MILLWRIGHT MANUAL: CHAPTER 15 Pumps Dynamic pumps. ‘Terms and definitions .. Radial flow pumps... Axial-flow pumps... Mixed-flow pumps .. Peripheral pumps Pump casings wn Pump impellers Choosing a centrifugal pump. Pump components Installing centrifugal pumps Maintaining centrifugal pumps. ‘Troubleshooting centrifugal pumps Positive displacement pumps.. Volumetric efficiency. Reciprocating pumps Rotary pumps Regulating positive-displacement pumps Maintaining positive-displacement pumpsDynamic pumps MILLWAIGHT—PUMPS CHAPTER 15 Pumps A pump is & machine that moves fluids (Liquids or gases) or semi-fluids (wood pulp or slurries). It moves them into, through, or out of a system, against the action of gravity and other forces such as friction. It does this by converting mechanical energy into fluid energy, using suction or compression. When itis designed to compress air or other gases it’s called a compressor. Pumps play an important part in power plants and industry generally. They are used to feed water to boilers, to convey or meter fuel and chemicals, and to circulate coolants and condensates. There are two basic classifications of pumps: dynamic and positive displacement. A dynamic pump is a machine that moves fluid by using centrifugal force to spin it outwards. It is better known as a centrifugal pump. The pump casing contains the impeller which gives kinetic energy to the fluid, also giving it velocity. The casing guides its motion and produces a smooth, continuous flow. They are generally used to convey large volumes of fluid, Centrifugal pumps are also known as non-positive displacement pumps. They allow the fluid to slip after the required pressure is built up. Slip is ‘caused when the centrifugal force created by the impeller is the same as the resistance in the discharge pipe. ‘The four categories of centrifugal pumps are based on flow; radial, mixed, axial, and peripheral flow. Terms and definitions Pump head Pump head is the pressure that a pump has to overcome to be able to move liquid through the system. This pressure is expressed in one of the following: * pounds per square inch (psi) + kilopascals (kPa) + bars (1 bar equals 100 kPa) ‘The pressure is then converted to a height of a column in which the pumped liquid can maintain. This height is measured in feet or meters and is simply called head. 18-1With different liquids the pump pressure must change to maintain the required head. For example it takes more pressure to maintain a required head of wood pulp than water. oOo Ay + Static} | 1 ot Jrotat static Static | sischarge heat discharge| head head + Pump | centresline a cin en static shead Pump ccentredtine Static suction! head contre-tine Figure 1 Total static head Several factors affect pump head and a description of these factors follows. Static suction lift Static suction head Static discharge head Total static head Frictional loss Velocity head Dynamic suction lift we The vertical distance from the liquid supply level to the pump centre line when the liquid supply level is below the pump centre-line (see Figures 1a and 1b). The vertical distance from the liquid supply level to the pump centre line when the liquid supply level is above the pump centre-line (see Figure 1c). ‘The vertical distance from the pump centre line to either the surface of the liquid in the discharge tank (see Figure 1a) or to the point of discharge (see Figure Ib and Ic). ‘The vertical distance from the liquid supply level to the surface of the liquid in the discharge tank or to the point of discharge. The pressure needed by the fluid to overcome friction as it moves through piping, valves and fittings in the system. Velocity head is the force causing the fluid to flow through a chamber which is due to the velocity of the fluid. This is equivalent to the static suction lift plus the velocity head minus all the frictional losses in the suction pipes and fittings. ‘MLWAIGHTMILLWRIGHT—PUMPS Dynamic suction head This is equivalent to the static suction head minus the velocity head and all the frictional losses in the suction pipes and fittings, Dynamic discharge head This is equivalent to the static discharge head plus the velocity head and all the frictional losses in the discharge pipes and fittings. Total dynamic head Total dynamic head is the term most used in industry to describe a pump's head. ‘+ For pumping systems which have suction lift (see Figures 1a and 1b), the total dynamic head equals the dynamic suction lift plus the dynamic discharge head. + For pumping systems which have suction head (see Figure 1c), the total dynamic head equals, the dynamic discharge head minus the dynamic suction head. ‘Vapour pressure and net positive suction head (NPSH) Vapour binding If pressure on the suction side of a pump drops below the vapour pressure of the liquid, vapour forms. This could partially or completely stop liquid flow into the pump. The pump is then said to be vapour-bound. This pressure drop could happen because of insufficient suction head, high suction lift, excessive friction head, or high liquid temperature. Cavitation If pressure inside a centrifugal pump drops below the vapour pressure, vapour bubbles form. The bubbles flow with the liquid until they reach an area of higher pressure (normally at the outer area of the impeller). They then collapse, producing a shock wave. This process is called cavitation. During cavitation, the bubbles collapse (implode). Liquid then suddenly fills the space, hitting and eroding the surface. This action causes vibration and noisy operation. If continued, this erosion causes the impeller to become imbalanced, which mechanically destroys the pump (bearing failure), Net positive suction head To prevent cavitation and vapour binding, and to ensure maximum flow through the pump, suction pressure must be greater than the vapour pressure of the pumped liquid, This required pressure at pump suction is called the net Positive suction head (NPSH). Capacity, rating, and size ‘The pump’s capacity is determined by the volume of liquid delivered per unit of time. For example US gallons per minute (USgpm) or litres per minute (min). “18-316-4 Slip factor This is the difference between the actual volume of liquid discharged by a pump and its theoretical capacity. It is expressed as a percentage of theoretical capaci Volumetric efficiency Volumetric efficiency is the ratio of the volume of Mid discharged to the theoretical capacity of the pump. It is also expressed as a percentage of theoretical capacity Rating and size Pumps are rated according to the capacity at a given head and speed (rpm). For example, a pump might be rated at: + 900 USgpm at 80 ft and 1150 rpm + 3400 Vin at 25 m and 1150 rpm. ‘The pump’s size is expressed as the diameter of the discharge nozzle, suction nozzle and impeller in inches or millimetres. For example: +3" x4" x 10" + 80mm x 100mm x 260mm. Radial flow pumps Radial flow pumps move the liquid out radially from the shaft’s axis. See Figure 2. The most usual of these is the volute pump. Volute pumps In volute pumps, the rotating impeller discharges the fluid into a spiral- shaped cavity called a volute. This is the most commonly used design (see Figure 3), Action 1. Fluid is fed into the centre (eye) of the impeller (see Figure 2) and flows into the blades. 