Pump Care Manual

A collection of centrifugal pump maintenance articles

TABLE OF CONTENTSTitle PageInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5You Need A Good Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Field Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Baseplate Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Initial Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Align Pipe Flanges to Pump Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Raised Face and Flat Face Flanges (Mating Combinations) . . . . . . . . . . . . . . . . . . . . . . . 10Pump Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Turbine Driven Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Keep Air Out of Your Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Air Pockets in Suction Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Testing for Air in Centrifugal Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Importance of Proper Suction Pipe Submergence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Waterfall Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Excessive Throttling Can Shorten the Life of Your Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 16Throttling Accelerates Erosion When Pumping Liquids Containing Abrasives . . . . . . . . . . 18Elbows at Pump Suction Opening Can Cause Trouble Unless Precautions Are Taken. . . 18Use a Thermometer to Measure Bearing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 20NPSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Packed Stuffing Box Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Are You Increasing Your Stuffing Box Packing Problems?. . . . . . . . . . . . . . . . . . . . . . . . . 23Stuffing Box Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Stuffing Box Cooling for High Temperature Applications . . . . . . . . . . . . . . . . . . . . . . . . . . 25Mechanical Seals

Part I - The Basic Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Part II - Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Part III - Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Part IV - Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Quench Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Constant Level Oilers - Operation and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Ball Bearing - Handling, Replacement and Maintenance Suggestions. . . . . . . . . . . . . . . . 34Grease Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Flexibly Mounted Baseplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Impeller Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Pump Vibration Anaylysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Pump Maintenance Records Pay Dividends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Goulds Offers A Complete Line of Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3

4

INSTALLATIONVery often problems with pump and motorbearings, shaft breakage and difficulty inaligning units stem from the improperinstallation of the pumping equipment.Inadequate foundations, bent or twistedbaseplates, and excessive pipe strain canall work together to make an otherwisesimple installation an operational andmaintenance headache for the life of theunit.

Here are some tips on how you canprevent these things from causingincreased downtime and higher thanexpected maintenance costs.

YOU NEED A GOOD FOUNDATIONThe importance of a good foundationcannot be overemphasized. Thefoundation must be heavy enough toprovide rigid support for the pump, motorand base combination and to resist thenormal forces encountered when the unitis in service.

A concrete foundation firmly attached to awell designed floor system would be themost satisfactory arrangement. When siteconditions make it necessary to supportthe pump on a metal structure, thestructural members should be selectedand designed to provide adequatestiffness and mass to support the unit anddampen any vibration that may bepresent. Unsupported wood floors andthin concrete pads should be avoided.

BASEPLATE INSTALLATIONRe-alignment of the pump and driver isrequired prior to final grouting of thebaseplate. Even though the unit mayhave been aligned at the factory prior toshipment, components tend to shift intransit, during handling, or because ofuneven foundation surfaces. Factoryalignments cannot be depended uponduring or after installation.

With the baseplate installed on thefoundation you need to adjust thebaseplate as necessary to level it andprovide a flat surface for the pump anddriver to rest. In some installations thereare strict baseplate flatness guidelineswhich need to be adhered to. A good rule

of thumb is to level the base to within.005” per foot in all directions. Othertypes of installations may require the baseto be level to within .002” per foot. This isusually done to avoid problems later witha condition known as “soft foot” and toassure that oil lubricated bearings receiveequal and adequate lubrication. It isusually necessary to remove the pumpand motor from the base to attain thislevel of flatness.

The baseplate is leveled using shims orwedges at various locations around thebase close to where the anchor bolts arelocated. Some bases may be equippedwith leveling screws which make this

5

(cont'd)

process somewhat easier. The wedges,shims or leveling screws are alternatelyadjusted as necessary to bring the baseto within the specified limit. Once donethe components are re-installed on thebase.

At this point, before grouting the unit, it isimportant to check the pump and motorfor “Soft Foot” and to check the “RoughAlignment” of the components. If thesechecks are not made now and the unit isgrouted in place, any changes that needto be made later become much moredifficult and expensive. Taking a fewminutes at this point to check and correctany problems that exist may save manyhours of work later.

Figure 1

BASEPLATE GROUTINGOnce the baseplate is properly installed, itmust be grouted. Grout is a concretematerial or multi-part epoxy compoundthat is used to fill the cast iron orfabricated steel baseplate so that whenhardened, the baseplate and foundation

become a unit. We recommend the useof a non-shrink grout for this purpose.The grout is mixed to a water-likeconsistency, and when poured should bepuddled to insure that it flows evenlythroughout the under portion of the

6

(cont'd)

baseplate, completely filling the base. It isrecommended that the cementatiousgrout be allowed to cure for at least 48hours. Refer to the epoxy groutmanufacturer's instructions for the propermixing and application of that product.Refer to your equipment instructionmanual for further details.

Figure 2

INITIAL ALIGNMENTThe proper alignment of your pump anddriver is important to assure trouble-freemechanical operation. Noisy operation,vibration, reduced bearing life, shaft andcoupling failures and wasted energy mayresult from faulty alignment. Beforeproceeding, you must know the thermalrise estimates of your equipment. Referto the pump and driver manuals for theseestimates.

The most common methods of measuringmisalignment are:

Straight Edge and Feeler Gauges – Thisis the easiest and least expensive methodof doing alignment but is also the leastaccurate. Used primarily for very smallpump/motor combinations where there isnot enough room to use more accurate,but larger alignment systems. Thestraight edge is laid across the flanges ofthe coupling hub and the feeler gaugesare used between the faces of thecoupling hubs. Shim changes areestimated and the alignment is attainedthrough a process of “Trial & Error”.

Usually you cannot attain the equipmentmanufacturer's alignment specifications

through the use of a Straight Edge andFeeler Gauges.

Dial Indicators – Used either singly or inpairs, as with the Reverse IndicatorMethod, the actual misalignment ismeasured by the indicator and through afew arithmetical calculations shimchanges are determined.

Lasers – Somewhat more complicated toset up but can be more accurate ifproperly used. The laser especially lendsitself to aligning shafts that are separatedby more than a few inches. Since themachines have the capability ofcalculating the shim changes required,once the operator becomes familiar withthe set-up he or she can do the alignmentof a pump / motor combination fairlyquickly and accurately. The primarydrawback of the Laser is its cost and, insome cases, its size, although continuousadvances in technology are making themachines both smaller and lessexpensive.

7

(cont'd)

Angular – With a non-spacer coupling,measure the space or gap between thehubs from top-to-bottom and fromside-to-side using a feeler gauge. Themeasurements obtained should be verynearly the same. If they are not, shim ormove the motor as necessary to satisfythe tolerance stated in your instructionmanual for angular alignment. Withspacer type couplings, a dial indicatorshould be used to obtain these readings.

