Pumps Classification

Pumps

Dynamic Pumps

Positive Displacement

Special

Peripheral

Centrifugal

Rotary

Reciprocating

Cryogenic Jet Ejector Jet Boosted Gas lift Ram (Hydraulic)

Radial Flow

Axial Flow

Mixed Flow

Single Stage

Multi Stage

Pumps Classification
Centrifugal
Mixed Flow

Radial Flow

Axial Flow

Single Stage

Multi Stage

Single Stage

Multi Stage

Open Impeller Semi Open Imp. Closed Impeller

Semi Open Imp. Closed Impeller

Semi Open Impeller Closed Impeller

Semi Open Impeller Closed Impeller

Pumps Classification
Rotary

Cam

Gear

Screw

Vane

Internal

External

Pumps Classification
Reciprocating

Piston

Plunger

Piston

Single Acting

Double Acting

Simple

Multiples

Fluid Operated

Mech. Operated

Simple Multiples

Simple

Multiples

APPROXIMATE UPPER LIMIT OF PRESSURE AND CAPACITY BY PUMP CLASS

Pump Selection
A wide range of pumps are available for most applications. In selecting a pump the following criteria should be considered:

Flow: Rate at which the pump will deliver, measured in gallons/hour (gph),
gallons/min (gpm); litres/hour (l/h) or litres/min (l/m).

Head: Maximum height to which the pump will deliver (neglecting piping
friction losses). This is also a measure of the pump's pressure.

Suction Lift: Needed where the water source is lower than the pump. Some
pumps are not self-priming and need to be below the water source to be fed by gravity.

Total Head

: This is the entire vertical distance from water source to

the tank.

Horizontal Distance: Pumps cannot move water very far by suction, even if
the lift involved is below it's limit. So if large distances from source to tank are involved the pump is normally located at the supply and the water pressure used. Adequate wiring must then be used to compensate for voltage drop. Large diameter pipes will minimise losses due to pipe friction. For large distances particularly if large volumes of water are required the simplest route may be to use standard 230 Vac pumps run from an inverter.

Power Consumption: Not the least important consideration in a remote

power system! Flow, Head, Pressure & Power Consumption are all related: for the same pump, the greater the lift the lower the flow and the more power used.

Pump Terminology
Shaft
Carries impeller, bearings. Transmits drive from prime mover.

Impeller -

Either open, closed or semi open takes medium From eye of impeller and imparts kinetic Energy to it. Support shaft and absorb axial thrust.

Bearings Head -

Pressure differential between suction pressure And discharge pressure.

NPSH

Net positive suction head. The minimum height (In metres) of a column of water required at The pump suction, over and above the liquid Vapour pressure to avoid cavitation

Eye

Opening by which the liquid enters the Impeller.

Series & Parallel - Differing methods of setting up pumps for operation. If A

greater flow is required pumps are set in parallel. If a greater pressure is required pumps are set in series.

The Principle of Operation

Impeller Classification According To The Mechanical Construction:1.Enclosed impeller, with shrouds or sidewalls enclosing the waterways from both sides. 2. Open impeller, with no shrouds 3. Semi-open or semi-closed impeller have one side shroud

4. Impeller Classification

Pump Start Up and Shut Down

1.Pump Start Up
After the pump has been installed and coupling alignment completed, an appropriate checklist may be consulted and these steps should be followed for a successful start up: 1. Check for sufficient proper lubrication for pump and driver. 2. Drive should be checked for correct rotation. 3. Pump suction valve should be fully opened.

4. Check pump and piping for leaks.

5. Pump casing should be vented. Open vent at top of pump casing until all air is expelled.

6. If product is hot, ample time should be allowed for pump casing to heat up. Pump casing and rotating assembly could distort from uneven heat transfer.

7. Before starting, rotate shaft by hand. It should be free with no rubbing.

8. Crack open discharge valve, don't fully open. A centrifugal pump uses less power at start-up with the discharge valve nearly closed. This practice will also prevent initial cavitation.

