquid between the gear teeth on the suction side and carry it around tothe slischarge side from where it is forced out into the discharge pipe These pumps are usualy fitted with ball or needle bearings, ‘The pack, ing may be either the standard compression type, or mechanical ceake may be used, Disassembly. The usual internal parts of the pump fs the pump bearings. ‘Tap or slip ‘Types. fot approve a pump for iF its shaft i¢ wor Drocedure required to gain access to the Mh age to an allowable rate noval of the endplate or plates housing the bearings from one or both ends of the shaft, depending on the type of construction used. ‘Slide the shatt from the pump casing, drawing the idler gear with it. Be sure not to ‘damage the gears by scraping or hitting them against the pump casing, Inspection. Examine the gear teth for cracks, serapes, wastage, nel corrosion, “Replace defective gears immediately. If the gens are corroded or eroded, consult the pump manufactures to see if = mor orrosion-resistant material is available for the gears. If 0, use it ber ‘cause there will be fewer emergency failures and the pump will have 1 longer ite. pump. the pump is fitted with a Do not scratch or injure 176 Examine the shaft for wear at the able reduction in the diameter of the shaft at this point, metaliing (Chap. 6) may be needed to re store the original diameter. Do at the stufing bx because the packing must be overtightened to reduce gland leak ‘ur, increases the shaft wear, and the power needed to drive the Replace the packing with new tings of a suitable material. When Gal seal, heck to ‘ee that i has lean smooth faces (Fig. 8a) and tmpacter' that the faces St tightly. If the Power) seal leaks, remove the seal im 4 pial heingbone-geartype pump. (Courten stuffing box. If there is @ measur- operation This, in mechani- late with the foating seat and these faces. Hold the seal faces178 dotary Pumps light and observe if each is flat and mirror smooth. A thumt atch across either face will cause troublesome leakage of the To recondition the seal faces, secure a flat plate or picce of aless, and fine lapping paper. Place the lapping paper on top of Fro. 0 Power) (2) Typical mechanical seal, (3) Lapping a sal face. (Courter at plate (Fig. 9-3b), making sure that no foreign material isu 'R. Pres the seal face lightly but firmly against the upturned abr surface of the lapping paper and describe about five figure eights, Keep the seat fat and avoid rocking. Rotate the seal face 80 dey describe five: more figure eights. Repeat this process until both a Fre, 04. Pump Sted with exteruldrive gears. (Countey of Power.) Rotary pump Maintenance 179 [aces appear polished flat. Carefully reassemble the seal parts, being sure the gasket under the seal plate is tight. Reassembly. Assemble the pump in the reverse order, inserting the packing after the shaft is in place. Figure 9-4 shows how the parts of 2 typical extemalgear pump go together. In pumps having external Iwarings, both ends of the shaft are sealed by packing or seals (Fig 94). INTERNAL-GEAR PUMPS Pups of this type are used for a wide variety of services and are builtin a number of different designs for special services. ‘The main. tenance instructions given here are applicable to many designs and should be helpful i all types of installations, Disassembly. Ifthe pump has a relief valve on the head, the valve nay be removed to lighten the weight of the head, if desired. When the valve is left in place, do not use a chain or eabie around the boxly to support the head during removal Use jackscrews to back the head away from the easing (Fig. 95a) The proper diameter and length of the jackscrews should be obtained from the pump manufacturer. When the head is backed away, remove it fom the easing, On large pumps having a heavy head, ft a clevs to the head (Fig {95b) s0 a hoist can be attached. The clevis may be placed in a hots cm ether side ofthe vertical centerline of the pump. Then, by turning the head slightly in the casing the clevis will be in the center of the head. This causes the head to hang balanced from the clevis.. Whee a hoist is not available for large pun Support the head. This makes it us position when reassembling the pump. In many designs of this type, when the head is being removed the fier stays on the idler pin. This part will fall off the pin ifthe heat i tted downward. Mechanics should keep their feet clear to pros vent injury by the idler, if it fall. Should the idler fall on a Hacd surface, check it carefully for possible damage before returaing it to the pump. File smooth all nicked or rough spots, Head Gaskets. If anew set of gaskets is not available, the original fiskets can be reused, if they were not damaged when the head wes emoved. Immediately after removing the original gaskets from, the ‘head, cover them with ccating of cup grease to prevent them fron drying out and shrinking.180 satary Pumps Clearance, With the lol semoved the cence better rotor and casing, between the idler bearing. and pi idler and th crescent onthe head shouldbe checked "The cetengy hhetween the face ofthe idler and the edge ofthe crescent should alo be This is done with a straightedge and feeler gage. Most checked, head removal. (3b) Clsis hole heavy end, ing Saran. (4) Tern to (nag, leence Te) crescent clearance. () Compusing ier thickness with crescent depth tesy of Viking Pump Co.) ump manufacturers supply tabulations of the recommended ances with the pamp. Where high temperatures or wcosts are met xr ge ances may be recommended by the pump manvfacturer. mended letras are wally avalale inthe form oft By comparing the actual clearances in tle pump with the recom values ti easy fo determine the extent of the wear and replacement