2. The rotating impeller causes fluid to discharged at its circumference at an increased velocity. A the fluid leaves the impeller, it moves outward at right angles to the shaft’s axes. (That is, it has tangential velocity.) It is flung into the volute at high velocity. 4, Because the chamber widens, the velocity of the fluid decreases and part of the velocity head is transformed into pressure. MILLWAIGHT PUMPSMILLWRIGHT—PUMPS Inlet Discharge Figure 2 Centrifugal pump action Impeller eye] Impaler Volute casing — Figure 3 Volute pump 16-5Diffiaser pumps Diffusers are used in pump casings to create multiple volutes. They are stationary, curved vanes in the casing which redirect the flow of the liquid. ‘The vanes direct the flow outwards thus forcing the liquid toward the discharge nozzle (see Figure 4). This type of pump is called a diffuser pump. Its chamber casing may be symmetrical Impeller eye Impeller — Stationary difuser Figure 4 Diffuser pump Axial-flow pumps In an axial-flow pump, the impeller moves liquid through the casing without changing its direction. The impeller has vanes like a ship's propeller. The pump develops its head by the lifting action of the vanes on the liquid. The liquid moves through the casing parallel to the shaft. See Figure 5. These pumps are usually mounted vertically. Impelier ‘Suction end Figure 5 Axial-flow pump MILLWAIGHT—PUMPS:They have little suction power and are usually mounted below the surface of the liquid being pumped. They have a large volume output flow, but relatively low discharge head. Mixed-flow pumps Figure 6 shows a mixed-flow pump. It combines characteristics of radial flow and axial flow pumps. It develops its discharge head by using both Centrifugal force and lifting action of the vanes on the liquid. This pump is ‘mounted verically or horizontally. Its used for low-head, high-capacity applications. Discharge flange, ——— oo ‘Suction end Figure 6 Mixed-flow pump Multiple staging ‘The pressure developed by a centrifugal pump with a single impeller is Jimited. Usually pumps must develop much higher discharge pressures than this. To do this, pumps are equipped with several impellers connected in series, these are called multi-stage pumps. The discharge of one impeller is connected to the suction of the next impeller and so on, MILLWRIGHT—PUMPS. “18-7Impeer Figure 7 Three-stage, mixed-low pump For example, Figure 7 shows a cross-sectional view of a three-stage, mixed flow pump. The liquid enters the suction of the first stage on the bottom, Liquid discharges from this stage through the chamber into the suction of the next impeller and so on until the liquid reaches the discharge outlet. This action increases the velocity of the liquid each time it passes through a stage thus pressure is increased at the discharge outlet. Peripheral pumps Peripheral pumps have the liquid entering at the periphery of the impeller. ‘The pump energizes it and discharges it out again at its peripheral. Regenerative turbine pump A regenerative turbine pump is an example of a peripheral pump. The impeller of this type of pump has a double row of vanes cut in its rim (see Figure 8). The impeller is then centred in a machined groove in the casing. Discharge port Figure 8 Turbine pump MILLWRIGHT—PUMPSWiLLWRIGHT PUMPS These pumps create high pressure for their size, so they are used in compact areas. They are suited for high-pressure, low-capacity service, They are often used as feedwater pumps for small boilers, as condensate retum pumps, and as hot-water circulation pumps. Action 1. The liquid enters at the outer edge of the impeller 2. As the impeller rotates, the vanes travel in a machined channel in the casing. This gives the liquid a forward motion, AS the liqu 4. Because of the channel's shape, the liquid returns between the vanes, speeds up, centrifugal force throws it into the channel This process is repeated several times. As a result, the liquid follows a spiral path around the outer wall of the casing, See Figure 9. It travels almost 360° around the casing to the discharge outlet, 6. Each time the liquid re-enters a vane, it receives an impulse, This series of impulses increases the pressure gradually from suction to discharge. iD) Figure 9 Spiral flow path in a turbine pump ‘The regenerative turbine pump can develop a discharge pressure several times larger than a radial flow pump can with the same impeller diameter and speed, Pump casings Split casings * Axially split casings are split along the axis of the shaft. The suction and discharge nozzles are usually in the lower half of the casing. The upper half is easly lifted for inspection Sha + Split | 8 Split horizontally, Split diagonally Figure 10 Axially split casings 7 7 curais~ to + Radially split casings are split at right angles to the shaft. Figure 11 Radially split casing Barrel casings Ina multi-stage, high-pressure, centrifugal pump, it is difficult to maintain a tight joint between the halves of a axial split casing or the sections of a radially split casing. Therefore, the inner casing is fitted into an outer casing called a barrel casing. See Figure 12. The barrel casing has no axial joints. The space between the two casings is subjected to the high discharge pressure. This tends to hold the sections of the inner casing together. Figure 12. Barrel casing Pump casing materials ‘The materials used in pump casings depends on the liquid that will be pumped. Table 1 shows the choices of casing materials for various pumped liquids. MILLWRIGHT— PUMPSTable 1: Pump casing materials FLUID Water, gasoline and other chemically neutral liquids PUMP MATERIAL * cast iron casings with bronze fittings Acids + mild * bronze + moderate + stainless steel + concentrated + 1. special stainless steel eg., Hastelloy 2. monel 3. nickel 4. rubber 5. ceramic Alkalis + mild + cast iron = moderate ° 1. Nivesist * concentrated 2. stainless steel + special stainless steel e.g., Hastelloy Slurries (chemically neutral) * up to “¥g* diameter solids + low % solids + moderate % solids * concentrated solids —_— MILLWRIGHT—PUMPS ‘+ rubber linings (with temperature limitations) +1. cast iron 2. Nivesist hard iron + hard iron . chrome steel » chrome steel Ni-hard manganese stee! Pra waeFigure 13 Impellor designs‘MILLWRIGHT—PUMPS Pump impellers Impeller design Impeller blades are curved to push the fluid efficiently. Their size, shape and amount of enclosure varies as shown in Figure 13 4 open impeller have vanes attached to a partial shroud on one side. b__ semi-open, single inlet impeller. A full shroud closes off one side. © closed, single-inlet impeller. These have an inlet on one side only. Shrouds close off both sides. These produces axial thrust which must be ‘overcome by using appropriate bearings or balancing holes. 