Pump - Wikipedia, the free encyclopedia. A small, electrically powered pump. Availability, Reliability, Maintainability, and Capability H. Barringer & Associates, Inc. Humble, TX Triplex Chapter Of The Vibrations Institute. Universal Pump Extended Life Program REMANUFACTURING, RECONDITIONING AND REPAIR. Using supplemental specifications and upgrading during pump repair provides reliability. AVT Reliability Pump Division carried out a review how to reduce cost and improve reliability of pumps in Food & Beverage sector. Pump Reliability: The Big Picture. Horizontally mounted lobe pump (right) shown with its electric motor (left) and drive- shaft bearing (middle)A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical action. Pumps can be classified into three major groups according to the method they use to move the fluid: direct lift, displacement, and gravity pumps. Pumps operate via many energy sources, including manual operation, electricity, engines, or wind power, come in many sizes, from microscopic for use in medical applications to large industrial pumps. Mechanical pumps serve in a wide range of applications such as pumping water from wells, aquarium filtering, pond filtering and aeration, in the car industry for water- cooling and fuel injection, in the energy industry for pumping oil and natural gas or for operating cooling towers. In the medical industry, pumps are used for biochemical processes in developing and manufacturing medicine, and as artificial replacements for body parts, in particular the artificial heart and penile prosthesis. Single stage pump - When in a casing only one impeller is revolving then it is called single stage pump. Double/ Multi stage pump - When in a casing two or more than two impellers are revolving then it is called double/ multi stage pump. In biology, many different types of chemical and bio- mechanical pumps have evolved, and biomimicry is sometimes used in developing new types of mechanical pumps. Mechanical pumps may be submerged in the fluid they are pumping or be placed external to the fluid. 10 Steps to Pump Reliability - Part 1. Establish a Pump Management Program. Ten Steps to Pump Reliability (Part 2). Pump Statistics Should Shape Strategies. By Kathy on October 1, 2008 in October 0. In addition, all plants had some type of pump reliability program in progress. Centrifugal Pump Training. Centrifugal Pump Training. The ever-present centrifugal pump is a critical component of most. How to start a pump reliability program. Enrollment Enrollment Requirements. In order to enroll in the program, applicants must have a conferred degree in mechanical engineering or a conferred degree in. A pump is a device that moves fluids. ![]() ![]() ![]() Pumps can be classified by their method of displacement into positive displacement pumps, impulse pumps, velocity pumps, gravity pumps, steam pumps and valveless pumps. There are two basic types of pumps: positive displacement and centrifugal. Although axial- flow pumps are frequently classified as a separate type, they have essentially the same operating principles as centrifugal pumps. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant through each cycle of operation. Positive displacement pump behavior and safety. Thus, positive displacement pumps are constant flow machines. However, a slight increase in internal leakage as the pressure increases prevents a truly constant flow rate. A positive displacement pump must not operate against a closed valve on the discharge side of the pump, because it has no shutoff head like centrifugal pumps. A positive displacement pump operating against a closed discharge valve continues to produce flow and the pressure in the discharge line increases until the line bursts, the pump is severely damaged, or both. A relief or safety valve on the discharge side of the positive displacement pump is therefore necessary. The relief valve can be internal or external. The pump manufacturer normally has the option to supply internal relief or safety valves. The internal valve is usually only used as a safety precaution. An external relief valve in the discharge line, with a return line back to the suction line or supply tank provides increased safety. Positive displacement types. If rotary pumps are operated at high speeds, the fluids cause erosion, which eventually causes enlarged clearances that liquid can pass through, which reduces efficiency. Rotary positive displacement pumps fall into three main types: Gear pumps - a simple type of rotary pump where the liquid is pushed between two gears. Screw pumps - the shape of the internals of this pump is usually two screws turning against each other to pump the liquid. Rotary vane pumps - similar to scroll compressors, these have a cylindrical rotor encased in a similarly shaped housing. As the rotor orbits, the vanes trap fluid between the rotor and the casing, drawing the fluid through the pump. Reciprocating positive displacement pumps. Colored School in Alapaha, Georgia, USReciprocating pumps move the fluid using one or more oscillating pistons, plungers, or membranes (diaphragms), while valves restrict fluid motion to the desired direction. Pumps in this