Mount the indicator base on the drivercoupling hub so that the indicator readson the face of the pump hub. Rotate bothshafts and read the indicator at 4 points,90° apart. The readings obtained will tellyou how far out of alignment yourequipment is from side-to-side as well asfrom top-to-bottom. Add or remove shimsfrom under the driver to correct thealignment. The amount of shimadjustment needed depends on theamount of misalignment present anddistance from the point of measurement tolocation of the shims.

Parallel — Using a straight edge rest theedge on top of the coupling hub and at90° to the top. The amount ofmisalignment is shown by the gap presentbetween the straight edge and the hub.On a spacer type coupling mount a dialindicator on the pump coupling hub sothat the indicator reads on the motorcoupling hub. Rotate both shafts andread the indicator at 4 points, 90° apart.The readings obtained will tell you how farout of alignment your equipment is fromside-to-side as well as top-to-bottom(elevation). Correct the top-to-bottomalignment first by shimming the driver asneeded one half the amount shown on theindicator. Correct the side-to-sidealignment by moving the driver asneeded, again, by one half the amountshown on the indicator. Recheck thetop-to-bottom (elevation) to make surethat it did not change during the process.Be sure to allow for the thermal riseestimates of both pump and driver.

Figure 3

8

ALIGN PIPE FLANGES TO PUMP FLANGESNever run pipe to the pump - always runpipe from the pump to a point several feetaway where the final pipe connection canbe made. This will help to minimizeexcessive pipe strain on the pumpnozzles. The piping must beindependently supported with anadequately designed pipe hanger systemthat will not allow the pump to carry theweight of the pipes or the liquid in them.

The system should also be designed toaccommodate whatever thermalexpansion or contraction is anticipated.After the piping has been made up, thealignment must be rechecked. Bycomparing this check with the initialalignment figures, the installer candetermine the amount of pipe strain whichhas been put on the pump nozzles. Thepiping should be adjusted if there is anysignificant change in the alignmentreadings.

Figure 4

9

RAISED FACE AND FLAT FACE FLANGES(MATING COMBINATIONS)Pumps of cast iron construction arefurnished with 125 or 250 lb. flat face(F.F.) flanges. Since industry normallyuses fabricated steel piping, the pumpsare often connected to 150 or 300 lb.1/16" raised face (R.F.) steel flanges.

Difficulty can occur with this flange matingcombination. The pump flange tends topivot around the edge of the raised faceas the flange bolts are tightened. Thiscan cause the pump flange to breakallowing leakage at the joint (Fig. 5).

A similar problem can be encounteredwhen a bronze pump with F.F. flanges isconnected to R.F. steel flange (Fig. 6).Since the materials are not of equalstrength, the bronze flange may distort,resulting in leakage.

To avoid problems when attaching bronzeor cast iron F.F. pump flanges to R.F.steel pipe flanges, the following stepsshould be taken (refer to Fig. 7):

1. Machine off the raised face on thesteel pipe flange.

2. Use a full face gasket.

If the pump is steel or stainless steel withF.F. flanges, no problem arises sincematerials of equal strength are beingconnected. Many customers, however,specify R.F. flanges on steel pumps formating to R.F. companion flanges. Thisarrangement is technically and practicallynot required.

The purpose of an R.F. flange is toconcentrate more pressure on a smallergasket area and thereby increase thepressure containment capability of the

joint. To create this higher gasket load, itis only necessary to have one-half of theflanged joint supplied with a raised face -not both. The following illustrations show4" steel R.F. and F.F. mating flangecombinations and the gasket loadingincurred in each instance.

Assuming the force (F) from the flangebolts to be 10,000 lbs. and constant ineach combination, the gasket stress is:

P (Stress)Bolt Force (F)

Gasket Area�

P (Fig. 8)10,000 lbs.

49.4 sq. in.203 psi� � �

P (Fig. 9) =

P (Fig. 10) =

10,000 lbs.

15.9 sq. in

�

� .630 psi�

It can be readily seen that the smallergasket, used with a raised face flange,increases the pressure containmentcapability of a flanged joint. However, itcan also be noted that there is nodifference in pressure capability betweenR.F. to R.F. and R.F. to F.F. flangecombinations.

In addition to being technicallyunnecessary to have a R.F. to R.F.mating combination, the advantages are:

1. The elimination of the extra cost forR.F. flanges.

2. The elimination of the extradelivery time required for anon-standard casing.

10

(cont'd)

11

PUMP START-UPAll of the factors that contribute tosuccessful pump operation must bechecked carefully before starting a new orrebuilt pump. The majority of failures orserious problems at start up can beavoided by just taking a few minutes toverify that all of the components andassociated systems are in operationalcondition.

Prior to coupling the unit, two checkswhich should always be made are: first,the unit turns freely by hand; and, second,the motor has been “bumped” andchecked for the correct hand of rotation.

Operating some pumps in the wrongdirection of rotation can severely damagethe unit and can lead to personal injury forthose nearby. A pump that does not turnfreely, with consideration given to the dragin the stuffing box or mechanical sealarea, usually requires some attention priorto starting.

If the pump shaft turned freely during theinitial phases of the alignment processthen something since that procedure haschanged. Going back through each of thesteps that followed the alignment inreverse will usually turn up the cause.

Causes can include pipe strain imposeddue to the weight of the liquid in thepiping, faults in the foundation or grouting,foreign material getting into the unit beforethe piping flanges were made up, etc.Whatever the cause, it must be identifiedand corrected before proceeding further.

Just prior to start up always make surethe correct type, quantity and quality oflubrication and / or cooling is applied tothe components as recommended by themanufacturer. This includes motorbearings, couplings, mechanical seals,packing and of course, the pumpbearings.

Once these checks have been made theSuction Valve on the pump may be fullyopened while the air inside the pump isvented. This fills the unit with liquid,covering the impeller eye and makes itready for start up. If the unit is in a“Suction Lift” type installation where thelevel of the liquid on the suction side ofthe pump is below the centerline of thepump casing, a vacuum priming systemmay be needed to evacuate the air fromthe pump casing or volute. In the case of“Self Priming” pumps the casing needs tohave some liquid added to it before handfor the “Self Priming” feature to work.

TURBINE DRIVEN UNITSWhen new or rebuilt turbine driven unitsare being started, it is important to protectthe pump from damage related to animproperly adjusted turbine. All turbinecontrols should be checked and verifiedprior to coupling it to the pump. Consultthe turbine manufacturer's instruction fordetails. When started, the unit should bebrought up to speed and flow as quicklyas possible in order to flush the new or

recently opened piping system andminimize the chance of pump failurecaused by small amounts of dirt or foreignmaterial in the sytem. Suction strainersare used to provide some protectionagainst this, but normally the openingsare much larger than the runningclearances of the rotating parts in thepump.

