Installation and Operation of Pumping Equipment

Installation and operation of pumping equipment
Installation and operation of pumping equipment Introduction Procedures prior to installation Pump set installation - foundation and bedplate Pump set lining up and final coupling Pipe work installation Electrical installation Initial start preparations Operation procedure Routine running attention INTRODUCTION Pumps when properly installed and given reasonable care and maintenance will generally operate satisfactorily long periods al a time. As pumps are built to a wide variety of designs for many different services, this chapter can only provide general information on typical problems. When installing a particular pump, it is essential to consult the manufacturers detailed instructions which will state any special precautions required. It is important to realise that in most cases pumping problems on site are caused by bad installation or operating system problems. It is, therefore, essential that proper care and attention is taken during installation to ensure successful operation. PROCEDURES PRIOR TO INSTALLATION Although various methods of installing pumps can be adopted, the instructions detailed in the manufacturer's instruction manual and in associated data sheets should be followed. Any departure from the procedures detailed should be based on good engineering practices. Inspection of equipment On receipt of the equipment, inspect and check it against the advice note. Examine the crate and wrapping before discarding them since parts and accessories are sometimes wrapped individually or fastened to the crate. Report any damage or shortage to me supplier. If the equipment is not installed immediately, it should be stored under conditions that will prevent deterioration due to damage or corrosion.
Storage Short term. When it is necessary to store a pump for a short time before it is installed, place it in a dry location where it cannot be affected by corrosion or dirt. Protective blanking plates, fitted before despatch from the factory, should not be removed. Ensure that the bearings and couplings are properly protected against the ingress of sand, grit and other foreign matter. To prevent rusting-in or seizing, lubricate the unit before storing and turn the pump set by hand at least once a week. Long term. More thorough precautions are required if the pump is to be stored for an extended period of time. Consult the manufacturer for full information on long-term storage. Cleaning prior to installation All parts of the assembly must be thoroughly cleaned before installation begins. All traces of rust preventative should be removed from the discharge and suction flange faces, exposed shafting, and alt coupling surfaces. Lay-out of pump parts for installation Avoid damage to components when handling or installing them. If suitable lifting tackle is not available, skids should be employed to transfer heavy weights to ground level. Loaded crates or individual components or sub-assemblies must never be dropped to the ground from a transport vehicle. Lay out individual components on suitable timbers or other clean surfaces in the order in which they will be fitted. Check the components against the packing list to ensure that all are available. Any packing or other protective material shall be removed before starting the installation procedure. PUMPSET INSTALLATION FOUNDATION AND BEDPLATE Since horizontal base plate pump sets are by far the most common equipment supplied, the following description will concentrate mainly on this type of plant. General Hydraulic and/or electrical plant is usually assembled on a single bedplate. The bedplate may, however, be supplied in two or more sections. To facilitate leveling and grouting, all components should preferably be removed from the bedplates (refer to 'Note' below).
To ensure satisfactory operation of the plant, it is essential that the bedplate be properly leveled, bolted down and grouted in. Pump set foundation An adequate foundation is essential. It should consist of a solid block of concrete sufficiently massive and rigid to provide continuous support for the bedplate throughout its whole length, and to maintain this support throughout the operating life of the equipment. The foundation level should allow 25 mm for leveling of the bedplate(s), and holes prepared to accommodate the foundation bolts. Each hole should be either 100 mm diameter if drilled or 100 mm square if shuttered. Grouting The main reasons for grouting are to prevent lateral movement of the bedplate to support the channel flanges, which, in turn, carry the machine pads and to reduce vibration. Grout should comprise one part portland cement and two parts sand (no aggregate) with sufficient water to produce a free flowing heavy cream consistency. The mixture described should flow easily under the bedplate and, in order to minimise settlement, it is best to mix the grout and let it stand for two hours, re-mixing it thoroughly before use but adding no more water. The exposed surfaces should be covered with hessian to prevent the grout cracking by too rapid drying. The Hessian should be kept damp until the grout is sufficiently set (about 48 hours). Leveling of bedplate Set up and level steel packers adjacent to and on each side of the foundation bolt holes to within 6 mm of the final height of the bottom bedplate pad. Follow this procedure round the plinth with packers each side of each hole, embedding them in concrete, preferably quick setting compound such as Fondu. Sling and lift the bedplate to insert the foundation bolts before positioning on the plinth. Align and level to correct height using laminated packers on top of the packers already set, as in previous paragraph. NOTE: In the case of smaller size bedplates, providing they have been checked to ensure that no distortion has occurred during transit or handling, it is acceptable practice to grout the bedplate with pump and motor mounted thereon together with the foundation bolts in one operation. Certain contracts may require special instructions in this regard in which case the contract documents should be consulted.
