This is a single license Digital eBook PDF File that is downloadable, and password protected
eBook Description
This book explains just how and why the best-of-class pump users are consistently achieving superior run lengths, low maintenance expenditures and unexcelled safety and reliability. Written by practicing engineers whose working career was marked by involvement in pump specification, installation, reliability assessment, component upgrading, maintenance cost reduction, operation, troubleshooting and all conceivable facets of pumping technology, this text describes in detail how to accomplish best-of-class performance and low life cycle cost.
Table of Contents
- Preface to the Fourth Edition
- Acknowledgements
- Chapter 1 Pump System Life Cycle Cost Reduction
- Initial Costs
- Installation Costs
- Energy/Operating Costs
- Maintenance and Repair Costs
- Loss of Production
- Pump Reliability Factors
- Chapter 2 How to Buy and Ship a Better Pump
- Specification Overview
- ANSI vs. API—How do They Differ?
- Process Industry Practices (PIP)
- Supplementary Specifications
- Specification Checklists
- Selecting a Knowledgeable Cooperative Vendor
- Design Weaknesses Found in API Casing Construction
- Bearing Housing Designs Merit Closer Attention
- Upgrading of Centrifugal Pumps
- Excessive Shaft Deflection
- Factors Affecting Bearing Life
- Documentation is Part of Initial Purchase
- Bid Tabulations Lead to Final Selection
- How to Ship Pump Sets
- Chapter 3 Piping, Baseplate, Installation, and Foundation Issues
- Pump Piping
- Field Installation Procedure for Pipe Spring Hangers and Pipe Supports
- Pump Baseplates and Grouting
- Pump Alignment
- Pump Suction Strainers
- Eccentric Reducers and Straight Runs of Pipe at Pump Suction
- Chapter 4 Operating Efficiency Improvement Considerations
- Total System Efficiency
- Energy Effectiveness
- Energy Operating Cost Savings Potential
- System Efficiency
- Creating Pump/System Head-Capacity Curves
- Parallel Pump Operation
- Additional Reliability Issues withParallel Operation
- Specific Parallel Pump Guidelines/Process Pumps
- Impact of Variable Speed Control on Parallel Pump Operation
- Multi-Pump Parallel Operation—Control
- Parallel Pump Operations Conclusions
- Grounding Ring Technology for Variable Frequency Drives (VFDs)
- How to Optimize the Overall
- Efficiency When Pumps are Operated as Both Pumps and Power Recovery Turbines in the Same System
- Understanding Periodic Switching of Process Pumps and Power Recovery Turbines
- Chapter 5 Improved Pump Hydraulic Selection Extends Pump Life
- Influence of Pump Hydraulic Selection
- Operating Speed
- Allowable Operating Region
- Suction Recirculation
- Mitigating Suction Recirculation Problems
- Suction Energy
- NPSH Margin
- NPSH Margin Reliability Factor
- Total Pump Hydraulic Relative Reliability
- Pump Reliability Impact from System Design
- Pump Sump Intake Design
- Water Hammer
- Chapter 6 Improvements Leading to Pump Mechanical Maintenance Cost Reduction
- Mechanical Maintenance Life Cycle Impact
- Pump Reliability Reviews Start Before Purchase
- Mean-Time-Between-Failure Calculations
- “ANSI Plus®” Mechanical Seal Gland
- Sealed Power Ends and Expansion Chambers
- Bearing Housing Seals in the Lubrication Environment
- Dual-Face Magnetic Bearing Housing Seals
- Features of Upgraded Centrifugal Pumps
- Advanced Lubrication Strategies
- Telescoping Shaft Seal Sleeve
- Dynamic Shaft Seal—an Occasional Alternative to the Mechanical Seal
- Consider Composite Materials in Centrifugal Pump Wear Components
- Chapter 7 Bearings in Centrifugal Pumps
- Pump Bearing Loads
- Radial Load
- Bearing Types Used in Centrifugal Pumps
- Pump Bearing Arrangements
- Bearing Life
- Bearing Lubrication
- Oil-Bath Lubrication
- Oil Ring Lubrication
- Oil Mist Lubrication Overview
- Grease Lubrication Overview
- Bearing Temperature
- Bearing Mounting and Radial Clearance
- Housing Fits
- Internal Radial Clearance
- Bearing Housing Sealing
- Angular Contact Ball Bearings in Centrifugal Pumps
- Bearing Preload
- Universally Matchable Single Row Angular Contact Ball Bearings
- Cages
- Recommended Bearing Applications Summarized
- MRC Pumpac® Bearings
- Double-Row Angular Contact Ball Bearings
- Double-Row Angular Contact Bearings with Two Inner Rings
- Roller Bearings in Centrifugal Pumps
- Sliding Bearings
- Pivoted Shoe Thrust Bearings
- Parameters Related to Pivoted Shoe Bearings
- End-Play and Radial Clearance
- Preload
- Lubrication
- Operation and Monitoring
- Bearing Housing Protection
- Chapter 8 Mechanical Seal Selection and Application
- Design of Mechanical Seals
- Types of Seals
- Seal Face Lubrication Enhancements Employing Laser Etching Technology
- Seal Flush and Environmental Control Plans
- Reliability Improvement in Mechanical Seals — Analysis of Design Considerations
- Basic Considerations for Seal Users and Manufacturers
- Designing for Decreased Failure Risk
- Case Studies Involving Conversion from and to Different Seal Plans
- Enhancing the Seal Environment by Using Advanced Flow Inducers and Bi-directional Internal Pump-arou
- Phasing Out Pump Packing
- Dual Mechanical Seal Designs and API-682
- Comparison of Different Dual Seal Arrangements
- More Mechanical Seal Case Studies
- What to Look for in Strategic Mechanical Seal Partnerships
- Chapter 9 Improved Lubrication and Lubricant Application
- Extending Pump Life by Understanding Lube Application
- Synthetic Lube Overview
- Balanced Constant Level Lubricators: How Cost-Effective?