4 closed, double-inlet impeller. These have inlets on both sides. This type has very little axial thrust. © screw-style impeller used in paper-stock pumps for suspended solids. ‘The screw acts as a mechanical draw to the impeller. £ axial-flow impeller used in axial flow pumps £ open mixed flow impeller used in mixed flow pumps. Impeller mounting Impeller(s) are mounted either on the end of the shaft or mid-shaft and is held in place in a variety of ways. When it is mounted on the end of the shaft the impeller: * is screwed onto a threaded shaft and butting against a shoulder. The hand of the thread must have a tightening action as the shaft rotates, + has a parallel bore with a sliding fit on the shaft. It is held in position by a shoulder or sleeve on one side, and a keeper (retainer) plate and nut (with a locking device) on the inlet side, A key is needed for a positive drive, + is installed on a tapered shaft. A key is also used for driving. A nut (with a locking device) and a keeper plate is used to hold the impeller on the taper. When it is mounted mid-shaft the impeller is driven by a key and held in place by: + assliding fit against a shoulder retained by sleeves and a nut * _asliding fit against sleeves and retained by nuts on both ends of the shaft Choosing a centrifugal pump Centrifugal pumps are used to pump a variety of liquids including slurries such as sewage, pulpy solids, grit, or gravel. Table 2 shows the pumps used for various fluids. 15-13Table 2: Choosing a centrifugal pump FLUID Clear, non-corrosive liquids at low or moderate temperatures Liquids above 120°C (250°F) Hydrocarbons, hot PUMP TYPE * single or double suction = single or double suction ‘+ multiple stage pumps (usually boiler-feed service at high pressure) = single suction; offen special refinery pumps designed for high temperatures IMPELLER TYPE Closed except for very ‘small capacities Closed except for very small capacities Closed with large inlets Corrosives (acid or alkali) + mild ‘strong shot Liquid slurries, * fine abrasives (particles pass through /g" mesh) + coarse abrasives ‘+ single or double suction + single or double suction (single cheaper if available for the required rating) + single suction; many refinery pumps are used to withstand high temperatures and suction pressures * single suction with end clearance wearing fits; if there are no corrosives or high temperatures, use rubber linings on metal pumps; use special rubber compounds for resistance to some chemicals ‘+ = single suction (small capacities hard to get) for large rocks (above 1* diameter) use dredge pumps with large impellers ‘operating at siow speed Closed except for very small capacities or where fluid forms scales on surfaces of moving parts Open to allow better application o rubber linings except in large sizes; sometimes also made in closed type Closed Pulpy solids ‘such as paper stock ‘= single suction: use double suction with special endclearance wearing fits only on very light concentrations of solids Closed (open was the standard until end-clearance wearing fits changed) 16-14 “MILLWRIGHT—PUMPSPump components Wear rings and plates To produce maximum pressure, the clearance between the casing and the suction passage of the impeller must be kept to a minimum. This prevents the circulating liquid from moving back to the suction side. This seal is provided by the fit formed by the rim around the impeller eye and the casing. ‘The required clearance is specified by the manufacturer. During operation, continuous leakage through this fit slowly wears away the surfaces, Some wear is allowable, but if it exceeds three times the initial clearance, the pump loses too much efficiency. Replaceable surfaces called wear rings ot wearing rings are incorporated into the design of the pump casing and/or impeller (see Figure 14). Some smaller pumps have wear rings in the casing only. Impeller << = Impeller casing Casing wear ring Casing Figure 14 Flat wearing rings on impeller and casing ‘Wear rings may be radial, axial or a combination of the two, They come in a variety of different configurations: flat, stepped (L-shaped), or labyrinth (see Figures 14 and 15). Casing casing wear Casing im impeller /rg ps Jing Casing / wear impetier 9 Impeller Impeller ring a Stepped b Labyrinth Figure 15 Other configurations of wear rings — tg MiLLWaIGHT— PUMPS‘Wear rings are held in position using one of the following methods: + ashrink fit + aspigot, a groove or pins + screw threads Figures 16a and 16b show two ways of mounting impeller wear rings. Impeller | wear i fing iy | Ly Figure 16 Ways of mounting wear rings Figure 17 Wear plate in position mourners 15-16Inlet MiLLWAIGHT PUMPS Corrosion and lubrication of wear rings Wear rings are made of materials, chosen to suit the pumped liquid. Often bronze or cast iron are used, When only one surface is fitted with a wear ring, the wear ring is made of a softer material than the mating surface. This allows most of the erosion to take place on the wear ring, ‘Wear rings are lubricated only by the pumped liquid, so their life is extended if their are always run in liquid Wear (cheek) plates With open impellers in radially split casings, wear plates (cheek plates) are used instead of rings. Wear plates are easily replaced plates which protect the front and/or back faces of the casing. Clearance between the plate and impeller can be adjusted by moving the shaft axially. This is usually done by using shims. Hydraulic balancing devices Axial hydraulic thrust is produced when the two faces of an impeller have different pressures. This may be eliminated by using opposing impellers as shown in Figure 18, Figure 18 Using opposed impellers Half the impellers have inlets facing in the opposite direction to the other half. If the inlets all face in the same direction, the axial thrust must be compensated. This is done with hydraulic balancing devices such as balancing holes, a balancing dram or a balancing disk. In single stage pumps balancing holes may be used to counteract the pressure differences, Figure 19 shows how the excess pressure that builds up in the back face of the impeller can pass through these holes into the suction side, 0 : = ae18-18 Ee. Pressure build up impater_[. Suction end —>| = Balancing hole Figure 19 Balancing holes (On multi-stage pumps a balancing drum or disk or combination of the two may be used. In Figure 20, any excess pressure built up in the back face of the impeller is allowed to pass through the radial clearance