The foundation bolts are to be grouted at this stage and each pocket filled with grout to within 25 mm of the top, thus providing a key for the final grouting of the bedplate. The bedplate is to be left in position until the grout has set hard (normally 72 hours). After foundation bolts are set, an accurate spirit level and steel straight edge should be laid on the various machined pads on the bedplate to check parallel and diagonal levels, and the amount of packing beneath the bedplate adjusted until all corresponding pads are level. A degree of level of 0.1 mm per 1000 mm length of bedplate is acceptable. To obtain this level, should the bedplate have been distorted to any appreciable extent in transit, it may be necessary to adjust packing under the bedplate and to tighten certain of the foundation bolt nuts to strain the bedplate down at certain points. It is for this reason that the foundation bolts are grouted in first. It should be remembered that when an adjustment is made, the level in another direction will change. After leveling and alignment is completed and all foundation bolts pulled down tightly, preparation for grouting the bedplate can commence. Shuttering should be erected all round the bedplate to a height of at least 76 mm above the lower flange of the channel to give a slight head on the grout; thus the boarding should normally be 102 to 115 mm high. The shuttering should be positioned such that when it is removed, a rectangular section of grout 76 x 50 mm wide remains around the outside of the bedplate. Saturate the top of the rough foundation with water and pour the grout between the shuttering and the bedplate until it passes beneath the lower flanges, so that when hardened it supports these by rising about 50 mm above the lower flanges. The flow should be assisted by agitating with a bent wire (or similar) from all sides and from-the centre of the bedplate. NOTE: It is important that the grout fills the cavity between the lower flanges and the foundation and must not shrink from the bedplate while curing. When the grout is set (normally about 48 hours) the shuttering should be removed and a smooth finish given to grout and foundation surfaces. Direct coupling In the case of the coupling being of a special type, the manufacturer's instructions should be referred to. Dowel pins, fitted after the machine is correctly aligned and bolted down, are intended to facilitate correct relocation of the machine if it is removed and replaced at any lime. Dowling is done at the time of installation.
PUMPSET LINING UP AND FINAL COUPLING Initial checks Examine the oil or grease used for lubrication for both the pump and driver bearings prior to start. Frequently equipment is left lying on site for many months and condensation or ingress of dirt and water from the external environment may occur. It is usually best to clean out the lubricant and replace it. The pump bearings should also be checked at this time. If they are of the ball bearing type, damage to the bearings can occur if the pump has been left in one set position for several months or near a source of vibration. Damage to the contact surface of the balls occurs; this is known as false brinelling and if the pump is run under this condition, the bearing will fail fairly rapidly. Pumps with this type of bearing, when required to be stored for several months should either have the bearings removed from the pump before storage or should be rotated a quarter of a turn every few weeks to prevent this happening. Plain bearings should be checked for corrosion and ingress of dirt which can cause damage when the pump is run. Turn the pump half-coupling to ensure that the pump rotating assembly is quite free and that no distortion or damage has occurred in transit. NOTE: In the case of a multistage pump with a balance disc, ensure that before rotating the shaft, the balance disc is clear of its mating renewable face to avoid galling. Check that the drive rotor is free to turn. Lining up pump and driver Mount the pump on the bedplate, taking care to ensure that the feet of the pump and the bedplate pads are perfectly clean and free from burrs. Locate the pump by means of the dowel pins, if supplied, before tightening the holding down bolts. The faces and periphery of the half couplings should be cleaned thoroughly to ensure that all rough or ragged edges are removed as these will give false alignment readings. Place the driver and/or gear box on the bedplate, having checked that the feet are perfectly clean and free from burrs and insert the holding-down bolts but do not tighten up. Check the height of the pump and driver and/or gear box couplings and insert shims (which must be clean and free from oil and burrs) under the driver and/or gear box feet to obtain initial approximate coupling alignment. Final coupling When running, the half-couplings should be separated by a gap dependent upon the type being used, and this distance should be confirmed from the general arrangement drawing.
