9/1/2022

Practical Pump Operation and Care

for Operators
Proman
September 2022

www.plantleadership.com

Objectives
In this workshop, you will learn:
 Types of pumps and lubrication systems
 Monitoring, operation and care of pumps

Agenda

 Introductions
 Module 1 – Pumps and Lubrication Systems
 Module 2 – Monitoring, Operation, and Equipment
Care

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Introductions

 Please introduce yourself to the

group, including:
– Years’ experience
– Units worked
– Expectations for this class

MODULE 1
PUMPS AND LUBRICATION
SYSTEMS

Module 1 Objectives

In this module, we will discuss:

 Basic Centrifugal Pump Components and
Operating Principles
 Basic Positive Displacement Pump Components
and Operating Principles
 Lubrication Systems

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Lesson 1
BASIC CENTRIFUGAL PUMP
COMPONENTS AND OPERATING
PRINCIPLES

Lesson 1 Objectives

In this lesson, we will discuss:

 How centrifugal pumps work
 Basic pump parts
 Seals and wear rings
 Common valve and piping arrangements

How Centrifugal Pumps Work

 Has a rotating
impeller
 Used to move large
volumes of liquid
with low velocity

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How Centrifugal Pumps Work

 Liquid is
discharged from
 Liquid is thrown the volute
off the impeller
due to centrifugal
force

 Liquid is drawn into

the eye

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Basic Pump Parts

Drive
Lube Oil Coupling
Motor
Reservoir Impeller
Gland
Discharge

Wear Rings
Suction

Pump Base
Guard Shaft

Casing

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Seals and Wear Rings

 Seals are devices that hold lubricants and

process fluids in place while keeping out
foreign material

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Seals and Wear Rings

 Stuffing box seals contain packing material

 Used in non‐toxic, nonflammable, non‐
polluting applications
 Packing goes in a packing gland

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Seals and Wear Rings

 Mechanical seals are two flat surfaces that

are in contact with each other to prevent
leaks
 One rotates, one remains stationary

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Seals and Wear Rings

 Held together using springs

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Seals and Wear Rings

 Seal flushes are small flows of liquid routed

to pump seal to reduce friction and remove
heat
– Can be process fluid or externally supplied liquid
 Seal pot is a reservoir containing a secondary
liquid at a slightly higher pressure than the
pump

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Seals and Wear Rings

 Wear rings are rings that allow the impeller and

casing suction head to seal tightly together
without wearing each other out
 Impeller ring rotates with impeller
 Casing ring is stationary
 Wear rings increase efficiency by minimizing
discharge‐to‐suction recirculation
 They also minimize seal and chamber pressure

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Common Valve and Piping Arrangements

DISCHARGE

Discharge Valve
Recycle Valve

RECYCLE Vent Valve

Suction Valve

SUCTION

Drain Valve

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Recycle and Minimum Flow Line

 A recycle or spillback is when a small percentage of

a centrifugal pump’s total flow is routed back to
the suction side of the pump.
 The minimum flow line maintains suction pressure
(head) to protect the pump from a “deadhead”
where there is not enough flow through the
pump.
 Most often seen in centrifugal pumps as excessive
heating and churning can occur when there is not
enough flow through the pump

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Lesson 1 Key Learning Points

In this lesson, you learned:

 How centrifugal pumps work
 Basic pump parts
 Seals and wear rings
 Common valve and piping arrangements

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Lesson 2
BASIC POSITIVE DISPLACEMENT
PUMP COMPONENTS AND
OPERATING PRINCIPLES

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Lesson 2 Objectives

In this lesson, we will discuss:

 How positive displacement (PD) pumps work
 Basic types of PD pumps
 Pump parts

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How Positive Displacement Pumps Work

 Use pistons,
diaphragms, gears,
or screws to move
a constant volume
of fluid
 Either rotary or
reciprocating

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How Positive Displacement Pumps Work

 Rotary pumps displace liquid at a constant

rate by using two rotating elements
 Reciprocating use a piston or plunger that
moves back and forth to displace liquid
 No theoretical limit to amount of pressure
that can be developed, so do not deadhead!
 They are self‐priming

