Powerpoint presentation on pumps and working

Ppt on pumps

1. 1 Pumps

2. 2 1. Basics - Introduction 2. Classification-Types of pump 3. Pump Operation 4. Pump Maintenance Key Topics covered

3. 3 The principle of energy conservation states that  energy is neither created nor destroyed . It may transform from one type to another. Basically, the pump changes  the energy  flow from mechanical to the fluid. This can be used in process operations which needs a high hydraulic force. This process can be observed within heavy duty equipment. This  equipment  needs low suction and high discharge pressure. Because of low force at suction part of the pump, the liquid will pick up from certain deepness, while at expulsion side of the pump with high force, it will drive liquid to pick up until reach preferred height. 

4. 4 A Pump is a mechanical device  which is used to move or raise liquids with the help of pressure otherwise suction. Or Machines designed to Transfer liquid (water, milk, oil chemicals, sludge etc.) from source to destination or Circulate liquid around system Or A machine for raising a LIQUID - a relatively incompressible fluid - to a higher level of pressure or head.

5. Pumps - used to raise Pressure of Fluid other than Air. Air Present in the pump circuit causes cavitation (Erosion of blades, abnormal sound & excess vibration) & as a result reduces pump performance & increase maintenance, so air must be vented at higher point. Compressor - A machine for raising a GAS - a compressible fluid - to a higher level of pressure. Water particle present in the Comp circuit causes damage to compressor internals , so water must be drained at lowest point.

6. 6 Heart is sort of like a pump, or two pumps in one. It pumps blood around your body.  Blood  provides your body with the oxygen and nutrients it needs. It also carries away waste. The  right side  of your heart  receives blood from the body  and  pumps it to the lungs . The  left side  of the heart r eceives blood from the lungs  and  pumps it out to the body . The sinus node generates an electrical stimulus regularly, 60 to 100 times per minute under normal conditions. The atria are then activated. The electrical stimulus travels down through the conduction pathways and causes the heart's ventricles to contract and pump out blood.

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8. 8 Plunger Pump

9. 9 Diaphragm Pumps

10. 10 Lobe Pump

11. 11 Gear Pump

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14. 14 Rotating and stationary components

15. 15 Impeller Main rotating part that provides centrifugal acceleration to the fluid Number of impellers = number of pump stages Impeller classification: direction of flow, suction type and shape/mechanical construction Shaft Transfers torque from motor to impeller during pump start up and operation

16. 16 Functions • Enclose impeller as “pressure vessel” • Support and bearing for shaft and impeller Volute case • Impeller inside casing • Balances hydraulic pressure on pump shaft Circular casing • Vanes surrounds impeller Used for multi-stage pumps Casings

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18. 18 The pump bearings  support the hydraulic loads imposed on the impeller, the mass of impeller and shaft, and the loads due to the shaft coupling or belt drive . Pump bearings keep the shaft axial end movement and lateral deflection within acceptable limits for the impeller and shaft seal. Bearings commonly used in pump are : Single stage Impeller Deep Groove Ball bearings 6312 , Double or multi stage Impeller Cylindrical Roller Bearings N311 or N307 , Angular Contact ball Bearings 7310 or 7307 (NDE Side Back to Back as per OEM) , Vertical Turbine Pump 29322 e – Spherical Roller Thrust Bearing 32208 - Tapered roller bearings for Screw Pump . Bearings

19. 19 Water System: Circulating water at the rate of 2 lacs m 3 / hr by 1200 pumps. Water System : Source The raw water drawn from Tapi River Variav Pump House 1: 90,000 m3/ day Dia 800mm X 30 KM pipe line Vertical Pumps – 4nos, each of capacity 1100m3/hr,H-129 mtr > Variav Pump House 2 : 1,36,400 m3/ day -Dia. 1500mm X 30 KM pipe line Vertical Pumps – 6 nos., each of capacity 1500m3/ hr , H-250 mtr

20. 20 Pump Classification Classified by operating principle

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22. 22 Type of Pumps Positive Displacement Pumps For each pump revolution Fixed amount of liquid taken from one end Positively discharged at another end If pipe blocked Pressure rises Can damage pump Used for pumping fluids other than water

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24. 24 Centrifugal Screw

25. 25 Cantilever Multistage

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29. 29 Centrifugal Pumps How do they work? Liquid forced into impeller Vanes pass kinetic energy to liquid: liquid rotates and leaves impeller Volute casing converts kinetic energy into pressure energy

30. 30   •  This is the most commonly used pump in industry.  • It works on the principle of centrifugal force.  • Centrifugal force is developed by a rotating part.  • The kinetic energy is converted to potential energy, which helps to increase the delivery pressure.   • When the impeller rotates, liquid is discharged by the centrifugal force from its center to the periphery.

