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Revitalizing Vertical Lineshaft Turbines

Learn the causes of wear, the ways to scout them out, and how to bring your vertical pump back up to speed. by David LaCombe, American Turbine There are three major reasons to revitalize a vertical turbine pump. One of the most obvious is to prevent an unexpected and complete pump failure, thereby disrupting critical system or plant operations. Secondly, increased clearances between the bowls and enclosed impeller skirts, increased clearances between the bowl shaft and bearings, and breakdown of the fluid passages reduce the hydraulic efficiency of the unit. Over time, running a badly worn pump can be just as costly as some system shutdowns. Finally, revitalization may be required where operational conditions have changed for example, alterations in pressure and capacity requirements due to fluid level variations. Revitalizing a vertical lineshaft turbine pump can involve a variety of processes, from adjusting the impeller position on a semi-open impeller pump to replacing the entire bowl assembly. In between these extremes, replacing bearings or shafts, flame-spraying coatings on shafts, applying coatings to flow surfaces, wear ringing close tolerance parts and replacing shaft seals are some of the more common refurbishing processes. Often, these intermediate repairs are more expensive than simply installing a new bowl assembly. Individual parts are costly, and such repair operations normally require considerably longer downtime than rebowling. While some companies offer complete repair facilities, any lineshaft turbine manufacturer will at least have some form of a rebowling program. Causes of Vertical Turbine Pump Wear Barring any operational problems and normal wear, there are two primary factors that cause a vertical turbine to deteriorate in performance: axial misalignment and pumping a fluid that the system was not designed to handle. Axial Misalignment Lineshaft turbine pumps are relatively simple and rugged pieces of rotating equipment. Their proper operation and performance, however, depends on delicate axial alignment. Referencing the rotational axis of the unit, all butted, machined surfaces must be perpendicular, and all Figure 1. A typical vertical registers, bushings and bushing housings must be turbine pump configuration concentric. The consequences of misalignment are vibration, undue wear and compromised performance. Fluid Properties and Suspended Solids

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The longest equipment operational life for a vertical turbine is generally obtained when pumping cool, clean water. Often is the case, though, that turbines are adapted for other fluids or have contaminants introduced into the fluid media that will degrade the machinery and reduce its useful life. Material erosion is expected in areas where rotating parts have a minimal clearance with stationary parts, such as an impeller rotating inside a bowl or a shaft rotating inside a bearing. However, certain constituents suspended in the fluid also contribute to erosion. Gases such as air, carbon dioxide or water vapor from cavitation can physically destroy the pump when they are entrained back into a liquid state. Suspended solids such as sand can cause the same results as a sand blaster. Finally, corrosion brought on by aggressive fluids deteriorates the wetted parts of the unit, creating additional turbulent flow channels. Monitoring Performance The only way to know that a turbine pump is deteriorating is to monitor its performance and compare the production and power usage to previous levels. A gradual decrease in production, increased vibration levels and increased power usage are all indicators that the pump may be wearing. Operational Problems The loss of production can have several causes, depending on the application. In a well pump, it could mean the water level is dropping. In any application, it can indicate that the bowl assembly is beginning to wear (i.e. the bowl and impeller clearance and/or the bowl shaft and bearing clearance is increasing). If the performance reduction is sudden and dramatic, the causes could range from a reduction in operational speed due to faulty controllers, power supply irregularities or other driver failures. Other causes include an impeller becoming dislodged from the shaft, or holes developing in some part of the flow channel. If the pump never met the expected performance to begin with and the unit uses a semi-open impeller, the lateral may not be properly adjusted. Also, check the application to make sure sufficient NPSH is available to prevent cavitation. The gases produced from cavitation decrease liquid flow rates simply because they take up the space where the liquid should be. Cavitation can eventually destroy the pump. Vibration Excessive vibration when the unit is first put into operation likely suggests an alignment or driver problem. Vibration that progresses gradually indicates that close tolerance parts are wearing due to normal operation, the pumping of unclean fluids or slight misalignments. In the case where vibration begins at startup, the first component to check is the driver. Disconnect it from the pump and operate it by itself. If the vibration level is the same, the problem is in the driver. If it operates much smoother, there is a problem in the pump itself. Check the straightness of the shaft extending through the driver and the shaft connections. Any rust inhibitors applied to the top of the discharge head must also be removed. These are some of the most common problem areas, but every point of connection has the potential for misalignment. Power Usage Abnormal power usage indicates problems as well. The lateral may not be set properly to prevent the impellers from dragging in the bowls, misaligned shafts may be forced into contact with the bearings (Photo 1), or the clearances around rotating parts may be too tight because of scale buildup (Photo 2). These situations will add to the driver load and cause it to consume more energy to produce the same amount of work.

