CENTRIFUGAL PUMP

P-4521A

MAKE: WORTHINGTON CENTRIFUGAL PUMP SERVICE: AMMONICAL WATER MIN. OPERATING TEMP: 40 C MAX. OPERATING TEMP: 70 C SUCTION PRESSURE: 16.0 Kg/cm2 DISCHARGE PRESSURE: 30.07 Kg/cm2 DIFFERENTIAL PRESSURER: 14.7 Kg/cm2 PUMP MATERIAL: CAST IRON AND CARBON STEEL

PUMP
Pump is a machine which adds energy into liquid to move it from
low elevation to higher elevation or low pressure to high pressure.

Pumps are divided into two main groups:

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Centrifugal pumps Positive displacement pumps

Within these two main groups there are many different types of pumps.

Mechanical Construction
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Between bearings: Impeller/s supported between two sets of bearings.

Overhung Impeller: Impeller overhungs a bearing support bracket.

Introduction of P-4521 PTwo stage centrifugal horizantal with radially split casing with casted top top flanged.

Casing Specification:
The first and second stage single volutes are opposed to reduce hudraulic radial thrust and shaft deflection. The liquid is conveyed from one to other stage by and an intergral casted crossover.The inter stage diapharagm too is integrally casted with casing. All the flow passages are accurately designed to minimize efficiency losses. We will discuss the clearances of different bushes and sleeves further.

Impellers, wear rings & intermidate bushing. Std. impellers with single suction closed type which were
keyed to shaft and secured by lock washer and nut, mounted face to face to balance hydraulic axial forces. Impeller first and then complete rotor are dynamically balanced to avoid vibrations and assure long trouble free life to seals and bearings.

Wear rings and intermidate bushing. The

casing and the impeller front are fitted with replaceable wear rings of cast iron placed with grab screws. Intermidate bushing is provided to reduce the flow leakage from second to first stage thus minimizing efficiency losses. Clearance b/w wear rings is 0.46mm. and clearance b/w intermidate bush and shaft sleeve is 0.43mm.

Shaft and Sleeve

Shaft made of C.S with first critical speed atleast 20% higher than
the maximum rotational speed. The bearing span is the shortest possible to minimize deflection.

Sleeve made of Cast Iron fitted on shaft with an interfarence of

0.02mm.

Bearing Assembly
Pump is fitted with standard anti-friction bearings lubricated by means
of an oil slinger. Double row self alligning type and thrust bearing is dual single row angular contact type. Constant level sight feed oilers are provided for easy inspection and refilling.

Single row angular contact ball bearings can support axial forces
in one direction and high radial forces. They must be axially adjsted againest a second bearing fitted in a mirror arrangement. Axial load carrying capacity is dependent on contact angle. The larger the angle the higher the load bearing capacity. Contact angle of 40 Deg. Can support high axial loads. Mounted on out board end in back to back (X) arrangement. Bearing No. 7308 B tvp

Self aligning double row ball bearing operating under normal

conditions can swivel approx. 4 deg misalignment about their center position. As a result they permit skewing between the inner and outer ring and can thus compensate misalignments, shaft deflections and housing deformations.

Angular contact ball bearing

Double Row self Aligning Ball bearing

Mechanical Seals
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Two multi spring balanced mechanical seals in tendum arrangement on both inboard and outboard side with O ring and backup ring. Material of balance faces CARBON and seat is of SILICON CARBIDE.

API Flushing Plan for seals

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API plan 22 for process seal and API plan 52 for buffer seal.

Why double mechanical seals are used?

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Double or tandem mechanical seals are typically used in services involving toxic, flammable, or hazardous liquid to prevent the liquid, or its vapor, from leaking into the environment due to a leak or seal failure.

Double seals arrangements

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Double seals

A double mechanical seal is a combination of two seals mounted back-to-back with a non-hazardous barrier liquid injected between the two seals at pressure greater than service pressure. The barrier liquid comes from an external source such as a pressurized reservoir in a closed loop piping system connected into, and out of, the seal gland.
Tandem seals

A tandem mechanical seal arrangement is also a combination of two seals but they are mounted in the normal position, as opposed to the back-to- back position of a double seal. A barrier liquid is also injected between the two seals from an external reservoir in a closed loop piping system but it is not pressurized.The barrier fluid is circulated by the centrifugal force effect of a pumping ring in the seal. The pressure in the stuffing box is higher than in the barrier chamber so when the inner seal fails the process liquid enters the barrier chamber and forces the buffer reservoir level to rise. The process liquid is piped out from the of the reservoir into a safe disposal area. Double and tandem seals are usually flushed using API Plan 52 or Plan 53.