of worn parts is necessary. “Figure OS shows where the Tolga Rotortocasing eerance ge clearance Rotary-pump Maintenance 18 rotor and casing fs measured. Distances A plus A, equal the total clearance provided between the rotor and casing, In Fig. 8d the the same is true for the total clearance between the idler pi and boshe tis while Fig. 9.5 shows the fecler gage clearance between the idler utvide diameter and crescent, ‘The methuxl for comparing the theek wwe the idle with the depth of the crescent is shown Ie Fig, 9 Rotor Removal. Unserew the pipe plug frum the draiu bole in the casi: This breaks the vacnuin between the rotor and easing to allow cis removal of the rotor. Loosen the packing nuts on the packing land and slide the gland out of the rotor beating sleeve. This exer’ Remove the lnck put and then drive the rotor forward and out of the easing with a hardwood block or a piece of soft bronze, hammering on the weed ‘bronze at the eoupling end of the pump shaft To remove the pump roller bearings, loosen the adjusting-nut lock screws and disengage the adjusting-nut locks. With a spanner wrersie Feanove the adjusting nuts from the bearing housing. Both roller bear nas can then be removed from the housing for inspection Bearing Cleaning. Wash the grease off the bearings in @ pail of clean gasoline or solvent. Inspect the bearings for damage. If thoy ie in good conaition, store them in a clean container 10 they wit +e ready when the pump is reassembled, Fricking. Remove the thrust-bearing nuts and take the housing off Ske the packing from the rotor bearing sleeve, Check the eondktg of the sleeve bushing in the rotor bearing sleeve. Replace it if ite wor. The bore of the bushing can be measured with « pair of inde Tumometers and checked against the dimensions recommended by the pump builder. (Checking Parts. When the pump is completely disassembled, check all parts, Replace those that are damaged or worn beyond the linek ‘commended by the pump manufacturer. Figure 64 shows how he idler-pin dimension should be measured. If the idler pin is worn Place both it and the idler bushing. ‘The idler pin may be romexc fra the head by fst taking off the idler-pin nut and then diving te pin out of the head. ire at an idler pio, Keep it a nearly straight as possible and tap Zito the head. Use a hardwood block so the face of the pis wil oe Re damaged. Tur the nut up tightly on the pin. ‘The oll groove st fhe Jer pin should be installed facing the center of crecest of an head,182, Rotary Pumps ales Bushing. If this bushing is wor, it may be removed in aa arbor press. When the idler disk is in position, press out the idler bushing and dk from the open end ofthe der. “To isa anew idler ‘oh eg aot igia! er Ni “a “pea teas te) Fic. 94. (a) Idlerpin dimensions (B) tdler in postion. (c) Casing sa (a) Points of gease: aplication. Ge) Of seal belo assent os ak (Courtesy of Viking Panp Co). 4 bushing, press the bushing In position so the end neat to the head flush with the surface of the idler. The idler disk may then be {nthe other end of the idler and pressed securely in position. Be does not extend beyond the face of the idler (Fig. 8.0). Casing, Examine this part. If the dimensions between the and the rotor exceed those recommended by the manufacturer, ceasing may be worn, Check its condition at the seal. This is Rotary-pump Maintenance 383 surface between the suction and discharge ports (Fig. 0-60). If this sutface i n good condition, the easing probably can be used. Repairs. When making major repairs, such as replacement of a sotor, itis usually considered advisable to also install a new head and. filler. When making minor repairs, where only an idler bushing and piv ate requited, other new pars usually are not necessary. When all the needed parts are available, the pump can be reassembled Reassembly. Replace the rotor sleeve on the casing. Use a coating of wonsetting liquid gasket material (ike Permatex) between the ating surfaces of the easing and rotor bearing sleeve. Tighten all the nuts securely. The rotor-bearing-sleeve jacket can now be assembled on the rotor bearing sleeve. Coat the inside radius at each end of the jacket with the liquid gasket material. Bolt the two halves together over the rotor bearing sleeve with a gasket installed between the mating faces of the jacket. Place the thrust-bearing housing oa the end of the rotor bear. ing sleeve and tighten the nuts securely. Tt is not necessary to use a susket between these parts in the pumps illustrated earlier, Before placing the rotor in the casing, carefully check the rotor shaft and remove all burrs and rough surfaces that could damage the ‘bushing in the rotor bearing sleeve. Smear the inside of the rotor. bbearing-sleeve bushing and the rotor shaft with a thin coat of grease or ofl (Fig. 96d). On large pumps it is advisable to support the weight of the rotor with a hoist. A cable sling can be placed around the rotor shaft, or around the teeth of the rotor, to carry the weight of the part while i is being assembled in the cas Place the end of the rotor shaft in the bushing and slowly turn the rotor back and forth while pushing it into the casing. Be sure the packing gland and the inner adjusting nut are placed over the end of the rotor shaft as soon as the shaft protrudes from the stuffing box, ‘These parts cannot be assembled over the end of the rotor’ shaft when the rotor is in position, Be sure the drain plug is still out of the «sing; this pening provides an escape for entrapped ait. ‘The span. ner-wrench holes in the adjusting nut should be on the side next to the packing gland. Force the rotor back into the casing as far as it will go. Insert both the tapered roller bearings in the bearing