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How Positive Displacement Pumps Work

 Reciprocating pumps
use the inward
stroke of a piston or
diaphragm to draw
liquid into a
chamber, with
another stroke to
discharge the liquid

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How Positive Displacement Pumps Work

 Diaphragm pumps
contain a flexible
diaphragm
 The diaphragm is
moved by a linkage,
compressed air or
other liquid

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How Positive Displacement Pumps Work

 Gear pumps contain

two rotating gears with
teeth in opposing
directions
 Liquid enters the space
between the teeth
 As teeth rotate, liquid
moves toward outlet

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How Positive Displacement Pumps Work

 Screw pumps are

rotary pumps that
displace liquid with a
screw
 Liquid enters the
pump, is trapped
between the casing
and the threads, and is
pushed out the
discharge

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Exercise

What types of pumps do you have in

your unit?

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Lesson 2 Key Learning Points

In this lesson, you learned:

 How positive displacement pumps work
 Basic PD pump types

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Lesson 3
LUBRICATION SYSTEMS

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Lesson 3 Objectives

In this lesson, we will discuss:

 Purpose of lubrication
 Lubricants
 Types of lubrication systems

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Purpose of Lubrication

 Lubricants are applied between moving surfaces

to reduce friction and minimize heating
 Circulate cooling fluids to cool seals, reduce
friction between moving surfaces, and minimize
heating
 Critical to prevent premature wear, heat buildup,
and equipment failure

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Lubricants

 Come in different forms and thicknesses

– Thin spray lubricant
– Thicker oil‐type lubricant
– Solid grease‐type lubricant
 Consist of a base (natural or synthetic hydrocarbon
plus additives
 Most important additives are corrosion inhibitors and
anti‐oxidants
 May also have anti‐foaming, emulsifiers, anti‐wear
components

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Lubrication Systems

 Lubrication systems circulate and cool

sealing and lubricating oils, which is
critical to keep pumps operating

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Types of Lubrication Systems

 Centralized systems – introduce lubricant into general

areas of a piece of equipment
 Drip feed – lubricant container mounted over a
bearing
 Forced feed – automatic or mechanical systems that
force oil into a device
 Grease fittings – receptacles that contain a ball check
valve and receive grease from a portable dispenser
 Oil mist – uses an oil distribution system to transport
oil through a mist generator to the lubricated parts

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Types of Lubrication Systems

 Recycling – returns oil to a reservoir where filtration

and cooling occur
 Ring oilers – metal rings that fit around and rotate off
a shaft to carry oil up the rings the shaft and bearings
 Splash feed – uses a moving part such as a crankshaft
to distribute the liquid by splashing drops of lubricant
our of a pool
 Wick feed – capillary action of a fibrous material pulls
oil to the bearings

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Typical Lube Oil System Components

Seal Oil
Tank
Oil Filter

Oil Cooler

COMPRESSOR
Relief
Valve

Oil Pump

Seal Oil
Oil Trap
Reservoir

Drain Pot

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Exercise

What type of lubrication systems do

you have in your unit?

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Exercise

What problems with lubrication have

you experienced?

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Typical Lubrication System Issues

 Water in oil
 Loss of lubrication
 Wrong type of oil
 Dirty oil
 High oil temperature due to fouled oil
coolers

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Typical Lubrication System Issues

 Incorrect oil level in bearing housing

 No grease to bearing
 Wrong slinger ring
 Lubramist system off (tripped and not found
by proper rounds), incorrect oil flow to
bearing, wrong oil in Lubramist system

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Exercise

What can operators do to avoid these

problems?