between the balancing drum and the balancing drum head. This pressure then returns to suction side of the pump. Pressure id m 470 pump suction Balancing chamber Balancing }—drum head ) Balancing a 3 drum Impeller. Figure 20 Balancing drum Balancing disks work on the same principle and the excess pressure passes through the axial clearance (see Figure 21). As the pressure fluctuates, the axial movement of the shaft changes the axial clearance which acts as a valve. Figure 22 shows a combination balancing drum and disk. This method combines the constant radial clearance of the balancing drum and the valving effect of the balancing disk. MILLWRIGHTPUMPSTo pury sudion® Coats | Impeler —y Balancing | _ Beencing —— Sgereg ——ayrcioa Smet — hi i Figure 21. Balancing disk Pressure bap i {Pi Balancing - chamber 3° Combination Balancing, head > = { I) i —— Combination Balancing, — st Figure 22 Balancing drum and disk combination Sealing Sealing may be done using mechanical seals or compression packing. They are assembled into a stuffing box which is a cylindrical recess in the casing around the rotating shaft of the pump. This minimizes leakage hetween the casing and the shaft, Mechanical seals Leakage from stuffing boxes is not wanted when fluids such as gasoline, acid, or ammonia are pumped. Also, compression packing does not work well at high pressures. In these conditions, pumps use mechanical seals to minimize leakage, ‘MILLWAIGHT— PUMPS 15-1918-20. Figure 23 shows a mechanical seal mounted into a stuffing box. Setscrews are used to hold it in place. O-rings are used as a secondary seal to prevent leakage from the mechanical seal to the housing and shaft. See Chapter 14: Seals. Pra, +t Figure 23 Mechanical seal Compression packing and lantern rings ‘Compression packing or simply packing is an effective method of sealing the bearing from the pump cavity. See Chapter 14: Seals. Figure 24 shows a stuffing box holding multiple rings of compression packing and a lantern ring. They are held in place by a gland. The gland is adjustable by tightening nuts to compress the rings for the desired fit. When a pump operates at negative suction pressure, air can be drawn into the casing. This stops the leakage needed for lubrication, To prevent this, the stuffing box is fitted with a lantern ring (also called seal cage) and a sealing liquid connection. See Figure 24. This connection may be external piping or an internal passage consisting of passage holes drilled in the casing. Lantern rings are also used on pumps handling abrasive fluids. The clean sealing liquid keeps the gritty substances out of the stuffing box. MiLLWRIGHT—PUMPSHand rotary 7] Figure 26 Removal of sleeves \MicLWRIGHT—PUMPS Glands hy) {] | f Rings of packin Lantern ring! peed Figure 24 Stutfing box with four rings of packing and a lantern ring Shaft sleeves Shafts can corrode and wear at the stuffing boxes. This weakens them and makes effective sealing with packing rings difficult. Therefore, shafts of smaller pumps are usually made from corrosion- and wear-resistant ‘materials. Larger pump shafts are usually protected by renewable sleeves as shown in Figure 25. These are made of stellite, stainless steel or chrome plated brass/bronze. Cooting Figure 25 Renewable shaft sleeves Shaft sleeves are normally a slide fit onto the shaft and are held in place between the impeller and the shoulder on the shaft. Some sleeves are also keyed to the shaft (see Figure 25). In time the sleeves may become seized to the shaft which makes it difficult to remove. An effective method of removal isto: 1. Grind two grooves with a small hand grinder (see Figure 26). The grooves should be ground 180° apart, axially along the sleeve. 2. Split the sleeve with a cold chisel, being careful not to damage the shaft. 18-21ee Pump bearings ‘The functions of bearings in a centrifugal pump are: + to support the shaft carrying one or more impellers + to allow the shaft to rotate with minimum friction + to keep the rotating shaft and impellers in correct position within the stationary parts of the pump. The two basic kinds of bearings used in pumps are + friction bearings + anti-friction (rolling element) bearings. Friction bearings In a small pump, the bearings are usually a bronze bushing. In other pumps, babbitt bearings may be used. These bearings allow the shaft to move axially, for adjusting impeller clearances. ‘These bearings are oil-lubricated: + Horizontal pumps use either drip-feed oiling, or if the housing has an oil reservoir, an endless chain or a ring riding on the shaft can supply oil to the bearings. + Vertical pumps use shafi-driven pumps to supply oil under pressure to the bearings. Anti-friction (rolling element) bearings Ball and roller bearings are more commonly used in today’s pumps. (Refer to Chapter 9: Bearings.) ‘+ On axially split pumps radial load bearing are used at both ends of the shaft. This is due to the axial thrust of the shaft being theoretically balanced. ‘+ On radially split pumps radial load bearing are used at the impeller end and combination (both radial and axial load) bearings are used at the drive end. Installing centrifugal pumps Pump mounting Details about installation and alignment of equipment are given in Chapter 22: Installation and Levelling and Chapter 23: Alignment, Both the Pump and the drive source must sit on a secure base. This base may be made of cast iron or fabricated steel. The base is bolted to a solid foundation to absorb vibration. Fabricated steel bases can be easily modified to suit minor design changes.Motor and spacer coupling are extra equipment Ail dimensions are in inches Oo not use for construction unless certilied = | Brock | Worae izes | ] | a is Pump size Size | Suction | charge | A 6 K te) vexaxe 7] 3a fs] o o [4 | wom 2yaK Ws ry a yp ed g m | 5 | ane | Baan pha yada te | a | sme deans p>} ada] & te fo | tape Sea 0 pr] apo a wf 3! Liam | ayant a} i] 3] & | 8s | ate ators so} etal & te | os | ec s}6] i] & ws | os” | atm | oxexs os} ede] e te | oe | dn bx6x s | 6 | 6 | & 8] 6 oxenir a} ets] e ty | be Tak c Paro Ste se fom fw foe fa dt viaxe 7.3 au | oss | as 2haKw 7] ox siow| |g DeaK ae ne si] me | araxe 7] 3 Siu | oe | 'S | 2x1 7 | ae sin | P| 8 | Scam so] x au le fo | tkexs a] 4 Snow te | th anext a] sae} re | oxen oft fin | ox | bxexs ofa Sin fom | Bxex 10: aft sin | |p oxen tts afd fan | as |e t wie} j i} 4 Figure 27 Typical general outline dimensions MILLWRIGHT—PUMPS . 7 . 