FACULTY OF CHEMICAL AND PROCESS ENGINEERING

TECHNOLOGY

Module 01:
Maintenance & Troubleshooting of Centrifugal
Pump
BVF 2214
Pump Operation and Maintenance Supervision

Lab Objectives

By the end of this lab, students should be able to:

1. Perform dismantle the component, inspection and troubleshooting of

Centrifugal Pump
2. Perform reassemble of the component.

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MODULE 01: MAINTENANCE & TROUBLESHOOTING OF CENTRIFUGAL PUMP

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1.0 INTRODUCTION

1.1 Centrifugal Pump

Pumps and turbines occur in a wide variety of configurations. In general

pumps add energy to the fluid - they do work on the fluid; turbines extract energy
from the fluid - the fluid does work on them. Turbo pumps are used to raise the level
of potential energy of the fluid and widely used in hydro and thermal power plants,
chemical industries, buildings and deep wells. They have relatively few moving parts
and reasonable efficiency.
One of the most common radial flow turbo machines is centrifugal pump. This
type of pump has two main components. An impeller attached to the rotating shaft,
and a stationery casing, housing, or volute enclosing the impeller. The impeller
consists of a number of blades (usually curved) also sometimes called vanes,
arranged in a regular pattern around the shall. A sketch of centrifugal pump is shown
in Figure 1.1

Figure 1.1: Diagram of basic elements of a centrifugal pump

As the impeller rotates the fluid is sucked in through the eye of the impeller
and flows radially outward. Energy is added to the rotating blades and both pressure
and absolute velocity are increased as the fluid flows from the eye to the periphery of
the vanes. The fluid then discharges directly into a volute chamber. The volute is
designed to reduce velocity and increase pressure.
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The volute casing with an increase in area in the direction of the fluid, is used
to produce essentially a uniform velocity distribution as fluid moves around the
casing into discharge opening. Impellers are of two types - open impeller and
enclosed or shrouded impeller. An open impeller is shown in Fig. where blades are
arranged on a hub or backing plate and are open on the other (casing or shroud)
side. Shrouded impeller is shown in Fig. where blades are covered on both hub and
shroud ends. A shrouded impeller will have no peripheral leakage.

Pump impellers can be single or double suction. For the single suction
impeller, the fluid enters through the eye from one side of impeller, whereas in
double suction impeller the fluid enters from both sides of the impeller. The double
suction type reduces end thrust on the shaft.

Pumps can be single stage or multi-stage. For a single stage pump, only one
impeller is mounted on the shaft, whereas for multi-stage pump, several impellers
are mounted on the same shaft. The stages are arranged in series, i.e., discharge
from one stage enters flows into eye of second impeller, and so on. The flow rate is
same from each stage but the pressure rises in each stage and therefore at the end
of last stage a very large pressure or head can be developed by multistage.

Industry Codes and Standards

 ANSI/API 610-1995 - Centrifugal Pumps for General Refinery Service - Covers

the minimum requirements for centrifugal pumps, including pumps running in
reverse as hydraulic power recovery turbines, for use in petroleum, heavy duty
chemicals, and gas industry services. The pump types covered by this standard
can be broadly classified as overhung, between bearings, and vertically
suspended.
 DIN EN ISO 5199 - Technical specifications for centrifugal pumps
 ASME B73.1-2001 - Specification for Horizontal End Suction Centrifugal Pumps
for Chemical Process - This standard covers centrifugal pumps of horizontal, end
suction single stage, centerline discharge design. This Standard includes
dimensional interchangeability requirements and certain design features to
facilitate installation and maintenance. It is the intent of this Standard that pumps
of the same standard dimension designation from all sources of supply shall be
interchangeable with respect to mounting dimensions, size and location of
suction and discharge nozzles, input shafts, baseplates, and foundation bolt
holes
 ASME B73.2-2003 - Specifications for Vertical In-Line Centrifugal Pumps for
Chemical Process
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 BS 5257:1975 - Specification for horizontal end-suction centrifugal pumps (16

bar) - Principal dimensions and nominal duty point. Dimensions for seal cavities
and base plate installations.