NOTE: If the motor is fitted with sleeve type bearings, the coupling gap must be set with motor rotor in its magnetic centre. Most motors have the magnetic centre marked, but for further details consult the motor instruction manual. Where dial gauges are available to check coupling alignment, follow the procedure shown in Figure l (b). Where these instructions are not available, the procedure in Figure l (a) may be used. Once final alignment is complete, the driver feet should be tightened down and the alignment re-checked. Check the coupling alignment after the pump set has been running for a period of four to six weeks (or until settlement of foundations is completed), then drill and ream the driver feet for dowel pins. NOTE: (a) Where possible, couplings should be aligned within 0.025 mm. i.e. 0.050 mm full indicator movement on dial gauge. (b) It must be emphasized that since pin and bush type couplings are designed to reduce the transmission of shock to bearings, etc, and do nut compensate fur misalignment they require the same accuracy of alignment as rigid couplings. (c) Some couplings notably double engagement gear type laminated metal element spacer type and rubber type couplings, can operate satisfactorily with a greater degree of misalignment. The greater flexibility of these couplings is intended to compensate for misalignment which may develop during operation, due to pipe work loads, settlement of foundations, etc. and does not preclude the need for accurate initial alignment. For procedure to be followed when aligning these couplings see separate instructions supplied by manufacturer. (d) Alignment procedures fur electric motors depend on motor construction. Motors with end shield mounted bearings can be aligned by moving the complete machine. This will not upset air gaps. Motors with bedplate mounted pedestal bearings are aligned by moving bearing pedestals. This will alter motor air gaps and stator must then be moved to equalise air gaps. Check air gaps at 12, 3, 6 and 9 o'clock positions, making measurements at both ends. Turn rotor through 180 and repeat measurements. No measured air gap should differ from the mean of measured air gaps by more than 5 %. (e) When checking the directions of motor rotation, ensure that the pump has been disconnected from its source of power, i.e. disconnect coupling/belt drive as appropriate. Axial alignment (Fig.1) Lay a straight edge across the rims or hub tops of the two half couplings and check radial alignment at quarter positions. Both couplings should be rotated and readings checked at quarter positions. Check the radial gap as shown, again at quarter positions and rotating both couplings. Any repositioning of the motor (see Note (d)) to correct for radial misalignment must be followed by a further check on gap clearance which should be carried out again at four points, at 90 to each other using either a taper or a parallel gauge in conjunction with feelers.
Parallel alignment (Fig. 1) 1. Clamp a dial gauge to the coupling halves as shown in Figure l (e) and zero the gauge. 2. Link the coupling halves so that both shafts can be rotated together. If the shafts cannot be linked together, mark each coupling half with a coincident line. 3. Rotate both shafts and take readings at each quarter revolution. If the shafts are not linked together, move first one shaft through a quarter revolutions, then move the other until the lines marked coincide. Take a reading and repeat at each quarter rotation. Angular alignment (Fig.1) 1. Clamp two dial gauges to the coupling halves as shown in Figure l (f) and zero the gauges. 2. Link the coupling halves or mark them as previously described. 3. Rotate both shafts thought 180 and note the gauge readings. If both gauge readings are the same (but not necessarily zero) the angular alignment in the vertical plane is correct 4. Rotate both shafts through a further 90 and note the gauge readings, if the readings are the same (hill not necessarily zero), the angular alignment in the horizontal plane is correct.
