CENTRIFUGAL-PUMP OPERATION

MYGAZEE ‘99

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Initial Start.

Starting a centrifugal pump for the first time can be a troublesome

experience unless our plant crew has made a thorough check of the unit during and
after installation. There are probably more unusual accidents and troubles during
initial starting of a pump than at almost any other time. Factors to be considered
in starting any centrifugal pump include pipe cleanliness, pump alignment, rotation,
lubrication, position of valves, stuffing-box and mechanical seals leakage, effect of
changes, bypass quantities, throttling of the discharge, and performance checks.

Pipe Cleanliness.

Multistage pumps, and many single-stage units, have close-clearance running

parts which must be protected from Abrasive particles often found in new piping
systems. In one subsidiary, Rust particles which lodge in the running clearance of a
large barrel type feed pump caused the unit to seize, requiring expensive repairs and
loss of pumping capacity during the ensuing shutdown.

Fig. 1. Temporary screen for pump inlet

This is but one example of damage caused by materials lodged in new piping.
Many others could be cited because this problem is rather common. To reduce the
possibility of larger abrasive particles from reaching the pump, install a flat or conical
strainer made up of No. 20 or 30 mesh window screen backed with ¼ inch mesh
screen. Place the screen in the suction line as close as possible to the pump suction
nozzle. Install pressure gauges on each side of the screen so the pressure drop across
it can be measured.

When starting the pump for the first time, watch both gages and when
a pressure difference occurs between the two, indicating the screen is clogged, stop
the pump and remove the dirt and scale from it. When the screen is clean, replace it.

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Continue cleaning and replacing, as necessary, until no further pressure drop occurs.
For most installations, the screen should be used for at least 24 hrs before being
removed.
Alignment.

Bring the pump to operating temperature by admitting liquid to the casing.

Check the alignment,. Turn the pump over by hand. It should turn freely , without
binding, scraping, or making any noise. Inspect the pump footings to see that any
device for expension of the casing are free and in good working condition.

Rotation.

Check the driver and pump rotation. When a polyphase driving motor is
used, touch the starter button just long enough to make the motor turn a few
revolutions. The pump shaft should turn in the direction of the arrow on the casing.

Figure 2a shows how to determine the direction of rotation of a horizontal

centrifugal pump. Stand at the driver end facing the pump. If the top of the shaft
revolves from left to right when viewed from this position the pump is said to rotate
clockwise. A counter-clockwise pump turns in the opposite direction when viewed
from the same point. For a vertical pump (Fig. 2b) look down at the top of the
pump. If a point on the shaft revolves from left to right, when viewed from this
position, the rotation is clockwise. When the shaft turns in the opposite direction its
rotation is counterclockwise.

Fig.2. Method of determining the

direction of rotation as specified by the
Hydraulic Institute (a) Horizontal pumps
and (b) Vertical pumps.

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Pump Bearings.

Before any pump is started its bearings must be carefully inspected, cleaned
and lubricated. With Oil-lubricated shoes sleeve bearings, thrust shoes (if used),
and drain plug. Flush out the housing, oil piping, cooler, pump, and sump tank with
kerosene, carbon-tetrachloride or safety solvent such as Klenco. Wash the bearing
parts throughly and reassemble them the housing. Flush entire system with
lubricating oil and allow it to drain to waste. This will ensure removal of any dirt,
metallic, or waste particles present in the bearings or lube sysem. Replace the drain
plug, caps, and other parts and fill the bearing as directed by the manufacturer or as
given later in this article.

Grease-lubricated ball, roller, and needle bearings are usually packed with
grease at the factory before the pump is shipped. So no lubrication may be
necessary before starting the pump. Check the condition of the grease by removing
the bearing housing cover. See that there is grease in the bearing. In general, do not
add any grease unless the pump manufacturer gives specific direction to do so. An
over-greased bearing may overheat soon after the pump is started. If it has,
replace as directed later in this article.