9. Start pump, watch discharge pressure gage. As soon as the pump pressure stabilises, open discharge valve slowly. Watch discharge gage, discharge pressure will fall off for few turns of the discharge valve until it is fully open. Important! Never allow pump to run too long with discharge valve closed.

2. Pump shut down

The discharge valve on a centrifugal pump should be partially closed before the drive is stopped in order to prevent reversed flow. Usually, there is a check valve in the discharge line to prevent such reversed flow.

Stop motor, and then open the warm up valve if the pump is to be kept at the operating temperature. Close the valve of the cooling water supply to the bearings and of water cooling stuffing box.

LUBRICATION
A lubrication is any substance, which, when inserted between the moving surface, accomplishes these proposes :
1- To reduce the wear and friction between the contact surfaces 2- To carry away the heat 3- To act as a seal for contamination .

4- To keep the surface clean

5- To carry and absorb heavy loads.

A. Lubrication System
"The lube oil pump draws oil from the power frames lube oil sump, through a suction strainer and supplies pressurized to the inlet of the power frames integral oil supply header. The lube oil supply header distributes the oil to the crossheads, Wrist pins and the main bearings through ports in the frame. A portion of the oil supplied to the wrist pins passes through radial holes in the pins and is direct toward the crankpin . bearings through the rifle-drilled connecting rod.

Lube-oil Systems.

Control Valve System

Automatic Recirculation Valve System

A.R.C. Valve Cutaway (Yarway Valve Co.)

Priming of Pumps

Capacity Regulation of Pumps

Caution

Chapter 2
Centrifugal Pumps

The Principle of Operation

1.1 Centrifugal pumps are classified into two main types: horizontal and vertical according to the shaft centre Line.

1.2 The centrifugal pump may be defined as any pump, which uses centrifugal force to move the liquid, which it pumps. This type of pump. Literally throws the Liquid out Liquid enters the eye of the impeller, at a designed suction pressure the rotation of the impeller then throw the Liquid radically out of the edge of the impeller where it is collected in the case of the pump which is called volute 1.3. The volute is the spiral - shaped casing surrounding the impeller. It collects the Liquid discharged by the pump and convert, velocity energy to pressure energy.

1.4 As the liquid produces pressure in the volute case, it also creates an unbalanced load on the shaft bearing (radial thrust), to reduce this, a flow splitter is added, so this called a double volute Casing.

1.5 The diffuser type case is another method. to over come radial thrust .The diffuser. is a stationary vane ring around the impeller which convert the velocity to pressure all around the impeller without having any high unbalanced redial thrust at anyone point.
1.6 Impeller classification according to the mechanical construction:

1. Enclosed impeller, with shrouds or sidewalls enclosing the waterways from both sides. 2. open impeller, with no shrouds 3. semi-open or semi-closed impeller have one side shroud 4. Impeller Classification

They can also be divided according to the:

1. Number of stages - single or multi-stage

2. Suction inlet - single or double suction

3. Position of shaft - horizontal or vertical 4. Type of casing - horizontal split or vertical split 5. Mounting - in-line or base-mounted

Volute Pump

Fluid Velocity Within A Volute Pump

Single-Stage, Single-Inlet Volute Pump

Diffuser Pump

Impeller Designs

Priming of Centrifugal Pumps Single Stage Pumps

Multi-Stage Pumps Priming:

Casings and Diffusers

Diffuser Type Centrifugal Pump.