- Splash Lubrication, Oil Rings and Flinger Discs
- Why and How to Protect Bearings Against Lube Contamination-Related Failures
- Lubricants, Base Stocks and Performance Tradeoffs
- Lubricants, Tests and Properties
- Lubricants and the Importance of Clean Products
- Chapter 10 Oil Mist Lubrication and Storage Protection
- System Usage
- “Purge Mist,” or “Wet Sump” Oil Mist
- Dry Sump Oil Mist is Advantageous
- Modern Plant-Wide Systems Enhance Safety and Reliability
- Environmental Concerns Addressed
- Economics of Dry Sump Oil Mist Lubrication
- Selecting the Correct Oil
- Oil Mist for Electric Motors
- Electric Motor Codes and Practices
- On the Safety of Explosion-Proof Motors for Class 1 Division 1 Service
- Long-term Storage of Pumps and Motors Using Oil Mist
- Chapter 11 Coupling Selection Guidelines
- Coupling Function
- Rigid Couplings
- Flexible Couplings
- Couplings for Centrifugal Pumps
- Chapter 12 Pump Condition Monitoring Guidelines
- Vibration Basics
- Predictive Condition Monitoring and Fault Tolerant Intelligent Drives/Controls
- Rotor Balancing
- Vibration Acceptance Limits
- Causes of Excessive Vibration
- Chapter 13 Pump Types and Materials
- Petroleum Refinery Service Pumps (API-610)
- API-610 Materials of Construction and Grade Levels
- Magnetic Drive and Positive Displacement Pumps
- Chemical Pumps
- Key Selection Criteria for Chemical Applications
- Canned Motor Pumps Make Important Inroads in Refinery Servces
- Paper Stock and Other Large Process Pumps
- Double Suction/Axially Split Case Pumps
- Sewage and Waste Water Submersible Pumps (Solids and Non-clog)
- Slurry Pumps
- Vertical Column Turbine (“VTP”) Pumps
- Bowl Assembly
- Vertical Enclosed Shaft-Driven
- Recessed Impeller Sump Pumps
- Bearing Materials
- Column Assembly
- Critical Speed
- Discharge Head Assembly
- Sump Design
- Split Flow Centrifugal Pumps
- Modern Pumps Have Stiffer Shafts
- Typical Pump Material Selection
- Chapter 14 Pump Failure Analysis and Troubleshooting
- Organizing Systematic Pump Failure Reduction Programs
- Chapter 15 Shop Repair, Spare Parts Availability & Procurement
- Shop Repair Procedures
- Moving from Repair-Focus to Reliability-Focus
- Combining Pump Maintenance with Systematic Pump Upgrading
- Chapter 16 Failure Statistics and Component Uptime Improvement Summary
- Pump MTBF as a Function of Component MTBF
- Examining Pump Repair Records and MTBF
- Gordon Buck’s Study of Pump Statistics
- Seal Mtbf Explored
- MTBF Simulations and Seal MTBF Levels Currently Being Achieved
- Target Pump and Component Lifetimes
- How Competent Manufacturers Improve Component Reliability
- Couplings
- Bearings
- Supplier/Customer Relationships
- Chapter 17 Breaking the Cycle of Pump Repairs
- Examining the Cost of Failures
- Pumps Have a Defined Operating Range
- Getting into Mechanical Issues
- Deviations from Best Available Technology
- More on Lubrication and Bearing Distress
- Two Different DN-rules Explained
- The Trouble with Oil Rings and Constant Level Lubricators
- Bearing Housing Protector Seals
- Ranking the Different Lube Application Practices
- Demand Better Pumps and Pay for Value
- Appendix 1 Pump Start-up and Shutdown Procedures
- Appendix 2 A “Hundred-plus Points” Summary of Pump Reliability Improvement Options and Considera
- Appendix 3 Supplementary Specification for API-class Pumps
- Appendix 4 Specification and Installation of Pre-grouted Pump Baseplates
- Appendix 5 Protection of Mechanical Seals in Non-operating Pumps
- Appendix 6 Explaining the Ingress Protection Code
- References
- Index
Authors:
Heinz P. Bloch and Allan R. Budris
e-ISBN: 9788770223119