Never start a pump equipped with Kingsbury-type thrust bearings without

first pouring enough oil into the bushing to protect the thrust shoes. Extreme care
must be exercised with all types of bearings on pumps to see that they have enough
clean lubricant, Watch for contamination and for dirt picked up during shipment.

Thrust Bearings.

Figure 3 shows the steps in priming two designs of Kingsbury thrust

bearings commonly used in centrifugal pumps. In the bearing in Fig.3a, fill the
housing with the correct. grade of oil until the level reaches the ring on the oil-level
gage. This resembles the gage shown in Fig. 4a. Remove the locking screw in the
top of the thrust-bearing cap and pour a liberal amount of oil into the bushing
(Fig.3a). Replace the locking screw, making sure it fits into the bushing, to prevent it
from rotating. Remove the vent plug at the top of the oil-pump body and pour in
enough oil to wet the parts of the oil pump. Watch the oil level in the gage glass after
the main pump starts. If the level stabilises too far below the marker, add oil until the
level is ½ (12.5mm) to ¼ in. (6.5mm) below the ring.

The bearing in Fig. 3b and 3c does not have an integral oil pump. It is,
however, filled in a manner similar to that described above for Fig. 3a. Be sure to
replace the locking screw tightly, to prevent the bushing from rotating. The
procedures given here apply to one make of Kingsbury thrust bearing. To be
completely safe, check the pump instruction manual before flushing and filling thrust
bearings of this type. The exact procedure may differ from that given here.

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Fig. 3. Filling thrust bearings

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Fig.4. Two types of commonly used oil level indicators.

Fig.5. Typical forced-feed lubrication system.

Sight Gage Glasses.

Figure 4a shows a bearing housing equipped with a typical sight gage glass. The bearing in
Fig.4b has a constant-level oiler. This device maintains a constant oil level in the bearing as
long as there is oil in its reservoir (oil bottle).

Lube-oil Systems.

Figure 5 shows a typical forced-feed lube-oil system for a horizontal

multistage centrifugal pump. It consists of an integral gear-type oil pump mounted
within the thrust-bearing housing and taking its suction from an oil reservoir mounted
below the pump shaft, as shown, a tubular oil cooler, piping, and pressure and level
gages. With this type of system, which is often used with large pumps having sleeve
bearings for the main shaft, clean and flush the bearings as outlined above, including

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the sump-tank reservoir and the oil cooler. Pour oil into each bearing bushing and fill
the sump tank until it is ¾ full, or more. Important: Fill the supply line to the
bearings so it will be full when the pump starts and there will be no delay in the oil
reaching the bearings. The system supplies oil to both the bearings of the main pump
and its driver. Some pumps have a centrifugal-type impeller on the end of their
shaft, instead of a gear pump.

Fig.5b. An advanced (Pure) oil mist lubrication system console

Ball Bearings.

Almost all modern pumps use ball bearings to carry radial or thrust loads, or
both. (These are usually lubricated by an advanced pure or purge mist
systems- (fig.5b). The types of ball bearings used for centrifugal pumps include
single-row deep-groove, double-row deep groove, double-row self-aligning, and
angular contact types made in double-and single-row designs. They may be grease-
or oil-lubricated, with oil being popular for the al rger sizes. Figure 6a shows a
typical double-type out-board bearing designed to take small axial thrust loads
during pump starts and stops. It consists of two angular-contract ball thrust bearings
mounted back to back. A locknut and washer hold this bearing and the rotor
assembly in correct position with respect to the rest of the pump.

Cooled Ball Bearings.

Where high temperatures are expected in bearing operation the race may be
surrounded by a cooling jacket (Fig.6b). Water or another suitable liquid is
circulated through the jackets during pump operation.

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Sleeve Bearings.
In horizontal pumps these resemble the bearing shown in Fig. 3b, except
that a thrust collar is not fitted. A spherical seat permits the bearing bushing to align
itself with the shaft journal. Bearing linings are removable.