Centrifugal Pump Performance

Characteristics of Centrifugal Pumps

Two Centrifugal Pumps in Parallel

Speed Variation

Two Centrifugal Pumps in Series

Pump Constructional Drawing and Components

Single stage Centrifugal Pump

Double Suction Single Stage Pump

Stage Centrifugal Pump With Opposed Impellers

Centrifugal Pump Troubleshooting

Cavitation
Whenever we find a centrifugal pump not performing well, the causes can usually be traced back to 3 common reasons:

Suction related problem

System related problem Mechanical related problem

Suction Related Problem

The liquid inside the impeller must behave like a solid column in order for the centrifugal pump to work. More liquid must replace whatever liquid forced out by centrifugal force. If the solid column of liquid is broken, by the presence of air, the pumping effect is reduced or broken, and the pump does not perform properly. Some of the common suction related faults are: Pump not primed Pump suction pipe not completely filled with liquid Suction lift too high Insufficient margin between suction pressure and vapor pressure Excessive amount of air or gas in the liquid Air pockets in the suction line

 Air leaks into the suction line Air leaks into the pump through the stuffing box or gland Foot valve too small

Foot valve partially clogged

Water seal pipe plugged Inlet of suction pipe insufficiently submerged Seal cage improperly located in stuffing box, preventing sealing fluid entering space to form a seal

System Related Problem

Speed too low Speed too high The total head of system higher than design pump head Wrong direction of rotation

The total head of system lower than design pump head

Specific gravity of liquid different from design Operation at very low capacity Viscosity of liquid differs from that for which the pump was designed Parallel operation of pumps unsuitable for such operation

Mechanical Related Problem

Foreign matter in the impeller

Misalignment
Foundations not rigid Shaft bent Rotating part rubbing on stationary part Bearing worn Wearing rings worn Impeller damaged Casing gasket defective, permitting internal leakage

Shaft or shaft sleeves worn or scored at the packing Packing improperly installed Incorrect type of packing for operating conditions Shaft running off-center because of worn bearings or misalignment Rotor out of balance, resulting in vibration

Gland too tight, resulting in no flow of liquid to lubricate the packing

Failure to provide cooling liquid to water-cooled stuffing boxes Excessive clearance at bottom of stuffing box between shaft and casing, causing packing to be forced into pump interior Dirt or grit in sealing liquid, leading to scoring of shaft or shaft sleeve Excessive thrust caused by a mechanical failure inside the pump or by the failure. of the hydraulic balancing device, if any

Excessive grease or oil in anti-friction bearing housing or lack of cooling, causing excessive bearing temperature Lack of lubrication Improper installation of anti-friction bearings Dirt getting into bearings Rusting of bearings due to water getting into hous Excessive cooling of water cooled bearing, resulting in condensation of moisture from the atmosphere in the bearing housing

Chapter 3

Impellers Arrangements and Axial Thrust

Axial Thrust
Axial Thrust in Single-Stage pumps Closed impeller

Axial Thrust in Double Suction Impellers

Axial Thrust

Axial Thrust in Multistage Pumps

In balancing thrust, several methods are in use:
Impeller stages arranged in opposing groups.

Opposed Groups

An arrangement with back-to-back (opposed) impellers.

Balanced Impeller.

Balancing Drum

Balancing Disc

Combination Balancing Disc and Drum.

Chapter 4

Pump Accessories

Pump Accessories
Wearing Rings Description Wearing and Pump Performance

Wear Ring Types

Flat Type Rings

L-Type Rings

Wear Ring Mounting

As it is not desirable for the casing ring of an axially split casing pump to be pinched be the casing, the ring will not be held tightly enough to prevent its rotation unless special provisions are made to keep it in place. One means of accomplishing this is to place a pin in the casing that will project into a hole bored in the ring, or, conversely, to provide a pin in the ring that will fit into a hole bored in the casing or into a recess at the casing split joint. Many methods are used for holding impeller rings on the impeller. Probably the simplest to rely on a press fit of the ring on the impeller or, if the ring is of proper material, or a shrink fit. Designers do not usually feel that a press fit is sufficient and often add several machine screws or setscrews located half in the ring and half in the impeller.

