MM O&U, Urea

Centrifugal
Pumps
Overview Report

Ahsan Latif
GTE
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About
Pump is a machine that imparts energy to the liquid.t
To move liquid from one point to another at same or higher elevation.
To increase pressure of the liquid.
A pump that works on the basis of centrifugal force is called Centrifugal
Pump. Liquid enters the suction nozzle and then into eye (center) of an
impeller. It spins the liquid sitting in the cavities between the vanes
outward and provides centrifugal acceleration. Fluid is pushed in a
tangential and radial direction by the centrifugal force

Capacity: The flow rate with which liquid is moved or pushed by the pump
to the desired point in the process. Head: The head is used to measure the
kinetic energy created by the pump. In other words, head is a
measurement of the height of a liquid column that the pump could create
from the kinetic energy imparted to the liquid.Static Suction Head (Hs):
Head resulting from elevation of the liquid relative to the pump center line.
Static Discharge Head (Hd): It is the vertical distance in feet between the
pump centerline and the point of free discharge or the surface of the liquid
in the discharge tank.Friction Head (Hf): The head required to overcome
the resistance to flow in the pipe and fittings. It is dependent upon the size,
condition and type of pipe, number and type of pipe fittings, flow rate, and
nature of the liquid.Vapor Pressure Head (Hvp): Vapor pressure is the
pressure at which a liquid and its vapor co-exist in equilibrium at a given
temperature. Pressure Head (Hp): Pressure Head must be considered
when a pumping system either begins or terminates in a tank which is
under some pressure other than atmospheric.

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Velocity Head (Hv): Refers to the energy of a liquid as a result of its

motion at some velocity ‘v’. It is the equivalent head in feet through which
the water would have to fall to acquire the same velocity.
Total Suction Head (HS): The suction reservoir pressure head (Hps) plus
the static suction head (Hs) plus the velocity head at the pump suction
flange (Hvs) minus the friction head in the suction line (Hfs).
HS = Hps + Hs + Hvs – Hfs
Total Discharge Head (HD): The discharge reservoir pressure head (Hpd)
plus static discharge head (Hd) plus the velocity head at the pump
discharge flange (Hvd) plus the total friction head in the discharge line
(Hfd).
HD = Hpd + Hd + Hvd + Hfd

Net Positive Suction Head (NPSH): Net Positive Suction Head (NPSH) is the
total head at the suction flange of the pump less the vapor pressure
converted to fluid column height of the liquid. Pump input or brake
horsepower (BHP): is the actual horsepower delivered to the pump shaft.
Pump output or water horsepower (WHP): is the liquid horsepower
delivered by the pump.
Pump Efficiency: The pump efficiency is the ratio of BHP and WHP.
Best Efficiency Point (BEP): is the capacity at maximum impeller diameter at
which the efficiency is highest.
Specific speed (Ns): is a non-dimensional design index that identifies the
geometric similarity of pumps. It is used to classify pump impellers as to
their type and proportions. Pumps of the same Ns but of different size are
considered to be geometrically similar, one pump being a size- factor of the
other.
Suction specific speed (Nss): is a dimensionless number or index that
defines the suction characteristics of a pump. It is calculated from the
same formula as Ns by substituting H by NPSHR.
Affinity Laws: are mathematical expressions that define changes in pump
capacity, head, and BHP when a change is made to pump speed, impeller
diameter, or both.

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Parts
Following are the major parts of pumps;

Bearings
Wear rings
Impeller
Casing
Diffuser
Stuffing Box
Seals/Packing

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API Pumps

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Overhauling Procedure
Single Stage Pump |

DISMANTLING
Drain all possible fluids from the pump case and bearing housing.Disconnect all
auxiliary piping which includes cooling water lines to bearing housing (inlet and
outlet), seal flush line inlet and out let.
Disconnect driver to pump coupling and remove coupling spacer.When disasse
mbling the pump, match mark, tag or otherwise identify all parts, and provide s
eparate container for small parts.
Hang pump load on chain block before dismantling pump from casing olute.
Remove back plate/leveling pate installed to support bearing housing.
To remove pump from casing volute, first remove studs and bolts, then use jack
bolts in the taps provided to break cover to case gasket joint.
Carefully slide pump from casing volute, ensuring that no touching takes place.
Once the pump has been removed from casing volute, shift the pump to
maintenance work shop to carry out further dismantling.
Remove impeller lock nut by turning it in the revolving direction.
Remove the impeller and impeller key from the shaft.Mechanical seal is dismantl
ed as per following steps:
a. If the seal has an outside drive collar, engage seal setter plates, then loosen
set screws prior to removal of mechanical seal assembly
b. Remove bearing bracket to cover cap screw
c. Slide pump cover, with seal attached, off pump shaft. Place the cover, with s
eal flange facing upwards, or work bench.
16.Use a puller to remove the pump half coupling.b. Ensure use of safe heating
method For fan cooled bearings, remove screws and remove the fan housing fr
om bearing bracket.
Remove the oil ring retainers.e. This is to avoid damaging the O-
ring in the bearing isolator.Pump shaft can only be removed in one direction. Pr
ess pump shaft from impeller end through the bearing bracket. g. Remove radia
l bearing from shaft
Remove locknut and lock washer and remove thrust bearing.
Use a puller to remove bearings.