AXIAL ALIGNMENT a & b
PARALLEL ALIGNMENT (c & d) ANGULAR ALIGNMENT (e & f) Fig 1 Coupling alignment
PIPEWORK INSTALLATION General It is essential that no load be imposed on the pump branches as this is liable to disturb shaft and bearing alignment resulting in excessive wear and possible seizure. The pipe work should therefore be independently supported and anchored against pipe thrusts. When erecting the pipe work the pump flanges should be the final closure joints. Check coupling alignment before and after the pump flanges have been tightened. Any alteration in alignment is indicative of pipe work loading on the pump branches and steps must be taken to remove the load.
Fig. 2 Do not overstrain the pipe work when connecting to pump Suction pipe work Where possible, arrange for the pump to operate on a positive suction. Eliminate all possibility of air pockets being trapped in the suction pipe work, e.g. ensure pipe work rises continuously towards the pump; where pipe diameter is reduced in direction of flow use flat topped taper pieces. The diameter of the suction pipe should be sized according to the flow and allowable head loss and may not, therefore, be the same diameter as the pump suction branch. A short straight length of pipe adjacent to the pump suction branch is desirable. Where a bend is unavoidable, it should be of the largest possible radius. The suction pipe should be accessible and not embedded in concrete. When choosing foot valves, strainers, bends, etc. select those which will provide minimal restriction to flow. Some care must be taken in the design of the suction inlet. Ideally the pipe end should be at a depth of at least five pipe diameters below the surface, and at least 0,5 mm from any
side wall. If the pipe must be at a depth significantly less than this, it is recommended that it be positioned within 150 mm of the side wall to reduce the possibility of vortex formation. Delivery pipe work It is essential to ensure that delivery pipe work is adequately supported and anchored to resist hydraulic thrust. When selecting valves for delivery pipe work, the following points should be noted: 1. The diameter of the valve is not necessarily based on the diameter of the pipe work and is dependent on flow. 2. Non-return valves should be sized to give a maximum flow velocity of 3 m/s. Where a surge vessel is fitted to the pipeline or pumps operate in parallel, consideration should be given to fitting non-slam type non-return valves. Where delivery pipes do not rise continuously and air pockets can form, it is important to provide some form of air release valve.
Expansion joints Care must also be taken when expansion or slip joints are used in the discharge and suction lines. These items are often employed to avoid transmitting any piping strains to the pump or to facilitate removal of valves or the pump without disturbing pipe work and to make erection easier by providing some latitude in the piping lengths to allow for any errors in the civil work or pipe manufacture. The use of these joints can, however, cause greater problems than they alleviate. The joints eliminate piping stresses but introduce a reaction and torque on the pump at its foundation. With the horizontal split case pump shown in Figure 3, an expansion joint used in the suction line results in a twisting moment being applied to the pump. This can produce casing distortions and bearing problems.
Fig. 3 The magnitude of the forces involved can be quite large. A vertical pump with side discharges (Figure 4), will have a side force equal to the discharge pressure times the effective expansion joint area.
Fig. 4 Precautions must be observed in the design of the piping and the positioning of the joints so that the reactions due to flow and pressure conditions are always absorbed by suitably placed supports.