category range from simplex, with one cylinder, to in some cases quad (four) cylinders, or more. Many reciprocating- type pumps are duplex (two) or triplex (three) cylinder. They can be either single- acting with suction during one direction of piston motion and discharge on the other, or double- acting with suction and discharge in both directions. The pumps can be powered manually, by air or steam, or by a belt driven by an engine. This type of pump was used extensively in the 1. Now reciprocating pumps typically pump highly viscous fluids like concrete and heavy oils, and serve in special applications that demand low flow rates against high resistance. Reciprocating hand pumps were widely used to pump water from wells. Common bicycle pumps and foot pumps for inflation use reciprocating action. These positive displacement pumps have an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pumps as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant given each cycle of operation. Typical reciprocating pumps are: Plunger pumps - a reciprocating plunger pushes the fluid through one or two open valves, closed by suction on the way back. Diaphragm pumps - similar to plunger pumps, where the plunger pressurizes hydraulic oil which is used to flex a diaphragm in the pumping cylinder. Diaphragm valves are used to pump hazardous and toxic fluids. Piston pumps displacement pumps - usually simple devices for pumping small amounts of liquid or gel manually. The common hand soap dispenser is such a pump. Radial piston pumps. Various positive displacement pumps. It consists of two meshed gears that rotate in a closely fitted casing. The tooth spaces trap fluid and force it around the outer periphery. The fluid does not travel back on the meshed part, because the teeth mesh closely in the center. Gear pumps see wide use in car engine oil pumps and in various hydraulic power packs. Screw pump. The screws are mounted on parallel shafts that have gears that mesh so the shafts turn together and everything stays in place. The screws turn on the shafts and drive fluid through the pump. As with other forms of rotary pumps, the clearance between moving parts and the pump's casing is minimal. Progressing cavity pump. This can be visualized as a central core of diameter x with, typically, a curved spiral wound around of thickness half x, though in reality it is manufactured in single casting. This shaft fits inside a heavy duty rubber sleeve, of wall thickness also typically x. As the shaft rotates, the rotor gradually forces fluid up the rubber sleeve. Such pumps can develop very high pressure at low volumes. Roots- type pumps. This design produces a continuous flow with equal volume and no vortex. It can work at low pulsation rates, and offers gentle performance that some applications require. Applications include: Peristaltic pump. It contains fluid within a flexible tube fitted inside a circular pump casing (though linear peristaltic pumps have been made). A number of rollers, shoes, or wipers attached to a rotor compresses the flexible tube. As the rotor turns, the part of the tube under compression closes (or occludes), forcing the fluid through the tube. Additionally, when the tube opens to its natural state after the passing of the cam it draws (restitution) fluid into the pump. This process is called peristalsis and is used in many biological systems such as the gastrointestinal tract. Plunger pumps. The suction and discharge valves are mounted in the head of the cylinder. In the suction stroke the plunger retracts and the suction valves open causing suction of fluid into the cylinder. In the forward stroke the plunger pushes the liquid out of the discharge valve. Efficiency and common problems: With only one cylinder in plunger pumps, the fluid flow varies between maximum flow when the plunger moves through the middle positions, and zero flow when the plunger is at the end positions. A lot of energy is wasted when the fluid is accelerated in the piping system. Vibration and water hammer may be a serious problem. In general the problems are compensated for by using two or more cylinders not working in phase with each other. Triplex- style plunger pumps. Adding a pulsation dampener on the pump outlet can further smooth the pump ripple, or ripple graph of a pump transducer. The dynamic relationship of the high- pressure fluid and plunger generally requires high- quality plunger seals. Plunger pumps with a larger number of plungers have the benefit of increased flow, or smoother flow without a pulsation dampener. The increase in moving parts and crankshaft load is one drawback. Car washes often use these triplex- style plunger pumps (perhaps without pulsation dampeners). In 1. 96. 