The document provides an overview of pumps, detailing their operation, classification, maintenance, and the principles of fluid dynamics involved. It discusses various types of pumps including centrifugal and positive displacement pumps, their components, efficiency calculations, and maintenance schedules to prevent breakdowns. Additionally, it highlights the importance of mechanical seals, common pump failures, and necessary inspections for optimal performance.

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Pumps

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

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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.

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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.

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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 receives 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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Plunger Pump

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Diaphragm Pumps

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Lobe Pump

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Gear Pump

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Rotating and stationary components

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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

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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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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

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 Water System: Circulating water at the rate of 2 lacs m3
/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

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Pump Classification
Classified by operating principle

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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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Centrifugal Screw

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Cantilever Multistage

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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

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• 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.

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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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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

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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​

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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​
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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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Pump Operations

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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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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

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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)

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

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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

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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.

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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.

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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.

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•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.

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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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Lifting/Rigging of Pump

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Laser Alignment

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

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Gland Packing Having Gland Pusher

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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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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

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

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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.

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PUMP PARAMETER

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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.

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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.

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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

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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

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Thank You