Mechanical maintenance

Pumps:
General
1.what is pump?
It is an equipment used to move a fluid from one point to another. By adding energy to it.
2.what are the three different types of pumps?
centrifugal pumps, b)reciprocating pumps, c)rotary pumps.
3.what is the principle of a centrifugal pump?
Centrifugal force is produced by rotating vanes or impeller. Liquid entering the center of the impeller
is picked up by the vane. Accelerated to a high velocity and thrown out by centrifugal force at a higher
pressure.
4.How does a reciprocating pump work?
By the reciprocating movement of a piston or plunger in a cylinder the liquid is displaced from suction
to discharge.
5.How does rotary pump work?
In this pump a rotator displaces liquid from suction to discharge by a circular motion.
6.In what way the centrifugal pump differ from the other two?
Rotary and reciprocating pumps are called positive displacement pumps because they positively
displace a volume of liquid with every stroke or revolution. But centrifugal pumps are not positive
displacement pumps. They only impart centrifugal force to the liquid.
7.which is the most widely used pump and why?
Centrifugal pumps.
They are 1)Simple design and construction. 2)Cheaper than the other types. 3)Has a wide range of
pressure and flows. 4)Needs very little attention. 5)Easy for maintenance and low repair cost.
6)Adapted to different types of drivers.
Centrifugal pumps
Parts and functions:
8.what are the principle elements of a centrifugal pump?
1)Rotary elements
1.shaft 2.impeller 3.coupling 4.oil rings.
2)Stationary elements
1.casing 2.stuffing box.
3)Auxiliary parts
1.foundation 2.foundation bolts 3.bed plate 4.shims for alignment.
4)Driver
1.electric motor/steam turbine
9.How are centrifugal pumps classified?
1. with respect to the stages of operation.
a) single stage b)multi stage
2. with respect to impeller.
a) single or double suction
b) straight or curved vanes.
c) open, semi open or closed.
3. with respect to axis of rotation.
a) horizontal
b) vertical

4. with respect to the driver.

a) electrical motor driven
b) turbine driven.
c) I.C. engine driven.
5.with respect to method of drive
a) direct connection
b) geared connection.
c) chain or belt driven.
6. with respect to output.
a) large capacity- low head.
b) medium capacity- medium head.
c) low capacity - high head.
10.How is velocity energy converted into pressure energy?
By the volute or diffuser vanes.
11.What is volute-type pump?
Volute is the spiral part of the casing which acts as a collector of the fluid discharged by the impeller.
12.What is diffuser of type centrifugal pump?
In this type diffusion vanes serve the purpose of the volute to convert velocity energy to pressure
energy.
13.How is the volute proportioned?
It forms a progressively expanding passage way for the liquid coming from the impeller. The casing is
so proportioned as to produce equal velocity flow all around the circumference and to reduce
gradually the velocity of the liquid as it flows out into the discharge.
14.What are the parts of an impeller?
1) Hub, 2) Vanes, 3) Shroud.
15.What is the suction eye of an impeller?
The inlet just before the point where the vanes start is called the suction eye.
16.What is the single suction impeller?
It is one which the liquids enters to the impeller from one side.
17.What is the double suction impeller?
It is in effect two single suction impellers cast back to back so that liquid enters from both sides.
18.What is the advantage of the double suction impeller to single suction?
The hydraulic axial thrust ids balanced considerably in the double suction type making an oversized
thrust bearing unnecessary.
It can operate at a lower NPSH than with a single suction.

19.What is the basis of selection of the type of impellers?

Cost and suitability to the service.
Open vanes - for heavy and viscous liquids and abrasive material.
Semi open - for slurry and semi viscous material. (one side shrouded)
Closed - for clean and light liquids(both side shrouded)

The closed impeller is the most efficient of all other types.

20.What is the purpose of the multi stage pumps?
When the total head developed by single stage pump is not adequate pumps are used in serious one
after another to boost up the pressure. When the different impellers are housed in a single casing it is
called multi stage pump.
21.What part plays the role of volute in multistage pump?
Diffusers.
22.What is disadvantage of multistage pump?
Low capacity.
23.Why are wear rings are used?
In a centrifugal pump there must be a running joint between the impeller and the casing that separates
the suction(low pressure) and discharge (high pressure) zones. the leakage of liquid through the joint
wears out the surface of the casing and impeller by erosion. replaceable rings are therefore provided at
this running joint to avoid costly repairs/replacement of the casing and impeller.
24.What is the function of the shaft sleeve?
A shaft sleeve protects the shaft preventing corrosion, erosion and wear from affecting its strength.
25.What is the function of the bearings?
The bearing take care of the axial and radial loads.
26.What are the type of the bearing s are used?
1) Deep groove ball bearing
2) Angular contact bearing
3) Journal (sleeve) bearing.
4) Roller bearing.
27.What are the common types of coupling used?
1.Rigid type(vertical pump).
2.Flexible type - a) rubber bush type, b)gear type, c)rubber below type, d)chain and sprocket type.
28.What is the advantage of the flexible coupling?
It can tolerate misalignment to some extent and does not allow the equipment to vibrate.