12

KEEP AIR OUT OF YOUR PUMPConventional Centrifugal Pumps are notdesigned to handle a mixture of liquid andgases. Pumping liquids containing asignificant amount of entrained gas canlead to serious mechanical and hydraulicproblems. A mixture of only 2% gas byvolume will cause a 10% reduction incapacity and 4% will cause a reduction ofover 43%. In addition to the loss ofefficiency and wasted power the pump willprobably be noisy and may vibrateexcessively. Entrained gases can causeshaft breakage, seal failures and in somecases accelerate corrosion.

Air may be present in the liquid due toleaky suction lines on suction liftapplications or a variety of other reasons.A free falling discharge into a tank or pitwill also cause excessive gas entrainmentand may cause problems for a pumpdrawing from that tank.

There are Centrifugal Pumps designedspecifically for applications whereentrained gases are encountered.

AIR POCKETS IN SUCTION PIPEAir pockets can be a source of trouble onpump installations involving suction lift.They can cause a loss of prime onstart-up as well as restrict flow in thesuction pipe to the extent that a reductionin capacity is experienced. Wheninstalling piping, suction lines shouldalways pass under interfering piping andwhere reducers are used, eccentric ratherthan straight reducers must be used.

Eccentric reducers are always installedwith the horizontal side on top. Suctionvalves should be installed with the stemshorizontal so that no air pockets areformed at the top of the valve near thebonnet. Figure 11 shows both the correctand incorrect method of installing piping.

Figure 11

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TESTING FOR AIR IN CENTRIFUGAL PUMPSThe amount of air which can be handledwith reasonable pump life varies frompump to pump. However, in no case is itexpected that a pump will give better lifewith air present than it would if the liquidwere entirely air-free. The elimination ofair has greatly improved the operation andlife of many troublesome pumps. Whentrouble occurs, it is common to suspecteverything but air, and to consider air last,if at all.

If air is present, the pump is likely tooperate with a certain amount of internalnoise. This noise can be described as a"gravel noise" - sounds very much mustas though the pump were handling waterfull of gravel. This is the same type ofnoise generally associated with cavitation.

In many cases a great deal of time,inconvenience, and expense can besaved by making a simple test for thepresence of air. We will assume thatcalculations have already been made toassure that the NPSH available is greaterthan that required by the pump (the noiseis not a result of cavitation). The nextstep should be to check for the presenceof entrained air in the suction.

When the source of suction supply isbelow the centerline of the pump, checkfor the conditions covered previously inthis manual.

When the source of suction supply isabove the centerline of the pump, a checkfor air leaks can be made by collecting asample in a "bubble bottle" as illustratedin Figure 12. Since the pressure at thesuction chamber of the pump is aboveatmospheric pressure, a valve can beinstalled in one of the tapped openings atthe high point in the chamber and liquid

can be fed into the "bubble bottle". Thepresence of air or vapor will show itself inthe "bubble bottle".

Obviously, the next step is to eliminate thesource of air since quantities present insufficient amount to be audible are almostcertain to cause premature mechanicalfailure.

Figure 12

14

IMPORTANCE OF PROPER SUCTION PIPESUBMERGENCEIf velocity of the water at the suction pipeentrance is too high, a vortex (commonlyreferred to as a whirlpool) is created,through which air flows downward to theend of the suction pipe and into the pumpcasing. Air in the pump casing causesrough and noisy operation and severevibration that in the course of a short timecan result in a broken shaft as well asother damage. If sufficient air reaches thepump to completely air bind it, dryoperation will cause metal seizure at theimpeller hub and wearing ring. Unlesscorrective action is taken, the rotatingparts will be damaged beyond repair.These difficulties can be avoided byselecting and installing a suction pipethrough which the fluid handled enters ata velocity not exceeding that shown onthe graph. A lower velocity and moresubmergence are good insurance againstthis type of air trouble.

Sump design for large double suctionpumps can become more complex, andappropriate sources such as the"Hydraulic Institute Standards" should beconsulted.

In many cases, centrifugal pumps functionimproperly because air gets into the pumpdue to:

1. The installation of a suction pipethat is too small in diameter.

2. The end of the suction pipe notbeing submerged deeply enough.

3. Both of the above undesirableconditions.

Figure 13

15

WATERFALL EFFECTLiquid falling directly on the foot valve inFigure 14 would carry air into the suctionline and could result in the pump losing itsprime and seizing while running dry. Thiscan also happen when a pump has aflooded suction as in Figure 15. In eithercase, the pump would be noisy.

The free fall shown in Figures 14 and 15is serious, but a line discharging verticallydownward under pressure, such as anorifice return line to a feed water storagetank, has even more effect, as shown inFigure 16.

If the returned liquid is heavily laden withair, or the sump is small, baffles may alsobe required as shown in Figure 14 toallow the air to separate before enteringthe pump suction.

The continued presence of entrained airand vapor in any liquid being pumped isextremely serious and should becorrected immediately. Any return lineshould be extended far enough away fromthe pump suction to prevent trouble, andbelow the surface of the water to minimizeair entrainment. Check your installationtoday and make sure YOUR pump is notsuffering from entrained air.

EXCESSIVE THROTTLING CAN SHORTEN THE LIFE OFYOUR PUMPA centrifugal pump should never beoperated continuously near shutoff or zerocapacity. To do so may shorten the life ofthe pump and greatly increase down timeand maintenance.

The difference between input horsepowerand water horsepower is transferred tothe liquid in the pump as heat. When onlya small percentage of rated flow is

allowed through the pump, the casingmay be unable to radiate the heatgenerated, and the liquid and the pumpmay rise to a dangerously hightemperature.

Hydraulic radial thrust is unbalancedwhen the pump is operating near shut-off,and this subjects the shaft to abnormaldeflection. The pump will be noisy, will

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(cont'd)

vibrate excessively, and may break shaftsfrequently.

Pumps are frequently rated for capacitiessufficient to handle maximumrequirements. They are also occasionallyselected to handle capacities requiredunder emergency operation or at somefuture predicted flow far in excess ofpresent demands. This procedure willminimize ultimate plant investment,duplication, and replacement with largerequipment at a future date. However, itmay require excessive throttling of thedischarge valve, resulting in severepunishment to the pump.

Fortunately, there is a simple method torelieve the pump of undue strain. Simplyextend a by-pass line from the pumpdischarge back to the source of supply. Athrottle valve or an orifice plate should beplaced in the by-pass line, and sufficientflow returned to allow the pump to operateat a capacity reasonably near its rating.

The bypassed liquid should never bereturned to the suction line immediatelyupstream from the pump, but shouldalways be returned back to the source ofsupply and discharged below the liquidlevel to avoid air entrainment.

If excessive throttling at the dischargevalve is required with the by-pass lineopen, actual system head and capacityrequirements should be reviewed and anew rating selected.

Excessive maintenance and shortened lifecan always be expected when a pump isoperated continuously at or near shut-off.A return line by-passing part of the flowback to the source of supply will allow thepump to operate near rated capacity andextend the life of your pumpingequipment.