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Photo 1. A misaligned shaft caused this bearing bore to be "whipped out."

Photo 2. Scale buildup in a bowl

Scale and other types of surface degradation can also build up in fluid passages. Unless other system changes occur, it is likely that a loss in production and reduced power consumption will be noticed. Debris around the suction screen can have the same effect. If the power consumption stays constant, but production levels drop, there is probably a hole somewhere in the fluid passages. The pump is doing the work; it just doesnt show up where its useful. The energy is being expended pumping some of the fluid back to the source. Making the Diagnosis Once a pump is disassembled and inspected and the pump components appear to be degraded abnormally, its time to decide whether the pump is repairable or if it should be replaced. But before making any repairs, pinpoint the cause so that the right problem is corrected. Visual clues often indicate exactly what the problem is. If you cannot determine the cause, contact the pump manufacturer for assistance. Visual Clues Wear patterns do give clues to their causes. Bowl shafts that come out hourglass shaped at the bearing locations usually indicate that the pump has been handling sand (Photo 3). Scoop marks in the bowls similar to a horses hoof print in the sand are signs that gas is in the fluid (Photo 4). Impellers that are coated black and cast iron bowls that are soft enough to cut with a knife are evidence of graphitization. Graphitization is reaction of the metals to a catalyst, such as carbonic acid, that removes the iron from the bowls and plates it onto the impeller.

Photo 3. Sand wear on a bowl shaft

Photo 4. The scoop marks in the bowl are sign that gas was in the fluid.

If a bowl bearing or the impeller bore at the top of a bowl with enclosed impellers is worn eccentrically and the corresponding wear on the rotating part is concentric, this indicates that there is
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a problem in a stationary part. Debris, such as small pebbles, can work themselves between the two surfaces. In some cases the faces of mating parts, such as the bowls or pipe, are not assembled or machined parallel. During assembly all parts should be clean and smooth so that they mate properly. Foreign material between the mating faces produces the same wear signs as faces not being machined parallel or bearing bores and/or registers that are not concentric with the rotational axis. If the wear on stationary parts is concentric and on rotating parts is eccentric, there is a problem in the rotating assembly. The shaft faces must be parallel to each other and the shafts should be straight to within .005" (TIR). The shaft coupling may have been installed into the tapered portion of the threads. The coupling must stay on the straight portion of the threads or it will tilt the shaft. Similarly, the ends of the shaft must be smooth and clear of debris. In both cases, improper assembly will simulate a bend in the shaft. The ends should be faced parallel after being straightened. If the ends are machined prior to straightening and then faced, they will no longer be parallel. Troubleshooting Information Above are just a few of the things that can happen. The variety of problems seen in one application will be few compared to all the applications that the manufacturer sees. Pump manufacturers can help you troubleshoot. When contacting them for assistance, give them all the data you have available. If a flow meter and pressure gauge are available, record flow and head readings at several points, including shutoff if possible. Take amperage and a voltage reading at those points also. Give some history on the pumps operation. Did the problem develop suddenly or gradually? Have there been any changes in the application, such as temperature fluctuations, fluid level variations, flow or head requirement changes, recent system maintenance operations or other developments that could possibly affect performance? The more information you give, the more likely it is the manufacturer can help determine the problem and suggest a solution. Rebowling Just the cost of downtime can easily outweigh the cost of rebowling versus repair. If minimizing downtime is critical to operational processes, a spare bowl assembly may be in order. In that instance a bowl assembly can be removed and replaced in one procedure, and the original unit can be repaired for future use. Taking it one step further, if the unit is a short-coupled pump a complete standby replacement may be advisable. When ordering a replacement bowl assembly, all design parameters need to be given to the pump supplier. In some cases the information may not affect the cost, but it will help the manufacturer determine what types of special adaptations will be required. That information can affect production time estimates. The minimum information that should be provided includes, but is not limited to, the following: head, capacity, operating speed, driver rating, fluid temperature, NPSH available, length limitations, width or diameter limitations, materials of construction, and bowl to pipe and shaft connection information. Column connections are the most difficult obstacle in rebowling. Threaded column connections are the simplest to match, because normally they are machined to a pipe thread standard. Flanged and bolted connections, which do not have standards with respect to mating to a bowl assembly, require exact measurements so that adapters can be made. Threaded enclosing tube connections are close behind the flanged pipe in the variations that can exist. Finally, the thread standards on the end of the bowl shaft must be matched. Although industry-wide thread standards exist for the shafts, exact dimensional information is still required to match it to the proper standard. If at all possible, at least the parts to be mated (enclosing tube bearings, shaft couplings, and column adapters) should be sent to the pump supplier to ensure that all pieces fit together properly.

