SUMMARY OF JOB CARRIED OUT BY ME.

MAINTENANCE OF FOUR STAGE CENTRIFUGAL PUMP

Centrifugal pump is a machine which uses centrifugal forces to achieve the transfer
of incompressible fluid form one point to another through a pipeline or lift liquid
form lower elevation to higher elevation. The centrifugal force occur as a result of
the rotation of the rotor of the pump. The pump rotor mainly consist of the impeller
and the shaft.
The general principle of centrifugal pump is that incompressible fluid enters the
impeller at the eye in a direction which is axial or nearly so, passes out through the
blade passages and is discharged at the periphery of the impeller with a velocity
relative to its which has an outward and backward circumferential component. The
absolute circumferential component in the forward direction of the relative
velocity. A centrifugal pump is essentially comprised an impeller which rotates
inside a liquid tight pump casing.
Four stage centrifugal pump is a sensitive equipment in any industrial operation
setup. To properly carry out maintenance activities for such an important
equipment to prevent breakdown of the equipment the following maintenance
activities are carried out. Cleaning, Lubrication, Replacing faulty parts, Preventing
of environmental deterioration, Testing and inspection.
DESCRIPTION OF VARIOUS PARTS
 Pump Casing: this is made of cast and consist of two halves which are bolted
together horizontally, correspondence with the pump center-line. It houses
the internal parts of the pump such as the impeller, diffuser, dynamics part
of mechanical seal, carbon bushed, and mechanical sleeve.
 Pump Rotor: This consist of the pump shaft and the impeller which is fitted
on the shaft. The pump rotor transmit the dynamic motor or steam turbine.
 Shaft: The pump shaft form the major part of the rotor. It is a solid shaft,
machine to accurate size with the necessary steel treatment. The shaft carry
the load of the pump. The pump impeller and other rotating parts of the
pumps are mounted on the shaft.
  Pump Impeller: This is the part that impact energy to the liquid to give it
velocity and momentum. This is the part that directs the products flow within
the impeller are the vanes / blades.
 Wear Rings: The wear rings are support surface on the outside of the
impellers eye and internally on the casing. The wear rings allows fluid
leakage between impellers and casing which serves as a hydraulic seal, it also
serves as a balance between suction and discharge.
 Bearings: This help to keep the pump rotor in a singular concentric position
and free of axial float.
MAINTENANCE PLANNING FUNCTIONS.
The maintenance planning functions include: Drawing up comprehensive
inspection program, Listing out intervention activities / periods, Preparing repair
strategies, Scheduling of jobs, Provision of necessary tools, equipment, spares.
Checking of work in progress, certification of completed jobs, job costing and report
writing.
TROUBLESHOOTING ON CENTRIFUGAL PUMP
1. No liquid delivered
Causes: Lack of prime, Suction lifted too high, Discharge head too high or
Impeller plugged.
Job Done: Full pump and suction pipe completely with liquid, If no
construction at inlet check for pipe friction losses. If static lift is too high
liquid to be pumped must be raised or pump lowered. Dismantle pump and
clean impeller.
2. Not enough pressure:
Causes: Speed too slow, Air leaks is suction piping or Mechanical defects
obstruction in liquid passage.
Job Done: Check the speed of turbine to be up to rated speed if not adjust
the turbine governor to give the required speed. Test flanges for leakage
suction line can be tested by plugging inlet and putting line under pressure,
Inspect impellers and shaft replace it damaged or vane sections badly eroded
and replace packing or mechanical seal.
3. Pump Operates for short time and then stop:
 Causes: Incomplete Priming, Air leaks in suction piping, stuffing box and
inadequate amount of coolant.
Job Done: Free pump piping and values of all air, correct any high points in
suction line and test flanges for leakage. Inspect the cooling water hire
through the sight glass for proper functioning if not clear the hire for good
circulation of the cooling water.
4. Excessive Vibration and Noise:
Causes: Cavitation or Bearing failure
Job Done: Correct the conditions that create cavitation e.g. Check pipe
connections or replace the inboard and the outboard bearing of the pump.
5. Broken Shaft:
Causes: Shock Overloads, Improper lubrication of bearing or Poor shaft
alignment.
Job Done: Check the system to determine the source of these overloads and
correct the situation before using the pump again, use the right lubrication
efficiently or Re-align shaft properly.
6. Broken Impeller blades:
Causes: Foreign solid Object in pump
Job Done: Dismantle pump, remove the foreign object and replace broken
impeller.
7. Rapid Seal and Packing wear:
Causes: Improper adjustment of packing gland
Job Done: Adjust mechanical seal or packing gland properly.