Characteristics
29. What are the main characteristics of the centrifugal pump?
1.Speed, 2.Heads (suction and discharge), 3.Capacity, 4.Power, 5.Friction and losses, 6.Efficiency.
30.What is the speed of a pump?
Revolutions per minute - rpm.
for motor driven pump the speed is fixed.(normally 3000 rpm).
for turbine driven pumps speed can be varied. but normally not done.

31.What are heads of a centrifugal pump?

1.Suction head or suction lift, 2.Discharge head, 3.Net head, 4.Discharge pressure
32.What is suction head or suction lift?
It is the difference in height between the surface oh f the liquid and the centre of the pump.
33.What is cavitation?
It is phenomenon that occurs in flowing liquid because the pressure falls below the vapour pressure f
the liquid. when this occurs liquid vapourises in the low pressure areas and forms bubbles. if it happens
at the inlet of the pump the bubbles are carried into the impeller to a high pressure side where they
suddenly collapse. the formation of these bubbles in low pressure area and their sudden collapse in the
high pressure area is called cavitation.
34.What is NPSH?
It is an abbreviation of the net positive suction head. it represents the minimum required margin
between the suction head and the vapour pressure of the liquid at a given temperature and capacity.
35.What are the symptoms and the consequences of cavitation?
The usual symptoms are noise and vibration in the pump and drop in head and capacity with a
decrease in efficiency. Cavitation results in pitting and corrosion of impeller vanes and casing.
Pitting is physical effect produced by the tremendous localized compression stresses caused by the
collapse of bubbles. Corrosion is due to the liberated gases from liquid.
36.Why is the discharge head generally stated in height of liquid?
Irrespective of the liquid the pump can develop the same height.
37.Does the discharge pressure vary with different liquids?
Yes, depending on the specific gravity of the liquid the pressure will vary.
Example: 1 mt of water =.1kg/cm.cm.
100 meters of water =100/10 = 10kg/cm2.
100 meters of oil (.8 sp.gr) = 100x 0.8/10 = 8kg/cm2.
38.Is the capacity variable? how?
yes, by regulating the discharge valve the flow can be varied.

39.What is the relationship of capacity to head, Horse power and efficiency?

1.the discharge pressure is maximum at no flow and decreases as the flow increases.
2.horse-power (load) increases with flow.
3.efficiency first increases reaches a maximum and then drops as the flow increases.
40.What is the characteristic curve of a pump?
It is a graph showing the relationship between head, power, efficiency and capacity of a pump.
41.What is the efficiency of a pump?
It is the ratio of the output horse-power to the brake horse-power(1hp = 746 watts).
Efficiency = H.P/B.H.P x 100.
42.How is liquid horse-power calculated?
One hp in British system is equal to 33000 foot- pounds per minute.
Therefore output hp = g x h x d / 3300

where g = flow gallons per minute. H= head in feet. D = density pounds per gallon
43.What are factors affecting the power requirement of a centrifugal pump?
1.Specific gravity of the liquid
2.Viscoscity of the liquid
3. Speed and 4. Flow rate.
44.What are the losses in a centrifugal pump?
1. Hydraulic: caused by shocks, eddy currents and friction fluid in its path through the impeller and
casing.
2.Disk friction loss: the power required to rotate the impeller in the surrounding liquid. This friction
increases with viscosity of the liquid.
3.Short circuit losses: circulation from discharge to suction due to clearance between casing and
impeller wear rings
4.Mechanical loss: due to friction in stuffing box and bearing.
45.How does an increase in viscosity of liquid affect the pump performance?
1.Increases load
2.Reduces the flow rate and head
3.Efficiebncy decrease due to the increase of friction.
46.What part of the pump decides the capacity if the speed is fixed?
The impeller.
47.How does change in impeller diameter affect the pump performance?
The peripheral speed of the impeller changes directly as the diameter
Capacity varies directly as the diameter q x D.
Head varies as d2
BHP varies as d3.
48.What is formula to calculate the approximate head of a pump at maximum efficiency?
H = [D/N1900]2
H = foot of liquid
D =diameter of impeller in inches.
N = speed in rpm.
49.If a pump run back wards what effect does it have on the pump performance?
1.Capacity drops considerably.
2. Head decrease.
3. Efficiency decrease.
4.Horse-power increase steeply.
Centrifugal pumps
50.What is the function of a stuffing box and packing?
To prevent leak through the clearance between the shaft and casing.
51.What is the packing used for normal duties?
Sift cotton or asbestos soaked in oil and in personated with graphite. Hard packing erodes the shaft
sleeve.
52.What is the disadvantage of a packed stuffing box?
A small leak has to be permitted through the gland for lubrication and removal of frictional heat.