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Performance Curve

TITLE BOX
The title box provides information about the pump model, size, speed, and
other identifying criteria specific to the pump. If checking the performance
of an existing pump, confirm that you are matching the pump to the
associated curve.
FLOW
To start your selection, identify the amount of flow you require from the
pump. For this example, we have chosen 300 gpm. Flow is indicated across
the bottom horizontal axis of the curve.
HEAD
You will also need to know the total head the pump is required to overcome
at the specified flow. For this example, we will use 100 ft. Head is indicated
in increments along the vertical axis. Follow 100ft across the curve
intersects your flow line which indicates your performance point.
IMPELLER TRIM
To accommodate different performance points, centrifugal pumps have the
capability of trimming impellers. By reducing impeller size, the pump can be
limited to your specific performance requirement. The impeller diameters
are listed on the left side of the curve and the performance for each trim is
shown across as a bold line. Our selection is between 10” and 11” so a trim
of 10.5” is appropriate
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Performance Curve
Knowing how to read a centrifugal pump curve is essential
to the health of your system. Running too far out on the
curve, or too far back, can cause damage to the pump,
excessive energy consumption, and overall poor
performance.

HORSEPOWER
Now that you have your performance point, we can determine the amount
of horsepower required. Horsepower is indicated across the curve as a
dotted line in this case at a downward angle. Our performance point is
between the 10hp and 15 hp lines, we estimate this selection to require 12
hp.
NPSHR
Net positive suction head required is important for proper pump operation.
This is the minimum amount of pressure on the suction side of the pump to
overcome pump entrance losses. If sufficient NPSH is not met the pump
will cavitate which will affect performance and pump life.
EFFICIENCY
When selecting the best pump for an application, efficiency many times is
an important factor. The higher the efficiency, the less energy required to
operate for a specific performance point.
MINIMUM FLOW
A centrifugal pump requires a minimum amount flow to be moving through
the pump to dissipate heat created. On the left side of the curve, minimum
flow is indicated by a vertical bold line; operation to the left of this line is
not recommended and can significantly decrease the life of the pump.
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Pump Overhauling
Reports
The pumps that were overhauled in the last month after
september. Major job reports are discussed for root cause
analysis.

1 P-1365

Observation
- Bush Worn Out
- Rotating Sleeve Eroded
- Impeller Worn Out
- Bush Seating Ovaled .

Activities Performed
- Prepared Rigging Arrangement
- Dismnatled the pump Assembly
- Replace Impeller and Bushes
- Runout and Clearance Checks
performed
-Pump assembled and installed back

Root Cause Analysis

- Sand Heavy Sludge comming in
suction.

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Pump Failure Analysis

Frequent Running issues in pumps.

Most of the pumps come into the shop for repair because of the following these
reasons:

Something is wrong with the bearings.

The pump’s seal is leaking too much.
Pump’s vibrations are quite high.

Rotor Packing
Visual Inspection.
Excessive wear causing leakage.
Dimensional Measures.
Overheating
Look for any crack / rubbing marks /damage
Look for the signs of cavitation or re-
Causes
circulation
Incompatible material for the service
Carry out DPT for checking of any minor
causes wear.
cracks
The service and/or flushing fluid is not
Check balancing holes or the vanes
clean or the fluid line is clogged
Ensure impeller is balanced
Soft material of the shaft or sleeve.
Check wear ring roundness / clearance
Check wear rings integrity with the impeller

Bearings
Premature bearing failures occurs because of the following main reasons:
Overheating
Over lubrication is the most common cause of overheating.
Loss of lubrication is also one of the main causes.
Over loading of bearings.
Contamination of the bearing Oil
Water, moisture & sludge are the biggest problems.

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