10
Debris in pipes Another major source of trouble on site resulting from piping is the debris left inside the pipe work. It is important that all the pipe lines connecting to the pump on the suction side be thoroughly cleaned out before the pump is connected. Damage to pumps frequently occurs on commissioning due to nuts, bolts and tools being drawn through. The effect of nuts, bolts, welding rods, etc. entering a pump designed lo operate with tight running clearances for high efficiency can be imagined. This can be avoided by putting a mesh screen into the pump suction temporarily during the initial running period until the pipelines are fully cleared. Hydro-testing Once the pipe work has been connected to the pump, it is advisable to hydro test the system. Leaks, particularly in the suction lines, can seriously reduce the pump's performance and indeed make it impossible to prime the pump in order to start it. Ancillary supplies After the main pipe work and valves have been installed and checked, any ancillary supplies required by a pump are connected. The systems used depend on the particular application the pump is used in. Typical examples of these services would be water flushing for the mechanical seal or stuffing box of the pump, water supply to cool the bearings or stuffing box and drain lines from the pump or its base plate to carry away leakage from the gland and priming and venting pipe systems. Detailed requirements for any ancillary services will be provided by the pump manufacturer prior to installation. ELECTRICAL INSTALLATION Once the mechanical work of installing the pump and driver set is completed, the electrical controls and instrumentation must be installed. The nature of this equipment varies enormously and is outside the scope of this book. This type of work is normally carried out by an electrical subcontractor, specializing in this type of work. INITIAL START PREPARATIONS Drive unit The drive unit is checked to ensure that it is functioning correctly. In the case of a threephase electric motor, it is essential to check the direction of rotation. This should be done with the shaft coupling disconnected (see under 'Final Coupling'), as some pumps can be damaged by reverse rotation. The motor is kicked over and the rotation noted. If incorrect, two of the three electrical supply cables are interchanged to reverse the rotation.
11
Electrical controls Once the driver has been checked, the next step is to test the electrical controls and instrumentation. Five types of control transducers are most commonly used. Pressure switches, flow switches, level probes, temperature detectors and limit switches. Controls are checked by carrying out trip tests; these consist of shorting each of the control transducers and checking that the panel reacts correctly. Instrumentation usually has to be calibrated on site. The procedures for this should be obtained from the instrument manufacturers. Where an electric motor is employed, the starter system is usually tested for correct operation together with any automatically operated valves or other equipment. It is most important to check the correct functioning of the electrical equipment before the mechanical equipment is operated. At the very least, the mechanical plant may not function correctly and at worst severe damage may occur to the equipment. For example, some types of starter can reverse the direction of an electric motor in mid-sequence. This will produce dangerous results, particularly if a large or high speed machine is being operated. Ancillary services Any ancillary services required by the pump must now be tested- For example, it is most important that a pump with an external flush supply to its packed gland or mechanical seal is not run without this supply, as severe overheating will occur after a short period of running with consequent damage occurring to the pump. Water supply Finally, and very fundamentally, it is important to ensure that a supply of water is available to the pump. On many occasions, the commissioning engineer has been called to site to test a pump only to find, on arrival, that no water is available. Needless to say, running a pump without water is not recommended. Vertical spindle pump When vertical spindle pumps are installed, there are often some additional checks to be made to those already described. With a vertical spindle pump of an open design impeller, the impeller clearance to the bowl of the pump has to be set and in some instances a p re-lubrication tank is provided to flush the bearings with water before start up. This must be tested for correct operation. Some of these pumps have oil fed bearings and the supply reservoir must be checked periodically to ensure it is full. Most pumps are fully assembled and checked at the manufacturer and do not require any internal adjustments on site. Vertical spindle pumps are an exception to this because, often due to their length, they are shipped in several pieces and, therefore, have to be assembled on site.