Wearing-ring Clearances for Single-stage pumps using nongalling materials

Methods of Checking Ring Clearances 1.Feeler Gauges

2. Dial Indicator 3. Micrometer

Maintenance of Impeller and Wearing

a. Removal of impellers b. If impeller rings c. Check the hub bore in the impellers

Shaft Seals
Stuffing Box

Packed Gland
A- The simplest shaft seal is the packed gland, in which a number of turns of packing are compressed axially by a gland. Disadvantages of the packed gland are: 1.Some leakage usually occurs. 2.Friction causes wear of the shaft or shaft sleeve. B- If pressure at the pump suction is negative, air can be drawn in through the stuffing box. The lantern ring (seal cage) issued to introduce liquid under pressure from pump discharge or external source. Flow of sealing liquid is axial in both directions. This prevents ingress of air or escape of hazardous liquids.

Typical Packed Gland with Lantern Ring

C- If the pumped liquid contains suspended solids, to prevent penetration of the stuffing box, the lubricant point can be situated in front of the first packing ring and flushed with clean liquid.

Packed Gland Arrangement (Severe Service)

Mechanical Seals
Single Mechanical Seal

Double Mechanical Seal

Single Seals-Balanced Single Spring Balanced Seals

Multi-Spring Balanced Seals

A multi-spring version of the balanced seal range, which includes a set screwed spring sleeve. The multispring design makes the seal bi-directionai for applications where the reverse rotation is anticipated.

Multiple Seals
Double Seals
Tandem Seals

Double Seals

Tandem Seals

Causes of Seal Failures

Vaporisation
Dry Running
Abrasives in Product
Sludging/ Bonding

Bonding

Causes of Seal Failures

Coking
Carbon Ring Erosion
Face Distortion
Broken Carbon Seal Rings O Ring Extrusion O Ring Overheating

Sleeve Damage, Preventing Follow Up Of Rotary Seal Ring

Vibration

Spring Distortion Or Breakage

Checklist of Identifying Causes of Seal leakage

Symptom
Seal spits and sputters (face popping) in operation Seal drips steadily

Possible causes
Seal fluid vaporising at seal interfaces

Corrective procedures
Increase cooling of seal faces Add bypass flush line if not in use Enlarge bypass flush line and/or orifices in gland plate Check for incorrect installation dimensions Improve cooling flush lines Check for gland plate plate distortion due to overtorquing of gland bolts Check gland gasket for proper compression

Faces not flat Carbon graphite seal faces blistered Seal faces thermally distorted

Symptom
Seal drips steadily

Possible causes
Spring failure Drive mechanism corroded

Corrective procedures
Replace parts

Seal squeals during operation

Amount of liquid inadequate to lubricate seal faces

Add bypass flush line if not in use Enlarge bypass flush line and/or orifices in gland plate.

Carbon dust accumulates on outside of gland ring

Amount of liquid inadequate to lubricate seal faces Liquid film evaporating between seal faces

Add by pass flush line if not in use Enlarge bypass flush line and/or orifices in gland plate Check for proper seal design with seal manufacturer if pressure in stuffing box is excessively high

Symptom
Seal leaks

Possible causes
Nothing appears to be wrong

Corrective procedures
Refer to list under seal drips steadily Check for squareness of stuffing box to shaft Align shaft, impeller, bearing, etc., to prevent shaft vibration and/or distortion of gland plate and/or mating ring
Increase cooling of seal faces Increase bypass flush line flow Check for obstructed flow in cooling lines Increase cooling of seal faces Increase bypass flush line flow Check for obstructed flow in cooling lines Align Check for rubbing of seal on shaft

Abrasive fluid

Seal life is short

Seal running too hot

Equipment mechanically out of line

Symptom

Possible causes

Corrective procedures
Clean out foreign particles between seal faces; relap faces if necessary Check for cracks and chips at seal faces; replace primary and mating rings.