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Typical Bowl Assembly Repair Operations If it is not the case that rebowling is less expensive than refurbishing, you will find that there are typically four areas within a bowl assembly that are economically repairable: the bowl bearings, the bowl shaft, the bowls (diffusers) and the impellers. Some manufacturers offer both repair and replacement services. Bowl Bearings Our first consideration is the bowl bearings. Most often they are bronze, rubber or a combination of the two. Other materials used include bronze backed rubber bearings (commonly called "marine" bearings), Teflon and carbon composites. The typical shaft/bearing clearance is .010", except when rubber bearings are used. In that case the clearance can run up to .030", which makes it a much more forgiving material in applications where abrasive solids are present. Bowl Shafts The bowl shaft is typically made of some grade of stainless steel rather than a carbon steel because of the resistance of stainless to abrasion/corrosion. If abrasive solids are pumped, chrome or other hard coatings are sometimes applied to the shaft. Unless the shaft is an abnormal size or material (making it expensive to replace) a new shaft is usually installed rather than refurbishing or coating the old one. The shafting is the heart of the pump. Make sure all shafts are straight and properly machined before assembly. Bowls and Impellers The third and fourth parts, which are limited to enclosed impeller pumps, are the bowls and impellers. Specifically, the areas around the impeller skirt and the adjacent area in the bowl are closely examined. The clearance between these two parts is typically around .015". If there is sufficient material available to bore the bowl and/or turn the impellers, wear rings can replace the worn material and bring the parts back into tolerance. In some cases, both parts require wear rings. In others, however, it may be possible to bore or turn one part, while the other accepts a wear ring specifically sized to meet the machined part. Wear rings are sometimes installed as part of the original assembly. Unless the fluid contains some particularly abrasive solids and the wear rings are made of materials to minimize the abrasive erosion, forego the expense of wear rings until the parts are worn. Then, during maintenance or repair operations, the parts can be machined to accept the wear rings. If wear rings are ordered with the original unit for easy replacement later, both bowl and impeller pieces are necessary to return the bowl assembly to its original tolerances. Column Pipe, Enclosing Tubes and Shaft Supports The next section of the pump to consider is the column assembly. The pipe may be pitted or encrusted with scale, or the coating may be damaged. The degree of roughness will be the determining factor as to whether the pipe should be reused, recoated, cleaned or replaced. The exterior of enclosing tubes, when used, take the same consideration as the pipe. The faces of the tubes should be inspected for leakage or damage, and the tubes themselves should be replaced when necessary (Photo 5). Enclosing tube bearings should have approximately the same tolerances as the bowl bearings (.010"). Open line shaft bearings should be replaced when they are visibly damaged. Most often they are rubber and can be purchased directly from the pump manufacturer. The condition of these bearings does not necessarily affect efficiency, but it is vital to supporting the shaft.