housing. Note: ‘The bearing should be assembled with the largest end of the inner aces together. “ 1 the same head gaskets are to be used, place the idler on the idler in and assemble the head in position. If new gaskets are to be used, Select them from those recommended by the manufacturer.it wy tun 4h placing the head on the pump, its easier i the heaul i ited away. from the casing slightly until the crescent enters the inside diameter of the rotor, ‘Then rotate the idler on the idler pin watil the idler teeth ae imesh with the rotor teeth. “Baise the heal until the face of the head. 4 i parallel ith the few of the easing, then work it into position, Care. stron be exercised sev the heal shots are not dane! during this News screw the er Bearing adjusting wit ft the Dearing honing er aljistings st position halt collar on the shaft mext a1 thw roller beatin stall the lock washge with ewan in the shalt. Statt the lack unt on the threads Slt oad tighten, Mend at feast ane tang of the Tok § aslwr dawnt the sata the lack at ist earings ose the spanner wrens (yruvided with worl tan thee onter adjusting sms aati the rotor i tight ne Ina anid the rutr slit eannot I turned. With pencil oF take a reference mark on the bearing howsing an the outer nut appeosimately four | is equivalent to 0.005 in. eax! clearance. Tighten the § hs, Ow ; ver adjusting nut, “Cheek the rotor to determine if i tues freely in the casing. HE not, adjust the nut antl the rator des tra ithe, ing nuts securely in position with the ad. easing, Lock both Justing-nut Tocks and the adjusting-int lack sevews i considered good practice to install a new set of packing rather: tho vine the okt packing, New pumps are usally packed with af stos packing, This is considered to be a universal 8 eesti. brat Sanitsrytype Pumps, “These must ten he dsssb and cleaned ‘ery thay: to ensure absolute purity of the food they handle. Many Hlesiuns are built specifically with this reqnirement in mind and have feos sell intricate parts. Disassembly and reassembly are relatively sionple Fiaure 9-7 shows the steps i disassembly of typical internaleg pump ean be lifted fr sant In the design shown here its buse (Fig, 97a) and carried to a suitable place to be washed, is unnecessary to loosen any part before removing the pump. If ferred. the puny can be disassembled on its base by removing four clamp serews (Fig, 9.7b) by hand. Note the grooves on the hea nbling e oy Fic 07, Steps in dsssembly ofan iteral-geartype saitry pump. (Cour casing, and back Hage. “These must be lined up when as pump. ‘ex of Viking Pump Cor) ne aRotary Pumps up the head (Fig. 9-7c). This exposes the inside of the pump. Replace the single-service gasket when reassembling the pump. Lift the easing from the assembly, exposing the rotor and idler (Fig. 97d). Now lift the idler out of the rotor. Frequently the idler will ift out when removing the head, If this happens, remove the head (Fig, 97e). Pull out the rotor and shaft (Fig. 97f).. This isa single part Note the O-ring seal on the shaft. This ean readily be removed, cleaned, and slid back on the shaft into the groove provided. Do not tise too! of any’ kind toda this Pick up the ack fasige and gasket and the pump is wow completely disassembled (Fig. 9-7). Replace the single-service gasket! when reassembling the pump. ‘To reassemble the pomp, start with the clean parts (Fig. 9:7h) and natch the groove on the head, easing, and back flange (Fig. 9-78). Follow the steps given above, but in the reverse order. Be careful when lowering the pump into its base. Turn the pump slightly so the spline on the ene! of the rotor shaft slips freely into the matching spline in the drive assembly, Do not run the motor when inserting the pump. EXTERNAL-SCREW PUMPS ‘Types. Figures 9-8 and 9-9 show two views of a typical external- screw pump used for handling viscous materials that do not have lubricating qualities. The pumping action is obtained by progressive movement of the screws which rotate in an accurately bored eylinder. Definite operating elearances ate maintained between the serews, one of which is left-hand, the other right-hand, To balance the hydraulic thrust, two pairs of screws are used. Each screw is prevented from rubbing against the meshing one by use of herringbone timing gears, ind from touching the body walls by two bearings that hold the shaft in radial position, These bearings and timing gears are outside the pump body and are lubricated by oil baths. Fill the gear housing to the correct level with the recommended grade of lube oil before start ing the pump. Priming. Remove the pipe plug from the discharge side ofthe body. Using a temporary fil ine, pour about 1 gal of oi into the pump while rotating the shaft by hand in the opposite direction from the rotation arrow. This causes the oll to work into the serews to seal them. Tum. the temporary fill pipe downward and aim it into a clean bucket. Start the pump, making sure it turns in the direction of the rotation arrow. When a solid stream of oil flows from the fill line, stop the Rotary-pump Maintenance e148 Sc pau td ith etal separately Inbelated tming ge | Courteay of Ster-Bath Gear & Pump Co, Inc.) * Tig oe Cas Babe ores ew f pup in Fg, 8, (Cote of Sr Bath Gar bump and remove the temporary piping, Replace the pig, The Damp snow ready to goon the ine Operation. Use a gon grade of SAE 40 hbrcating fl forthe tin ing gears.” Replace the ol atleast once every 6 mone, more olen ithe pump operate in ity tn. Check the ol el the "ming eat housing and rear cover before starting the pump. Allow the sting bors to onze small amount of guid while the pump runs. They should lek about one drop every 20 30 see Dismantling the Pump. Close the sucton and discharge