15-23Pump manufacturers may supply general base drawings to suit the various sizes available, or they supply pump-specific installation drawings. Figure 27 shows general outline dimensions for a Type-CL pump from Bingham Williamette. These can be used to design a suitable base, Base mounting Base mounted pumps have mounting lugs on the bottom of the pump casing. See Figure 27. Any change in the temperature of the pump while operating can cause the pump to lift and become misaligned with the coupling. Centre-line mounting In centre-line mounting, the pump body is carried on lugs extending from the centre of the pump casing which rest on the base. See Figure 28. Because the pump casing expands in both directions from the shaft centre line during operating temperature, there is very little effect on coupling alignment. Figure 28 Centre-line Bo 2a — eae [1] mounting Close-coupled mounting In a close-coupled pump the motor shaft extends through the pump casing, ‘The impeller is then mounted directly onto this shaft. The pump casing is normally mounted directly onto the motor casing. See Figure 29. Discharge port ‘ Motor Motor 1 shatt [Impeller Suction eng Co ____._ 7) Figure 29 Close-coupled pump 5 MiLLWRIGHT—PUMPSMILLWRIGHT—PUMPS Pump start-up ‘After the pump and drive are properly mounted and aligned, precautions ‘must be taken before start-up, Check to ensure that: + the unit will tum over freely by hand * the pump is driven in the direction shown on the pump casing + all bearings are properly lubricated * the pump is primed + all air from the seal housing is vented + plenty of quenching fluid is flowing to the seals Caution! When starting a pump for the first time, follow the manufacturer's instructions. Safety Safety is the first consideration when any maintenance is done, When ‘working on pumps, the following precautions must be taken: 1, Always lock out and tag all electrical controls. 2. Shut off, lock and tag all main valves to and from the pump, including the seal-fluid supply. Drain the pumps. This is important with suction-head mounting, 4. Flush the pump if it has been pumping acids or any other substance that could injure workers. Maintaining centrifugal pumps Preventive maintenance During preventive pump maintenance, the following are inspected: ‘+ volume and temperature of liquid leaking past the packing + oil level (see Oil lubrication systems in Chapter 6: Lubrication) *+ bearing temperature and noise (vibration analysis) + joints and seals for leaks * flow rates at operating conditions Routine maintenance Routine maintenance consists of changing worn parts without major downtime, 15-25‘Bingham Type CL Open Impeller Process Pump — Adjustable Bearing 2c 154 00 164-8 LUnnumbered pars in the illustrations are the same as the cortesponding parts shown with numbers, PAA PART PART no. | oescaiption no. | oescniPrion 0. 2a | casket volute 18 | Retainer Ring hrust Bearing 2-8 | GaskerSleeve va | shatt 64-8 | Cover-Radial Bearing M2.C | Gasket Bearing Cover 192.0 | Lockwasher-Beating 185 | Lanter Ring 120 | "0 Ring 132.8 | Lockwasher-Impsier 166 | tnpoties Retainer 105 | Thvyst Beating 134 | Stuting Box isa | Sunt Glass war | fade! Beanng lita | detect: Dscoutboars | 171 | shat Sleeve | } 170 | Locknut searing 140.8 | Detector Discnboara 196 | Packing | 13 | impetier 142 | MuAdusting 208 | shims 1 | volute 144 | Capserew-impetler 213.4 | keydmpeler 1s} slut 154 | Inspection Cover | 2138 | Key Shatt Extension 17 | Giana |__| HessnaBeanng | Figure 30 Sectional print of a pump 3-3 - . MiLLWRIGHT PUMESWhere needed, do the following + replace the compression packing * inspect and, if necessary, replace the shaft sleeve + change the oil Pump overhaul ‘A pump overhaul generally consists of: + inspecting/replacing the impeller + inspecting/replacing the wear rings or plates * _ inspecting/replacing the shaft and shaft sleeve * inspecting the stuffing box and replacing the compression packing or mechanical seal ‘+ replacing all bearings and seals Pay attention to the condition and size of fit in things such as spigots, sleeves, impellers, and bearing housings. Also, check the shaft and wear-ring run-out before and after tightening the impeller. Pump manufacturers supply: + adrawing showing the positions of all parts. For example, Figure 30 is @ sectional or cutaway print of a pump designed by Bingham Williamette. * an information sheet showing details such as pump rating, model, packing seal, and bearing details (see Figure 30) * an installation and service manual giving step-by-step routine for general overhaul Troubleshooting centrifugal pumps ij Table 3 on the next two pages contains tips for troubleshooting centrifygal pumps. MILLWRIGHT—PUMPS . . 18-27Table 3: Troubleshooting centrifugal pumps Trouble Cause Correction Failure to deliver 1. pump is not primed 1. prime the pump liquid 2. speed is too low 2. increase speed by changing drive ratio 3. dynamic discharge head 3 raise the pump is too high 4, worn wear ring 4. replace wear ring and adjust clearance to the required amount 5. wor impeller 5. replace impeller 6. plugged intake line 6. clear intake line 7. wrong impeller direction 7. ensure direction matches the direction arrow on the pump Reduced capacity or 1. ai leakage in the inlet line 1. check for cracks in the Pressure inlet plumbing and tighten or replace all faulty joints 2. air leakage through the 2. replace packing stuffing box 3. insufficient inlet pressure 3. increase the suction head for the vapour pressure of or decrease the suction the liquid lift 4. excessive ai in the 4. reduce turbulence or supply tank install baffles Pump overloads the 1. speed is too high 1. reduce the speed Clad 2. viscosity of the liquid 2, check the specification different then sheet for the pump and recommended for the make the required pump. changes 3. mechanical resistance in 3. disconnect the drive and the pump rotate pump by hand to find area of resistance. repair necessary areas ‘MILLWRIGHT—PUMPSTable 3 continued: Troubleshooting centrifugal pumps Trouble Pump vibrates 7 2 Cause misaligned coupling Insecure foundation unbalanced impelier due to a chipped blade unbalanced impelier due to excessive cavitation bent shaft worn bearings Correction realign drive to pump secure mounting bolts and if necessary, re-grout repair and replace impeller, and screening at the inlet line repair and replace Impeller, and increase Suction pressure replace shaft replace bearings Pump casing shows wear abrasive slurry being pumped abrasive chemicals being pumped, 12 repair casing by means of welding or installing an insert. replace the pump casing with a more Suitable material for the Pumped liquid Excessive packing wear incorrect grade of packing shaft Is scored or rough shaft sleeve is scored or rough abrasives between packing and shaft due to faulty sealing overheating replace with proper grade * reduce shaft diameter then use appropriate Packing size * replace shaft replace shaft sleeve check and correct the faulty sealing, * ensure cooling supply to the stuffing box is operational * ensure gland nuts are Rot too tight Pump casing damage Impact Uneven base Freezing examine internal parts for damage or interference and repair or replace necessary items repair damaged lugs and Temount