Figure 1.2 Centrifugal Booster Pump

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Figure 1.3: Detail Diagram Centrifugal Booster Pump

Table :1.1 : Centrifugal Booster Pump Part List Name

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2.0 JOB DISCRIPTION

2.1 Equipment
Centrifugal Booster Pump ( Brand :EBARA Model: AM6-PC )

2.2 Material and Tools

1. Spanner size (related size)
2. Mallet (soft Hammer)
3. Lifter

2.3 Procedures
2.3.1 Dismantling components of the pump:
1. Disconnect the electrical wires entering the electric motor cover
2. Dismantle the Pressure Control (PC) and Valve (see figure 2.1 and 2.2)

3. Remove the Fan Cover (15) with use hammer mallet

4. Remove the Fan (14) with pull the washer slowly with screwdriver

5. Remove the 4pcs Tie Rod Screws (22)

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6. Extract the Motor Frame (12) and Adjusting Ring (21)

7. Remove the 4pcs Tie Rod Screws (51)

8. Extract the Casing (1)
9. Use rubber mallet and screwdriver to extract External Pump Casing (37)

10. Unscrew the Mechanical Seal Kit (11K) and Washer (91)
11. Extract;
1st level: Stage Housing (62), Impeller (7) Diffuser (9),
2nd level: Stage Housing (62), Impeller (7), Diffuser (9),
3rd level: Casing (68), Impeller (7) and Mechanical Seal Kit (11K)

12. Finally figure inside Motor Bracket (3) after extract 1st level, 2nd level and 3rd
level
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2.3.2 Inspection and repairing

 Condition of the sleeve to be checked.

 Check the place where mechanical seal is fixed, to find out grooves and
markings.
 Impeller, key, shaft, and top cover are kept clean to check the impeller for
corrosion, pitting, cavitation, and wear.

 Checking of impeller blade are to be done for narrowing.

 For key check the crack and key way.

 Clearances of sleeve and shaft, impeller and shaft, wear ring, stuffing box
throat bushing and shaft.

(sleeve and shaft - 0.03 to 0.04mm, impeller and shaft - metal to metal fit
to 0.13mm).
 If all are ok, start assembling of pump.

2.3.3 Reassembling Components of the pump:

1. Assembling to be done in reverse order of dismantling.

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3.0 Data Collection:

Table 3.1
APPLICATION

1. For all horizontal centrifugal pumps on A/B trains and utilities.

SCHEDULING

1. 12 monthly (Annual)
PURPOSE

1. To ensure that the Pump is serviced as per manufacturers data.

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PLANNING & PREPARATION

ISOLATIONS REQUIRED

1. Electrical isolation on pump drive motor.

2. Mechanical isolation (if strainer fitted).

SAFE SYSTEM OF WORK

1. Complete EIC and notify Day shift Supervisor.

2. Complete JHA & TBT
3. Obtain a permit to work.
4. Apply LOTO at Local isolation point.

PPE REQUIREMENTS
1. Correct gloves for task
2. Safety glasses
3. Coveralls
4. Safety boots
5. Safety helmet

Finding/
No Task to be performed
remarks

1. General visual inspection of pump and surroundings

2. Ensure all securing bolts are present and tight.

3. Check constant level oiler is working.

4. Drain oil and refill bearings brackets with clean oil.

5. Clean oil sight glass if applicable.
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6. Remove /check and prove clear seal flush lines

Inspect shaft seal for damage/leaks & signs of wear, check all screws
7.
are present and tight.

8. Clean suction strainer

9. Check and remove coupling guard

10. Visually check coupling and rotate shaft

11. Check coupling and bolts /screws for tightness.

Check pump motor shaft alignment

RECORD READINGS FOR SHAFT ALIGNMENT

Horizontal-

Vertical -
12.
READINGS AFTER CORRECTION (If Required)

Horizontal-

Vertical -

Post routine checks (when pump on line);

13 Visually inspect joints and seals for leaks.

14 Adjust pump shaft seal gland if applicable.

Check bearing temperature and compare to pump manual

15.
…………………………………………………………..

Check pump and motor vibration compare to pump manual or

16. standard
………………………………………………………………….

NOTES:
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4.0 REFERENCES

1. Pump Handbook 4th Edition, by Igor J. Karassik (Author), Joseph P.

Messina (Author), Paul Cooper (Author), Charles C. Heald (Author) ISBN-13:
978-0071460446