Vertical deepwell turbine pumps use either water-lubricated bearings

(Fig.6b) or oil-lubricated bearings (Fig. 6d). With the first type the liquid pumped
serves as the lubricant and no supply from the surface is needed. Oil-lubricated
bearings are inside a shaft-enclosing tube and are fed oil from the ground surface by
a lubricator mounted on or near the pump drive.

Lubricants.

Many manufacturers recommend a straight correctly refined turbine-type

Petronas Jentram type neutral mineral oil for centrifugal pumps. Normally it should
not contain any free acid, chlorine, sulfur, or more than a trace of free alkali. Based
on tests by ASTM standard methods, the oil should at least have the physical
characteristics given in Table 2-1.

Oil characteristics Napthene-base oil Paraffin-base oil

Flash point, C............ 165.5 min 182.2 min
Saybolt Viscosity at 37.7C 65.5 SSU min 60 SSU min
Pour Point, C........... -15 max 1.6 max
Steam Emulsion value 75 sec max 75 sec max
Table 2.1 Recommended lube-oil characteristics for centrifugal pumps

Pump Service Ambient Temp. C Greasing Interval

8 hour day:
7-day week Low 6 months
7-day week High 3 months

24 hour day:
7-day week Low 6 weeks
7-day week High 3 weeks

Table 2.2 Greasing Interval for Vertical ball-bearing Pumps

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Grease-lubricated ball bearings are generally packed with lubricant before

shipment. Over-greasing must be avoided because it is probably the most common
cause of overheating. Many pump manufacturers recommend a sodium-soap grease
carrying not less than 82 per cent of a high-grade filtered mineral oil having a
viscosity of not less than 150 SSU at 37.7 C. The melting point must not be less
than 148.8 C and The penetration at 25 C should be 275 to 330. In addition, the
grease should not separate on standing, nor should it form gum, become sticky,
harden, decompose, or corrode. Check to see that the grease is free of abrasive
particles (sand, dirt, lime, etc.), resins, and mineral salts. Table 2-2 gives the
greasing-interval recommendations of one pump manufacturer. Note that this is for a
vertical pump. Time intervals for greasing bearings in horizontal pumps will vary
somewhat, depending on the type of bearing, pump service conditions, and other
factors.

Fig.6. (a) Double type outboard bearing. (b) Water lubricated bearing for deepwell turbine pump
(c) ball bearing with cooling jacket (d) Oil lubricated bearing for deepwell turbine pump.

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Regreasing.

To replace the grease in a new or used antifriction bearing, remove the

bearing from the shaft. Using a brush, wash the race, balls, and other parts with
warm kerosene or carbon tetrachloride. Soak the bearing in one of these solvents
until the grease on it starts to dissolve. Use an innert-air hose to blow the grease off
the bearing parts.

Wash the bearing housing out with the same solvent. When both it and the
bearing are clean, flusih both with clean mineral oil. Allow the oil to drain to waste.
Check the cleanliness of the bearing by rotating it slowly. If it turns smoothly, you
can assume it is clean. Do not use kerosene or carbon tetrachloride at a
temperature higher fhan 50 C when cleaning the housing and bearing.

Pump Exterior.

Clean all external surfaces of The pump and its driver. Use rags or waste to remove
dirt, dust, oil drippings, globs of grease, and similar matter. It is important to have
the pump spotless if accidents and other operating troubles are to be avoided.

Check the suction and discharge piping to see that flanges and screwed
joints are tightly made up and will not leak. Where automatic valve operators are
used, check their operation by opening and closing the valves several times. To be
sure that the valve operating mechanism is working satisfactorily, use the manual
controls to open and close the valves.

Auxiliary Piping.

Check the auxiliary piping and liquid supply by opening the cooling-water
supply and discharge valves (Fig. 9) and observing the liquid flow. Where an
independent oil pump is used, start it and check the pressure and flow in the various
lube-oil lines. Check the cooling-water and oil flow at the pump bearings. See that
the stuffing-box jackets and smothering glands, if used, have a sufficient supply of
clear cool water.

Pump Drive.

