Centrifugal Pump & troubleshooting guide

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Centrifugal Pump & Troubleshooting Guide

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Course Table of Contents

1. Introduction
2. Pump Classification

2.1. Centrifugal Pumps
2.2. Mixed Flow Pumps
2.3. Axial Flow Pumps
2.4. Type and Construction based on:

2.4.1. Suction Design

2.4.1.1. Single 2.4.1.2. Double       

2.4.2. Number of Stages     

2.4.2.1. Single                    
2.4.2.2. Multistage

2.4.3. Guide Vanes

2.4.3.1. Volute                    
2.4.3.2. Turbine

2.4.4. Casing Construction

2.4.4.1. Radially Split                    
2.4.4.2. Axially Split                    
2.4.4.3. Double Casing

2.4.5. Impeller Shrouds

2.4.5.1. Open
2.4.5.2. Partially Open
2.4.5.3. Closed

2.4.6. Shaft Position

2.4.6.1. Horizontal                    
2.4.6.2. Vertical

3. Centrifugal Pump Basics

3.1. Principle of Operation
3.2. Pressure Concepts
3.3. Hydraulics - A Few Basics
3.4. Vapor Pressure
3.5. Pump Cavitation
3.6. Pump NPSH - Net Positive Suction Head
3.7. Pump curves / Pump Performance Curves / Pump Characteristic Curves

4. API � 610 Types and features

4.1. Overhung   

4.1.1. Flexibly Coupled            

4.1.1.1. Horizontal                

4.1.1.1.1. Foot Mounted : OH1                                
4.1.1.1.2. Center Line Mounted : OH2

4.1.1.2. Vertical

4.1.1.2.1. In-line Bearing Frame : OH3

4.1.2. Rigidly Coupled

4.1.2.1. Vertical

4.1.2.1.1. In-line : OH4

4.1.2.2. High Speed Integral Gear : OH5

4.2. Between Bearing

4.2.1. 1st and 2nd Stage

4.2.1.1. Axially Split : BB1                    
4.2.1.2. Radially Split : BB2

4.2.2. Multistage

4.2.2.1. Axially Split : BB3                    
4.2.2.2. Radially Split

4.2.2.2.1. Single Casing : BB4                                
4.2.2.2.2. Double Casing : BB5

4.3. Vertical Suspended

4.3.1. Single Casing

4.3.1.1. Discharge Through Column

4.3.1.1.1. Diffuser : VS1                                
4.3.1.1.2. Volute : VS2                               
4.3.1.1.3. Axial Flow : VS3

4.3.1.2. Separate Discharge (Sump)

4.3.1.2.1. Line Shaft : VS4
4.3.1.2.2. Cantilever : VS5

4.3.2. Double Casing

4.3.2.1. Diffuser : VS6                    
4.3.2.2. Volute : VS7

4.4. Wear Ring Running Clearances
4.5. Mechanical Seal Types / Arrangement / Plans
4.6. Cooling Water Piping
4.7. Lube Oil System

5. Conventional and Interactive Skill Tests with evaluation
6. Games � Component assembly

6.1. Overhung Pump � OH
6.2. Between Bearing Pump � BB
6.3. Vertical Suspended Pump � VS

7. Technical Glossary
8. Troubleshooting Guide

� Failure or deviation symptoms

o Pump does not deliver
o Insufficient capacity delivered    
o Insufficient discharge pressure developed    
o Pump loses prime after starting    
o Pump requires excessive power    
o Stuffing box / mechanical seal leak excessively   
o Packing / mechanical seal has short life    
o Pump vibrates or noisy    
o Bearing have short life    
o Pump overheats and seizes

� Around 45 specific root-causes have been identified similar to the few listed below:

o Pump not primed    
o Suction lift too high    
o Insufficient margin between suction pressure and vapor pressure    
o Total head required by process lower than pump design    
o Specific gravity of liquid different from design    
o Operation at very low capacity    
o Parallel operation of pumps unsuitable for such operation    
o Misalignment    
o Bearings worn out    
o Wearing rings worn out    
o Rotor out of balance causing vibration    
o Improper selection, fitting or usage of mechanical seal    
o Lack of lubrication

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