pump correctly ‘examine casing for crack: and repair. overhaul pump before putting it back in service oo MILLWRIGHT—PUMPS: 15-29Positive displace- ment pumps 15-30 Positive displacement pumps (or simply displacement pumps) are used where a constant flow or a measured amount of flow is critical. The two classifications of displacement pumps are: + reciprocating + rolary Volumetric efficiency In theory, a displacement pump expels the same amount of fluid (Liquid or {gas) as it takes in. But, due to internal leakage, this is not always true. As the system pressure increases, s0 does this leakage. The degree to which this happens is called volumetric efficiency. It is expressed as a percentage: Actual outpat 1996, Theoretical output Volumetric efficiency Reciprocating pumps ‘A reciprocating pump uses a back and forth motion to pump fluid. This ‘motion gives the fluid a pulsating flow. Two types of reciprocating pumps are piston /plunger and diaphragm. They both increase and decrease the area of the cavity, which pumps the fluid. As this area changes, valves are used to give the fluid one direction. The movement of the piston or diaphragm in one direction is called the stroke. The distance it moves is called the stroke length. ‘The amount of liquid pumped per stroke of a reciprocating pump depends on the cross-sectional area of the piston, plunger or diaphragm, and on the length of the stroke. That is, it depends on the volume of liquid displaced per stroke. Plunger and piston pumps Both plunger and piston pumps are connected to a crankshaft or eccentric which gives it a reciprocating movement. The difference between these types of pumps, is: + the plunger pump has its plunger sliding inside packing + the piston pump has its packing sliding with its piston. “These pumps are best for low flow rates and high-suction lifts but are not suitable for dirty or viscous fluids.mii wrigiit PUMPS Plunger pumps A plunger pump has a plunger which displaces the cross-sectional area of a chamber. See Figure 31. With the use of check valves, the liquid is permitted {o enter one side and exit the other. These pumps are often found in metering situations, where a measured amount of liquid is to be expelled. Outlet Figure 31 Single-acting plunger pump Single-acting piston pumps A piston pump has @ piston which slides inside a eylinder (see Figure 32). ‘The cylinder acts as a chamber and as the piston moves in the eylinder it displaces most all the fluid in the cylinder. Single-acting refers to only one side of the plunger/piston doing the Pumping. It has a single set of inlet and outlet valves, The pump discharges every other stroke. A pump system may contain two or three single-acting ‘pumps linked together. The action of a single-acting plungerfpiston type is: 1. Plunger/piston extends: + outlet valve opens * inlet valve closes * fluid is forced out of the chamber 18-3118-32 2. Plunger/piston retracts: + outlet valve closes nlet valve opens + fluid is sucked into the chamber mi 3. Land 2 repeat. Figure 32 Single-acting piston pump Double-acting piston pumps In double-acting pumps, both sides of the piston moves fluid. The piston discharges at each stroke. The action of a double-acting plunger/piston type is: 1, piston extends (see Figure 33a): The liquid is: + drawn in the left side of the cylinder + forced out the right side 2. piston retracts (see Figure 33b): The liquid is ‘+ drawn in the right side of the cylinder + forced out of the left side iT —PUMPSFigure 33 Double-acting piston pump Packing For efficient pumping, itis important to prevent leakage between the plunger and the chamber or between the piston and the cylinder wall. (Chapter /4: Seals describes various types of packing.) * In plunger pumps, V- or U-ring packing is used. See Figure 34. + In piston pumps this is done in one of two ways: ~ with a series of cast iron rings which are fitted into grooves in the perimeter of the piston Figure 34 Piston packing (MILLWRIGHT—PUMPSDiaphragm pumps ‘The action of these pumps is similar to the action of plunger/piston pumps. A diaphragm (Glexible membrane) moves instead of a piston. The diaphragm separates the pumped fluid ftom the mechanism, preventing leakage and corrosion. A fuel pump operates in this way, because it is important that fuel pumps do not leak Piston Diaphragm = a Sef pataner Figure 35 Diaphragm pump In Figure 35, the diaphragm is attached to the piston by the retainer. The reciprocating movement is caused by the eccentric shaft. This gives the diaphragm its pumping action. Reciprocating pump valves Check valves ‘The check valve for the liquid end of a reciprocating pump is opened and closed by the pressure difference above and below it. This pressure 4ifference is caused by the pumping action. 16-34There are many different check valve designs. The type used is determined by the operating pressure and the properties of the pumped liquid. ball check valves are used where free 0 needed. See Figures 36, Flow Figure 36 Ball check valve disc seat and stem are alloy, usually bronze. Spi a pring pening of suction and discharge is stem guided check valves are used for low pressures. See Figure 37. The Flow Stem Figure 37 Stem-guided check valves. Disk seat wing guided check valves ate used for moderate or high pressures. Figure 38 shows a wing-guided valve with bevelled face. It is used for high pressure, clear liquids, MILLWRIGHT—PUMPS : : 15-35158-36 Spring Figure 38 Wing-guided check valves + flap check valves are used for low pressures and free flow of semi-solids (see Figure 39). They are primarily found in diaphragm pumps. Figure 39 Flap check valve Rotary pumps In rotary pumps, fluid (liquid or gas) is positively displaced at a constant rate by rotating parts. The flow is continuous and the discharge smooth. They are used for fuel, lubricants, hydraulic oil, and other liquids of various viscosities, including gases and liquified gases. Rotary pumps have a closed casing. Gears, vanes, lobes, screws, or rotary pistons rotate with a minimum of clearance in this casing. Rotary pump systems may have fixed or variable delivery. This means: + fixed delivery—always delivering the same volume at a given speed. Gear, vane, and piston types are all used in these systems, + variable delivery—delivering volumes varying from zero to a given maximum. Only vane and piston types are used in these systems. WILLWRIGHT—PUMPSMILLWRIGHT—PUMPS Gear pumps Lubricating systems often use small gear pumps. This pump has a pair of meshed gears enclosed in a casing. One of the pair drives the other. The ‘meshing teeth prevent the liquid from flowing back to the inlet (suction) side. There are intemal and external types: External gear pumps have two oppositely-rotated, externally-cut gears inside one casing (see Figure 40), External Figure 40 External gear pump Internal gear pumps have one internally cut gear and one externally cut ‘gear. They are separated on one side by a crescent-shaped partition (see Figure 41), Discharge External gear \ A | tora Figure 41 Internal gear pump 18-3718-38 Action of gear pumps 1 ‘uid enters the pump at the inlet port into the space between the gear teeth. 