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Shafts

This brings us to shafts, which are commonly available in two materials: stainless steel or carbon steel with an alternative wear surface. Some grade of stainless steel is often used when aggressive fluids are handled. In open lineshaft pumps, if the wear is not excessive enough to Photo 5. Worn enclosing tube bearing weaken the shaft and it is threaded the same on both ends, it can be turned over and reused. This places a new wear surface in contact with the column bearings. Care must be taken, though, in examining the faces of the used shafts. Recesses in the ends of the shafts may form ridges in the opposing faces that will need to be removed before the unit is reassembled. Under the same conditions, similar methods can be used on the carbon steel shafts, such as placing new sleeves on the opposite end of the shaft or renewing the hardened coatings. Much like the bowl assembly, consideration needs to be given to the cost of simply replacing the parts instead of repairing them. Discharge Heads The most visible part of the pump, the discharge head, generally requires the least maintenance. Most of the repairs are performed on the shaft seal, whether it is a stuffing box or a mechanical seal. Packing in the stuffing box should be replaced to control leakage. Stuffing box or seal housing bearings need to be checked to make sure the shaft is properly supported. Send mechanical seals to the original manufacturer or a local repair expert for inspection. Drivers Last but not least, the condition of the driver should be reviewed. The thrust bearings should be checked to ensure that they are not excessively worn. Motors upgraded to premium efficiency or at least replaced or rewound can significantly increase overall pump performance. Motors, gear drives and engines should be inspected by specialists to determine any maintenance procedures that will optimize the systems performance. Other Repair Considerations The fluid passages of the bowl and impeller are often overlooked by maintenance personnel. If they are damaged or pitted or have a particle buildup or eroded coatings, there can be a significant decrease in efficiency. Coatings are normally applied to the interior of the bowl assembly, mainly to enhance efficiency. Although they are applied for protection in some cases, the velocity of the fluids and suspended solids being pumped often makes it difficult to keep the coating intact. Cleaning, recoating or replacing the affected parts are all options, depending on the severity of the problem. Repair Specialists Who should inspect the unit and perform repairs? Make sure its someone who is experienced and qualified to work specifically on vertical turbine pumps. Some problems are specific to vertical turbines and require a trained eye to identify them. Whenever possible, send the complete pump to the repair shop. When it is torn down and ultimately reassembled, there will be no question that the parts fit. If the fits are not checked until theyre in the field, the cost of having personnel and equipment waiting while adjustments are made can be high.

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Why Revitalize? Assume a 12" bowl assembly is in operation and the bowl/impeller clearances change from .015" to .064"(1/16"). The loss in capacity would be in the neighborhood of 10%, and the loss in bowl efficiency would be approximately 2.5 points. Unless the pump has some type of speed controller, such as a variable frequency drive or an engine that can be accelerated, that loss in capacity cannot be regained. In the case that other parts of the system, such as the discharge or column pipe, become irregular from damage or buildup, some capacity can be regained by opening valves. However, more power will be expended to meet the same production rate. A 1000 gpm pump operating at a total dynamic pressure of 100 psi will cost between $200 and $300 more per year to operate per point drop in overall efficiency. That is assuming operations of eight hours per day, every day of the year, with a power cost of $0.10 per KW-h. The bottom line is that the user pays more in operational costs when operating a vertical turbine pump that has deteriorated beyond its original design tolerances. The challenge maintenance personnel are faced with when the pumps performance is no longer acceptable is to determine the most cost-effective option either eliminating the cause of the deterioration or minimizing its effects. Dont wait for a catastrophic failure. Perform regular maintenance repairs when downtimes are acceptable. Otherwise, the pump system will inevitably break down when it is least desirable. David LaCombe is the Engineering and Operations Manager for American Turbine Pump Company. He has been with the firm for 10 years. He is also a graduate petroleum engineer from Texas A&M University. Back to Pump Zone
Copyright 1998 AES Marketing, Inc. Pumps & Systems Magazine All Rights Reserved 123 N. College Ave., Suite 260 Fort Collins, CO 80524

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