valves Disconnect the fesible coupling, and the suction and dacharge anges Dain the pump. Remove the pump fom the badplate nce ofthe land stud nots. Remove the tning gear housing and rear cove. Mark the rear bracket for reassembly ‘Remove th fae bracket; the bearings and of seals wil remain int Next remove the mina lock mate aod lack washers. Mar the tig ger for a108 Rotary Pumps Disconnect the front head bracket, being careful not to damage the lock-nut threads, ‘The bearing and oil seals will remain in the bracket. ‘Withdraw the rotating elements from the eylinder. Remove the bear. ings and theie spacegs from the brackets, ‘Timing-gear Renewal. If new timing: gears are to be installed on the rotating elements, they mast be tinted before key slotting. Spare ears are supplied in matched pairs with one ke key-slotted. The reason for this is that the timing: gear position on the shaft determines the eritical clearance between the pumping screws In the average serew pump the change in clearance between the mesh. ing serews is about 0.001 in fr each 0.004-in. distance in circumference at the pitch diameter of the timing gear. Since the normal axial ance of meshing serews varies with the size of pump andl the viscosity of the fluid that the pump was designed for, accurate key slotting is essential for proper operation. ‘The original screw clearances are stamped on the pump body at the bracket flange. This number repre. sents total clearance. One half of it is the proper axial distance be. thween the meshing serew threads ‘ake the old timing gears ofthe shafts and push the new gears half- way onto their shaft diameter. Put the key in the slotted gear. Inter. mesh the rotating elements. Adjust the free timing gear until the de. sired screw clearance is obtained. Drive the timing gears all the way hhome. Check the clearances. If satisfactory, replace the rotating ele ment in the body and reassemble the pump without the stuffing-box packing. The pump should now turn freely by hand. If not, cheek and repeat the foregoing until proper results are obtained. | When satisfactory, disassemble the pump. Check the serew clearances as before, If correct, mark the timing gear from the key slot in the shaft. Cut the Key slot in the gear with the greatest precision possible. Re- place the gear with the key in place Check the serew clearances as before. 1f satisfactory, assemble the puinp and check for free rotation, If the key slot cut does not give the proper clearances, eut another key slot to get proper results, Timming screw pumps is a tricky job. Unless st fs done accurately, there i litle point in doing it. However, periodic checks of the pump and replacement of timing gears as they wear are the best means of obtaining long service. Experience has shown that pump life is ex: tended three or mote times by careful timing-gear maintenance. If the timing gears are damaged suddenly (by foreign matter in the Buid © being pumped) itis possible to effect temporary repairs by turning the 4 Bears on the shaft so the undamaged faces will be used. tenance - 189, Rotary-pump Me Sear Lubrication, The timing-gear housing on these units has been lesizned (or standard operating conditions of speed and horsepower. niter these conditions, sf the off reservoir is Blled to the level indi jatedton the avinvlow, ample lubrication will be provided forthe timing cers ant tke hone Bearings contained in the hosing Towever, if the application requis a spec considerably different tHe design speed, the Iniller recommends the following procedure Sn starting the units CL) Henvoxr the two it. pipe plugs over the Tesriygs andl the Al plug on the top center of the housing With the pump rsnning at vated speed, add SAE 40 oil theongh tive fll hole until oil is transmitted to the oil holes provided in the Inner buarings. (3) Replace the pipe plugs. (4) Repeat this pro: cure peically to ensure proper lubsication and extended pump i Spare Parts, For normal sage, the only spares necessary are bear. The primp visually wears af a slow unilorm rate unless abrasive ‘ls are handled. A. periadic ebeck of pressure vs, capacity will \ the operator the condition of the pump, For those istallations where lengthy shutdowns cannot be tolerated, «is eocommended that a complete rotating element be purchased for Th linetype pumps a liner should be kept on hand in addition to the rotating element for fast rebuilding in the Bek. When ordering Spore part, state the pump size and seval number and wse the part numbers specified by the builder ‘Pump Reassembly. Insert the rotating elements into the pump frm the tear end. Replace the front and rear brackets, esing the taper dowel pins to secre the proper ligament, natal the front bearing spacers the front brarings the timing ear spacers and gears on the ‘hates Lock them wp sith the lock washers and foc nots. Replace the rearend all beatings and lock them in position withthe Tock svashers and lock nits Check the rotating clements for ease of rotation, If necessary, ad just the bracket alignment sintil the pomp tums trey. Replace the fear cover, Poston it with the dowel pins. “This locks the shaft eval. Check for ease of rotation. Tighten the gland stud nats in accordance with the general instructions given earlier. Replace the tining gear housing. Rell the housing and the rear cover with SAE 40 lube ol, Prime the pump and it seedy for service. Check the unit frequently for 48 hr after i put int service following sa-everbeol or dasaINTERNAL, REW PUMPS Prey Fleurs 910 shows ane popular type of intemal screw pump. tre Sul uit for punping viscous hgh having abviesting po i that the Haig gears ate contained in the same casing ag the: pumping sevews, [Soci of Sergstoal sew of «stew pam