preventive maintenance of pumps - calgary pump … · predictive and preventive maintenance for...
TRANSCRIPT
![Page 1: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/1.jpg)
Predictive and preventivePredictive and preventive
maintenance for Pumpsmaintenance for Pumps
C. Dale Alleyne P.Eng
Alleyne Machinery Consulting Inc.
![Page 2: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/2.jpg)
Two Main Causes of Pump FailureTwo Main Causes of Pump Failure
� Seals
� Bearings
� These Account for 80% + of pump Failures
![Page 3: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/3.jpg)
Four areas to Concentrate PMFour areas to Concentrate PM
ProgrammeProgramme
� Vibration
� Lubrication
� Operation
� Maintenance
![Page 4: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/4.jpg)
VibrationVibration
� Three Categories of Pump
– Large Unspared Pumps
– Smaller and Spared Pumps
– Very small or unimportant Pumps
![Page 5: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/5.jpg)
Large Unspared PumpsLarge Unspared Pumps� Continuous monitoring via a permanent
system.
Reasons:
Want to catch problems early as may have an effect on
Production - big $$$
If machine fails, the cost of repair is very high thus the cost
of Monitoring system easily Justified
Consider pumps 750 kW and larger (unspared)
1000kW and larger (spared)
![Page 6: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/6.jpg)
![Page 7: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/7.jpg)
![Page 8: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/8.jpg)
![Page 9: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/9.jpg)
CriteriaCriteria
� Radial BearingsAlarm at 50-60% of bearing clearanceTrip at Bearing clearance
� Thrust bearingsAlarm at 50% of BabbittTrip at 100% of Babbitt + .25mm (.010”)Dual Voting
� Other alarms/ trips within capability ofMonitoring System
![Page 10: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/10.jpg)
Bearing TemperaturesBearing Temperatures
� Large unspared pumps should have RTDs
in bearings
� Set alarm at 10-20OC over normal
� Trip depending on Plant Philosophy
![Page 11: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/11.jpg)
Smaller Spared PumpSmaller Spared Pump� Use a Walk About Hand Held programme
� Set frequency of checks based on site
MTBM (monthly, 2 months, 3 months)
� Need to set a schedule for running the spare
Pump1 day every month, 1 day every 2 months, 50/50
![Page 12: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/12.jpg)
![Page 13: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/13.jpg)
Very Small or UnimportantVery Small or Unimportant
PumpsPumps
� Not included as part of a vibration
programme
![Page 14: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/14.jpg)
![Page 15: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/15.jpg)
What We Are Looking ForWhat We Are Looking For
� An increase in vibration level (sudden or
Trending)
� An indication from readings as to the Cause
of Vibation
![Page 16: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/16.jpg)
CriteriaCriteria
� Well Balanced and aligned pump should
run at 1 mm/sec.
� Should consider removal for correction at
levels above 8 mm/sec
� Use spectral analysis to determine cause
![Page 17: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/17.jpg)
LubricationLubrication
� Grease
� Self Contained Bath with ring or Slinger
� Oil Mist
� Circulating or pressurized Systems
![Page 18: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/18.jpg)
GreaseGrease
� Sealed for Life
� Re-greasable
![Page 19: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/19.jpg)
Re-Re-GreasableGreasable bearings bearings
� Need to be installed correctlyOne shield only - on inboard side, Grease passages both
sides of Bearing cavity.
� Grease flushed on Regular intervalssay 3 months. Outlet passage open, add new grease till
new grease is seen coming out of outlet.
![Page 20: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/20.jpg)
Self Contained Bath with ringSelf Contained Bath with ring
or or SlingerSlinger� Need to monitor level
� Need to change oil periodically
� Oil change in conjunction with running ofSpare Pumps
� No oil analysis required (not economic)
![Page 21: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/21.jpg)
Oil MistOil Mist� Clean cool constant supply
� No changing of oil required
� Provides best environment for bearings and
thus longest life.
� System may be costly to install
![Page 22: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/22.jpg)
Circulating or pressurizedCirculating or pressurized
SystemsSystems
� Need to monitor Oil system for:
Level, Pressure, Temperature and Filter dP
� Need to test oil Periodically
Test for Viscosity, Metal, dirt and water
![Page 23: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/23.jpg)
OperationOperation
� Pump Performance
� Mechanical Seal Auxiliaries
![Page 24: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/24.jpg)
Pump PerformancePump Performance
� Performance test done periodically
Verify Pump on curve
Ensure suction screen not plugged
Ensure no internal wear or damage
![Page 25: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/25.jpg)
![Page 26: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/26.jpg)
Seal AuxiliariesSeal Auxiliaries
� Check that flush lines are flowing
� Steam quenches are operating and at the
right rates
� Seal pot levels are correct
� Done daily by Operators (training)
![Page 27: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/27.jpg)
MaintenanceMaintenance� Ensure all fits and tolerances are to OEM
std.
� Take care in mounting Rolling Element
Bearings (Temperature <120oC)
� Ensure rotor is well balanced
to API 4W/N in-oz or 6350W/N gm-mm
� Do a Precise alignment (.002” or .05mm TIR)
Use Laser tools
![Page 28: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/28.jpg)
![Page 29: Preventive Maintenance of Pumps - Calgary Pump … · Predictive and preventive maintenance for Pumps C. Dale Alleyne P.Eng Alleyne Machinery Consulting Inc](https://reader031.vdocuments.site/reader031/viewer/2022013114/5b93658f09d3f206218d4559/html5/thumbnails/29.jpg)
TrainingTraining
� Important that Operators and Millwrights be
Trained if we expect high pump Reliability
� Operators: Pump operation, Seal operation
(What to do & what not to do)
� Millwrights: Vibration analysis, Alignment,
Lubrication Maintenance techniques