Check the motor, turbine, engine, or other drive to see that it is lubricated
and ready to operate. Whenever possible, solo-run the drive independently of the
pump to see that it is in good operating order. Follow the manufacturer’s
instructions for drive operation. Remember, the drive generally is not supplied by
the pump manufacturer. So directions for drive operation may, or may not, be
included with the pump instruction manual.

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Priming.

Prime the pump by one of the methods given by the manufacturer’s

recomendation. Take care to see that the suction pipe is full of liquid and that there
is enough reserve in the supply system to keep the line full while the pump operates.
Reduced flow into the suction pipe of a centrifugal pump can lead to
overheating and extensive damage to the pump.

Position the Valves.

Open the suction valve wide. Never use it as a throttling device for pump
flow. With a medium- or high-head centrifugal pump it is best to start with the
discharge gate valve closed. This is because the pump requires less power input
when primed and operated at full speed with the discharge valve closed.

Mixed-flow-type centrifugal pumps often require greater power input when

started with the discharge valve closed than when it is open. Axial-flow-type
centrifugal pumps almost always take more power when started with the discharge
valve closed. So it is common practice to start these two types with the discharge
gate valve open. But to be certain, check with the pump manufacturer.

The Hydraulic Institute recommends that, except in the case of axial or

mixed-flow pumps, units driven by squirrel-cage induction motors having
reduced-voltage starting control should always be started with the discharge gate
valve closed. With this type of motor using across-the-line starting, the discharge
gate valve can be opened before the pump is started. But the length of time the
electrical disturbance caused by the starting cycle lasts may be reduced by keeping
the gate valve closed.

Standard Motors.

General-purpose synchronous motors of ratings up to 500 hp (372.8 Kw)

at 80 per cent power factor, and those having speeds of 500 rpm or higher at unity
power factor, have sufficient pull-in torque to start centrifugal pumps with the
discharge gate valve closed. At higher ratings and speeds below 500 rpm, standard
synchronous motors do not have enough pull-in torque to start a pump when its
discharge gate valve is open. Specially built motors can, however, be obtained to
start under these conditions. The remarks above on the starting methods for
induction motors also apply to synchronous motors.

Where a centrifugal pump must be started with the discharge gate valve
open and the starting current must be held to a minimum, use a wound-rotor
induction motor where alternating current is available. This type of motor develops
full-load torque without taking an excessive line current. A d-c motor can also be

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used, if a suitable power supply is available. It will develop full-load torque without
the line current’s exceeding 125 to 200 per cent of the normal full-load current.

Pump Warmup.

With pumps handling hot water or other hot liquids, the casing, rotor, and
other parts must be brought to within a temperature of 10 to 38 C of the liquid
before the unit is started. This prevents unequal expansion, with the possibility of
contact between the moving and stationary parts. Some long pumps actually bow
or arch when the top half is hot while the bottom half is cold.

Open the vent valve on top of the casing and admit warm liquid to the
pump. Use one or more casing drains to increase the liquid flow from the pump,
thereby reducing the time required for warm-up. Boiler-feed pumps, and units
handling valuable or toxic liquids, cannot economically be warmed up in this
manner. Instead, a jumper line around the discharge check valve is used. Hot liquid
flows through this line, into the pump, and out the suction pipe. In a 4.542 Cubic
meter/minute feed pump, a warmup flow of 37.8 liter/minute is enough to bring
the pump temperature to within 38 C of the liquid handled.

Pumps having labyrinth leakoffs in the stuffing box generally do not need a
jumper line. Drainage through the leakoff is usually of sufficient quantity to keep the
pump warm, if the leakage is made up with hot liquid from the suction line. At liquid
temperatures of 175 C or higher, a period of 3 to 4 hrs. should be allowed for
pump to warmup, when starting from a cold condition. Shorter intervals may be
used when the pump is warm before heating is begun.

Starting the Pump.