fied wih tel timing gear (Courtey of Sie Bath Gear © Pus Gor Ditasrembly, Close the suction and discharge valves, Disconnect the flexible coupling and suction and discharge flanges. ‘Deve ae renee nama the pump trom the hedplate and, ater disconnecting ey ea ne. remove the packing gland, front head rea head eae we Ming Wek nuts and lock washers. Withdraw the rotating clement, 1f connplete dismantling of the pump i desire, renee oe fea ira The bearings may be inspected without removing then from the head, Timing-gear Renewal for external-serew pumps cal to those described earl Dismantling the Rotary Eley ings, the bearing inner races, washers from the shaft the shafts, Follow the general instructions given abovel ‘The procedures and clearances are identi Rotary pump Malntenance 191 positions. Do not remove the pumping screws. They are pinned to the shafts Reasembling the Rotating Element. Replace the timing gears tn {heir marked positions on the shafts, Lock the gears in place, using lock washers and lock nuts. Replace the front-head bearing, inves sane sn tock in place with snap rings Pump Reassembly. Iotermesh the rotating elements, Insert the sats in the rear-head assembly. Slide the rotating element with the tvar head into the pump body. Replace the front head with the ewe ioas in place, using tapered dowel pins to ensure proper Insert the rear-head body dowel pins. Replace the'loek wat Jock nuts on the rear-head bearings tom freely. Heplce the rearchead cap, lube-l line, and pump coupling bub Hemount the pump on the bedplate and reconnect the suction el . (b) Endplte removal. (Cour Fee 9:19, (4) Flow in a camand-piston pe Js) ri gl Ot ry eto lasy of Kinney Manufocturing Diotaon, Th— Ry Pumps 4 When replacing the ball bearings, a similar Procedure is followed, Use care that the bearing does not cock while ft ie being pressed on, Make sure the bearing is seated against the shoulder on the shaft 30 it is square with the FLEXIBLE-ROTOR PUMPS Tepes. Figure 9-184 and b shows two designs fitted with neoprene impellers.” In pumps of this type the impeller blades are compressed hy an offset plate at the top of the casing, producing a vacuum that Mes the suetion effect at the pump inlet, ‘ aintenance. The only wearing element in pumps of this design isthe impeller. ‘To replace it the endplate is removed irom ths casing ial the tnpeller is slipped from the shaft. “The shaft is elthe: slotted (Piss 9-18a) or ited with a key (Fig. 9-18). Be carefulto caent new Sasket for the plate, if the old one is worn CAM-AND-PISTON PUMPS Types. Figure 9-19a shows a typical. cam-and-piston pump and the itection of flow through it. ‘The working details of kant ot this design are shown in Fig. 9-19. Maintenance. To get at the internal parts of the Pump, remove the - endplates (Fig, 9.19). ‘These can be slid off the shaft ends nfs re. inoving the nuts holding the plates in position, Where the interna] rear is extensive, replacement of the cam, piston, and liner (if used) §s generally necessary. These parts are easily slid out of the pump casing, PART THREE Reciprocating Pumps224 io this regard, Lower the pump damage the standing valve, Operation. Choose stroke within the recommended range and Jus the number of strokes per ininute to give the desited pumping Mex He sure the pumping speed is within the allowable limits for the unit. Use of a tong stroke combined with a slow recommended becanse 1 Reciprocatiig, Pumps to the well slowly s0 it does not pimping speeds ‘ficiency is usually better and there is less Operate the pump at reduced speed for the first few thousand > Meokes if i is @ new oF reconditioned wit own, stop a stationary-barrel unit w A traveling-bar lovnstroke, operative. If the pump must bp shut h the plunger on the upstroke. srel pump is best stopped at the lowest point of Hs Ws prevents sand from settling in the wait while itis aren LL Trouble Shooting Reciprocating Pumps STEAM PUMPS General. Steam pumps are noted for their long operating periods with litle more than routine lubrication and inspection. But like all other pumps, these units can and do develop troubles, Typical com: ‘mon troubles include failure to discharge. low discharge pressure, shot. stroking, speed too high, long.stroking. vibration, stalling, discharge- pressure fluctuation, and excessive stilfing-box leaks, These troubles are analyzed below’ in the same manner as in Chaps. 4 and 6 ISCHARCE PUMP DOES NOT Suetion Lift Too High: At sea level steam pump handling cold water should not havea sutin hit greater than 22 ft Check the lit hy comnecting a vacuum gage at the pump suction inlet. Ifthe lit exceeds 22 f either lower the pump x01 closer to the water level or raise the water level 30 i scone to the pump. Pump Not Primed. rime the pump by filig the suction line above the foot valve with cold liquid, Ope aby vents on the pump ais chnege side and leave them open until the Pump and piping are free ofa, Suction Air-bound: Check for lsks in the sition pipe by sealing cach end with blind flanges and putting the pibe under pressure of 5to 10 pi ofthe liquid handled. Seal all leaks snd joints Prime the pump and test i, after removing the blind flanges. Be sure to use 1 bcharge check valve whenever possible. This eliminates the need of the pump's compressing air to the discharge pressure because the check valve will usually open af a lower pressure. ‘Suction Line Vapor-bound: Check the suction head when handling hot liquids, For water at 212 Fa stati nuction head of at least 15 ft ‘235,= Reciprocating Pumps 's needed, When changing a pump over from a hot to a cold coo! the liquid end hefore operating it on a suction lift Use a hose ot allow the pump to cool in the aie, * Obstructions in Suction Line; Check