12
OPERATING PROCEDURE The following procedure outlines the most important steps involved in pump operation. Any departure from this procedure must be based on good engineering practice. Priming Priming a centrifugal pump involves the removal of air, gas or vapour from the suction pipe work and pump casing. As centrifugal pumps are generally not self-priming, they must be primed prior to start up. If this is not done, the pump will not operate and, in addition, serious damage to water lubrication bushes could result. The simplest method of priming is to arrange the pump so that it has a positive suction pressure. The pump can then be fitted by opening the air cock provided. Where a positive suction is not possible, it is normal practice to fit a foot valve and strainer to the suction pipe inlet and use one of the following methods of priming: 1. Back priming from the delivery using a bypass round the non-return valve. It is important to ensure that the suction pipe work and valves are rated for the delivery pressure. 2. Using a tundish fitted at the highest point on the pump casing, fill the pump and suction pipe work using an external water supply. 3. Vacuum priming equipment, such as an air or water operated ejector (jet pump) or a rotary exhauster, can be used to draw water from the suction into the pump casing. Venting is an operation carried out to remove any trapped air pockets in the system and may be necessary on the suction pipeline as well as the pump. Many modem designs of pump are inherently self-venting. The volute of the pump is arranged so that air pockets cannot form. However, some types of pumas, particularly multistage and side or bottom discharge pumps do require venting. Normally suitable venting cocks or automatic vent valves are fitted. Pipe lines also often have air release valves fitted at high points to vent out trapped air pockets. In a new system, the pump should stay fully primed from shut-down to start-up, making further action unnecessary. However, foot valves are liable to wear or jam and may lose the prime after a short period. It is advisable, therefore, to check the state of prime before start-up. CAUTION: It is important that air does not leak into the pump during operation, as even if the pump operates under such conditions, serious damage may result.
13
14
Starting 1. Before initial start-up, disconnect the drive coupling and check the rotation of the driver. An arrow on the pump casing indicates the correct direction of rotation. 2. Check the pump shaft for freedom of rotation. 3. Where external scaling water is to be provided, check that the supply is available at the specified pressure (normally 65 to 100 kPa above pump suction pressure). 4. Ensure pump and suction pipe are correctly primed. 5. Ensure suction isolating valve (if fitted) is fully open. 6. Ensure delivery isolating valve is closed. NOTE: Where starting conditions have been checked, the pump may be started with an open delivery valve. 7. Where a surge vessel is fitted in the pipeline, check that the air volume is correct. 8. Start the driving unit according to the manufacturer's instructions. 9. Open the pump delivery valve slowly until the required pressure or flow is obtained. CAUTION: a. Prolonged running with a closed delivery valve can damage pump internal components and must be avoided. b. If the delivery pressure does not build up, stop the pump and repeat priming operation. NOTE: Ideally, a pump should have a non-overloading power absorbed characteristic (Fig. 5). The electrical equipment is then sized for this maximum power and the pump can then be operated over its whole range without danger of overloading. However, in many cases, it is not possible to achieve this type of characteristic. Pumps of low specific speed (i.e. centrifugal pumps) often have rising power characteristics (Fig. 6) and are thus usually started against a closed discharge valve. This reduces the total power demand required at start up and thus reduces the peak current drawn during the starting cycle. As soon as the pump is up to speed, the discharge valve is then opened fully, Pumps with a high specific speed, i.e. axial flow units, usually have a drooping power characteristic (Fig. 6). These pumps are never started against a closed discharge valve; to do so would require a much larger motor than necessary for normal operation and additionally higher rated switchgear would be needed. This entails unnecessary cost. If it is essential for the system to have closed valve on start up, a bypass tine can be installed.
15
Stopping the pumping equipment This procedure may seem very simple and in many cases it is. A typical sequence of operation for shutting down the pump set might be: 1. First shut down the driver (as the pump stops the discharge non-return valve shuts and prevents reverse flow of liquid through the pump). 2. If the pump is not required for some time, the suction and discharge isolating valves can be closed and any ancillary services such as cooling or flushing lines can be shut down. 3. Finally, in some instances, it may be desirable to drain the pump set, i.e. if maintenance is required. This simple procedure, however, can become rather more complicated. When pumps have to be stopped and started at frequent intervals, automatic control equipment is often used this might consist of actuators fur valves or systems to prevent the pump losing rime or systems to automatically re-prime the pump. Additionally, a fair amount of electrical control and instrumentation may also be used so that the pump sets can be monitored and operated from remote locations. Where an axial flow pump is used and operates against an open discharge, it may be found that, after switching the pump off, a syphon is created which will result in the reverse flow of water through the system. In this case, a syphon breaker system is obviously necessary.