53.what modifications are done to prevent liquid leaking out through a gland packing or to
prevent air entering the pump?
A provision of a lantern ring in the stuffing box and a special seal oil system. A suitable sealing fluid
will be circulated under a pressure higher than the stuffing box. The oil will slowly leak into the pump
and will the internal liquid.
54.What is a mechanical seal?
It is a mechanical device which serve the same purpose as a gland packing. The sealing surfaces made
of dissimilar materials are held in continual contact by springs. One surface is connected to the shaft
and rotating while the other is stationary and connected to the frame. It is more dependable efficient
and leak free than the conventional stuffing box.
55.Why are mechanical seals used?
For many services a conventional stuffing box with packing is unsuitable where a leak is unsafe and
undesirable. Mechanical seals provide a leak free operation of the pump.
56.What does a mechanical seal consist of?
The assembly consists mainly of two sections.
1. Stationary (the seat)
2. Rotating (the face)
Stationary parts:
a) seat, b)seat ring, c)flange, d)steam cooling as an additional fitting.
Rotating parts:
a) retainer, b) springs, c)thrust ring, d)wedge, e)carbon, f)snap ring.
57.Why the rubbing faces wear each other out quickly?
The materials used are selected for their ability to run together with little friction.
o
58.What is material used for seal?
Tungsten carbide or cast iron or ceramic.
59.What is the material used for wedge and seat ring?
Teflon or glass filled teflon or asbestos filled teflon on the basis of the operating temperatures.
60.How are the rubbing faces kept cool and lubricated?
By providing a liquid line from the discharge piping , if necessary through a cooler.
61.what are the main causes of a mechanical seal failure?
1.Due to overheating if the pump runs dry.
2.Foreign material getting lodged between the carbon and seat.
3.Damage to any part due to wear, corrosion etc
4. Excessive vibration.
Lubrication
62.What is friction?
When two surfaces are rubbed together a force is generated which tends to oppose this motion. This is
friction.
63.Can there be friction between two smooth metallic surfaces?

No matter how smoothly metals are machined the surface shows tiny ridges and crevices under a
microscope.
64.What is the result of friction?
Over heating and wear out of metals.
65.How is friction overcome?
By lubrication.
66.What is the principle of lubrication?
The surfaces are separated by a thin film of the lubricant.
67.What are the two types of lubricants used?
Lubricating oil and grease.
68.What is the advantage of oil over grease?
1.oil is in liquid form whereas grease is semi solid.
2.Becaause of its fluidity oil is particularly useful in high speed machines.
3.Oil removes heat from the bearings oil can be cooled and re circulated to maintain bearing
temperature.
4.Circulating oil removes dirt and metallic fillings from the bearings.
5.it is easy to check and change.
69.Is any type of oil good for every machine?
No. depending on the type and location of services the oil should possess certain specific properties to
ensure good lubrication. The grades of lubricants are decided by specialists and they should not be
changed.

70.What are the major properties of lube oil? What is the function of each property?
1.Viscosity - for fluidity and film thickness. Decided by the load of bearings and the speed of the
machine.
2.Viscosity index - for maintaining viscosity at varying temperatures.
3.Pour point - for ability to flow at colder places of service.( in cold machines or for storage and
transportation in cold climates)
4.Flash - for safety against ignition.
5.Oxidation ability - to prevent decomposition in prolonged use or storage.
6.Detergent qualities - to keep the lubricated areas clean at all times.
71.What are the generally used systems of lubrication?
1.Forced feed system where a separate pump is used to force the lube oil through the bearings
2.Splash rings. The rings rotate along with the shaft and lift the oil from the oil chamber with every
rotation.
3.direct lubrication of the bearings where the bottom row of balls is submerged in the oil level.
72.Is over greasing a disadvantage?
Yes. The bearing will get over heated due to churning and expansion of the grease. The bearing
housing should not be more than half full when the pump is idle.
73.What is the disadvantage of over filling a bearing housing with lube oil?
Over heating and bearing failure, besides waste and loss of valuable lubricating oils.
74.How does a constant level oiler (popularly known as the chicken feed oiler) work?