the suction pipe and strainer a ver tha they ave free of rst, debris, and other obtructions Ce Heros: Exanine the fot valve to ae that it opens wide, rat « threaded type, be sure that the suetion pipe i not stewed tee Ghck the pump suetion valves. ‘They should watt easily without jamming \orn Parts Worn suction valves, ptonrod packing, of piston Packing ean cause a pump to lose sition, Examine the primp seat ‘alves and seats and piston and rod packing. Rephace valves, sete Or packing, as necessary Ty badly worn liquid evinders image | Tuo Much Steam Cushion 16 the pump has eshion vals, aja hen uni the rated stroke fe oblaned, "When Poy setae continously and tis not ted with eushion vaNey It ny be na sy to dil or cut release les between the steam tad akan Wrong Labrcont: Check to sce that the steams nde as ac vate nupey of the cae gene of bang a Stam Vale Leaks: Stearn leaking past the valve prevents the trom completing it stroke, once pases the exhaon rent Re the old valve ana ext and replace with new hart ocking Too Tight: Check for «sal amount of leakage around seat the steam and lige elinders Tf there ona lakes tee ing ton tight. Loosen the gland. the puny stl sore cies the liquid: piton packing. It may have abated nee Git 2 Ai Lut Duple punpsshorttoke exces w theres too much gas a air othe hid pumped. Coney ‘he suction hokop to prevent the entane ofa, met Incorecty Set Vales: Check the pun instructions t see tit valves ate set correctly. See Chap. 12. Be sure thee coouee snotion to ive the desired stoke length Set the adjsog a necestry, "Nat thickness can be reduced to ntease tee in’ pomp, i necessary necessary to rebore the liners anxl replace the old pistons, PUMP SHORT-STROKES Trouble Shooting Reciprocating Pumps * sor Shoulders in Steam Cylinder: Rebore the cylinder and Bt oversize rings and piston. Adjust the stroke to its full length to prevent more wear of the eylinder bore. When the bore wear is not excessive i i uamiccessary to replace the piston and rings with oversize ones. PISTON HITS HEAD Excessive Lost Motion: The stroke is tow long when the piston strikes the evlindler head. Reduce the lost motion to give the rated stroke wth the cushion valves almost shut. Excessive lost motion in duplex pomps prevents overlapping of the pistons, leading to slugaishness, © Cushion Valees Need Adjustment: Close the cushion valves enough ty prevent the piston from striking the eylinder head at the rated spees! of the pump. If the pump is to operate for extended periods at low syed, adjust the cushion valves to prevent shortstroking, Be sure to ‘suljust the valves before increasing the pamp speed to its rated valuc For best results, adjust eushion valves while the pump runs. Piston Rings Worn: IF the rings on the steam piston are badly worn they will not hold the cushion. “Replace worn rings; rebore the lines, if necessary. Leaky Liquid Valves: This can lead to long-stroking. Replace worn valves with new ones LOW DISCHARGE PRESSURE Steam Pressure Low: Check for throttling action in the steain line ahead of the steam cylinder. Throttling may be caused by a partially closed valve, obstruction in the pipe, or a leak. Repair, Packing Tight: Loosen steam- and liguid-end packing until there is 4 small amount of leakage at both points. Back Pressure High: Check against the rated back pressure for the pump. See if any valves are partially closed in the exhaust line. Valves or Rings Worn: Inspect the steam piston rings and valves for Replace with new or repaired parts DISCHARGE PRESSURE FLUCTUATES Speed Higher Than Rated: Slow the pump to its rated speed. Be "certain there is enough suction head to fl the liquid cylinder. Re- charge the cushion chambers if their air supply is low. With a viscous liquid, heat it to provide easier fow into the pump.228 Reciprocating Pumps Tight Packing: This leads to variation in the discharge pressure, well as vibration and noisy operation at low speeel, Lansen the gland a the steam and liquid eylinders wutil there iva slight feakage from Hoe lands on the steam avd liquid cxlinders. At regolar intervals, Fheck the Tiquid-piston packing for swelling, Pony Not Primes Sow this steam shove Pump Not Mbgueds tet the wlation bolts, flexible / Inseker or shidingholt support tw see Hat ashi not case mis, Dump tesnperatiree rises to the operating level wot pata strain on the staan of liguidl evtiners, distorting, thee primp. See Chap. 12 for details of Foundation bolts and supyposts for stearn pumps Suction Lift Too High of Suction Aie-bound: See iw sehen Check the piping to sew that i hese items, abovel POMP STOPS Valve 7 n valves can cause a steam: pump to stop, rmeudesl by the manufactuser, Leakage of the steam valve may eause uplex pump to hesitate or stop as it passes mid-stroke, A simplex pump may stall at the end of its stroke when its steam valve leaks. ubles Incorrectly set or worn ste Alsways set the st 1m valves in the manner recom: PUMP RUNS TOO FAST Suction-line Troubles: Air leaks in the suction, too much gas o aie in the liquid handled, excessive suction lift obstruction in the suction pipe, or insufficient submergence of the suction bell or strainer can lead to overspeeding. Check for air leaks with a lighted candle when there is no danger of igniting fumes or liquid. Or test the Kine hydrostaically bby Manking it off and putting it under pressure. See that there are’ ho high points in the line. ‘Slope the line doven fromm the pump to the suction wel. 7 When there is too much gas or air in the liquid pumped it will separate Yrors the liquid at points where a vacuum exists. One mans ufacturer suggests using a tank in the suction line near the pumps Fit the tank with a float-actuated vacuum pump to remove gis alr leaving