Figure 17

17

THROTTLING ACCELERATES ERROSION WHENPUMPING LIQUIDS CONTAINING ABRASIVESWhen pumping liquids containing abrasivesolids some errosion of the pump impellerand other parts is to be expected. Theuseful life of the unit is reduced not onlyby the quantity of abrasives present, butalso the physical characteristics of thesolids and the velocity of the mixturethrough the pump. Throttling a unitaccelerates the wear even more bycausing localized higher velocities andre-circulation within the impeller andcasing. With a pump operating at its bestefficiency point, the majority of solidsmake only one trip through the unit.Throttling the unit increases the internalre-circulation and allows the abrasiveparticles to scrape against the inside ofthe pump a number of times before finallybeing discharged.

Often a plant design calls for pumps to beoversized to accommodate futurerequirements or the occasional upsetcondition. Again, a discharge by-pass lineshould be considered to help allow thepump to operate at a better point on thecurve and at better efficiency and reducedinternal re-circulation. Often there-circulation line is directed back into thetank or sump to provide additionalagitation and mixing.

ELBOWS AT PUMP SUCTION CAN CAUSE TROUBLEUNLESS PRECAUTIONS ARE TAKENProperly installed suction piping is ofextreme importance in obtainingtrouble-free operation in anydouble-suction type centrifugal pump.

If an elbow is required at the pumpsuction flange, it should always be in avertical position. Where, because ofspace limitations or other peculiarities ofthe installation, an elbow must be usednear the pump suction flange in anyposition except vertical, it should never beinstalled unless there is a minimum of twodiameters of straight pipe between theelbow and the pump flange (see Figures18 and 19).

Without this straight run of pipe, theincoming liquid, because of centrifugalforce, tends to pile up on the outside ofthe elbow. If the liquid enters the pumpsuction directly in this condition, it will notbe evenly distributed between the twoinlets of the double suction impeller. Thisunbalance will cause noise and generallyunsatisfactory operation of the pump (seeFigure 20).

A device for relieving this condition isillustrated in Figure 21. It is a simplebaffle that can be made in any shop.Inserted in the straight length of pipeadjacent to the pump flange, it will

18

(cont'd)

equalize the flow and assist materially inimproving pump performance.

Figure 18 Figure 19

Figure 20

Figure 21

19

USE A THERMOMETER TO MEASURE BEARINGTEMPERATURESPump bearing temperatures arefrequently estimated by placing a handlightly against the bearing housing orshell. If the bearing is “cool” or “warm,”we feel assured. If it feels “hot,” we maybecome concerned and spendconsiderable time and effort to reduce thetemperature until the housing feels only“warm” without any clear idea of theactual operating temperature.

Unfortunately, the human hand is not anaccurate thermometer and can give adanger signal falsely. A temperaturewhich feels “hot” varies from 120° to130°F depending on the individual.Above this temperature the human handis worthless in estimating temperature.Grease lubricated ball and roller bearingscan be operated safely at temperaturesup to at least 200°F. In fact, the upperoperating limit on anti-friction bearings isdetermined solely by the temperature atwhich the lubricant fails and begins tocarburize. Bearing temperatures up to160°F are extremely safe. Operation ofbearings at this temperature is not at allundesirable, as a better flow of lubricantcan be expected. This gives a clearindication of why a thermometer isnecessary to determine bearingtemperature.

All bearings operate at some temperatureabove that of the surroundingatmosphere, unless cooled. Heat isgenerated within the bearing due to rollingfriction of the balls or rollers, and by thedrag of the ball or roller separator cage.Some heat may be added by conductionalong the pump shaft from the liquid withinthe pump and from external sources inclose proximity. The amount of heat

which can be dissipated is dependent onthe cooling area of the bearing housingand the temperature and motion of thesurrounding air. The net result is a stableoperating temperature. Once thistemperature has been established, it willremain constant until one or more of thevariables changes. A stable temperature,no matter how hot it may feel to thehuman hand, is not necessarily anindication of danger so long as it does notexceed the upper limit of the lubricant.The temperature should be establishedaccurately by thermometer and recordedin a convenient location.

A pronounced increase in temperature isan indication of danger and a signal toinvestigate. One shot of grease should beadded to the bearing, but if this does notreduce the temperature immediately, noadditional grease should be added. Theunit should be checked for unnecessaryloads, such as coupling misalignment, orimproper packing adjustment. Atemperature increase may not be anindication of impending bearing failure orexcessive load, but could be due entirelyto an increase in temperature of the liquidbeing pumped, or to an increase in thesurrounding temperature during the warmsummer months. Heat transfer due toincreased liquid temperature can beminimized by connection of a quenchinggland with cold water from the plantsupply line.

Bearing temperatures are frequentlyincreased by lubrication practices.Excessive or over-greasing which resultsin complete packing of the bearing shellwith grease greatly increases theresistance to rotation and the amount of

20

(cont'd)

heat generated. Removal of excessivegrease from the bearing housing will lowerthe bearing temperature considerably.Most pumps handling hot liquids areequipped with quenching glands andwater cooled bearings so that the actualoperating temperature within the bearingmay be lower than the ambienttemperature of the surrounding air. Hightemperature greases should not be usedwith water cooled bearings as poorgrease fluidity and inadequate lubricationmay likely result.

Occasionally when pumps are first startedthe bearings seem to run extremely hot.This high temperature is frequentlycaused by the grease seals not thebearings. As soon as the seals areseated, the temperature will drop to anormal level.

NPSHThe most maligned of all pump criteria isactually a simple physical phenomenon.NPSH, net positive suction head, isdefined by the Hydraulic Institute as “thetotal suction head in feet of liquidabsolute, determined at the suction nozzleand corrected to datum, less the vaporpressure of the liquid in feet absolute.”

The key to the problem is vapor pressure.Every liquid exerts a pressure on itssurroundings which is dependent ontemperature. When this pressure is equalto the pressure of its environment, the liquidis said to boil or turn to vapor. For example,at sea level a pan of water on a stove willboil at 212°F. This means that the vaporpressure of water at 212°F is equal to theatmospheric pressure 14.7 psia.

The amount of space a liquid occupies isvery small compared to the amount ofspace occupied by the equivalent amountof liquid converted into vapor. Forexample, 1 pound of water at 50° Foccupies a space equal to about a pint(16 oz.) of soda. One pound of watervapor at 50° F would occupy a space ofover 1,700 cubic feet, nearly the size of a15’ x 15’ x 8’ room. One pound of water

vapor occupies about 10,000 times thevolume of an equal mass of water.

Figure 22 is a profile and end view of atypical open impeller. An impeller isessentially a spinning wheel and as suchcentrifugal force creates a low pressurearea at the center point “A”. In addition,pressure is lost due to liquid frictionbetween the suction nozzle and theentrance to the vane. One other sourceof pressure loss is due to the shock of thevane hitting into the liquid stream.