Seal drips steadily

Secondary seals nicked Replace secondary seals or scratched during installation Check for proper lead in O rings overaged chamfers, burrs, etc. Secondary seals hard and brittle from compression set Secondary seals soft and sticky from chemical attack

Bearings
Sleeve Bearing

Common Antifriction Bearings

Shaft Bearing and Assembly of Bearing Bearing Lubrication Assembly and Orientation

Shaft Sealing - Assembly of the Seal

Chapter 5

Pump Performance & Efficiency

QH Curves

Graph of Pump Performance:

Tightening top cover with recommended torque for pump

Trouble Check List

No Liquid discharge No liquid discharge from the pump may be caused by:
1. Pump not primed. 2. Speed too low - check to see whether or not motor received full voltage. 3. Suction lift too high or insufficient NPSH. 4. Impeller or piping plugged. 5. Wrong rotation.

6. Air leaks or pockets in suction line.

Insufficient Liquid discharge

Insufficient liquid discharge may be caused by:
1. Speed too low.
2. Discharge head higher than anticipated. 3. Suction lift too high or insufficient NPSH. 4. Impeller or piping partially plugged. 5. Wrong rotation 6. Air leaks or pockets in suction line. 7. Mechanical defects (worn wearing rings or impeller damage). 8. Foot valve too small.

Insufficient Pressure
Insufficient pressure may be caused by:
1. Speed too low.
2. Air or gases in liquid. 3. Impeller diameter too small. 4. Mechanical defects (worn wear rings or damaged impeller). 5. Wrong rotation.

Surges in Performance
Surges in performance may be caused by:

1. Air leak in suction line.

2. Air pocket in suction line. 3. Not enough NPSH available. 4. Air or gases in liquid. 5. Impeller plugged.

Excessive Power
Excessive power consumption may be caused by:

1. Speed too high. 2. Head too low (pumping too much liquid). 3. Specific gravity or viscosity of liquid pumped is too high.

4. Mechanical defects (bent shaft, worn wear rings, etc.).

Noisy Pump Operation

Hydraulic noise
1. Cavitation 2. Insufficient NPSH. 3. Suction lift too high. 4. Air in liquid.

Mechanical defects.
1. Shaft bent.
2. Bearing worn. 3. Rotating parts binding

Water Hammer Operation of Pumps

If so, you have to understand the condition of these changes and variables:-

Reducing Head

Reducing Capacity

There are several means to protect the pump from such possible damage:
1. Liquid temperature relays which shut down the unit if the liquid temperature exceeds a predetermined maximum.

2. Constant open by-pass between pump discharge and first valve piped back to suction source.

3. Low suction pressure control which will shut off the unit should the suction pressure drop below as established minimum. NEVER THROTTLE PUMP ON SUCTION SIDE.

Chapter 6 Deferent Types of Pumps

Rotary Pumps

Trouble shooting (rotary pumps)

PUMP NOT UP TO CAPACITY
Suction lift too high. Bubbles form to use up part of pump displacement. Suction strainer clogged or of insufficient area. End of suction pipe insufficiently submerged allowing air to be drawn into pump. Suction pipe too small, too long, or has fittings to increase pipe friction abnormally and cause liquid to vaporise. stuffing box improperly packed so air is drawn in. air leaks in suction piping. Speed too low. Head bypass or return line partly open.

PUMP TAKES TOO MUCH POWER.

Speed too high. Liquid heavier or more viscous than specified for pump. Obstruction in discharge line causes pump to operate above rated pressure. Stuffing box packed too tightly. Rotating elements bind and wear excessively.

PUMP IS NOISY.
Insufficient liquid supply. Suction pipe too small in diameter. Air leaks in suction or stuffing boxes. Pump out of alignment. High spots on rotating elements. Relief valve chatters.

PUMP WEARS RAPIDLY.

Grit or dirt in liquid. Pipe strain on pump casing. Pump operating against excessive pressures. Corrosion roughening rubbing surfaces.

Pump running dry.

PUMP STARTS THEN LOSES PRIME.

End of suction line not immersed deeply enough. Liquid vaporizing in suction line. Air or gas pockets in system.

Air leaks in suction line.