the liquid ‘Check for an excessive suction lift or obstruction in the liquid by connecting a vacuum gage near the pump. The suction lift not be more than 22 ft for pumps handling cold water. Clean logged ‘plies and stzainers befar altgmpling to. operate the Trouble Shooting Reciprocating Pumps 229 \When the suction line does not have sufficient submergence, vortoxes are formed around the pipe, allowing air to be drawn into the pump, Tower the bottom of the pipe further into the liquid or deepen the sition sump oF tank, Vortexes can be temporarily prevented by Boat ive planks of wood around the intake pipe. Tiquid-piston Packing. Worn: Open the liquid eylinder and inspect HC the liner i baelly worn, rebore or replace the piston packing rings it Fita new piston and packing the piston may be the ouly work reuited check the valves for wear or ebsteictions Where the wear is minor, epachins, While the liquid evul ts oper, Replace worn valves. Re obstructions present EXCESSIVE PACKING WEAK Piston-rod Defects: Worn or bent piston rods can cause uneven wear of the packing, leading to early replacement. Check for burrs on the rox, too, Replace badly damaged rods with new or repaired ones, Alo check for misalignment of the pump. Rod Lifts A shoulder in the steam ot liquid eylinder can cause the rod to lift at the end of its stroke, wearing the packing away and per mitting blowby. Adjust the stroke so the piston rides over the cylinder counterbore. POWER ruMrs Some of the troubles met with power pumps have the same general couises as in steam pumps. “Typical troubles, and their cures, are listed below in the same manner as for steam pumps. POWER INPUT EXCESSIVE High Discharge Pressure: Inspect the piping system for a closed salve increase inthe relie-vave setting, of an obstruction inthe pip- ing. Where the piping layout has been altered, or newly installed, Calculate the friction loss in the pipe and Stings. This should not ‘exceed the rated maximum head of the pomp. In extreme cases, it is posible to reduce the diameter ofthe liguid pistons to prevent over- loading the pump driver. But tis much simpler to reduce the speed of the pump until the power igput equals o is less than the rated cutput of the driver. Also check for a high-viscosity liquid exusing caxcessive friction in the discharge pipe. The effect of viscosity can tbe overcome by heating the quid to make it more Suid, increasing230 Heci, ating Pumps the pipe sizo, or reducing the speed of the pump drive. Lastly, & for packing that is too tight, producing an extra friction load ‘on Pump plungers. Remove old packing and replace it with new ting of the correct grade and size. he careful not to overpack; allow ‘oom for swelling ofthe packing during operation of the pump, PUMP DOES NOT DISCHARGE See the sane bea Many of the cases nt uler Steam Pumps, earlier in this chapter, ven there apply exqually well to power pumpal PIPING VinnavEs Undersize Discharge Pipe: Use a larger size of discharge line, fit Possible to change the piping. If this cannot be done, install an ‘chamber in the discharge line, close to the pump. ‘This will reduee the} Pressure surges in the pipe. "When two or more power pumps die] charge into # single manifold located a distance away, connect equal ing lines between the pump discharge pipes. Shortening an unde size or correctly sized discharge line will also help reduce exceas vibration, Undersize Suction Pipe: Install a suction air chamber close to Pump suction inlet to reduce the pressure-surge pulsations d pump operation. Increase the size of the suction pipe, or reduce I length. If the liquid is flashing in the suction line, install a booster Pump to increase the liquid pressure above the vapor pressure, "This unit should preferably be a centrifugal pump. Or the height of t Hiquid level can be raised to give the desired pressure incresse POWER END IS Noisy Crosshead or Guides Worn or Loose: Badly worn guides must b bored out and new oversize crossheads fitted to the pump. In gem do not undertake a job lke this, until iis approved by the pump m ufacturer. On crossheads with adjustable shoes, shim the shoe or locate it to give the original clearance specified by the builder Speed Too High: Lower the pump speed to the recommended Crosshead or Crankpin Loose: Remove old worn pins and with new or rebuilt ones. “Adjust the bearings to suit the new Bearings Worn or Loose: Check the connecting-rod bolts, ua torque wrench. Replace worn bearings; tighten loose ones, Trouble Shooting Reciprocating Pumps on Gears Faulty: Check the gear backlash and alignment. Ifthe lash is wrong. adjust it to the recommended limits, If the gears are badly ‘wor, they may require replacement. Align new and old gears to give ven tooth bearing LIQUID EXD 18 NOISY Excessive Suction Lift The higher speeds adopted for power pumps 1 recent years have made a lower suction lift desirable. In somne esigas a Suetion head is required to force the liquid into the pump cylinder. Check with the pump manufacturer for his recommendations on the use of a suction lift or a fooded suction or suction bead. tn genera, a suction lit of 22 ft as allowed for other types of reciprocat {ng pumps, is unsuitable for power pumps. Gas or Air in Liquid: Inspect the suction piping for leaks at joints, around valve stems, and at other points where air can enter. the system, Where gas or air leaves the liquid at the reduced pressure existing in the suction pipe, and the liquid end is noisy or vibrates excessively, Bt a separating chamber close to the pump suction con rection. Equip the chamber with an automatic gas or air vent to re ‘move any vapor formed, Valve Troubles: Weak or broken springs lead to pounding of valves. Renew worn springs. Springs