PUMP Oleh Rais bin Maat Institut Latihan dan

PUMP Oleh: Rais bin Ma’at Institut Latihan dan Pembangunan Infrastruktur Ikram 6/13/2021 ITi. Di 1

PUMP Inlet Shaft 6/13/2021 Outlet ITi. Di 2

PUMP • Is a very important device in transporting liquid, air or gas • Pump is required in water supply system, fire fighting system, central air conditioning system where water, air or gas need to be transported or circulated 6/13/2021 ITi. Di 3

TYPES OF PUMPS • Centrifugal Pump / Impeller Pump • Displacement Pump 6/13/2021 ITi. Di 4

CENTRIFUGAL PUMP • • • Pump casing Impeller Driving shaft Coupler Motor 6/13/2021 ITi. Di 5

Pump Positions 6/13/2021 ITi. Di 6

CENTRIFUGAL PUMP Filter 6/13/2021 ITi. Di 7

BINAAN PAM • • Suction inlet Discharge outlet Impeller Shaft Casing Base & Footing Vibration damper 6/13/2021 Bearing Coupling Bleeding valve Pressure relief valve ITi. Di 8

PUMP CROSS SECTION Outlet Inlet 6/13/2021 ITi. Di 9

Impeller Pump Casing Shaft Outlet 6/13/2021 ITi. Di 10

PUMP CASING • Pump casing consists of the molten casing with the suction and discharge flanges, the outlet diffuser who gives the casing its helical shape and the cover 6/13/2021 ITi. Di 11

IMPELLER • The most important part of the pump that it determine the discharge rate, pumping head, suction head and number of revolutions • Consist of two circular plates, between these, the blades are fitted. One of the plates or both plates has a center hole which is the suction inlet (single suction / double suction) • Three group of impeller design namely Radial Impeller, Semi Radial Impeller and Axial Impeller 6/13/2021 ITi. Di 12

HOW IMPELLER WORKS • Because of impeller blade rotation there axial forces and these forces depends on the pressure difference of the two sides of the impeller • These pressure differences make the liquid flows and develop suction and pumping power 6/13/2021 ITi. Di 13

TYPES OF IMPELLERS 6/13/2021 ITi. Di 14

WORKING PRINCIPLES • A centrifugal pump must have water in the pump casing, if there is air inside, no pumping effect will occur. • When the impeller rotates the water inside the impeller is thrown out from the center of the impeller. The water velocity increases by the channels in the impeller and the water that the impeller throws into the pump casing has to be replaced. 6/13/2021 ITi. Di 15

WORKING PRINCIPLES • The water that was thrown out create a negative pressure. This negative pressure in the center of the impeller draws water from the suction pipe into the impeller and it continues as long as the impeller rotates 6/13/2021 ITi. Di 16

DISPALCEMENT PUMP • • 6/13/2021 Piston pumps Gear pumps Membrane pumps Solid vane pumps ITi. Di 17

PISTON PUMP 6/13/2021 ITi. Di 18

PISTON PUMP • The pump can either be single acting or double acting. Single acting piston are just using the top part of the piston. Double acting piston use both top and bottom parts, one side sucking water the other side discharging water • Piston pumps are equipped with one suction valve and one discharge valve for each side 6/13/2021 ITi. Di 19

GEAR PUMP • Two design, single and dual impeller • In dual impeller design the motor drives one impeller and the other impeller is a slave impeller. The fluid is trapped between the casing and the impellers and is forced out as the impellers rotate • Is has to be lubricated and suitable for hydraulic and lubricating pump and not suitable for water pump 6/13/2021 ITi. Di 20

GEAR PUMP Outlet Shaft to motor 6/13/2021 ITi. Di 21

SCREW PUMPS • Consists three screw impellers in one casing • One screw driven by the motor and the threads drives the other screws, every revolution will trap a volume of fluid and transport it along the screws to the outlet. The volume will decrease and the fluid is force to the discharge • It can produce high pressure • Use as fuel and lubricating oil pump 6/13/2021 ITi. Di 22

SCREW PUMP Outlet Inlet 6/13/2021 ITi. Di 23

PUMP DATA • Flow in m 3/hour • • Pumping head (meter) Suction head (meter) Revolution per minute Power consumption (motor h. p or k. W or ampere) Efficiency Pipe diameter (inlet and outlet) Power supply requirement (volt, amp, 1 ph or 3 ph) • IP Index 6/13/2021 ITi. Di 24