Figure 22

21

(cont'd)

If the pressure at point “A” is lower thanthe vapor pressure of the liquid beingpumped, the liquid boils or vaporizes.When this occurs, the vapor occupiesmany times the volume of the liquid,consequently the performance in terms ofmass flow is greatly decreased.

When the vapor enters the vane area,condensation or collapse of the vaporbubble occurs as soon as the pressure ishigher than the vapor pressure. Since thepressure is generated by the vaneworking on the liquid or vapor, thecollapse always happens at the surface ofthe vane. The crackling noise associatedwith cavitation is this collapse takingplace.

When the vapor bubbles collapse on thevane surface, energy is released in theform of an implosion which will takeparticles of metal out of the surface. Thiscauses the familiar pitting of the vane.

Thus, NPSH required is simply theamount of pressure necessary to keep theliquid from vaporizing at the “eye” orcenter of the impeller. It is made up of thelosses due to friction and shock plus thenatural pressure reduction due tocentrifugal force.

PACKED STUFFING BOX LUBRICATIONShaft sealing is the necessary evil tocentrifugal pump operation. Mechanicalseals and packing are the two methodsused to accomplish a seal.

It must be understood that while thesesealing devices act in different ways to dothe same job, there is work being donewhich generates friction and heat.Because of this, they require both coolingand lubrication.

Packing does not and should notcompletely eliminate leakage, but ratherthrottles it to a tolerable limit. Thereshould always be some drippage from thegland for good packing lubrication.

The choice of stuffing box lubricantdepends on the pumpage, temperatureand pressure. Obviously, if the liquidpumped is a poor lubricant or containsabrasive solids, the packing will beseverely damaged. Should the liquid beat or near its vapor pressure, the heat

generated in the bearing surface areamay cause flashing with the resultant lossof lubricating properties.

Figure 23 illustrates the most commonmethod of supplying lubrication to thepacking. The pumpage is simplyby-passed from the discharge volute intothe stuffing box. This is used when theliquid and operating conditions are suchthat the pumpage will provide adequatelubrication. Part A in Figure 23 is thecage ring. Its function is to provide anannular channel for even distribution ofthe lubricant.

Figure 24 illustrates a method oflubrication used when the pumpage isheavy or thick, such as paper stock. Inthis case, the cooling fluid is supplied to acage or lantern ring which is placed in theback of the stuffing box. This methodprevents the pumpage from entering thethroat bushing and will minimize wear andclogging. The cooling fluid is forced into

22

(cont'd)

the stuffing box at a higher pressure thanis in the area between the back of theimpeller and the stuffing box with a portionentering the pumpage through the throatbushing. The remainder of the coolingfluid is forced along the shaft to cool andlubricate the packing.

Care must be exercised in the choice ofexternal lubricant. The primary concernwill be compatibility with the pumpage. Inmost cases water will suffice forlubrication, but serious product damagemay result if a chemical reaction occurs.

If water is undesirable, grease oil or aliquid with good lubricity and chemicalcompatibility should be selected.

Figure 23

Figure 24

ARE YOU INCREASING YOUR STUFFING BOX PACKINGPROBLEMS?Normal stuffing box leakage usuallyranges from 40 to 60 drops per minutewhich is adequate to cool and lubricatethe packing. Stuffing boxes for pumpswith very large shaft diameters may needto leak as much as a small stream toprovide sufficient cooling and lubrication.On units handling clear liquids, thepumpage itself becomes the coolant andlubricant. A seal flush line is piped upfrom a point on the pump casing to theseal water inlet. As the unit is operated,pumpage flows naturally to the stuffingbox. An external sealing liquid is neededif the pressure at the stuffing box isnegative, as in a Suction Lift situation, or ifthe liquid being pumped has suspendedsolids, or is highly volatile with poorlubricating qualities.

If the pressure at the stuffing box isnegative, air in the atmosphere will be

drawn into the packing. If enough airenters the pump through the packing it ispossible for the unit to lose its prime orseize the pump altogether. A liquidbarrier such as seal water, helps toprevent this.

The sealing liquid is piped externally tothe stuffing box and distributed betweenthe rows of packing through a seal cageor lantern ring. Some of the sealing liquidwill be drawn into the pump, and theremainder will trickle out of the stuffingbox. In this case, the sealing liquid actsas a coolant, a lubricant and a barrieragainst the entrance of air as well. If theliquid pumped has solids in suspension,the stuffing box should be sealed withclean water from the plant water supply orsome other source. The use of plantwater assures a positive seal on thestuffing box during the priming period.

23

(cont'd)

If the pressure at the stuffing box ispositive and the liquid is clean, the naturalflow of liquid trying to escape to theatmosphere will cool and lubricate thepacking. In this case it is not necessary toconnect either a flush line from the pumpcasing or an external supply of seal water.The additional pressure of the supply willincrease the pressure at the stuffing boxunnecessarily and require the packing tobe tightened further to control theleakage.

If the pumpage contains suspendedsolids special consideration needs to begiven to both the type of packing beingused and the supply of seal water. Ifallowed to leak, the solids in the pumpedliquid will collect on the rings of packingand score the shaft sleeve. Externalsealing with clean plant water isrecommended.

The pressure of the seal water supply, atthe stuffing box connection, should bebetween 5 and 10 PSIG above thepressure acting on the stuffing box. Thiswill insure a flow of liquid along the shaftsleeve and into the pump helping toprevent the entrance of solids.

If the pumpage is toxic, volatile or cannotbe contaminated, a non-soluble lubricantmay be introduced at the seal cage orlantern ring. A quench type gland isoften used to dilute and carry away anyleakage of the pumped liquid which mightescape past the packing.

Recommendations for stuffing box sealingliquids are tabulated below. They shouldbe used as a guide for new pumpinstallations and when reviewing existinginstallations.

STUFFING BOX PACKINGPacking is generally a rope-like materialcontaining some type of lubricant, usuallygrease and graphite, Teflon™, mica orsome other lubricating substance. Theinitial impregnation is intended to serve asthe primary lubricant for the start-up andbreak-in period. After start-up otherlubrication must be provided to prolongpacking life. This lubrication is most oftenprovided by the pumpage.

Packing supplied by ITT Industries FluidTechnologies can be broken down intotwo primary classifications: general andspecial.

General

Packing supplied for general serviceapplications is braided, long filamentvegetable fiber material impregnated with

grease and graphite flakes. This packingis best suited for low speed, lowtemperature and low pressureapplications on cold water and generalservices. It has a pH range of 4 to 10which enables it to withstand mildly acidicor alkaline solutions. It’s the leastexpensive of the packing types available.

Special

A. Chemical and Solvent Applications

A wide variety of packing is available forsevere chemical or solvent applications.Typical types include Teflon™impregnated vegetable fiber packing,pure Teflon™, Grafoil™ and puregraphite, Kevlar™, lead packing, variouscombinations of these and othermaterials. Your choice of packing should

24

(cont'd)

be based on the nature and concentrationof the chemicals or solvents beingpumped.