8, William Bruggeman significantly reduced the size of the triplex pump and increased the lifespan so that car washes could use equipment with smaller footprints. Durable high pressure seals, low pressure seals and oil seals, hardened crankshafts, hardened connecting rods, thick ceramic plungers and heavier duty ball and roller bearings improve reliability in triplex pumps. Triplex pumps now are in a myriad of markets across the world. Triplex pumps with shorter lifetimes are commonplace to the home user. A person who uses a home pressure washer for 1. Industrial- grade or continuous duty triplex pumps on the other end of the quality spectrum may run for as much as 2,0. Run on compressed air these pumps are intrinsically safe by design, although all manufacturers offer ATEX certified models to comply with industry regulation. Pump Statistics Should Shape Strategies. How are your operations doing on pump MTBF? How do you compare with the best of the best? Examining pump repair records and MTBF (mean time between failures) is of great importance to responsible and conscientious pump users. In view of that fact, the preface to the 2. Pump User’s Handbook (Ref. For the sake of convenience, these failure statistics often are translated into MTBF (in this case, installed life before failure). In an effort to avoid arguments on statistics, during the early 2. For a well- managed and reasonably reliability- focused U. S. The refinery would count as a repair incident the replacement of parts—any parts—regardless of cost. In this case, a drain plug worth $1. MTBF statistics. Only the replacement of lube oil would not be counted as a repair. A best- practices plant’s total repair cost for pumps would include all direct labor, materials, indirect labor and over- head, administration cost, the cost of labor to procure parts, even the prorated cost of pump- related re incidents. There exist many references to the stated average cost of pump repairs: $1. We believe this indicates, in relative terms, a repair cost reduction, because a 2. It also can be reasoned that predictive maintenance and similar monitoring have led to a trend toward reduced failure severity. Using the same bare- bones measurement strategy—and from published data and observations made in the course of performing maintenance effectiveness studies and reliability audits in the late 1. Table I have been estimated. Other studies of pump statistics In early 2. Gordon Buck, John Crane’s chief engineer for Field Operations in Baton Rouge, LA, examined the repair records for a number of renery and chemical plants to obtain meaningful reliability data for centrifugal pumps. A total of 1. 5 operating plants having nearly 1. Table II. The smallest of these plants had about 1. All facilities were located in the United States. In addition, all plants had some type of pump reliability program in progress. Some of these programs could be considered as “new,” others as “renewed” and still others as “established.” Many of these plants—but not all—had an alliance arrangement with John Crane. In some cases, the alliance contract included having a John Crane technician or engineer on- site to coordinate various aspects of the program. Not all plants are refineries, however, and different results can be expected elsewhere. In chemical plants, pumps have traditionally been “throw- away” items as chemical attack can result in limited life. Things have improved in recent years, but the somewhat restricted space available in “old” DIN and ASME- standardized stuffing boxes places limits on the type of seal that can be fitted. Unless the pump user upgrades the seal chamber, only the more compact and simple versions can be accommodated. Without this upgrading, lifetimes in chemical installations are generally believed to be around 5. Target pump and component lifetimes Based on the lifetime levels being achieved in practice in 2. Table III are recommended and should be considered readily achievable. It should again be emphasized that many plants are achieving these levels of installed lives. The actual operating life of a seal would be approximately one- half of its installed life. Nevertheless, to reach these pump lives, the pump components themselves must be operating at the highest levels. An unsuitable seal with a lifetime of one month or less will have a catastrophic effect on pump MTBF, as would an under- performing coupling or bearing. Upgrades can reduce maintenance costs Many “standard” ANSI and ISO- compliant pumps were designed decades ago—when frequent repairs were accepted and plant maintenance departments were loaded with personnel. Unless selectively upgraded, a “standard” pump population will not allow 2. We are intending primarily to provide pump failure statistics on relatively inexpensive ANSI and ISO pumps, as well as API- compliant (“traditional”) refinery centrifugal pumps. But, this article also should remind the reader of important issues that cannot be overlooked in attempting to extend pump life. Pump sealing, advanced bearing housing protection and bearing lubrication topics are of primary importance (and the author would be pleased to alert you to specifics at either his or another relevant Website). It goes without saying that unscheduled maintenance often is one of the most significant costs of ownership, and failures of mechanical seals and bearings are among the major causes. Therefore, in recent years, improved pump designs and the management of mechanical reliability issues have led to significant increases in the pump MTBF rates for many process plants. Back in the 1. 