SHAFT SEAL • To prevent leakage along the shaft pump must have one or two shaft seals • The most common sealing is the stuffing box with a packing, the plait packing are of ring shape, they are mounted in the stuffing box and seals along the shaft 6/13/2021 ITi. Di 25

STUFFING BOX 6/13/2021 ITi. Di 26

STUFFING BOX ADJUSTMENT 6/13/2021 ITi. Di 27

MECHANICAL SEAL • Longer lifetime, Less leakage, No shaft wear, Low maintenance cost • Consist of Two parts, one mounted on pump casing, the other mounted on the shaft • The shaft part meet the casing part, the contact surface rotate and seal, the spring keep the two surfaces together, the contact surface are extremely smooth and there is a thin liquid film (water) to lubricate the surfaces 6/13/2021 ITi. Di 28

MECHANICAL SEAL 6/13/2021 ITi. Di 29

MECHANICAL COUPLING • It is used to transmit the torque between two rotating shafts (motor shaft and pump shaft) • Alignment is very important 6/13/2021 ITi. Di 30

COUPLING 6/13/2021 ITi. Di 31

TYPES OF COUPLING • Flexible coupling (belt or chain) • Rotating stiff coupling – different types of membrane and tooth coupling, handle small misalignment • Rotating elastic coupling – made of elastic parts (rubber or plastic positioned between metal parts) 6/13/2021 ITi. Di 32

VALVE • Manual valve – one each at suction and discharge pipe for the purpose of control • Non return valve – at discharge pipe to prevent back pressure from damaging the pump when it stops pumping 6/13/2021 ITi. Di 33

FILTER/STRAINER • To prevent solid particle from entering pump that will damage it • Normally installed at the end of the suction pipe 6/13/2021 ITi. Di 34

PUMP ASSEMBLY 6/13/2021 ITi. Di 35

SEWERAGE PUMP 1 P. H MOTOR 6/13/2021 ITi. Di 36

DIESEL TANK PUMP 1 P. H 6/13/2021 ITi. Di 37

COOLING TOWER PUMP 6/13/2021 ITi. Di 38

CHILLED WATER PUMP 6/13/2021 ITi. Di 39

WATER TANK PUMP 6/13/2021 ITi. Di 40

ELECTRIC MOTOR 6/13/2021 ITi. Di 41

TYPES OF MOTORS • Single Phase, 240 V, 50 Hz, up to 3 h. p • Capacitor start – low torque and low speed • Universal motor – high torque and high speed – for small size motor • Three phase motor, 415 V, 50 Hz, higher h. p • Squirrel cage (commonly used) or slip ring motor 6/13/2021 ITi. Di 42

SQUIRREL CAGE MOTOR 6/13/2021 ITi. Di 43

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SLIP RING MOTOR 6/13/2021 ITi. Di 45

SLIP RING AND ROTOR Wound Rotor 6/13/2021 Slip ring ITi. Di 46

CARBON BRUSH & SLIP RING 6/13/2021 ITi. Di 47

MOTOR STARTER • To reduce starting current • To avoid simultaneous starting of motors after restoration of supply disruption • To control operation of motors • To provide protection for motors 6/13/2021 ITi. Di 48

TYPES OF STARTER • • • DOL (Direct On Line) - < 3 h. p Star – Delta - > 3 h. p Auto – transformer - > 3 h. p Rotor resistance - > 10 h. p Soft starter (electronic starter) 6/13/2021 ITi. Di 49

DOL STARTER - no voltage reduction at starting 6/13/2021 ITi. Di 50

DOL STARTER Contactor, Thermal Overload Relay, Start and Stop button 6/13/2021 ITi. Di 51

AUTOTRANSFORMER STARTER 6/13/2021 ITi. Di 52

MOTOR PROTECTION • • • Short circuit – fuse, MCB, MCCB Overload – thermal overload relay Earth fault – ELR, E/F relay Single phasing – S. P Relay Reverse phase sequence – R. P. S relay 6/13/2021 ITi. Di 53

INDEX OF PROTECTION (I. P) • IP NUMBERS • First Number represent protection from ingress of water/moisture • Second Number represent protection from solid particles 6/13/2021 ITi. Di 54