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Lubrication System Operation

 Switch or replace oil filters

 Switch oil coolers or back flushing
 Collect and record vibration levels and readings
 Check oil levels and add if needed
 Check grease supply and add grease
 Change oil
 Sample oil for water and contamination
 Check bearing temperatures
 Monitor proper operation of oil centrifuges

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Lesson 3 Key Learning Points

In this lesson, you have learned:

 Purpose of lubrication
 Lubricants and types of lubrication systems
 What operators can do to help avoid
lubrication failures

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Module 1 Summary

In this module, you learned:

 Basic Centrifugal Pump Components and
Operating Principles
 Basic Positive Displacement Pump Components
and Operating Principles
 Lubrication Systems

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MODULE 2
MONITORING, OPERATION, AND
EQUIPMENT CARE

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Module 2 Objectives

In this module, we will discuss:

 Monitoring and Operation of Pumps
 Pump Care
 Troubleshooting

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Lesson 1
MONITORING AND OPERATION

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Exercise

Why must we inspect pumps?

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Exercise

 Pumps move liquids through the process

 Because they have parts that are moving
constantly they are subject to wear and failure
 This can result in:
– Process shutdown
– Off‐spec production
– Incidents

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Lesson 1 Objectives

In this lesson, we will discuss:

 Safety considerations in working with pumps
 Rounds vs. Pride Rounds
 Performing field checks
 Placing centrifugal pumps in and out of service
 Placing PD pumps in and out of service
 Swapping pumps

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Safety Considerations

 You must know the hazards of

inspecting rotating equipment
 These hazards can include the
following:
– Hazardous fluids/materials
– Slipping/tripping due to leaks
– Getting body parts, clothing or
gear caught in moving parts

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Safety Considerations

– Precautions include:
• Proper PPE
• Housekeeping (cleaning up seal
leaks, etc)
• Lock out /tag out and isolation
procedures must be followed

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Rounds vs. Pride Rounds

 An effective round requires more than a digital

reading
 The operator must observe the pump carefully
 Evaluate what is observed
 Initiate appropriate action if required

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Performing Field Checks

 Equipment will wear down or break over time

 Basic equipment care is important because it:

Reduces Reduces Off‐

Increases
Equipment spec
Reliability
Damage Production

Warns of Reduces
Possible Equipment
Failure Downtime

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Performing Field Checks

Look Listen Smell

Excessive
Chemical
vibrations or Vibrations
smells
leaks

Loose parts
Unusual noises Burning
(nuts or bolts)

Signs of
Knocking or
cracking or Solvent smells
rattling
wear

Loose wiring,
Whining or
tubing, piping Unusual odors
humming
or connections

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Performing Field Checks

Feel Data
Compare readings
Excessive heat or
on round sheets
unusual
to previous or
temperature
expected values

Feel for vibrations

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Performing Field Checks

Audio: Cavitation of a Pump

Audio: Bearings Failure in a Motor

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Placing Pumps in Service

 Putting pumps in service properly supports increased

reliability
 Ensure all downstream equipment is lined up and
ready
 Ensure pump is ready for startup
 Ensure all auxiliary systems are lined up
 Warm up all equipment as needed
 Start pump
 Ensure flow rate on discharge is as expected
 Conduct routine inspections

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Placing Centrifugal Pumps in Service

Close
Prepare
Wear
Open
Crack
Open Drain
Prime
open
Observe
Prepare Valve
pump
Suction Mover
appropriate
Start the
Recycle PPE!
Valve
Suction
ValveValve
parameters
Pump fully
Open discharge valve gradually DISCHARGE

OPEN
CLOSE Discharge Valve
Vent Valve
Recycle Valve OPEN
CLOSE

RECYCLE
Prime Mover

Suction Valve Bleed

Start Air
Switch
CLOSE
OPEN

SUCTION
CLOSE
OPEN

Drain Valve Check Bearing Oil

OPEN
CLOSE Level

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Exercise

What is different about placing a PD

pump in service?

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Placing PD Pumps in Service

 Lubrication system
 Self‐priming

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Swapping Pumps

 Prepare prime mover Pump B

 Prepare Pump B
 Close Drain Valve
 Crack open Suction Valve, bleed air, open the
valve fully
 Open Recycle Valve
 Start Pump B

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Swapping Pumps

 Open Discharge Valve gradually and observe

header pressure
 Observe parameters
 Gradually close Discharge Valve Pump A
 Stop prime mover Pump A
 Close Recycle Valve
 Close Suction Valve
 Open Drain Valve gradually
 Open Vent Valve when liquid from drain stops

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Lesson 1 Key Learning Points

In this lesson, you learned:

 Safety considerations in working with pumps
 Rounds vs. Pride Rounds
 Performing field checks
 Placing centrifugal pumps in and out of service
 Placing PD pumps in and out of service
 Swapping pumps

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Lesson 2
PUMP CARE

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Exercise

What are the most common complaints

that Maintenance has about Operations?
Are they justified?