The following steps are usually suitable for starting a centrifugal pump in
good operating condition:

(1) Turn on the cooling-water system for the pump bearings,

stuffing boxes, and mechanical seals, if these parts are
liquid-cooled.
(2) Start the auxiliary lube-oil pump, if one is fitted, and check the
oil flow to the bear- ings and other parts of the pump.
(3) Open the suction gate valve, and close or open the discharge
gate valve, depending on the starting procedure to be followed.
(4) Close all the drains in the casing and suction and discharge
piping.
(5) Prime the pump.
(6) Open the warmup valve if the pump is not at the right
temperature.
(7) Open the recirculating valve.
(8) Start the driver and bring the pump up to speed.

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(9) As soon as the pump is up to rated speed, open the discharge

gate valve slowly.
(10) Check the leakage from the stuffing boxes.
(11) Adjust sealing-liquid flow to ensure packing lubrication. A
flow of 3 to 7 liter/min to each stuffing box is usually sufficient.
(12) Check the pump bearings for lube-oil flow.
(13) When there is sufficient flow through the pump, close the
recirculating valve.
(14) Check the pump suction, discharge, lube-oil, cooling-water,
and sealing-water pressures and temperatures. Bearing
temperatures generally should not exceed 65 C during pump
operation.

The above steps are suitable for almost all centrifugal pumps. Some steps
may be omitted with smaller units not having separate cooling and oil systems. If the
pump shows any signs of trouble while being started such as overheated bearings or
packing, excessive vibration or noise stop the unit immediately. Inspect the pump
for the cause of the trouble and take corrective action before starting the pump
again.

Fig. 10. (a) Internal seal used with clean liquid

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Fig 10 (b) External seal for dirty liquids

Stuffing Boxes.

On pumps using discharge liquid for the stuffing boxes (Fig. 10a) close the
sealing-liquid valves while the pump is being started on a suction lift. When liquid is
being discharged by the pump, open the sealing valves. Adjust until there is a slight
but constant leakage of liquid from the stuffing-box glands. With an external
seal-liquid supply (Fig. 10b) turn on the control valve before starting the pump.
Figures 10c and 10d show two other sealing arrangements.

Bypass Use.

The recirculation or bypass connections should be cut in whenever the

pump must run at shutoff or at 20 per cent or less of its rated capacity. Be sure the
recirculated or bypassed liquid flows to a lower-pressure area where it can release
some of its heat before returning to the pump. Then, there will be no danger of the
pump’s overheating. The bypassed liquid is often returned to the source of suction
supply, but not directly to the pump suction.

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Fig 10 (c) External grease seal for non-lubricating liquid, or where water cannot be used.

In boiler-feed pumps the maximum allowable temperature rise usually

recommended is 10 C. But when the pump handles cold water a higher rise 15 to
38 C may be permitted. The exact rise allowable limits must be obtained from the
pump manufacturer. A rule of thumb often used is: To limit the temperature rise of
the water in a boiler-feed pump, do not reduce the capacity below 113 liters/min
per 100 hp or 74.5 Kw input to the pump at shutoff. Many centrifugal boiler-feed
pumps have an orifice in the bypass line. The orifice is sized to pass the minimum
safe-flow quantity for the pump.

Excessive throttling of the discharge gate valve can also lead to overheating
of a pump. When only a small percentage of the rated flow is allowed to pass
through the pump, the casing may be unable to radiate enough heat to keep the
temperature constant. This is because the excess horsepower put into the pump,
over that delivered by the liquid, appears as heat in the liquid. Noisy operation,
over-heating, and shaft breakage are some of the operating troubles that may result.

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Fig. 10 (d) Seal cage next to impeller keeps abrasive liquid away from packing or mechanical seal.

Standby Pumps.

When keeping a standby pump hot by circulating hot liquid, use the
following operating methods:

(1) Circulate cooling

water through the bearings, packing boxes, and lantern rings.
(2)Circulate oil to the bearings.
(3) Start the pump once each 8-hr shift, bringing it up to full speed
and operating it for 3 or 4 minutes if they are not in the RCM
convention.