31. 31 Reciprocating pump Displacement by reciprocation of piston plunger Used only for viscous fluids and oil wells Rotary pump Displacement by rotary action of gear, cam or vanes Several sub-types Used for special services in industry

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33. 33 Dynamic pumps Mode of operation Rotating impeller converts kinetic energy into pressure or velocity to pump the fluid Two types Centrifugal pumps: pumping water in industry – 75% of pumps installed Special effect pumps: specialized conditions

34. 34 Main components • Pumps • Prime movers: electric motors, diesel engines, air system • Piping to carry fluid • Valves to control flow in system • Other fittings, control, instrumentation End-use equipment • Heat exchangers, tanks, hydraulic machines What are Pumping Systems ​

35. 35 Pumping System Characteristics Head ​ Resistance of the system ​ Two types: static and friction ​ ​ Static head ​ • Difference in height between source and destination ​ • Independent of flow  ​  Static head consists of ​ • Static suction head ( hS ): lifting liquid relative to pump center line ​ • Static discharge head ( hD ) vertical distance between centerline and liquid surface in destination tank ​ Head (in feet) =  Pressure (psi) X 2.31 ​                              Specific gravity ​ ​ ​ ​ ​ ​ ​

36. 36 Flow increase System resistance increases Head increases Flow decreases to zero Zero flow rate: risk of pump burnout Relationship between head and flow

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40. 40 Pump Operations

41. 41 How to Calculate Pump Performance Pump shaft power (Ps) is actual horsepower delivered to the pump shaft Pump shaft power (Ps): Ps = Hydraulic power Hp / pump efficiency ηPump Pump Efficiency ( ηPump ):  ηPump   = Hydraulic Power /  Pump Shaft Power • Pump output/Hydraulic/Water horsepower (Hp) is the liquid horsepower delivered by the pump Hydraulic power (Hp): Hp = Q (m3/s) x Total head, hd - hs (m) x ρ (kg/m3) x g (m/s2) / 1000  hd - discharge head  hs – suction head,  ρ - density of the fluid  g – acceleration due to gravity

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50. 50 Duty point: rate of flow at certain head Pump operating point: intersection of pump curve and system curve Pump suction performance or Net Positive Suction head (NPSH) Cavitation or vaporization: bubbles inside pump If vapor bubbles collapse Erosion of vane surfaces Increased noise and vibration Choking of impeller passages Net Positive Suction Head NPSH Available: how much pump suction exceeds liquid vapor pressure NPSH Required: pump suction needed to avoid cavitation

51. 51 Variable Speed Drives (VSD) Speed adjustment over continuous range Power consumption also reduced! Two types Mechanical: hydraulic clutches, fluid couplings, adjustable belts and pulleys Electrical: eddy current clutches, wound-rotor motor controllers, Variable Frequency Drives (VFDs)

52. 52 Benefits of VSDs Energy savings (not just reduced flow!) Improved process control Improved system reliability Reduced capital and maintenance costs Soft starter capability

53. 53 Pump Maintenance Schedule Clean bearing bracket from any oil if found. Check oil drain plug. Lubricate the bearings. Inspect suction and discharge flanges for any leak. Inspect pump casing for any unusual damage signs. Inspect the seal. If the pump is offline check the coupling and its shims for any damage. Pump Maintenance

54. 54 It is vital to schedule pump preventive maintenance to avoid an unexpected breakdown of the equipment. Below are common points of failure in centrifugal pumps and the pump maintenance procedures required: 1. Bearings and Points of Lubrication Ensure the bearings, lubricant levels, and lubricant quality are maintained in proper condition.  Follow the pump manufacturers guidelines for lubricant changes, lubricant type, and bearing operating temperature. 2. Pump Vibration Excessive vibration in the bearings indicates an impending breakdown as it causes an unsustainable rise in temperature. If you notice excessive vibration in your centrifugal pump, you should have it checked out immediately. It could be a result of misalignment, cavitation, or normal wear.

55. 55 3. Shaft Sealing A sudden decrease in the efficiency of your centrifugal pump may be due to a broken shaft seal. Leaks from a broken seal reduce the pump pressure required to lift a column of fluid. Inspect the shaft seals for any physical signs of damage/leakage and replace the seal where necessary. 4. Impeller Clearance An increase in the impeller to casing clearance can reduce the head pressure of the pump, negatively impacting pump discharge pressure. Routinely inspect impeller clearance and carry out clearance adjustments where necessary. These standard maintenance procedures for centrifugal pumps can be carried out in accordance with the pump manufacturer’s instruction manual.  Normal maintenance intervals are quarterly, biannually, or annually depending on the type of pump application.

56. 56 Following the pump manufacture’s pump maintenance schedule will ensure that your centrifugal pumps are serviced when due to prevent costly downtime and expensive pump repairs.  The following are some elements of an effective schedule: Determining maintenance frequency: How often do your centrifugal pumps require general maintenance or replacement of parts? What is a good time to schedule maintenance on the pumps to prevent downtime on operations? Asking these vital questions will help you to come up with a good strategy. However, be sure to create a maintenance schedule that is consistent with the manufacturer’s guidelines. Physical inspection: As often as required, carefully inspect mounting points, seals and packing, pump flanges, filters, and couplings for signs of damage, leaks, or accumulation of grease, dirt, or debris to ensure that the pumps function optimally. Plan to replace parts as soon as problems occur by procuring spares.