2. Itis then carried around the casing to the discharge port. 3. Atthe discharge port the meshing of the teeth restrict the oil from returning to the inlet port thus forcing it out. Sliding-vane pumps A sliding-vane pump has a rotor set slightly off centre in its casing. Vanes in the rotor are free to slide in channels, pushed outwards by centrifugal force as the rotor rotates. See Figure 42. Suction Discharge. port Figure 42 Sliding vane pump (unbalanced type) Because of the offset, the vanes create chambers of different sizes as it rotates around the casing. They are bigger near the intake and smaller near the outlet. Action of sliding-vane pumps 1, The fluid is drawn into the chambers at the inlet and is carried around by the vanes. 2. As the chamber passes over the outlet, the chamber reduces in size and the fluid is forced out. Unbalanced vane pumps Because the pumping action is on only one side of the pump, the basic vane pump is said to be unbalanced (see Figure 42). This means that the high- pressure fluid, exerts a force in one direction. High-capacity bearings are needed to accommodate this force. Balanced vane pumps ‘A balanced vane pump is made by mounting the rotor in the centre of an elliptical case with two inlets and two outlets. The fluid is drawn in and discharged during each half-revolution. See Figure 43. MILLWRIGHT— PUMPSRotor Suction port MILLWRIGHT—PUMPS Discharge port Stiding vanes Figure 43 Balanced vane pump In this action, the opposite forces produced by the pumping action balance cach other, reducing stress on the bearings. Light- or medium-service bearings can be used. Also, the volume delivered is larger. Variable-capacity vane pumps In these pumps, the rotor may be centred or off-centre in various directions. ‘This is done by moving the pressure-chamber ring as shown in Figure 44, Figure 44a shows the rotor centred. The spaces between the rotor and ring are even and there is no pumping action, Figure 44b shows the ring at its highest point within the housing. This is a point of maximum discharge. The left side is suction and the right side is discharge. Figure 44c shows the ring at its lowest point within the housing. This also is # point of maximum discharge. The lefi side is discharge and the right side is suction, 1839Figure 44 Moving the pressure-chamber ringMILLWAIGHT—PUMPS Automatic controls with a spring-loaded governor are built into the pump. ‘They vary the flow to meet demand; levels are pre-set. Ifthe discharge rate is seldom changed, itis adjusted manually. These systems sometimes rely on Pump action rather than relief valves to limit pressure. External vane pumps ‘An extemal vane pump has an oval rotor rotating centrally in the housing One sliding vane separates the inlet and discharge ports. See Figure 45. As the rotor rotates, it carries fluid from the inlet port to the discharge port. The vane maintains a seal between the rotor and the housing. Sliding ‘Suction port Discharge Port Figure 45 External vane pump Flexible member pumps A flexible member pump uses a flexible tube, liner, or vane to carry fluid from the inlet to the discharge por. Flexible tube pump A flexible tube pump uses a rotor with two lugs mounted on the periphery, 180° apart. See Figure 46. These lugs compress the tube against the housing. This forms a seals that prevents the liquid from returning to the inlet port. As the rotor rotates it forces the liquid around the housing to the discharge port. Rotation is relatively slow (up to about 200 rpm) with pressures up to 100 psi. It discharges liquid every half a revolution. This pump is used for measured flow of liquids such as food products (juice), paint, chemicals, slurry, sludge, and pulp. 18-411542 =f Flexible Suction (0) tube port 4 —. Figure 46 Flexible tube pump Flexible liner pump A flexible liner pump uses an eccentric rotor to force the internal walls of a flexible liner outwards against the housing. It discharges liquid once per revolution. The liner has a divider between the discharge and inlet ports. This divider prevents the liquid from returning to the inlet port. Its operation and usage are similar to the flexible tube pump. Discharge por Suction por Eccentric rotor Figure 47 Flexible liner pump MiLLWaIGHT PUMPS(MILLWRIGHT—PUMPS Flexible vane pump A flexible vane pump has a rotor with flexible vanes. The vanes carry the liquid around the housing from the inlet to the discharge ports. An insert is mounted between the discharge and inlet ports. The insert compresses the vanes and forces the liquid out. See Figure 48. These pumps rotate at moderate speeds (up to approximately 6000 pm), They are used to transfer liquids such as coolants, Insert Suction Gj Discharge port if] port Rotor with fionble vanes Figure 48 Flexible vane pump Lobe pumps A lobe pump has two rotors, each with one, two, or three lobes. See Figures 49a, b, and c, These rotors are placed in a casing with a set of external timing gears which synchronize the lobes, The liquid is trapped in the pockets formed by the lobes and the casing. The motion of the lobes carries the liquid around the casing to the outlet, [If the pump is taken apart, check the timing gears for mate marks. These ‘marks are often put on at the factory to aid re-assembly. Caution! Ifyou cannot see any mate marks, put on a set before taking the gears apart. Make sure that only one set of mate marks is visible. Screw pumps AA screw pump uses a screw to move the fluid from the input to the outlet. ‘They may have, one, two, or multiple screws. Single screw pump A single screw (progressive cavity) pump has one rotor (screw) inside a stationary lobed casing called a stator (see Figure 50). This pump acts much like a lobe pump. The cavity is produced between the inside surface of the rotor with the stator, while the outside surface of the rotor remains in contact with the stator to prevent the fluid from moving back to the inlet, 18-43‘Suction pot oe Discharge —> port Suction | Figure 49 Single, two-lobe, and three-lobe pumps 15-44 MILLWRIGHT—PUMPSMILLWaIgiT—PUMPS Suction port Saw | = (\ CNS) Figure 50 Single-screw pump Two-screw pump ‘The two-screw pump has two rotors each with two opposing screw threads (one left and one right hand). See Figure 51. One rotor is the drive and stays in proper mesh by means of timing gears. Discharge fe Rotor with ‘opposing screws <| Ke port Figure 81 Two screw pump Multiple-screw pump The multiple-screw pump has multiple rotors. The centre (drive) screw thread has one hand and the other screw threads have the opposite hand. As the Screws rotate, the liquid is carried between the threads and the casing, axially towards the outlet. The threads are in constant mesh with each other, restricting the fluid from returning to the inlet. Axial piston pump An axial piston pump has its pistons positioned axially in the pump. The pistons connect to a drive shaft which rotates. A cylinder block houses the pistons. The cylinder block rotates against a stationary valve plate which houses the intake and outlet ports. See Figure 52. 