When the pump is on hot-oil or other service where the liquid handled may
coke or plug the passages, start the pump twice each 8-hr shift. Standby boiler-feed
pumps are generally held in readiness with the suction and discharge gate valves
open at all times. Be sure to have sufficient liquid in the suction well, tank, or pond
when keeping a pump on standby.

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Fig. 11. Typical boiler-feed pump log

Fig. 12 Cooling jacket for stuffing box operating at 120 C, or higher

Operating Checks.

While the pump runs, make the hourly checks listed below: bearing
temperature, suction and discharge pressure, lube-oil temperature and pressure,
leakoff flow, discharge flowmeter, stuffing-box leakage, cooling-water suction and
discharge temperature and pressure, input to the pump driver and the oil level in the
pump and driver bearings. Keep an hourly record of all these readings, using a log
sheet (Fig. 11) developed for the particular installation. When the pump is fitted
with water-quenched glands (Fig. 12) shut off the quenching-water supply before
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frying to determine the leakage from the stuffing box. Otherwise, the
quenching-gland flow may be mistaken for leakage from the stuffing box (Fig. 10).
The condition of the packing box can often be checked by feeling the gland while
the pump is running (Fig 13). When the pump handles cool liquids, the gland
handles cool liquids, the gland should not be too hot to touch. With hot liquids this
test cannot be used because heat is transmitted from the liquid pumped to the
gland.

Fig. 13. Checking stuffing-box temperature by hand.

Check ring-oiled or ball sleeve bearings every hour to see that the oil rings
(Figs. 3 and 4) are taming freely and supplying enough oil to the bearings and
shaft. With any pump having oil-lubricated bearings it is wise to rotate the shaft a
few times by hand before starting for the first time when the oil is cold and the
bearing surfaces dry. This starts a flow of lube oil to the bearing surfaces, reducing
the possibility of overheating of the bearings during starting.

When making the hourly round of a pump, listen to the sound it makes while
running. Any change in the sound should be carefully checked because it may be the
first sign of impending trouble. Increased vibration and sudden changes in the
bearing temperatures are other indicators of possible operating troubles.

Steam-turbine-driven Pumps.

Warm the turbine before starting by opening the steam exhaust valve and all
drains on the steam inlet and exhaust, and the turbine casing. Rotate the shaft at
least once by hand to see that it is free. Heat the turbine casing by cracking the
steam-inlet throttle valve and allowing a small amount of steam to pass through to
the exhaust line. Allow steam to enter the casing until the unit reaches its operating
temperature. Open all drain valves wide to remove all condensate from the casing
and steam lines. When the lines and casing are dry, close all drains, open the throttle
valve, and quickly bring the turbine up to rated speed. The governor will then take
over control of the turbine speed. Prepare the pump driven by a turbine in the same
manner as described earlier for other centrifugal pumps.

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Balancing-chamber Leakoff.

Be sure that the leakoff from the balancing chamber of a multistage pump is
always open while the unit runs. Shutting off flow from the chamber may prevent the
drum from functioning, severely damaging the pump. When the pump is used in
boiler-feed service, connect the balancing-chamber leakoff to the nearest
convenient liquid tank on the suction side of the pump. Since this is at a lower
pressure than in the chamber, leakoff liquid will automatically flow while the pump
operates. In general, do not connect the leakoff line to the pump suction nozzle or
pipe.

Mechanical Seals.

These are now used instead of packing in every pumps. When applied to
high-pressure high-temperature service, some seals have a quench connection.
Others, known as double seals, are used where the liquid is corrosive or abrasive.
This type generally has an auxiliary pump and reservoir. The small auxiliary pump
circulates lube oil through the seals to lubricate and cool them. Start the auxiliary
pump and establish oil circulation before the main pump is started. Pumps handling
clean cool liquids sometimes bypass a small portion of the discharge to the
mechanical seals to cool and lubricate them. Be certain to open any valves in these
and the quench connections before starting the main pump.

Casing Gasket.

