Pumps and their maintenance

Chapter Two
2.1. Installation:

We start the process of installation that includes the following:

2.1.1 Installation book:

Made by the manufacturer to guide customers for installing efficiently operation
and to able to reliance an the pumps at any time .that s why (installation book) should
be available for whom may be concerned and should be read carefully before installing
the pump.

2.1.2 Preparation for shipment:

After assembling the pump flanges surface should be cleaned and corned by rust
resistance material such as oil or grease, as for the sharp ends thread if may be taped
with a hard plastic tapping.

2.1.3 Care of equipment in the field:

 Pump should be stored in safe dry places.
 Actual joint and brasses should be kept away from sand, stones and mud.
 If the pump is to be stored for along time then it should be dehydrated by means
of hot air ,actual joint and brasses should be in separated by rust resistance
material and placed in plastic bags attached by part name and number, it is also
preferable to fill the pump by kerosene.

2.1.4 Pump location:

Pump location should be revised, make sure that there is enough room around the
pump for maintenance purposes becomes split pump type requires sufficient space to
kept the upper casing, center fugal pumps with multi equipment with cylindrical
casing need a space in front of it to with draw the casing without drubbing it, and if
the location permits pump should be installed in the place that achieve the least length
for wit drawing line.

2.1.5 Foundation:
The base in which pump chases is to rest on is any structure that weight enough a
constant solid base under the overall space of the pump to with stand any shock or any
regular movement above it, concrete frame built on solid ground is the most
convenient for this purpose.

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 Pumps and their maintenance

2.1.6 Piping:
After fixing the pump on the base, we start connecting pump curb rings (flanges)
with piping lines as follows:

2.1.7 Suction Piping:

suction pipe should be short straight and with large diameter to decrease flow
resistance, vertical bendings should be avoided to prevent accumulation of air pebbles ,
if static compressor is equipped then the suction pipe should be inclined toward the
pipe direction, usually the diameter of the suction pump is larger then the pump
suction curb ring , it is preferable to use eccentric reducers to connect between then
and if the source of the liquid is lower then the eccentric reducer should be installed in
straight side in the upper side and vice versa. Difference in diameter surface should
not exceed 4inches to avoid disturbance to the motion of the fluid in suction and if it
was necessary then vented eccentric reducer and long radius elbows should be used.

2.1.8 Discharge piping:

gate valve and non return valve are used in discharge pipes pipe where non return
valve is equipped between the gate valve and pump to prevent the return of the high
pressure fluid to return back to the pump from the discharge pipe when the pump
accidentally brakes off or when arias in pressure across in a parallel connected pump
because in this case the pump shaft may rotate inversely , or if the pressure differences
dangerous to them. As for gate valve, it is used for isolating the pump when being
repaired or maintained or inspected.

2.1.9 Suction strainer:

When the pump is designed to pump fluid that contains particles then its part will not
be effected , but if the pump is discharge for pumping clear fluid then the strainer
should be equipped to suction pipe, temporary filters may be used when starting the
pump to hold all left out in suction convection in advance putting the pump in service,
to pressure gage are installed in front and right after the strainer where the
determination of how dinty is the strainer can be concluded by defference pressure
reading of two gage.
After making sure that in pipes are cleaned these temporary strainers may be removed
or kept as desired.
The manufacturer may be counseled to specify the permissibility of strainer.

2.1.10 Instrumentation:
There are many instrument that are important to be equipped on the pump to observe
its performance and condition mostly pressure gauge toward suction pipe and outer
toward discharge pipe at place where it could be monitored easily further more
pumping range gage may be installed if necessary and these gouge may be equipped
with graphometer to print out the pumping condition at any time.

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 Pumps and their maintenance
There may be used to equipped spaced , heat vibration, lubrication gage especially if
the operating monitoring is applied away from the pump and the reading of gauge age

needs to be transfer from pumps room to control room to such down the pump if the
reading exceeded the critical ranges .

:Operation .2.2
Pump is selected to pump a certain pumption range with a certain discharge rang
when rotating in the estimated spaced, these indication are specified according to
conditions to cover most of operating priced of the pump.
Pumps with positive displacement can not change its pumping ranges unless by
changing its spaced or by installing return line to by passing. As for centrifugal pumps
it has wide range of pumping ranges beginning from zero to its maximum level.
Pumping range depend upon flow obstacles which decrease or increase the flow rate
another technique used is to increase or decrease the speed of pump to change the flow
rate while restricting to the hydraulic, mechanic and thermo dynamic limits.

:Priming 2.2.1
Most centrifugal pump are designed to be filled completely by fluid leaving no room
for gases vapor and air by sucking them from the highest point in the pump before
start operating especially if it was to be used for the first time. And some pumps are
:designed where no need for such a procedure such as
Self Priming long rotors pumps, low compressor pumps, low speed pumps where it is
not practical prime them. Foot valve installed on the lower vertical edge of the suction
pipe to hold the fluid from leaking are used for this purpose tanks to prime the suction
pipe or return pipeline from discharging to suction or by introducing an inducer to the
.pump propeller

Final checks before start up:2.2.2

Brasses tapes should be removed and washed by kerosene then filled by a new clean
oil that matches the manufacturer recommendations. Check that the pump revolution
and flow pipes are matched in direction as for the centrifugal pump it should be
revolved manually to find out if there are any obstacles so it can be handled before
operating.

