Оглавление
Robert X. Perez. Pump Wisdom
Table of Contents
List of Tables
List of Illustrations
Guide
Pages
Pump Wisdom. Essential Centrifugal Pump Knowledge for Operators and Specialists
Preface
1 Principles of Centrifugal Process Pumps
Pump Performance: Head and Flow
Operation at Zero Flow
Impellers and Rotors
The Meaning of Specific Speed
Process Pump Types
Process Pump Mechanical Response to Flow Changes
Recirculation and Cavitation
The Importance of Suction Specific Speed
What We Have Learned
References
2 Pump Selection and Industry Standards
Why Insist on Better Pumps
ANSI and ISO vs. API Pumps
What We Have Learned
References
3 Foundations and Baseplates
Securing Pumps in Place – With One Exception
Why Not to Install Pump Sets in the As‐Shipped Condition
Conventional vs. Prefilled Baseplate Installations
Epoxy Prefilled Baseplates
How to Proceed If There Is No Access to Specialist Firms
What We Have Learned: Checklist of Foundation and Baseplate Topics
References
4 Piping, Stationary Seals, and Gasketing. Pipe Installation and Support
Sliding Supports and Installation Sequence Deserve Special Attention
Monitoring Pipe Stress While Bolting Up
Flange Leakage
What to Do Prior to Gasket Insertion
Spiral Wound and Kammprofile Gaskets
Pipe, Hydraulic Tubing or Flexible Connections?
Gusseting
Concentric vs. Eccentric Reducers
Vibration Problems in Piping
Proven Ways to Control Piping Vibration
Addressing Piping Vibration Issues
Small Bore Piping Issues
What We Have Learned
References
5 Rolling Element Bearings
Bearing Selection Overview and Windage As a Design Problem
Radial vs. Axial (Thrust) Bearings
Oil Levels, Multiple Bearings and Different Bearing Orientations
Upgrading and Retrofit Opportunities
Bearing Cages
Bearing Preload and Clearance Effects
Bearing Dimensions and Mounting Tolerances
What We Have Learned
References
6 Lubricant Application and Cooling Considerations
Lubricant Level and Oil Application
Issues with Oil Rings
Pressure and Temperature Balance in Bearing Housings
Cooling Not Needed on Pumps with Rolling Element Bearings
Oil Delivery by Constant Level Lubricators
Black Oil
Lubricant Application As Oil Mist (Oil Fog)
Desiccant Breathers and Expansion Chambers
What We Have Learned
References
7 Lubricant Types and Key Properties. Lubricant Viscosities
When and Why High Film Strength Synthetic Lubricants Are Used
Lubricants for Oil Mist Systems
What We Have Learned
References
8 Bearing Housing Protection and Cost Justification
Noncontacting Bearing Protector Seals
Contacting Bearing Protector Seals
How Venting and Housing Pressurization Affect Bearing Protector Seals
Cost Justification Overview
Advanced Bearing Housing (Bearing Protector Seal) Summary
What We Have Learned
References
Note
9 Mechanical Sealing Options for Long Life
Still Using Packing?
General Overview of Mechanical Seals
All Flush Plans Have Advantages and Disadvantages
Always Obtain the Full Picture
Seal Chamber Pumping Ring (Circulating Device) Technologies
Lessons Apply to Many Services
What We Have Learned
References
10 Pump Operation
Starting Centrifugal Pumps
Surveillance of Pump Operation
Optimum Pump Switching Interval
Centrifugal Pump Shutdown
Addressing Post Start‐up Issues
Avoiding Parallel Pump Operating Problems
Additional Start‐up and Monitoring Tips
What We Have Learned
References
11 Impeller Modifications and Pump Maintenance
Maintenance Essentials
Superior Maintenance Requires Upgrading
Impeller Upgrading with Inducers
Distance from Impeller Tip to Stationary Internal Casing Components
Impeller Trimming
Impeller Wear Rings
Vane Tip Overfiling and Underfiling
Carbon Graphite Wear Rings and Bushings
What We Have Learned
References
12 Lubrication Management
How Bad Is Water Contamination?
Avoid Solids Contamination
Avoid Questionable Oil Storage and Transfer Practices
Periodic Audits
What We Have Learned
References
13 Pump Condition Monitoring : Pump Vibration, Rotor Balance, and Effect on Bearing Life
Vibration and Its Effect on Bearing Life
Monitoring Methods Differ
Vibration Acceptance Limits
Causes of Excessive Vibration
Rotor Balancing
What We Have Learned
References
14 Drivers, Couplings, and Alignment
Driver Selection
Coupling Selection and Installation
Installation and Removal
Alignment and Quality Criteria
Consequences of Misalignment
Thermal Rise and Predefinition of Growth
What We Have Learned
References
15 Fits, Dimensions, and Related Misunderstandings
Low Incremental Cost of Better Pumps
Pump Pedestals and Bearing Housings Should Not Be Water‐Cooled
Summary of Bearing‐Related Issues
Constant Level Lubricators
Bearing Housing Protector Seals (“Bearing Isolators”)
Motor Lubrication Summary
Mechanical Seal Issues
Hydraulic Issues
Impeller Hydraulics
Mechanical Improvement or Upgrade Options
Process Pump Repair Dimensions
What We Have Learned
References
16 Using Failure Statistics and Root Cause Analysis Findings to Guide Reliability Improvement Efforts
Mean‐Time‐Between Failures and Repair Cost Calculations
Performing Your Own Projected MTBF Calculations
Older Pumps vs. Newer Pumps
Reliability Reviews Start Before Purchase
Structured Failure Analysis Strategies Solve Problems
The “FRETT” Approach to Eradicating Repeat Failures of Pumps
Analyzing Pump Failure Data
Why We Use Reliability Tools
Cumulative Failure Trends
Addressing Pump “Bad Actors”
What We Have Learned
References
17 Repair, Replace, or Modify?
Repair or Replace?
Repair and Spare Part Philosophies
Making the Business Case for Centrifugal Pump Upgrades
Payback Time Examples
Example 17.1 Upgrading Mechanical Seals in a Pipeline Pump
Installation Costs
What Is the Payback Period for Example 17.1?
Example 17.2 Upgrading Slurry Service Pump Casings
What Is the Payback Period for Example 17.2?
Some Final Advice on Upgrades
Centrifugal Pump Hydraulic Rerates
Rerate Case Study
Replacing Existing Pump with an Entirely Different Model Pump
What We Have Learned
References
18 Centrifugal Pump Monitoring Strategies
Pump Monitoring Recommendations Based on Criticality
How to Use This Matrix. Example 18.1: High Environment Impact (Follow dashed arrows in Table 18.2)
Example 18.2: High Production Impact (Follow dashed arrows in Table 18.3)
A Survey of Vibration Sensors
Wireless Sensors
Wired Sensors with Dynamic Outputs
Wired Loop‐Powered Vibration Transmitters with 4–20 mA Outputs
Evaluating Sensor Information
Vibration Monitoring Analysis Requirements
More on Sensor Technology
What We Have Learned
References
19 Final Thoughts
Index. a
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