B. High Pressure or TemperatureApplications

Packings of varied materials andarrangements can be supplied for mostapplications involving high pressuresand/or temperatures. Combination sets ofvarious types of foil, plastic or braidednatural and man-made fibers are commonfor use with these applications. Yourchoice should be based on shaft speedsand the severity of the pressures andtemperatures involved.

Often consultation with your ITT IndustriesSales Representative or local packingsupplier can provide alternative solutionsto what may be considered an impossiblesituation.

Figure 25

STUFFING BOX COOLING FOR HIGH TEMPERATUREAPPLICATIONSHigh temperature applications presentcertain inherent problems which do notarise when pumping lower temperaturefluids. Special attention must be given tothe stuffing box and packing arrangementto assure a long and useful life.

In centrifugal pumps fitted with packing,there are high temperature optionsavailable, such as jacketed stuffing boxes,to help extend the life of the packing. Asthe temperature and pressures increaseor as the pumpage becomes morevolatile, corrosive or toxic, packingbecomes more of a problem. Sincestuffing boxes need to leak to provide thecooling and lubrication for the packing,this leakage can cause serious safety andhealth issues in the plant. In someapplications the few drops of leakage canvaporize harmlessly into the atmosphere.In others, there can be no leakage to theenvironment at all.

Because they eliminate this leakage,mechanical seals have largely replacedpacking for these sorts of applications.However, when using mechanical seals,care must be taken to be sure that therebe liquid film between the seal faces at alltimes. If the liquid separating the sealface surfaces were to flash to vapor andallow the faces to touch, seal failure isnearly guaranteed.

There are several ways to help keep theseal faces and sealing fluid cool:

1. Cooling liquid can be circulatedthrough a Jacketed stuffing boxwhich is an option for many of ourmodels, including the 3196. Thechart on the next page shows thecooling water required for variousapplication temperatures.

2. A cool compatible liquid from anoutside source can be injecteddirectly into the seal chamber.

25

(cont'd)

Goulds Model 3196 with non-cooled stuffing boxw/quench type gland. Standard configuration with5 rings of packing and lantern ring illustrated.

3. The pumpage can be cooled in aheat exchanger and returned to theseal chamber.

Either (2) or (3) can be used bythemselves or in combination with (1).

Figure 26

Figure 27

26

TYPE 4TaperBore™ PLUS Seal Chamber

TYPE 5Jacketed BigBore™ Seal Chamber

Maintains propertemperature control(heating or cooling)of seal environment.

MECHANICAL SEALS . . . PART I - THE BASIC SEALA mechanical seal is a sealing device thatprovides a seal between rotating andstationary parts, thus keeping the liquidbeing pumped inside the pump. Today,the design of liquid handling equipmentwith rotating parts usually include thefeatures necessary for the use of amechanical seal. Some of theadvantages mechanical seals offer overconventional packing include:

1. Reduced friction and power lossesbecause of lower drag in thestuffing box.

2. Reduced leakage from the stuffingbox.

3. Reduced shaft or sleeve wear.

4. Reduced maintenance.

The wide variety of styles and designstogether with extensive experience allowsthe use of seals on practically any sealingproblem.

A mechanical seal must seal at threepoints:

1. Static seal between the stationarypart and the housing.

2. Static seal between the rotary partand the shaft.

3. Dynamic seal between the rotatingseal face and the stationary sealface.

Figure 28 shows a basic seal with thesecomponents:

1. Stationary seal part-positioned inthe housing with preload on the

O-ring to effect sealing and preventrotation.

2. Rotation seal part-positioned onthe shaft by the O-ring. The O-ringseals between it and the shaft andprovides resiliency.

3. The mating faces - The faces areprecisioned lapped for a flatness of3 light bands and a surface finish of5 microinches.

4. Spring Assembly - Rotates with theshaft and provides pressure tokeep the mating faces togetherduring periods of shut down or lackof hydraulic pressure.

5. Driving member positions thespring assembly and the rotatingface. It also provides the positivedrive between shaft and the otherrotating parts.

6. End movement - As wear takesplace between the mating faces,the rotating face must move alongthe shaft to maintain contact withstationary face. The "O" ring mustbe free to move.

The principle of operation of a mechanicalseal is fairly straight forward: Liquidpressure in the seal chamber along withsome type of spring arrangement forcesthe faces together. Due to capillaryaction, a thin film of lubricant separatesthem and keeps them from touchingunder normal circumstances. Thepressure of the liquid, the spring pressureand this very thin layer of liquid betweenthe faces reduces the leakage of thepumped fluid past the seal to a point nearzero. These basic components are a part

27

(cont'd)

of every seal, secondary sealing systemsconsisting of “O” rings, “V” rings, gaskets,etc. complete the assembly.

The form, shape, style and design willvary greatly depending upon the serviceand manufacturer. The basic theory,however, remains the same.

Figure 28

MECHANICAL SEALS . . . PART II - TYPESMechanical seals can be classified intothe general types and arrangementsshown below. Understanding theseclasses provides the first step in properseal selection.

Single SealsInside, outside, unbalanced, balanced

Double sealsUnbalanced or balanced

Single Seals, Inside Unbalanced(Figure 29)

The single inside seal mounts on the shaftor sleeve within the stuffing box housing.

The pumpage is in direct contact with allparts of the seal and provides thelubrication for the faces. The full force ofpressure in the box acts on the facesproviding good sealing to approximately200 PSIG. This is the most widely usedtype for services handling clear liquids. Acirculation or by-pass line connected fromthe volute to the stuffing box providescontinual flushing of the seal chamber.

Single Seals, Outside Unbalanced(Figure 30)

This type mounts with the rotary partoutside of the stuffing box. The springsand drive element are not in contact with

28

(cont'd)

the pumpage, thus reducing corrosionproblems and preventing productaccumulation in the springs. Pressuresare limited to the spring rating, usually 35PSIG. Usually the same style seal can bemounted inside or outside. The outsideseal is easier to install, adjust andmaintain.

Single Seals, Balanced(Figure 31)

Balancing a seal varies the face loadingexerted by the box pressure, thusextending the pressure limits of the seal.A balanced rotating part utilizes a steppedface and a sleeve. Balanced seals areused to pressures of 200 PSIG. Their useis also extensive on light hydrocarbonswhich tend to vaporize easily.

Balanced outside seals allow boxpressure to be exerted toward the sealfaces, thus allowing pressure ranges toabove 150 PSI as compared to the PSIGlimit for the unbalanced outside seal.

Double Seals

Double seals use two seals mounted backto back in the stuffing box. The box ispressurized with a clear liquid from anoutside source. This arrangement is oftenused on slurry service or where there canbe no release of the pumpage to theenvironment because the condition of theinner seal can be monitored by checkingthe characteristics of the seal flush liquid.