1.The oil level in the bottle is higher than the actual level in the housing. It is held high due to the
lower pressure than atmosphere in the air space above the bottle.
2.When the housing level comes down the seal between the bottle and oil- lead-line breaks and air gets
into the bottle.
3.This air pushes the oil down until the seal is restored.
75.Can the oil level in the bottle be fully depended up on?
No. some times the lead line can be plugged. Periodical check of the actual level is necessary.
Centrifugal pump Operations
76.What is the start up procedure of a centrifugal pump?
1.Check a) general readiness, b)lubrication, c)Cooling water.
2.Rotate the shaft for free movement.
3. Check discharge valve closed.
4. Prime the pump and open suction valve wide.
5. Start the pump and bring to normal speed-check direction of rotation.
r6.Check the pressure gauge to ensure that the pump has developed pressure. i.e. it has picked up
suction.
7.Open the discharge valve gradually.
77.Why should the pump be primed?
Centrifugal pumps work well when the casing is full of liquid. Therefore all gases must be vented out.

78.How is priming done?

1.Top casing vent alone will be open and all other drains shut.
2 Liquid will be filled in form
a. Suction line by crack- opening suction valve.
b. Through the by-pass of check valve in the discharge line.
c. Through the flushing oil line where it is provided.
79. What provision is given for priming pumps in vacuum service? Why?
A. Air will b sucked into the system if the vent is open to atmosphere. Hence, the casing vent is
connected back to the vapour space of the suction vessel to displace gases.
80. What is the special purpose of small by- pass valves around the discharge check valves?
80 These are warm up lines. with a small flow through the pump into the suction a spare pump can
always be in readiness.
81.What harm can be done for a hot pump, if proper warming up operation is not carried out?
Uneven expansion of the pump elements will cause seizing of parts. It may lead to a seal leak
and also may result in rupture due to thermal stress.
82. Is pouring of cold water on a hot pump, a desirable practice?
No. it is dangerous since the sudden contraction can cause damage
83.Should the discharge valve be closed before starting the pump?
The initial load on the motor to put the pump into rotation is quite high to overcome friction of
the moving parts. If the discharge valve is open, the motor can be overloaded due to the liquid
pumping also. So the general practice is to start the pump with discharge valve closed.

84.What is the purpose of the check valve?

To prevent back flow in the event of the stoppage of the pump. The pump can rotate in the reverse
direction if there is back flow, which can lead to damage.
85.What is the shut down procedure of a centrifugal pump?
1.Close the discharge valve.
2.Stop the pump.
86.Why some pumps are provided with flushing oil connections?
When the liquid normally pumped is very heavy and viscous, shutting down the pump may cause
congealing and plugging. In such cases, a thin oil (gas-oil) is provided to flush out the casing as soon as it
is shut down, or else it should be kept hot by circulation of hot oil from the discharge.
87.Why should you not shut off cooling water flow through a hot pump even when it is only a hot
spare?
The hot pumps are generally provided with cooling water to stuffing boxes and pedestals. The water will
get overheated and salts will deposit plugging the water lines.

Centrifugal pump Routine checks

1. Check seal for over heating and leak.
2. Check motor for
a) Vibration,
b) Abnormal noise,
c) Temperature by feel,
d) Lubrication,
e) Load (ammeter).
3.Check coupling guard whether

a) Properly secured,
b) Touching the shaft.

4. Check pressure gauge

a) In working condition,
b) Body screws loose or not,
c) Inlet valve need only be crack open.

5.Check pump lubrication

a) Normal oil level,

b) Prove oil lead to the housing clear,
c) Physical appearance of the oil,
d) Oil splash ring rotating.

6.Check bearings

a)Temperature by feel,
b) Abnormal noise,
c)Vibration.

7.Check cooling water

a)Temperature by feel,
b)Quantity.

8.Check valves around the pump

a) Suction and discharge valves wide open,

b)Wheels secured,
c)Gland, bonnet leaks.

9.Check the area house keeping must be clean always.