15~ 45Drive shaft Drive shaft tlange (swash pate) Piston rod Valve plate slot (stationary) Rotation “ Outlet port Inlet port Figure 52 Axial piston pump The drive shaft is at an angle to the cylinders. This angle is called the housing angle. Action of an axial piston pump 1. The drive shaft rotates the cylinder block and the pistons. 2. When the housing angle is other than zero degrees, the distance between the piston and valve surface continually changes. 3. Each piston moves away from the valve surface during one half of the revolution, causing suction and inflow. 4, Each piston moves foward the valve surface during the second half of the revolution, causing compression and discharge. Fixed and variable capacity If the housing angle is fixed, the pump delivers a constant volume and is @ fixed-displacement pump. If the housing angle is variable as shown in Figure 53, the pump’s volume is also variable, + in Figure 53a housing angle is zero, piston stroke length is zero, and there is no pumping action. + in Figure 536 there is a small housing angle with some stroke length and some fluid is pumped. + in Figure 53c there are maximum housing angle, stroke length, and pumping capacity. MILLWRIGHT”PUMPSPiston stroke length | a they No pumping action Piston stroke length 4 Housing Tangle Increased pumping action Piston stroke length . ~~ Housing jg Maximum pumping capacity Figure 53. Varying housing angle to affect pumping MILLWRIGHT” PUMPS “15-471648 Radial piston pump A constant displacement, radial piston pump has a rotating, eecentrie shaft rather than a cylinder block. The piston cylinders are contained in the fixed housing of the pump. See Figure 54. Each piston has a check valve for fluid to enter and another for fluid to exit. ‘Suction port Figure 54 Radial piston pump Action 1. As the eccentric shaft rotates (180°) from the high to low point, the piston cavity fills with fluid. 2. As the eccentric shaft rotates the other 180°, the piston cavity discharges the fluid, 3. This cycle acts on every piston in sequence. Regulating positive-displacement pumps ‘The capacity of displacement pumps is usually regulated by varying their speed. Their output is only slightly affected by pressure variations, dropping gradually as pressure rises. Excessive pressure is relieved by a pressure relief valve that redirects fluid after it reaches a set pressure limit. At the preset pressure limit, the valve opens and dumps excess fluid back to the supply. Without a pressure relief valve, a blocked line may cause the motor to stall or the pump to break. ‘MILLWAIGHT—PUMPSMILLWRIGHT—PUMPS Maintaining positive-displacement pumps Pumps must be installed and maintained properly. A pump should be ‘mounted on a strong, rigid base and aligned with the power source. See Chapter 22: Installation and Levelling for details. Repairs ‘The amount of allowable wear for a pump depends on the demands put on it. If it operates at 60% to 70% capacity, a small amount of wear can be tolerated. If it works at 100% capacity, there must be no wear. Other factors in judging acceptable wear are size, make, and style of pump, cost of repairs, and company policy. ‘A wor pump can be: + discarded + sont to a commercial overhaul depot + repaired in the plant Troubleshooting Table 4 on the next two pages contains troubleshooting tips for positive- displacement pumps. 15— 49Table 4: Troubleshooting positive-displacement pumps Trouble External leakage around the shaft a Cause Shaft seal worn Correction Inpect the bearings and replace if necessary and replace the shaft seal as specified. Pump doesn't deliver fluid 1 Drain line plugged Closed shut-off vaive in suction line; pump mounted below fluid level. Pump did not prime Pump shaft rotates in wrong direction Oil level too low in tank Oil intake pipe or suction filter clogged Air leak in suction line. This prevents priming or causes noise and Irregular pump action Oil viscosity too high for the pump to pick up and prime Broken pump shaft or rotor 8a, 8b. Clear drain line Inspect valve and open fully. Bleed air from the pump; prime or lubricate. Inspect suction line for air entry and repair Reverse immediately to prevent seizure and breakage Add recommended oll; check level on both sides of tank baffie to be sure line is submerged Clean or replace filters. Filter capacity should be at least twice the pump capacity. Tighten and seal the connection Use thinner oil and follow recommendations for temperature and service Heat oil for cold-weather startup Replace the pump ig 60 MILLWRIGHT”-PUMPSTable 4 continued: Troubleshooting positive-displacement pumps Trouble Pump does not develop pressure Relief vaive setting too low Relief valve is sticking open Leak in hydraulic contro! system (cylinders or valves) 1 2, 3. Free re-circulation of oil to 4a the tank through the system Pump shaft sheared due to rotor seizure. Relief vaive venting 4b 6. Correction Block the machine travel or stop oil circulation. test with pressure gauge. Set relief valve to Fecommended pressure. Remove relief valve clean and Inspect thoroughly Test this independently by progressively blocking off the circuit Check the direction-control valves The valve return line may be open Aspect and replace necessary parts or entire pump Test the venting circuit by blocking the vent line near the relief valve Pump makes unusual noise 9 ‘Smal air leak at pump suction piping joints Air leak at pump shaft packing Relief valve chattering due to air leak at pump intake or shaft packing Coupling misalignment Partially clogged intake line oF fiter, or restricted intake pipe. Debris pulled into intake Air bubbles in intake oil Tank air vent plugged Pump running too fast 10. Filter too small 10. Test by pouring pumped fluid on the joints while listening for a change in the sound of operation Test by pouring pumped fluid around the shaft while listening for a change in the sound of operation Check as for 1 & 2 Replace shaft seal and realign the pump Clean the lines and fiter to prevent cavitation Disassemble and clean the lines and pump. Check that retum lines are below oil level and separated from intake Open tank air vent through a breather opening or air filter Check for recommended maximum ‘speed and reduce accordingly Capacity may be correct only when clean. The filter should be twice pump capacity MILLWRIGHT—PUMPS” 15-5115-52 MIL WRIGHT FUMES: