CENTRIFUGAL PUMP:

MAINTENANCE & TROUBLESHOOTING

Qchem Qatar

1|Page
 PART 1 CENTRIFUGAL PUMP INTRODUCTION
Basic Function of Pumps
Centrifugal Pump Basic Theory
Centrifugal Pump Operation
Classification of Pumps
Pump application
Centrifugal pump components
Casing
Volute
Inlet flange and inlet
Packing
Mechanical seals
Pump Bearings
Shaft
Impellers
Effect of Entrained Solids
Diffuser blades
Pump cut-water
Wear rings
Pump Components Material
Pump Installation Arrangements
Pump Intake Structures
Priming Devices
Arrangement of Measurement Points
Shaft Couplings
Pump Nozzle Loading

2|Page
 PART2 CENTRIFUGAL PUMPANALYSIS

Introduction to Pump Analysis

Pumping Concepts
Capacity
Head
Static Suction Head (SSH)
Static Discharge Head (SDH)
Total Static Head (TSH)
Friction head
Velocity head
Minor head loss
Pump Efficiency and Power Input
Pump Head-Capacity Curve
Pump Operating Range
Characteristic Relationships ForCentrifugal Pumps
Example

3|Page
 Part3 Pumps cavitation &NPSH

Vapor Pressure

Pump Head Needed

NPSH

Available head

Example

Cavitation

Reasons and disadvantages

The cavities form for five basic reasons

I. Vapourization

II. Air ingestion

III. Internal recirculation

IV. Flow turbulence

V. The Vane Passing Syndrome

4|Page
 Part 4 Pump losses
1. Loss types

2. Mechanical losses

3. Hydraulic losses

4. Loss distribution as function of specific speed

5. Summary

5|Page
 Part 5 Centrifugal pump Hydraulic Balance

Axial thrust of a Centrifugal pump

Single stage pumps

Double suction impeller

Multistage pumps

Balancing Devices.

Balancing drum

Balancing Disks

Combination of Balancing drum and Balancing disc

6|Page
Part 6 Bearing , Lubrication and seals

Bearings and shaft

Principles of Lubrication
Friction
Bearing Materials
Bearing type
Lubrication System
Anti-frictional bearing
Types of Wear
1. Adhesive Wear
2. Abrasive Wear
a) Ploughing
b) Cutting.
c) Cracking (brittle fracture).
3. Surface Fatigue
4. Erosive Wear
5. Corrosive Wear
Pump reliability
Components of an rcm program
Introduction to reliability-centered maintenance
RCM and failure analysis
Failure descriptors
Failure descriptors
Failure causes
Method of detection
Maintenance activity
Functions
Failure- Failure mode Failureeffects - Failure consequences
Maintenanceaction
RCM information worksheet
Failure examples
Pump
Seal bearings
Root cause failure
Balance- Coupling Failure- Alignment
Seals types
seals components

7|Page
 Part 8 Predictive Monitoring Techniques
Condition Monitoring Technologies
• Vibration Analysis
• General Analysis Method
• IR Thermography
• Ultrasonic Leak Detection
• Oil and Wear Particle Analysis
• Motor Circuit
• Surface Flaw Detection
• Liquid Penetration
• Magnetic Particle
• Sub-Surface Flaw Detection
• Ultrasonic Thickness
• Eddy Current
• Radiography
• Fluoroscopy
• Endscope (Borescope) inspection

8|Page
Part 9 Life cycle cost

Life cycle cost

Key components

• Initial capital cost

• Operating/energy costs

• Replacement/wear part costs

• Maintenance and repair costs

• Disposal costs

LLC centrifugal pump features

Mechanical design

Hydraulic design

Efficiency degradation

Packaging the pump set

9|Page
 Part 10 Pump problems and repair
Three type of problem

Principles of Installation of Pumps and Drivers’

A good pre-installation program

Operational check

Pump Preventive Maintenance

Monthly

Annually

Pump Repair

Field Checks during Removal

Diagnosing Pump

Excessive shaft axial end play

Bent shaft

Shaft radial movement

Stuffing box squareness

Detailed Inspection Procedures

Inspection of Parts

10 | P a g e