2.2.3 Starting up and Stopping Procedures:

Usually where a medium high pressured centrifugal pumps are started to discharge
value remains closed where there is a relation between the power and the output when
the discharging value is closed so manufacturers recommend that a small radius
return line pipe is installed between discharging and suction sections to reduce the
possibility of over heating of the pump when starting up and gradually closed while
opening the discharging valve. As for low pressured (Mixed Flow) pumps (high remind
speed) and propeller pumps they should be started up with an open discharging valve.
And since most of used pumps are centrifugal pumps operated by means of an electric

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 Pumps and their maintenance

motor, then the procedures recommended to start up a closed discharging valve type
pump as follow:
1. Prime the pump by filling it with fluid and remove air, gases and steams, open
suction valve and close strainer valves.
2. Open brasses cooling valves (If there is any).
3. Open cooling fluid valve of gland box.
4. Open anti stuffing.
5. Open preheating fluid valve until the pump reaches ideal operating temperature
then close it.
6. Open return pipe valve if the pump from the type of working without relief
pumping.
7. Start the motor.
8. Gradually open discharge valve.
9. Monitor purl from the stuffing boxes.

2.3. Maintenance:
Due to variances of the pumps by design, size, power and material used in making the
pump there is no general program for maintenance that why manufacturer's guide book
should by thoroughly revised in case of maintenance of pump.
The steps follows should be taken to maintenance the pump:

2.3.1 Daily observation operation of the pump:

The operator should focus on any change of Sound, burbling, over heating of brasses
while operating, along with a revision of the rang , pressure reading at least once every hour,
revising graphometeric readings daily and if there were not normal, then the pump will require
special checking.

2.3.2 Semi-Annual Inspection:

Axial adjustment between pump and motor should be revised and corrected if needed
refilling oil to brasses and making that grease boxes are filled and checking if the existing
grease is still in good condition. As for glands make sure that it is free to move check for its
condition chivies it if needed measure vibration at the specified paces and compare it with old
once and record them.

2.3.3 Annual Inspection:

A complete inspection applied on the pump for every year of service in addition to
semiannual inspection where the brasses are un installed and inspected for crack defect, or
wear and covered by oil or grease.

2.3.4 Complete Overall:

It is not easy to set a constant concept for complete overall because it may very according to
quality, operating condition, structure, material used, type of pumped fluid and finally

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 Pumps and their maintenance

economic factor which is determined by comparing the coast of overall to expenses due to
decrease of the pump efficiency and temporary failure due to brake downs. Operating
condition may require a monthly overall or once every four years or more. The need of over
all may occur due to lade of efficiency of the pump, overall on motor irregular sound, over
vibrating. If there was no stand by pump the full overall parts should be kept for
emergencies, there may be need to make the overall in the factory if them was no sufficient
experience or equipment in the site.

2.3.5 Spare and Repair Parts:

The quantity and type of spare parts are determined according to the conditions, if there was
no qualified staff to maintain the pump then dependence upon the manufacturer is necessary.
Several number and type of the part should be specified when invoicing spare parts order to the
manufacturer.

2.3.6 Record Of Inspection And Repairs

Overall record should be filled and attached to the pump with a complete specification for
part that requires special attention and handling, leaving a space for notes and observations
and symptoms of failures, range of wear and solution suggested. In any case costs of repairs
and maintenance should be registered and filled along with hours of operating to estimate the
feasibility of any adjustment to material or structure of the pump.

2.3.7 Diagnosis Of Pump Troubles:

Mostly hydraulic troubles such as an ability to match the desired rate of pumping range or
failure to reach the required pressure or priming defects after starting or mechanical troubles
appear in form of over consuming power, disturbance in stuffing boxes brasses defects, over
vibrations, breakage to part of the pump.
May be there is found Interference in the defect or failure diagnose, such as increasing the
wear (corrosion) around the clearance regions of moveable parts, it describing as mechanical
failure but it appear thus form of decrease of the power of pump to pumping the certain
rate(varied) without occurring any vibrates or mechanical failures.
Generally, the failures which appear on the pump are tabulated wanting exposure of failure
and proclamation the causes which may be appear thus as in the following tables.

The table shown offers probable causes and solutions to the most
common problems encountered.