Before starting split-casing pumps for the first time, tighten the casing bolts.
If the manufacturer recommends using a torque wrench, do so. This will ensure that
sufficient pressure is obtained on the paper or asbestos flange gaskets. After
tightening flange bolts, tighten the shaft-sleeve nuts on packed pumps. Then the
sleeve will rotate properly with the shaft.

Couplings.

Some gear-type shaft couplings must be filled with oil or grease before the
pump is started for the first time. Do not over-fill oil-type couplings because the
pack-oil may leak out while the pump operates, damaging the pump room walls,
ceilings, lights, or other fixtures. Figure 15 shows the three steps to be followed in
filling grease-packed gear-type couplings.

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Fig. 15. Steps in packing a gear-type coupling. (a) Pack grease over grid and teeth. (b) Draw up cover and fasten with bolts. (c)
Lubricate at least once every 6 months, using a grease gun.

Starting Marine Pumps.

Centrifugal pumps in shipboard uses are usually motor- or turbine-driven.

On some small vessels the pump may be belt-driven from an electric motor or an
engine shaft. Use the same starting procedure given earlier, except that more than
one valve may have to be opened in the suction line when the pump is connected to
a manifold. In general, the discharge gate valve can be left open, if desired, if the
pump is driven by a d-c motor. For most other drives the discharge gate valve
should be left in the position described above.

Belt-driven pumps need not be aligned quite so accurately with the drive
shaft as coupled pumps. This is because the belts can operate with some
misalignment of the shafts without excessive wear. But to obtain best life from the
drive belts, align the shafts and sheaves as accurately as possible. Then the belts will
last longer and will operate more quietly.

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Fig.16. Chart for best operating scheme.

When to Start Second Pump.

In some services, like boiler-feed, condenser-circulating water, and others,

there is a definite point at which it is economical to start a second pump to aid the
first in delivering to the system they serve. With circulating-water pumps this
condition usually occurs in the spring and fall of the year. Below a certain water
temperature, running the second circulating pump reduces the overall plant efficiency
because the input to the pump motor exceeds the additional generator output
produced by the better vacuum. But above this temperature, the reverse holds true
the extra output from the generator is greater than the input to the pump motor and
the plant efficiency is higher. Figure 16, when used with the heat-rate correction
chart furnished by the turbine manufacturer, helps show when to start or stop the
second circulating pump, if the plant is fitted with two.

Example: A turbine-generator unit operating at 100,000 kw shows a net

change of 0.3 per cent in the gross heat rate when its 600-hp
second circulating pump is started. Should the pump be left
running or be stopped?

Solution: Enter Fig. 16 at the left at a gross generation of 100,000 kw

and draw a straight line through the change in gross heat rate,
0.3 per cent in this case. Prolong this line until it intersects
reference scale K. From this point draw a straight line through
the circulating-pump horsepower. Extend it to the right. Scale

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Q shows the circulating pump should be stopped to secure the

best net heat rate for this particular unit.

In actual operation, start or stop the second circulating pump, depending on

whether it is idle or running. Then note the change in the condenser back pressure
(vacuum). Find the corresponding change in the unit heat rate from the turbine
manufacturer’s curve. Solve as described above.

Pump Shutdown.

When the liquid supply is above the pump centerline, close the discharge
gate valve, then the suction gate valve. Shutoff the power immediately. When the
liquid supply is below the pump (suction lift), close the suction gate valve, then the
discharge gate valve. Immediately after, shut off the power or steam to the driver.
This procedure keeps liquid in the pump, preventing damage should the unit be
started before being primed. If the pump has a recirculating line, close its valve
before the pump stops. Open the warmup valve if the pump is to be kept warm.

When a pump operates against a high discharge pressure it should be

stopped in three steps:

(1) Partially close the discharge valve.

(2) Shut off the power.
(3) As soon as the power is off, close the discharge valve rapidly.
The discharge valve should be tightly closed by the time the pump
stops rotating.

Then there is no possibility of backflow causing the pump to turn in a

reverse direction This procedure also prevents water hammer in high-pressure lines.
If the pump is not to be started, hang a suitable tag on it. Do not shut off the cooling
and sealing liquid supply until the pump shaft has stopped turning. When the pump
cannot be run against a closed gate valve, stop the motor or turbine before closing
the discharge gate valve.