having greater tension may. prevent valve chatter, but check to see that there is enough suction bead to ‘open the valves against them before using heavier springs. Valve chatter and other noises can usually be reduced somewhat by operating the pump at a lower speed. When the liquid end does not fll during the suetion stroke the pump may be turning at too high a speed or the svetion-valve spring may exert too much force. Reduce the pump speed or spring tension, or both, to correct this condition. Check pomp alignment. ‘The unit should be level and adequately supported. Pump Speed Too High: With thick viscous liquids, reduce the pump speed to a value which will permit adequate time for fow into the colinder. Heating the liquid to reduce its viscosity and reducing the ‘alve-spring tension will also help improve flow into the pump, METERING PUMPS Metering and proportioning pumps often develop troubles re- sembling those given for steam and power pumps. But radial-piston snd sucker-rod pumps develop troubles different from both steams andeae Reciprocating Pumpe power pumps. They are considered separately below, while m Pumps are considered here. Suction Many metering pam ana suction lit no’ gecater than 10-f. builders suggest a minima value of 15 Ff the Hiquid pumped, Sings many metering pups handle cheinicals, there i a possibility of ay cheanieal reaction occurring between the liquid and the anaterial of Which the piping is made. -Esidence of such a reaction is the formation ‘ts in the suetion, Check to see that the pipe material is stiiciently& ae ae resistant to prevent a reaction of this type. Replace the pipe, if ne sary. Allow aerated liquids to stand before feeding them into pump suction, Packing. Excessive tightening of the phinger packing ean seriou ovetload the drive of a metering pump because the motors used generally of relatively small rating, Keep the packing adjusted at tuimes to prevent this condition. On pumps equipped with a lant Ning for water-washing or lubricating the plunger, check to sce tl the ring is adjacent to the holes supplying the cooling water. Ei inspect the ring visually or use a wire probe to determine its posii From time to time it may be necessary to add a packing ring: beh the lantern ring to maintain the lantern position as the packing. and the gland is tightened, Piping, Blow out all piping connected to a metering, pamp starting it for the fist time. Do not start these small pumps with valve closed in the discharge line. Some proportioning pumps can checked by connecting a compound pressure gage to the liquid ey der. With the pump operating, the gage needle should show a sl ‘scum during the suetion stroke and rated discharge pressure du the discharge stroke, Excessive vacuum or discharge pressure indicate that the suetion or discharge line has obstructions in it ‘Trouble shooting of diaphragm-type pumps is simple. If aw Stops with the plunger in the extreme discharge position, and gas airis being discharged from the safety valve, or there is a constant charge of air or gas when the safety-valve lift ring is pulled, the pragin of the master valve has burst. "When the pump will not forward and there is a constant discharge of air or gas from the oil chamber, then the main diaphragm has burst When the pump operates but does not discharge liquid, blecder Valve to break a possible air lock Check whether the feed shutoff assembly is in the out position and also check the and seats for leaks, Trouble Shooting Rectprocting, Pumps 235 sgertype pumps discharge on both the forward and return sirokes. Ifthe pump stops in the extreme discharge position and there isa constant discharge of air or gas from the exhaust outlet in the taster valve, check the tripper device, the lower valve seat, and the pump diaphragm. If the pump operates intermittently or stops com pletely, remove the pilot valve and check the fipper-arm hearing. valve Tsk, and valve drive pin. When the pump operates but does not dis charge liquid, check us above. Also cheek the suction-end eap and the ‘ir piston for worn or broken rings. Other Troubles. See the various troubles listed under Steam Pusmps aul uiuler Power Pumps. Many of these apply to metering and pro. portioning pumps of the reciprocating-piston and plunger types. AXIAL: AND RADIAL-PISTON PUMPS ‘There are three major indications of troubles in units having axial ‘or radial pistons. ‘These are (1) reduced capacity, (2) reduced pres: sure, and (3) excessive noise. “All are traceable to excessive wear, if the liquid handled is clean and free of large solids. Where the liquid ‘5 Kept clean and free of abrasive matter and other solids, wear in these pumps is relatively slow. These pumps operate for long periods with relatively tte attention other than routine inspection, lubrication, and cleaning. Wear usually occurs frst in the piston or eylinders, or both. It in- creases the running clearances, permitting more and more liquid to escape from the discharge to the suction side of the pump. As the wear gets worse, pump operation may become noisier. So check the pump capacity, discharge pressure, and noise level to find if any troubles have developed. REDUCED CAPACITY OR PRESSURE Clogged or Leaking Suction: Snake out the pipe, IF the capacity is tll low, test the suction pipe for leaks as described earlier. Plug all sir and liquid leaks before operating pump. Liquid Level Too Low: Check to see that the suction strainer is be- Jow the lowest liquid level in the oll reservoir, Replenish the system when any oil is lost. Oil Too Thick: Check the oil viscosity at the pumping temperature to be sure itis in the range recommended by the manufacturer. This 1 usually somewhere between 100 and 500 SSU, depending on the