Balanced and unbalanced designs areavailable to meet specific pressures.

Cartridge Seals

Recent advancements in sealingtechnology have made Cartridge TypeSeals the preferred type for manyapplications. The advantages include thatthey are available in all of the previouslymentioned configurations, they are selfcontained, completely assembled on theirown shaft sleeve, can accommodate pumpimpeller adjustments and are significantlyeasier to install. The problems of having toassemble the pump, mark the sealchamber location on the shaft or sleeve,disassemble the unit, install the seal andre-assemble the pump are eliminated. Afurther advantage is that you do not needto handle the delicate sealing faces orother components.

29

Figure 32

Split Seals

Sealing technology has advanced evenfurther in the area of Split Seals. Splitseals are usually a cartridge type sealwith the added advantage of being splithorizontally at the centerline. Since theseal can be separated into halves, placedaround the shaft and reassembled, takingthe pump apart to install it is unnecessary.The primary disadvantages are that theseal components need to be veryaccurately aligned and, since you arehandling many of the individual parts ofthe seal, extra care needs to be taken toprevent damaging any of the components.

Seal Chambers

Seal life can be significantly extended bythe proper selection of the sealenvironment. By providing better coolingand lubrication by increasing the circulationnear the seal faces, the life of the seal isgreatly increased. The design of thechamber can be as simple as justincreasing the bore diameter in the area ofthe seal to increase the liquid capacity oras complicated as adding a taper to thesides and including ribs, vanes or fins tofurther induce circulation around the faces.

Manufacturers offer differentconfigurations for different applications. Aseal chamber suitable for a clear liquidapplication maybe totally unacceptable fora viscous application or one containingabrasive solids. Usually as theeffectiveness of the seal chamber incooling and lubricating the seal goes up,so does the cost of that design. Thatadded cost can easily be more than offsetby a reduction in the number of sealfailure in the pump’s life time.

Figure 33

30

Tape Bore VPE

MECHANICAL SEALS . . . PART III - SELECTIONThe proper selection of a mechanical sealcan be made only if the full operatingconditions are known. These conditionsare as follows:

1. Liquid

2. Pressure

3. Temperature

4. Characteristics of liquid

5. Pump model

Liquid – Identification of the exact liquidto be handled provides the first step inseal selection. The metal parts must beresistant to the effects of the pumpage.These parts are available in steel, bronze,stainless steel, Hastelloy and a widevariety of other alloys to meet specificneeds.

The seal faces must be able to resistboth corrosion and wear. Carbon, varioustypes of ceramics, Stellite, silicon carbideand tungsten carbide are a few of thevariety of materials which offer bothexcellent wear properties and corrosionresistance.

The elastomers in the seal can be madeof any number of different compoundsincluding Teflon™, Viton, Buna N whichcompletes the proper materials selection.

Pressure – the proper type of sealconfiguration, unbalanced or balanced, isbased on the pressure that the seal will besubjected to. Unbalanced seals are usedin applications with pressures up toapproximately 200 PSI. Balanced sealsare usually required for pressures above200 PSI.

Temperature – The temperature will, inpart, determine the material of the othersealing members. Synthetic rubbers areused to approximately 250°F, Teflon™ to500°F. and other, more exotic elastomersto 750°F and above. Cooling the liquid inthe seal chamber by use of coolingjackets or heat exchangers to coolflushing liquid , often extends seal life andallows for a wider selection of materials.

Characteristics of Liquid – Liquidscontaining abrasive solids can createexcessive wear and shorten seal life.Double seals, very hard faces and clearliquid flushing from an external sourceallows the use of mechanical seals onthese difficult applications. On lighthydrocarbons, balanced seals are oftenused even though pressures are low topromote longer seal life.

Pump Model – Mechanical seal selection,installation and application varies with thepump model. Not all seals fit all pumps.Seal chamber configuration, pumpdischarge pressures and temperaturesmay not present ideal design conditionsfor the seal. Consult your ITT/FTC PumpSales Engineer for selection of the properpump and seal for the service.

31

(cont'd)

MECHANICAL SEALS … PART IV - TROUBLESHOOTINGWhen discussing mechanical sealproblems, the following analogy may bemade: Mechanical seals behave verymuch like bearings. Conditions that leadto bearing failure also lead to mechanicalseal breakdown. Let’s consider theseconditions.

Misalignment - One of the main causesof mechanical seal failure is misalignment.This commonly occurs when seals areinstalled by personnel not trained inproper mechanical seal installationpractices. If the seal is installed so thatthe mating faces are not parallel to eachother and perpendicular to the shaft, therotating face will try to square itself withthe seal causing uneven wear on themating faces.

To prevent this problem, check to be surethat the seal is properly installed. Therotary unit must run parallel with the shaftand the stationary seat must beperpendicular to the shaft. Be sure thegland is drawn up evenly. This willeliminate the possibility of the improperlyaligned stationary seat. Do not overtightenthe gland - little more than finger tight isall that is generally needed in lowpressure applications. Make sure allgaskets and/or O-Rings are properlyinstalled.

Lack of Lubrication - To operateproperly, the mechanical seal matingfaces must run on a liquid film. If there isno film, the seal will overheat and fail.Because this failure can occur in a matterof seconds, it is extremely important thatthe liquid film be present whenever thepump is in operation or about to be putinto operation. Lack of lubrication at theseal faces is commonly experienced whenhandling hot water or light hydrocarbons

near their vapor pressure. To insurelubrication and dissipate heat, flushingmust be provided at the seal faces.

Be sure seal flush piping is used whenemploying balanced seals - the typeusually recommended for liquids havinglow specific gravities. The slightadditional cost of bypass piping is a goodinvestment when handling liquids neartheir vapor pressure.

Overheating - In some types ofmechanical seal failures, overheating andlack of lubrication go hand in hand. This isespecially true during the hard face heatchecks. On examining a hard face thathas heat checked you can see that thestress cracks are confined to the surfacein direct contact with the carbon matingface. These surface cracks are causedwhen there is an intense heat buildup onthe surface of the hard metal, while thesubsurface of the part remains at ambienttemperature. Since the surface metal isnot allowed to expand in a lineal directionbecause of the subsurface temperature,the surface buckles upward and cracks.The edges of the cracks, which areslightly raised above the face, begin toshave material from the carbon matingface.

Other symptoms of overheating aredamaged elastomers (O-rings). Thiscondition is easily recognized because theelastomers will show cracking on thesurface and harden.

To eliminate this type of failure, be surethe seal is operated in an environmenthaving a lower temperature than the limitsof any of its component parts.