Remember, an idle pump will partially drain through the glands while not
operating. So be sure to prime it before starting again. Never run any centrifugal
pump dry. Serious damage will almost always result. When the pump is on standby
service, its suction and discharge gate valves should be left open. Do not tighten the
gland nuts to prevent leakage from the pump unless they can be loosened quickly
when the unit is started.

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Flushing Plant Piping.

At PP(T)SB, it is mandatory to flush the piping with liquid discharged by

one or more pumps (if used) . The end of the pipe is connected to the sewer or
some other disposal point and water or other liquid is pumped through. This
process serves two purposes it is a convenient way of cleaning any refuse or other
matter from the new piping and it permits a good check of the performance of the
pump.

When flushing the piping a good opportunity is afforded for checking the
stuffing-box packing (if used). Check the packing box by feel as soon as the pump
starts and regularly thereafter while the pump runs. If the box overheats or begins to
smoke, shut the pump down immediately. Allow the box to cool and start the pump
again. Check its temperature as before (Fig.13). If it overheats, stop the pump
again. It may be necessary to start and stop the pump several times before the
packing is ‘worn-in’ and some of the liquid pumped can leak through to lubricate it.
If the box continues to overheat, inspect and repack it.

Pneumatic Pumps.

Air-driven sump pumps are popular in our industrial and construction jobs.
Before putting a unit of this type into service:

(1) Blow out the air-supply hose to remove any water or dirt before
it is attached to the pump.
(2) Pour a small amount of clean ISO #10 oil into the live-air inlet.
(3) Remove the oil plug and fill the lube-oil reservoir with the same
grade as in (2), above.
(4) Check the air-exhaust pipe to see that its outlet is above the
water level and free of dirt and other obstructions.
(5) Connect the air-supply hose. Maintain an air pressure of at
least 6.5 Kg/Cm2 at the pump. Some pumps use other pressures be
sure that the pressure at the pump air inlet is not more than 5 per
cent below the rated inlet pressure.

Mount the pump on a flat stone or board so that it is above any muck or
settlings in the sump. If the liquid being pumped is extremely dirty, place the pump in
a wire basket or screened box. When the pump is taken out of service overnight,
drain all water from it and disconnect the air-supply and exhaust hoses. Pour a small
amount of oil into the live-air inlet, connect the air hose, and allow the pump to idle
for about a minute. Disconnect the hose.

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Spare Parts.

The number of spare parts which should be kept on hand varies with the
pump application. Thus, aboard ship more parts are generally carried than in a
stationary plant. Most manufacturers recommend that the minimum number of
spares should be one set of shaft bearings, one set of shaft sleeves, one set of
wearing rings, and a supply of suitable set of packing or mechanical seals for the
stuffing boxes. On vital jobs where a standby pump is not installed, stock a
complete spare rotating element.

When ordering spare parts, always remember to give the manufacturer the
following information: serial number of pump, size and type of pump as given on the
pump name-plate, the exact number of the part as listed in the pump instruction and
parts manual, and the name of the part, as listed. Where possible, give the complete
symbols stamped on the old part. This is important information hence our pumps are
not purchased off-the shelve.

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References:

(1) Hydraulic Institute. (2) Ingersoll-Rand Co. (3) Peerless Pump Div. (4) Layne & Bowler, Inc. (5) Westinghouse Electric
Corp. (6) Allis-Chalmers Mfg. Co. (7) Power. (8) Worthington Corp. (9) Falk Coupling Div, Borg-Warner Corp. (10) Ebara
Corporation. (11) Pacific-Hiro pump Div, Shin Nippon Machinery (12) EKK Eagle Industry Co. Ltd. (13) Lubrication Systems
Company. (14) American Petroleum Institute. (15) Institution of Electrical and Electronic Engineers. (16) Institution of
Diagnostic Engineers.

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