97. MTBF rates of six months to 1. Today, most reliability- focused plants have pump MTBF rates that track the tabulations found in Tables I through III. Important improvements have been achieved by paying proper attention to pump components with the highest failure rates. Buried in Table I is information from a plant with more than 2. MTBF in excess of nine years. This, as one might suspect, is a facility that looks at mechanical and process interactions. The reliability professionals at this plant fully understand that pumps are part of a system and that the system must be correctly designed, installed and operated if consistently high reliability is to be achieved. It should be pointed out that plants of this type are conducting periodic pump reliability reviews. Reliability reviews start before purchase The best time for the first reliability review is before the time of purchase. This subject is given thorough treatment in Ref. It is rather obvious that individuals with reliability engineering backgrounds and acute awareness of how and why pumps fail are best equipped to conduct such reviews. This implies that these contributors should have an involvement in the initial pump selection process. Individually—or as a team—those involved should consider the possible impact of a number of issues, including the ones mentioned above. They merit close attention and are again summarized for emphasis: Keep in mind the potential value of selecting pumps that cost more initially, but last much longer between repairs. The MTBF of a better pump may be one to four years longer than that of its non- upgraded counterpart. Consider that published average values of avoided pump failures range from $2. This does not include lost opportunity costs. One pump fire occurs per 1. Having fewer pump failures means having fewer destructive pump fires. Remember that there are several critically important applications where buying on price alone is almost certain to ultimately cause costly failures. Included are the following: Applications with insufficient NPSH or low NPSH margin ratios . At a minimum, then, these are the six services where spending time and effort for pre- purchase reliability reviews makes much economic sense. Such diligent reviews concentrate on typical problems encountered with centrifugal pumps; an attempt is made to eliminate these problems before the pump ever reaches the field. Among the most important problems that the reviews seek to avoid are: Pumps not meeting stated efficiency; Lack of dimensional interchangeability; Vendor’s sales and/or coordination personnel being reassigned; Seal problems and compromises in materials, flush plans, flush supplies, etc.; Casting voids (repair procedures, maximum allowable pressures, metallurgy, etc.); Lube application or bearing problems . Perform your own projected MTBF calculations Although not perfect from a mathematician’s perspective, simplified calculations will give an indication of the extent to which improving one or two key pump components can improve overall pump MTBF . Say, for example, there’s agreement that the mechanical seal is the pump component with the shortest life, followed by the bearings, coupling, shaft and sometimes impeller, in that order. The anticipated mean time between failures (operating MTBF) of a complete pump assembly can be approximated by summing the individual MTBF rates of the individual components, using the following formula: 1/MTBF = . An assessment was made of probable failure avoidance that would result if shaft defections could be reduced. It was decided that limiting shaft defection at the seal face to a maximum of 0. It was similarly judged that a sizable increase in seal housing dimensions to allow the installation of the newest seal configurations would more than double the MTBF of seals. By means of such analyses, all of the components under consideration for upgrading were examined, the life estimates collected and the latter used in MTBF calculations. In Equation (1), LLL and L represent the life, in years, 1,2,3. Using applicable data collected by a large petrochemical company in the 1. The results are presented in Table IV. As an example, a standard construction ANSI B7. MTBF of 1. 2, bearing MTBF of 3. MTBF of 4. 0 and shaft MTBR value of 1. MTBF of 1. 0. 7 years (actual operating hours). By upgrading the seal and bearings, the estimated achievable pump MTBF (actual operating hours) can be improved by 8. Table IV thus shows the influence of selectively upgrading either bearings or seals or both on the overall pump MTBF. Clearly, choosing a 2. MTBF seal and a six- year MTBF bearing (easily achieved by preventing lube oil contamination via superior bearing housing seals), had a major impact on increasing the pump MTBF and—assuming the upgrade cost is reasonable—may well be the best choice. As has been noted, a typical pump failure, based on actual year 2. This includes costs for material, parts, labor and overhead. Let us now assume that the MTBF for a particular pump is 1. This would result in a cost avoidance of $2. In addition, the probability of reduced power cost would, in many cases, further improve the payback.
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