External Gear Pumps

Operation of an external-gear pump

External-gear pump impellers

External Gear Pumps

Exploded view of an external gear pump

Internal-Gear Pumps

Troubleshooting Gear Pumps

No liquid delivered:

Pump not primed

Wrong direction of rotation Clogged inlet Air leaks on inlet side of pump or through shaft seal Relief valve pressure setting too low or held off seat by foreign material

Not enough liquid delivered:

Air leaks in inlet pipe or through shaft seal Pump speed below rating Inlet lift higher than pump rating-check with vacuum gage at pump inlet Not enough inlet pressure casing liquid to vaporize in suction linehot or volatile liquids more apt to experience this

End of inlet pipe not immersed deeply enough, causing p-ump to intake liquid/air mixture
Pump badly worn or damaged Clogged inlet

Not enough liquid delivered: ( Condt.)

Relief valve pressure setting too low or held off seat by foreign material Liquid is thinner or less viscous than specified

Pump works for a while and then quits:

Leaky inlet piping Inlet lift too high Air or gas in the liquid

Pump takes too much power:

Pump speed or discharge pressure in excess of specification Liquid is thicker or more viscous than specified Packing gland too tight, causing high friction in shaft seal Improper packing used, causing high friction in shaft seal Pump not properly aligned

Pump too noisy:

Air or gas in fluid being pumped Air leaking into inlet pipe or through shaft seal Inlet velocity too high due to using inlet piping smaller than pump inlet opening Inlet pipe not submerged deeply enough or too close to return line causing pump to intake liquid/air mixture Relief valve chattering Wrong direction of rotation

Pump not properly aligned

Lobe Pumps

Screw Pumps

Single- screw pump

Two-screw timed pump

Three- screw pump

Vane Pumps

Sliding-vane pump

ROLLINGVANE PUMP

Location of Seals on Rotary Pump Shaft

Rotary Piston Pumps

Flexible-Member Pumps

Flexible-impeller pump

Plunger Pumps

Plunger Pump (Single-Acting)

Plunger Pumps

Power Driven Plunger Pump Cross-Section

Plunger Pumps

Power Driven Triplex Pump

Diaphragm Pump

Mechanically Actuated Diaphragm

Submersible Pumps
Identification General Description

Drivers

Possible Problems
The pump is no longer starting The pump is no longer sucking The pumped medium is too little The pressure is too low

The pumped medium is unstable

The pump is running loudly The pump is stuck The drive is overloaded The stator life time is too short The rotor life time is too short The shaft seal is leaking

Possible Causes ( Remedy Overleaf )

In new pumps or stators : the static traction is too great .

The pump electrical equipment is not compatible with the electrical supply .

The pressure is too high .

There are foreign bodies in the pump . The temperature of the liquid medium is too high ,the stator is too ductile . The stator has swollen , the elastomer is not compatible with the medium . The solids content of the medium is too high and leads to blockages . The liquid medium sediments or hardens when left to stand .

Possible Causes ( Remedy Overleaf )

There is air in the suction pipe .
The suction pipe is leaking . The shaft seal is leaking . The rpm is too low . With reduced diameter rotors : operating temperature has not been reached . The suction is too great or pressure too low ( cavitation ) The pump is running dry . The stator is worn out , or temperature of liquid is too low . The stator material is brittle .

Possible Causes ( Remedy Overleaf )

The rotor is worn out . The pump and drive are not axially aligned .

The elastic element of the coupling is worn out .

The roller bearings are destroyed . The rpm is too high . The viscosity is too high . The specific weight of the medium is too high . The stuffing box is incorrectly tightened . The packing is not suited to the liquid medium . Mechanical seal : rotation is incorrect . Mechanical seal : mechanical seal and mating ring have failed Mechanical seal : elastomers damaged , swollen or brittle .

Remedy
Fill the pump up , then pump through manually using a suitable appliance ; if necessary use glycerine as lubricant in the stator . Check order information . Examine electrical installation ( possibly 2 phase operation ) . Measure the pressure with a manometer and check against order details . Remove foreign bodies and eliminate possible damage . If the liquid medlum temperature cannot be lowered , use a reduced diameter rotor .