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Lesson 2 Objectives

In this lesson, we will discuss:

 Conducting detailed pump inspection
 Performing minor pump maintenance
 Prepping pumps for maintenance (LOTO)

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Conducting Detailed Pump Inspection

 Inspect the following:

– Check and record suction and discharge pressures
– Check lubricant levels
– Check seal flush system
– Check for abnormal noise and vibration
– Check for proper operating temperatures
– Check pump rates and instrument outputs to the
flow controllers of the pump
– Check for missing coupling guards

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Performing Minor Pump Maintenance

 Change pressure indicators

 Change oil
 Add oil to equipment
 Adjust packing glands as needed

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Prepping Pumps for Maintenance

Operators are Notifying someone when

Four main the equipment is not
responsible for areas of working
making sure the responsibility:
Preparing equipment for
equipment can be maintenance
worked on safely
Obtaining a permit

Returning the equipment

to service

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Prepping Pumps for Maintenance

1. De‐energize the equipment

2. Isolate the equipment

3. Drain, purge, clean or clear the equipment

4. Lock it out per Lock Out Tag Out (LOTO) procedure

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Prepping Pumps for Maintenance

 Verification is the last layer of protection for

the worker

Options for Checking bleeders for pressure

verification
include:
Checking start / stop switches

Verifying there is no flow or pressure on gauges

Opening vents

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Prepping Pumps for Maintenance

 The Operator is responsible for:

– Going out to the field with the maintenance
personnel to verify there is zero energy on the
equipment
– Informing the maintenance personnel of process
and surrounding work hazards

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Exercise – Lockout this Pump

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Lesson 2 Key Learning Points

In this lesson, you learned:

 Conducting detailed pump inspection
 Performing minor pump maintenance
 Prepping pumps for maintenance (LOTO)

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Lesson 3
TROUBLESHOOTING

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Lesson 3 Objectives

In this lesson, we will discuss:

 Common pump failure modes
 Pump troubleshooting

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Common Pump Failure Modes

 Seal or packing failure

 Pump driver failure
 Coupling
 Bearing
 Cavitation
 Vapor lock

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Common Pump Failure Modes

 Excessive vibration
 No fluid on barrier seal
 Wrong rotation after maintenance
 Overheating
 Overpressure
 Leakage

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Troubleshooting Over‐pressurization

 Check for deadheading

 Check for back pressure
 Verify correct valve position
 Shutdown pump if necessary

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Troubleshooting High Temperature

 Check for proper lubrication

 Check for deadheading
 Shutdown pump if necessary

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Troubleshooting Cavitation
Cause Solution
Suction pressure reduction Increase suction pressure, slow pump
down, check level of suction vessel,
check for restrictions, check design
Liquid temperature increase Lower liquid temperature
Flow rate too high Reduce flow rate
Separation and contraction of flow due Check design and find cause of viscosity
to change in viscosity change
Undesirable flow conditions due to Locate obstructions or sharp turns and
obstructions or sharp turns correct
Pump is not suitable for the system Check design
curve
Low liquid level Increase liquid level

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Troubleshooting Leakage

 Check where pump shaft exits housing

 Check for overheated seal
 Check pumped liquid composition and
temperature
 Tighten or replace packing
 Replace mechanical seal

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Troubleshooting Pump Shutdown

 Check over‐speed trip

 Check for power failure
 Check flow, pressure or vibration sensors
 Check motor trip out

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Lesson 3 Key Learning Points

In this lesson, we will discuss:

 Common pump failure modes
 Troubleshooting pumps

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Module 2 Summary

In this module, you learned:

 Monitoring and Operation of Pumps
 Pump Care
 Troubleshooting

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