Maintenance of Pump
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Dismentling Procedur.
Remove all flanged connection, flusing of seal piping and drain piping. Drain oil from both bearing housings and remove oilers. Remove coupling spacer piece b/w coupling hubs. Remove coupling hub from pump shaft. Remove outer bearing cover and outer water shied and lock nut and lock washer. Remove oil slinger ring. Unbolt bearing housing and remove it. Remove mech. Seal sleeve locking arrangement. Unbolt and remove hard face adapter plate. Gently remove mech. Seal retainer assembly and sleeve. Remove impeller lock nut and washer and finally remove impeller from shaft of inboard side. Repeat these steps from outboard side but dont remove or loosen impeller and impeller lock nut. Pull the shaft with 2nd stage impeller gently. Remove pump base bolts from foundation plates.

Maintenance of Pump
Work Done:
1. 2. 3. 4. 5. 6. 7. 8.

Dynamically balanced the shaft with impellers assembled. New impeller and casing wear rings were installed.(interfarance=_____ Clearance= 0.46mm ). New intermidate bushing and shaft sleeve were installed.(Interfarance=_____ Clearance= 0.43mm) New mech. Seals were installed. Inserting of bushing in bearing housing to maintain clearance with bearing housing and bearing OD. Clearance= 0.025mm. New set of bearings were installed. Old casing were replaced with new one. All material of w/rings, bushing and sleeve was CAST IRON.

Installation procedure of bearings

There are two methods in use for mounting a bearing on a shaft. 1. Heating the bearing to expand the inner race and shrinking it on the shaft.
2.

Forcing the bearing onto the shaft. the first method is preffered. Heat the bearing in an oil bath or on induction heater to a uniform temperature of 108 C. when heated quickly mount it on the shaft.

Checks for MECH. SEAL installation.

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Check the od of sleeve and id of retainer must be with in tolerance of + 0.05mm and ovality must not exceed 0.025mm. Check the surface finish of sleeve ensure that there are no sharp edges or burrs. Check that the leading edge of sleeve last shoulder over which the seal must passed is chamfered at 10 deg. For a length of 3 mm. Ensure the flatness of seat and blance face. Ensure the sleeve material must be corrosion resistant and with sufficient hardness. Any elastomeric seal component made of ep rubber must never come into contact with mineral oils and or greese.

Assembling of Mechanical Seal.

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Locate springs in the holes in the seal retainer. Assemble the thrust ring into the retainer taking care to line up the notches on the outside diameter with the dimples in the retainer. Assemble the back up and o ring into the seal face.then fit this face assembly onto the thrust ring already in the retainer, taking care to line up the grooves on the face outside diameter with the dimples in the retainer. Using mechanical seal assembling fixture gently compress the springs and locate the lock ring into its groove, with the ends b/w 6 to 12 mm(depending on the seal size) from the small hole or slot in the retainer. Allow the seal to extend to its free length and check the grub screws are fitted and are clear of the bore of the retainer. There are two circumferential lines cut into the outside wall of the seal retainer. One goes through the tapped holes for grub screws have metric threads. The other line serves as a visible guide showing whether or not the seal has been correctly set to its working length, if it is correct the thrust ring should line up with this second scribed line when the seal installation is complete.

ALLIGNMENT
alignment means that the centerline of the pump is aligned with the centerline of the driver. it is critical with sealed pumps especially if we are using rotating seal designs where the springs or bellows rotates with the shaft. A little misalignment at the power end of the pump is a lot of misalignment at the wet end, and unfortunately that's where the seal is located in most pump applications. Misalignment will cause many problems: y The pump bearings can become overloaded. y The misalignment could be severe enough to cause contact between stationary and rotating seal components: y The wear rings can contact.
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The shaft or sleeve can contact the stationery face of the mechanical seal. The impeller could contact the volute or back plate.

ALIGNMENT
Regardless of the alignment method we select, we should also check the following:
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A straight shaft that has been dynamically balanced. Good wear rings with the proper clearance. The correct impeller to volute, or backplate clearance. The elimination of "soft foot". Eliminate all pipe strain. Good bearings installed on a shaft with the proper finish and tolerances. A good mechanical seal set at the proper face load. The closer the seal is to the pump bearings the better off you are going to be. we must level the pump and driver. If the pump is aligned without being level, the oil level will be incorrect and we will develop bearing problems. we then take a series of radial and axial measurements to see where the pump is located in respect to its driver (motor).