Check whether the liquid medlum agrees with the order requirements . possibly change stator material .
Increase the liquid part of the medium .

Remedy
Clean the pump and rinse through after each run . Increase the suction liquid level . prevent turbulence and air bubbles at the inlet . Check seals and tighten pipe connections . Stuffing box : tighten or renew . Mechanical seal : renew seals , eliminate solid deposits . In the case of adjustable drives : Increase the rpm .

Warn up the pump ( stator ) to operating temperature first of all .

Decrease suction resistance . Lower the temperature of the liquid medium , install the pump at a lower location .

Remedy
Fill up the pump , provide for dry running protection , move the pipes . Replace with a new stator or ensure correct liquid temperature . Fit a new stator check the liquid medium agrees with order details ; If necessary change the stator material . Change rotor , ostablish the cause . Wear and tear , corroslon , cavitation ; If necessary change to different material or coating .

Replace relevant parts , carefully reseal and lubricate .

Re align the unit .

Use a new connection and re- align the pump . Replace roller bearings , lubricate , reseal .At higher temperatures observe the lubrkant and the bearings .

Remedy
In the case of adjustable drives : lower the rpm .

Measure the viscosity and compare with order details . If necessary adjust viscosity or change the drive .
Measure specific weight and compare with order details . If necessary adjust specific weight or change the drive . Service stuffing box xcording to page 7.4 , If necessary renew worn shaft . Replace fitted packing with another packing type . Change electrical connection . Replace relevant rings with new ones . Replace elastomers . Check whether the liquid medium agrees with order details , If necessary change material .

Chapter 7 Alignment & Preventive and Predictive Maintenance

Alignment of Machinery

Offset Alignment
Angular Alignment

Flexible Coupling
Speed, in r.p.m. Offset Tolerance, in mm
Angular Tolerance for Coupling Diameters up to 400 mm Angular Tolerance for Coupling Diameters from 400 to 600 mm

2500 ~ 4000 1300 ~ 2500

0.010 0.025

0.020 0.050

0.030 0.070

Below 1300

0.040

0.080

0.100

Rigid Coupling
Speed, in r.p.m. Offset Tolerance, in mm

Angular Tolerance for Coupling Diameters up to 400 mm

Angular Tolerance for Coupling Diameters from 400 to 600 mm

2500 ~ 4000

0.010

0.020

0.020

Below 2500

0.015

0.030

0.030

Misalignment

Figure 7-1

Keep It Straight

Eccentricity
Hot Alignment Check Pipe Strain Limits
Pump and Equipment Checks Shaft Run Out, Deflection Lift

Concentricity Of Sleeve
Concentricity Of Stuffing Box Squareness of the Stuffing Box

Preventive Maintenance Necessary What is Preventive Maintenance?

A bona fide preventive maintenance program should include:
Non-destructive testing

Periodic inspection
Preplanned maintenance activities Maintenance to correct deficiencies found through testing or inspections.

Reasons for Preventive Maintenance

Increased Automation Business loss due to production delays Reduction of insurance inventories Production of a higher quality product Just-in-time manufacturing Reduction in equipment redundancies Cell dependencies Minimize energy consumption (5% less) Need for a more organized, planned environment

Why Have a PM Program

Better conservation of assets and increased life expectancy of assets, thereby eliminating premature replacement of machinery and equipment. Reduced overtime costs and more economical use of maintenance workers due to working on a scheduled basis instead of a crash basis to repair breakdowns.

Timely, routine repairs circumvent fewer large-scale repairs.

Reduced cost of repairs by reducing secondary failures. When parts fail in service, they usually damage other parts. Reduced product rejects, rework, and scrap due to better overall equipment condition. Identification of equipment with excessive maintenance costs, indicating the need for corrective maintenance, operator training, or replacement of obsolete equipment.

The Law of PM Programs

Preventive Maintenance Program Risks How to Have a Successful PM Program
Preventive Maintenance Execution

Motivating Preventive Maintenance Workers