16
17
ROUTINE RUNNING ATTENTION As soon as the pump has run up to a speed, a number of routine checks must immediately be carried out. 1. Soft packed glands must be checked to ensure that there is a slight leakage from the gland. This lubricates and cools the gland. Excessively tight glands cause wear to the shaft or sleeve and the pump uses excessive power. 2. The bearings of the pump and driver must be checked to ensure that there is no overheating. As a general rule, it should be possible to hold a hand on a bearing housing without discomfort, although some designs do run at a greater temperature. A common cause of overheating with anti-friction bearings is over or under packing with grease. 3. Where auxiliary services are required by the pump, such as flushing or cooling supplies, these must be checked to ensure they are operating satisfactorily. If possible, pressure gauge readings should be taken to ensure that the pump is operating at the correct duty. On the suction side, an unduly low reading may indicate a blockage in the line or a valve not fully open. Similarly on the discharge side, an unduly high reading would indicate the same. It is important that the pump runs within the correct band of differential head that it was designed for. When a differential pressure reading is too low, the pump may start to cavitate which can cause damage if allowed to continue for a long period. A very low discharge pressure may be the result of a valve left open in the system, or the system characteristics not as originally calculated. It is equally important when monitoring the operation of a pump that the pump is not run for long periods at too high a differential pressure and hence at too low a flow rate. As a general indication, a pump should not be run at less than 15 % of its best efficiency point flow rate. In many types of pump operating at reduced flows can cause overheating in the pump (Fig.7). Since no pump is 100% efficient, the inefficiency in the pump's conversion of power into hydraulic energy results in heat, which is transferred to the liquid passing through the pump. The severity of the temperature rise in the pump depends on the ratio of the quantity of liquid passing through the pump to the amount of heat generated by the pump per unit time. When liquids containing abrasive particles are pumped, low flow rate operation also greatly increases the internal wear in the pump the abrasive particles recirculate in the pump instead of passing straight through. If closed valve or low flow rate operation is unavoidable, a bypass system should be used and adjusted when the pump is running to maintain a minimum of 15% flow through the pump. Low flow operation also imposes unacceptably high thrusts on volute casing designs. This ultimately results in shaft failures. Most pump installations with electric motor drivers have an ammeter installed. This instrument is a good indication of running problems. If the ammeter is running at a higher value than it should, then the pump may not be running at the correct duty. This can be checked with pressure gauges. Also, if the pump is not running freely, a packed gland
18
may be too tight or solids in the liquid may have built up behind the impeller or in the eye ring areas. Other problems to look for when the pump is running are excessive vibration and noise from the pump. Vibration can be caused by misalignment of the pump and driver or distortion of the pump by the pipe work or distortion of the base plate due to foundations shifting. This can be checked and corrected if necessary. Vibration can also be caused by hydraulic problems, either in the system or in the pump. One of the simplest examples of this is cavitation which can occur under the conditions already mentioned. This problem will result in the pump running roughly and making loud cracking noises, which are caused by vapour bubbles collapsing in the pump water passages. Vibration can also be set up in the pipe work system; this may be due to resonance set up by throttling or other restrictions in the system, the use of short radius bends at too high a flow rate or possible water hammer in the system on start up. All of these factors can cause a particular installation to vibrate or operate noisily.
19

Installation and Operation of Pumping Equipment

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Installation and Operation of Pumping Equipment

Transféré par

Droits d'auteur :

Formats disponibles

Installation and operation of pumping equipment