Table of Rotary pumps diagnoses

Symptom Possible cause of trouble

Pump fails to discharge 1,2,3,4,5,6,8,9,16
Pump is noisy 6,10,11,17,18,19
Pump wears rapidly 11,12,13,20,24
Pump not up to capacity 22, 3,5,6,7,9,16,21
Pump starts .then loses suction 7,10, 1,2,6

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 Pumps and their maintenance
Pump takes excessive power 23, 17,20. 15, 14

Suction troubles System problem(cont.)

pump not properly primed.1 pump runs dry.13

suction pipe not submerged.2
strainer clogged.3
foot valve leaking.4
suction left too high.5
air leaking into suction.6
suction pipe too small.7
system problems
wrong direction of rotation.8
low speed.9
insufficent liquid supply.10
excessive pressure.11
grit or dirt in liquid.12
viscosity higher than specified.14
obstruction in discharge line.15
mechanical troubles
pump worn.16
drive shaft bent.17
coupling out of balance or alignment.18
relief valve chatter.19
pipe strain in pump causing.20
air leak at packing.21
relief valve improperly seated.22
packing too tight.23
corrosion.24

Table of Reciprocating pumps diagnoses

Symptom Possible causes of trouble

Liquid end 1,2,7,8,9,10,14,15,16
Power end noise 17,18,19,20
Overheated power 10,19,21,22,23,24
Water in crank ease Water in crank 25
ease oil leak from crank ease
Rapid packing or plunger wear 26,27
Pitted valve or seats 11,12,28,29
Valve hanging up 3,11,30
Leak at cylinder valve hole plunges 31,32
Loss of prime 10,13,33,34

Suction troubles Mechanical troubles

insufficient suction pressure.1 valve broken or badly worn.14

paritial loss of prime.2 packing worn.15
cavitaion.3 obstraction under valve.16
left too high.4 main bearing loose.17
leaking suction at foot valve .5 bearing worn.18
acceleration head requirement too .6 oil level low.19
high
system problems plunger loose.20
system shocks.7 main bearing light.21
poorly supported piping abrupt .8 ventilation inadequate.22

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 Pumps and their maintenance
turns in piping pipe too small, piping
misaligned
air in liquid.9
overpressure or overspeed.10
dirty liquid.11
dirty environment.12
water hammer,13
Table of Centrifugal Pumps diagnoses
Symptoms
Pump does not deliver water
Insufficient capacity deliver
Insufficient pressure developed
Pump loses prim after starting
Pump required excessive power
Stuffing box leaks excessively
Packing has short life
Pump vibrates or noisy
Bearing have short life
Pump overheats and seizer
Suction trouble
pump not primed.1
pump or suction not completely .2
filled with liquid
suction lift too high.3
insufficient margin between suction .4
pressure and vapor pressure
excessive amount of air or gas on .5
liquid
air pocket in suction line.6
air leaks into suction line.7
air leaks into pump through stuffing.8
boxes
foot valve too small.9
foot valve partially clogged.10
inlet of suction pipe insufficient .11
belts too tight.23
driver misaligned.24
condensation.25
seals worn.26
oil level too high.27
valve spring broken.32
cylinder plug loose.33
ring seal damaged-0 .34
Possible causes of trouble
16,17,22,23,,1,2,3,4,11,14
2,3,4,5,6,7,8,10,11,14,17,20,22,23,29,30,31
5,14,16,17,20,22,29,30,31
2,3,5,6,7,8,11,12,13
15,16,17,18,19,20,23,24,26,27,29,33,34,37
36,38,39,40,,13,24,26,32,33,34,35
12,13,24,26,28,32,33,34,35,36,37,38,39,40
2,3,4,9,10,11,2,122,23,25,26,27,28,30,35,36
41,4,43,44,45,46,47
24,26,27,28,35,36,41,42,43,44,45,46,47
Mechanical troubles
foreign matter in impeller.23
misalignment.24
foundation not rigid.25
shaft bent.26
rotating part rubbing on station part.27
bearing worn 28
wearing rings wrong.29
impeller damaged.30
casing gasket defective.permiting internal .31
leakage
shaft sleeves worn or scored at packing.32
shaft running on center because of worn .35
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 Pumps and their maintenance
submerged
water seal pipe plugged.12
seal cage improperly located in .13
stuffing box
System troubles
speed too low.14
speed too high.15
direction of rotation wrong.16
total head of system lower than .17
pump designed pump
specifie gravity of liquid different .19
from design
viscosity of liquid different from .20
design
operation at very small capacity.21
parallel operation of pump .22
unsuitable for such operation
bearing
rotor out of balance causing vibration.36
gland too tight resulting in no flow of .37
liquid to lubrication pack in
cooling liquid not being provided to water.38
cooled stuffing box
excessive clearance at bottom of stuffing .39
box between shaft and casing causing
packing to be forced into pump interior
dirt or grit in sealing liquid leading to .40
souring of shaft sleeve
excessive thrust caused by mechanical .41
failure inside pump or by failure of hydraulic
balancing device if any
excessive grease or oil in antifriction .42
bearing housing or lack of cooling causing
.excessive bearing temperature
lack of lubrication.43
improper installation of antifriction .44
bearing
dirt bearing.45
rusting of bearing from water in housing.46
Excessive cooling of water cooled bearing .47
resulting in condensation of atmosphere
.moisture in bearing housing
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Pumps and their maintenance

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