Pump Wisdom Problem Solving for Operators and Specialists

ISBN-10: 1118041232

ISBN-13: 9781118041239

Edition: 2011

Authors: Heinz P. Bloch
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Description: PUMP WISDOM was compiled to explain elusive failure causes. Some have to do with pump selection, others have to do with overlooked installation criteria or are simply the result of small deviations that add up. In other words, while a certain assembly dimension may be allowed to reach a defined upper limit, allowing another, and yet another deviation to reach its upper limit on the remaining pump components will lead to operation in a vulnerable region where frequent failures occur. This book sheds light on the issue and, quite unlike any other condensed text, shows exactly what to do so centrifugal process pumps don't fail again.

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Book details

Copyright year: 2011
Publisher: John Wiley & Sons, Limited
Publication date: 5/6/2011
Binding: Hardcover
Pages: 224
Size: 6.00" wide x 9.25" long x 0.50" tall
Weight: 0.990
Language: English

A consulting engineer residing in Montgomery, texas, Heinz. P. Bloch has held machinery-oriented staff and line positions with Exxon affiliates in the United States, Italy, Spain, England, The Netherlands, and Japan. His career spanned several decades prior to his 1986 retirement as Exxon Chemical's regional machinery specialist for the USA. Since his retirement from Exxon, he has been in demand throughout the world as a consultant and trainer in the areas of failure avoidance, root cause failure identification, and reliability improvement. Mr. Bloch is the author/co-author of thirteen books and over 200 other publications on subjects related to machinery reliability and failure avoidance. He is the Reliability and Equipment Editor of Hydrocarbon Processing magazine and has served as chair of the annual conference program for Hydrocarbon Processing's Process Plant Reliability Conference for a number of years.

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
Pump Selection and Industry Standards
Why insist on better pumps
ANSI and ISO versus API pumps
What we have learned
References
Foundations and Base Plates
Securing pumps in place-with one exception
Why not to install pump sets in the as-shipped condition
Conventional versus pre-filled base plate installations
Epoxy prefilled base plates
How to proceed if there is no access to specialist firms
What we have learned: Checklist of foundation and base plate topics
References
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 versus eccentric reducers
Vibration problems in piping
What we have learned on piping and gasketing topics References
Rolling Element Bearings
Bearing selection overview and windage as a design problem
Radial versus 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
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
Lube application as oil mist (oil fog)
Desiccant breathers and expansion chambers
What we have learned
References
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
Bearing Housing Protection and Cost Justification
Noncontacting bearing protector seals
Contacting bearing protector seals
How venting and housing pressurization affect bearing protector seal performance
Cost justification overview
Advanced bearing housing (bearing protector) seal summary
What we have learned
References
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
Bibliography
Pump Operation
Starting centrifugal pumps
Surveillance of pump operation
Centrifugal pump shutdown
What we have learned
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
What we have learned
References
Lubrication Management
How bad is water contamination?
Avoid solids contamination
Avoid questionable storage and transfer practices
Periodic audits
What we have learned
References
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
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
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
Failure Statistics and Structured Failure Analysis
Mean rime between failures (MTBF) and repair cost calculations
Performing your own projected MTBF calculations
Older pumps versus newer pumps
Reliability reviews start before purchase
Structured failure analysis strategies solve problems
The "FRETT" approach to eradicating repeat failures of pumps
What we have learned
References
Index
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