57. 57 Replacing the lubrication: Changing the lubricant in your centrifugal pump is essential to prevent damage of the bearings, but it must be scheduled according to the manufacturer’s instructions. You might, however, want to increase the frequency of replacement if you use the pumps more frequently than indicated. Inspecting the electric motor: The electric motor is the powerhouse of the centrifugal pump. Since it contains both mechanical and electronic components, it requires frequent maintenance to function correctly. Include physical inspection and testing of the motor in your pump maintenance schedule to check for loose electrical connections, faulty windings, blocked vents, overheating problems, etc.

58. 58 Centrifugal Pump Maintenance Checklist When carrying out routine maintenance for your centrifugal pumps, use this checklist to ensure that they are restored to optimal working conditions: Mechanical part inspection: Are all mechanical parts (seals and packing, pump flanges, filters, couplings, etc.) in good working condition? (Y/N) Electrical testing: Are all electrical/electronic parts (motors, switches, etc.) in good working condition? (Y/N) Lubricant: Is the lubricant in good condition? (Y/N) When last was it changed? 

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60. 60 Lifting/Rigging of Pump

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68. 68 Laser Alignment

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76. 76 MECHANICAL SEAL VS GLAND PACKING Leakage Ratio:- 1:800 Power Saving:- 50% of Gland packing Fluid SavingArea Cleanliness Safety of Environment and Human

77. 77 Gland Packing Having Gland Pusher

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79. 79 DISCUSSION ON MECHANICAL SEAL A device, which seals by axial contact pressure between relatively flat surfaces in a plane right angle to shaft axis. Purpose:- To prevent/Reduce leakage from two matching surface. Type Of Seal:- Static Seal:- Sealing takes place between two parts that don’t move relative to each other. Flange Joint, Pump casing joint. Dynamic Seal:- Sealing takes place between two moving part. Shaft-casing, Piston-Cylinder

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84. 84 TYPE OF MECHANICAL SEAL By Design Pusher type(Spring) and Non pusher type(Bellow) By Load Balanced Seal and Unbalanced Seal Number Of Spring Single spring Seal and Multiple spring Seal Type of construction Component Seal and Cartridge Seal Solid Seal and Split Seal

85. 85 COMPONENT OF MECHANICAL SEAL Component:- Rotary Seal Face Stationary Seal Face Springs Retainer Sealing/Flushing media O rings

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88. 88 MATERIAL OF SEAL ` Ceramic:- Aluminum Oxide Silicon Carbide Tungsten Carbide Ni-Resist Steel GFPTFE:- Glass Filled Teflon INSTALLATION Keep area clean and dust free. Check pump parameter. Check shaft/sleeve surface at elastomer area. Use proper jacking. Don’t use hammer. Check that seal is developed for the same application.

89. 89 PUMP PARAMETER

90. 90 MECHANICAL SEAL FAILURE OBSERVATION POSSIBLE CAUSE Initial slight leakage, decreasing over the time. Initial more leakage. Initial slight leakage. Black powder outside of seal. Seal failure in very short duration. Not to worry. Lapping was improper. Problem with static seal. Pump parameter to be checked. Insufficient lubrication, High pressure on seal faces. Abrasive liquid, Excessive end play, Vibration.

91. 91 MECHANICAL FAILURE OBSERVATION REASON REMEDY WEAR TRACK ON WIDER SEAT FACE WIDER THAN NARROWER FACE WIDTH EXCESSIVE RUNOUT SHAFT BENT EXCESSIVE VIRATION MISALIGNMENT ELIMINATE THE PUMP PROBLEM WEAR TRACK ON WIDER SEAT FACE NARROWER THAN NARROWER FACE WIDTH OVER COMPRESSION IMPROPER DESIGN EXCESSIVE SYSTEM PRESSURE INSTALL THE SEAL PROPERLY CONSULT THE MANUFACTURER NO WEAR TRACK CLEARANCE BETWEEN MATING SURFACE ROTARY HEAD GRUB SCREW LOOSE INSTALL SEAL PROPERLY. USE PROPER LOCKING SCREW.

92. 92 OBSERVATION REASON REMEDY CORRODED PITTED CARBON CHEMICAL ATTACK BY LIQUID USE PROPER MATERIAL FOR SEAL STICKY OR SWOLLEN ELASTOMER CHEMICAL ATTACK ON ELASTOMER USE PROPER MATERIAL FOR ELASTOMER CHEMICAL FAILURE

93. 93 OBSERVATION REASON REMEDY ELASTOMER HARDENED EXCESSIVE HEAT REDUCE HEAT RADIAL CRACKS ON HARD FACE INSUFFICIENT FLUSHING FLOW OVER COMPRESSION POOR HEAT DISSIPATION ADEQUATE FLUSHING CORRECT INSTALLATION COOLED FLUSHING COKE DEPOSITS OUTSIDE OF SEAL HIGH TEMPERATURE VAPOUR OF MEDIA EFFECTIVE JACKET COOLING THERMAL FAILURE

94. 94 Thank You