NAME : ABDUL NAFE

SEAT NUMBER : B1333001

SUBJECT : MAINTANENCE AND

SAFETY

TOPIC : PUMS AND COPRESSORS

FAILURE MAINTANENCE REMEDY

SUBMITTED TO : MISS MEHWISH

 PUMPS

Some problems arise with greater frequency than others. By understanding how and why, preventative measures can
be applied to reduce productivity loss, maintenance costs and operator frustration.

The ability of hydraulic diaphragm metering pumps to inject precise, controlled amounts of chemicals under
pressure makes them particularly well-suited to a wide variety of process control applications. Keeping these pumps
up and running efficiently demands careful attention to proper installation and maintenance procedures.

LOCATION LOGIC:

One of the first decisions faced by pump users is where to locate the pump. This may seem like a very simple
matter, but all too often its where many pump problems begin. An ill-considered placement, where the pump
is exposed to extreme temperature conditions, or too far from the supply vessel, can be the source of
considerable trouble down the road.

Clogged or blocked suction strainer

System discharge pressure greater than pump internal relief valve setting

Starved suction

Pumps properly installed with piping fully supported prevents stress on component connections. The installation of
unions will help simplify pump servicing to the supply vessel as practical, to help minimize friction loss in the
suction piping.

Failure to do so could result in a situation similar to the following:

Clean or replace (suction line was not flushed prior to making connection to pump, permitting solids or
debris such as pipe sealant, tape, etc. to enter and block check valves)

Check and reset relief valve (within pump rating)

Insufficient NPSH. Shorten suction piping, increase suction piping size or suction head.

Probable Cause

Insufficient hydraulic oil

Clogged or blocked check valves, or check valves held open by solids

Remedies

Fill the pump to proper level.

Problem: A leading Gulf Coast chemical manufacturer experienced total operating failure shortly after start-up of
several new metering pumps equipped with electronic capacity control actuators.

Solution: The service technician discovered that the installation contractor had removed the pumps! actuators from
factory-supplied baseplates, resulting in serious misalignment problems.

SUCTION PIPING

Nearly 85% of all metering pump operating problems can be directly attributed to suction difficulties, either because
of undersized suction piping or due to blockage and/or restrictions in the suction line.

Probable Cause

Partially clogged/dirty suction strainer

Insufficient hydraulic oil

Leak in suction piping

Remedies

Clean strainer

Fill to proper level

Repair piping

PUMP MOTOR FAILS TO START

Probable Cause

Blown fuse or tripped breaker

Open thermal overload in motor starter

Low line current

Open circuit in limit switches, timers or other control devices in pump motor starter circuit

Motor damage

Remedies

Replace fuse after correcting cause of overload

Reset after correcting cause of overload. If malfunction recurs, check heater size
 Determine cause and correct

Reset

Check motor for physical damage that may hinder operation

PUMP RUNS BUT FAILS TO DELIVER

Probable Cause

Insufficient hydraulic oil

Check valve(s) lodged open by solids

Worn or dirty check valves

Remedies

Fill to proper level

Clean or replace

Clean line

Open valve

PUMP FAILS TO DELIVER RATED CAPACITY

Probable Cause

Incorrect capacity setting

Insufficient hydraulic oil

Starved suction

Internal or external relief valve set too low for system conditions and is relieving

Remedies

Readjust capacity setting

Fill to proper level

Increase suction piping size or suction head

Reset valve to correct setting and within pump rating

 COMPRESSOR
For compressor failure of accurate diagnosis cooling system maintenance to determine the root cause vital
tar.hats, recognize the symptoms and to evaluate the fault allows the diagnosis by quick and safe as technical
personnel and so failure in proper repair works yaplabilir.sout systems generally classified into three categories.

Externally visible faults

Slippage or breakage of the compressor belt
Compressor does not work (the rotation)
Operation of the pump (to return)
Operation of the fan (to return)

Internal Failures
Internal fault can be generally identified by the working pressure and temperature monitoring. Seeing many of the
mechanical failures can be diagnosed by voice and touch, and without the need for any special equipment.

Damaged compressor valves or pistons

The expansion valve actuators failures

Electrical Faults
Refrigerant causing a malfunction in the cooling plants use the system in question is the three effects.
There is insufficient level of refrigerant in the system. (Less loading)
If you have excessive amounts of refrigerant in the system (overload)
Refrigerant; oil contaminated with moisture in the air and other gases.

Compressor Fault Causes and Remedy

failure in the compressor causes and removal methods are as follows.

Rise of gas pressure discharged from the compressor

Malfunction Causes Remedy Fault

Mixing air into the refrigerant Interfering air is discharged.

Condenser high temperature, the amount of not less Congestion occurring in the water system is
cleaned.

Calcification of the condenser pipe, deterioration of water Pipes are cleaned, repaired water
distributing system distributing system.

The collection of condensed refrigerant in the condenser Learn more liquid collected in the
condenser.
 Lack of compressor outlet valve fully open Said valve is fully opened.

Problem Cause Solution

Compressor will not 1. No electrical power. Turn on power.

operate. Push the reset button.

2. Low oil level. Check oil level. Replace your oil if necessary

3. Pressure switch not making See pressure switch adjustment.

contact.

4. Pressure in the tank is below the See pressure switch adjustment.

cut-in pressure. Replace pressure switch to one that has a lower cut-in
PSI

Excessive noise in 1. Loose pulley, flywheel, belt, belt Tighten any loose ends.
operation. guard, cooler, clamps or
accessories.

2. Lack of oil in crankcase. Check for possible damage to bearings

Replenish the oil level.

3. Piston hitting the valve plate. Remove the compressor cylinder head and inspect for
foreign matter on top of the piston. Add a new gasket
and reassemble the head.

4. Compressor floor mounting Tighten the bolts on the air compressor. It may also be
loose. a good idea to replace your vibration pads

5. Defective crankcase. Repair or replace.

Knock occurs while 1. Connecting rod bearings. Replace rod.

compressor is
loading.
Problem Cause Solution

Knock - same cycle as 1. Main bearings. Replace bearings.

R.P.M.

2. Connecting rod bearings. Replace rod.

3. Loose flywheel. Tighten.

2. Wrist pins, wrist pin bearings. Replace piston assembly.

3. Loose connecting rod nut. Tighten.

Milky oil in oil 1. Water entering oil reservoir due a. Pipe air intake to less humid air source.
reservoir. to compressor operating in high
humidity environment.

b. Service unit (change oil, clean or replace air cleaner

element, more often, at least every 45 days or 500
operating hours for oil changes.

c. Drain tank daily.

Excessive oil 1. Restricted air intake. Clean or replace air filter.

consumption.

2. Oil leaks. Tighten bolts or replace gasket.

3. Worn piston rings. Replace rings.

4. Wrong oil viscosity. Drain oil, refill with oil of proper viscosity.

5. Compressor tilted too much. Level compressor. Vibration pads may help with this

6. Scored cylinder. Replace cylinder.