INDEX OF PROTECTION 6/13/2021 ITi. Di 55

Pressure Relief And Vibration Damper 6/13/2021 ITi. Di 56

Pressure and Temperature 6/13/2021 ITi. Di 57

Pressure Gauge and Control Valve 6/13/2021 ITi. Di 58

Valve, Pressure Gauge, Pressure Switch 6/13/2021 ITi. Di 59

DIESEL PUMP 6/13/2021 ITi. Di 60

SUBMERSIBLE PUMP • Very compact centrifugal pumps with the motor and pump integrated in one piece and immersed in the water so no problem with suction head • The most important part is the seal to prevent water from entering the motor and cause electrical fault 6/13/2021 ITi. Di 61

Submersible Pump – Motor and Pump in one unit 6/13/2021 ITi. Di 62

SUBMERSIBLE PUMP Supply cable Float switch 6/13/2021 ITi. Di 63

START OF A CENTRIFUGAL PUMP • Before start-up, check the following: • Stuffing box should be accurately tightened. The shaft should be easy to turn by hand • If sealing water is used, check the water supply is connected • If the motor has been disconnected, check the direction of rotation 6/13/2021 ITi. Di 64

Continue • Pump must be filled with water. On top of the casing there is usually a valve fitted, this is used to fill the suction pipe and pump casing with water. Turn the impeller to make sure no air is left inside the casing • Make sure suction valve and discharge valve are open • Start the pump 6/13/2021 ITi. Di 65

PUMP CONTROL • Operation of the pump is controlled manually or automatically • Automatic control is using sensors such as water level sensor (float switch, float less relay), pressure switch or from fire alarm control board 6/13/2021 ITi. Di 66

PUMP MAINTENANCE • Mechanical maintenance • Electrical maintenance 6/13/2021 ITi. Di 67

MECHANICAL MAINTENANCE • Check ball bearings, the pump and the motor for jarring sound, cavitation and vibrations • Check the temperature of ball bearing by hand, warm but we can hold on for a short period of time • There should always be a drip leakage from the seal • Check the discharge and suction pressure • Check the current flowing to the motor 6/13/2021 ITi. Di 68

Wear Parts 6/13/2021 ITi. Di 69

PUMP COMMON FAULTS • No water flow: • Pump and suction pipe is not filled with water, air trapped inside, perform bleeding • Pump does not speed up, check motor, starter and incoming supply • Pumping head is too high, discharge pipe is blocked, check for possible cause including valve • Suction head is too high, check blocking at the intake or strainer is blocked or non-return valve is damaged 6/13/2021 ITi. Di 70

Continue • Impeller is jammed, solid object in the water can build up in the channels of the impeller, open the pump and inspect • Pump rotates slower than normal, check pump bearing failure or motor having problem • Flow rate reduced – blockage in suction pipe or impeller 6/13/2021 ITi. Di 71

PUMP IS VIBRATING • • • Bad alignment Impeller is imbalanced Pump is sucking air Damaged ball bearing Excessive clearance Unbalance rotor or shaft 6/13/2021 ITi. Di 72

MOTOR IS OVERLOADED • • • Mechanical problem Bearing faulty Foreign particles Shaft damage or wear Damaged shaft lining 6/13/2021 ITi. Di 73

MOTOR MAINTENANCE • • Check supply voltage for all phases Check cable connections for tightness Check stator and rotor insulation level Check carbon brush (slip ring motor) still good and adequate pressure • Check protective devices, contactors, relays and other starter components are in good working condition 6/13/2021 ITi. Di 74

COUPLING ALIGNMENT 6/13/2021 ITi. Di 75

MOTOR BEARING LUBRICATION 6/13/2021 ITi. Di 76

BEARING LUBRICATION NIPPLE 6/13/2021 ITi. Di 77

LUBRICATION NIPPLE 6/13/2021 ITi. Di 78

SEALED BEARING 6/13/2021 ITi. Di 79

MOTOR OVERHEATING • • Check for overload Clogged air shield or ventilation air passage One phase out Unbalanced terminal voltage Shorted stator coil Faulty connection Rotor rub bore (stator) Inadequate ventilation 6/13/2021 ITi. Di 80

MOTOR NOISY • • • Fan rubbing air shield Fan striking insulation Loose on bed plate Faulty bearing (loose or without lubrication) Air gap not uniform Rotor unbalance 6/13/2021 ITi. Di 81

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