32

(cont'd)

Abrasive Damage - Abrasive damage isa common cause of seal failure. Whenminute abrasive particles work their waybetween the seal faces, they can groovethe mirror finish of the faces or they canleave deposits from evaporation of theliquid. When these deposits build up onthe shaft they will freeze the sealingelements to the shaft and eliminate allseal flexibility. This condition can beparticularly acute when teflon sealingwedges are incorporated in the seal.Abrasive particles may become imbeddedin the teflon, and can cause shaft weardirectly under the sealing member.Abrasive liquids must be kept out of thestuffing box if at all possible.

Corrosion - Corrosion failure is easilyrecognized in most cases. Metal partsshow signs of pitting, or the sections aretotally corroded away. We will not attemptto go into a discussion of corrosion, but itshould be remembered that the metalsections of mechanical seals are usuallymuch smaller than the metal section of apump. Therefore, they can withstandmuch less corrosion attack. It is a goodrule not to downgrade the metallurgy ofthe seal from that of the pump. When indoubt, select the more noble metal for theseals. (This is a general rule and does nothold true for all applications.)

QUENCH GLANDSA gland is a device used to compress thepump packing or provide support for amechanical seal face in the stuffing boxof rotating or reciprocating machinery.

In particular, on centrifugal pumps, theprimary function of a gland is to exert thenecessary pressure on soft packing tohold it in place and to control the leakageof fluid from the stuffing box. It’s alsoused to prevent air from entering thepump casing through the stuffing box. Inthe case of a mechanical seal, the glandacts as a clamp holding the stationaryseal face in concentric alignment with theshaft axis and in perpendicular alignmentwith the rotating seal face.

The quench gland has a hollow portionadjacent to the shaft outside the stuffingbox. This hollowed area can serveseveral purposes.

The gland can be used to remove heatfrom the shaft. Water, oil or other coolingis passed through the hollow portion and

as it passes, it collects heat from the shaftand packing. Quenching in this mannerpermits pumping liquids at temperaturesmuch higher than those normally allowedby the limits of bearing and packinglubrication. The quench lowers thetemperature of the shaft at the packingand where it enters the bearing topermissible limits.

The same quench gland may be used toprevent the escape of toxic or volatileliquid into the environment. Again water,oil or some other suitable fluid is fedthrough the gland, flushing away theundesirable leakage to a waste receiver.

In some cases the gland is just used as acollector for the stuffing box leakage.There is no flushing connection - only adrain line to carry away any leakage fromthe stuffing box.

Because of the quenching, flushing orcollecting function, a quench gland mustbe made to fit the shaft closely on the

33

(cont'd)

outboard end. If not close fitting, liquidwould be allowed to spray or splash outalong the shaft. Three separate methodsmay be used to achieve the close fit.First, the clearance between shaft andgland may be established by holding theI.D. of the outboard end of the gland to aclose tolerance in comparison to the O.D.of the shaft in that area. This type ofclearance cannot be restored withoutusing a complete new gland and possiblya new shaft or new sleeve.

Second, the clearance may beestablished by using a replaceablebushing machined as above and pressedinto a bored fit in the gland. This will allowrestoring the clearance by changing onlythe bushing but would not compensate forany wear on the sleeve or the shaft.Third, auxiliary packing may be used.This may consist of a single ring ofpacking, a series of “V” rings and/or “O”rings - these are normally held in place byfitting them into a machined groove - or itmay consist of several rings held in placeby an auxiliary gland.

CONSTANT LEVEL OILERS - OPERATION ANDADJUSTMENTITT Industries oil lubricated pumps comewith a variety of methods of distributingthe oil to the bearings. Some, such as the“X series” power frames use a flood oilarrangement with a sight glass mountedin the side of the bearing frame forchecking the level. Others use the sightglass and oil rings to pick the oil up fromthe sump and distribute it to the bearings.Still some current models and many of theolder models use a bottle - type constantlevel oiler.

A cutaway of these oilers is shown inFigure 34. The oil stays in the bottle aslong as the oil level in the bearing housingis level with the mouth of the bottle.When the oil level drops, air enters thebottle allowing oil to flow out until the oillevel in the bearing housing is again up tothe mouth of the bottle. The oil level inthe bearing housing therefore staysconstant.

The oiler bottle rests on a leveling bar thatcan be screwed up or down and locked inplace. Raising the leveling bar raises the

oiler bottle mouth and therefore the oillevel in the bearing housing. The oilsetting must be checked in the field. Tocheck setting remove oiler bottle – dustcap assembly, and lift leveling barassembly from oiler body (see Figure 35).Setting should be the same as that shownin the pump instruction book. The oiler isusually set so that the oil either:

1. covers half of the lowest ball in aflood oil lubricated ball bearing, or

2. is ¼” above the bottom of the oilring in a ring oiled bearing.

The level must be set carefully. Toomuch oil is almost as bad as no oil at all.

Be sure the oiler is clean when it isinstalled in the pump. Piping from theoiler to the pump must be level. If theoiler sags, the oil level in the housing willdrop which could possibly ruin thebearing. Fill the oiler bottle with theproper oil, and place in the oiler body.The bearing housing is filled when the

34

(cont'd)

bubbles of air entering the oiler stop andthe level in the bottle remains constant.Never pour oil directly into the oiler bodysince you could easily overfill it.

Figure 34

Figure 35

BALL BEARINGS – HANDLING, REPLACEMENT ANDMAINTENANCE SUGGESTIONSBall and roller bearings are carefullydesigned and made to watch-liketolerances. They give long, trouble-freeservice when properly handled andmaintained. They will not stand up toabuse.

Keep Clean

Dirt getting into the bearing duringinstallation causes probably 90% of earlybearing failures. Cleanliness is a mustwhen working with bearings. Somethings that will help are:

1. Do not open bearing housingsunless absolutely necessary.

2. Spread clean plastic, newspapersor rags on the work benches and atthe pump. Set your tools and thebearings on these coveredsurfaces only.

3. Wash your hands. Wipe dirt, chipsand grease off tools.

35

(cont'd)

4. Keep the bearings, housings, andshaft covered with clean plastic orcloths whenever they are not beingworked on.

5. Do not open the boxes or unwrapnew bearings until you’re ready toinstall them.

6. Flush the shaft and housings withclean solvent before reassembly.

Pull Bearings Carefully

1. Use a sleeve or puller whichcontacts just the inner race of thebearing. (The only exception tothis is some double suction pumpswhich use the housing to pull thebearing.)

2. Never press against the balls orball cages, only against the races.

3. Take care not to cock the bearing.Use a sleeve which is cut squarely,or puller which is adjusted to drawthe bearing off the shaft squarely.

Inspect Bearings and Shaft

1. Examine the bearing carefully.Scrap it if there are any flat spots,nicks or pits on the balls or races.Bearings should be in perfectcondition to be reused.

2. Turn the bearing over slowly byhand. It should turn smoothly andquietly. If not, scrap the bearing.

3. Whenever in doubt about thecondition of a bearing, scrap it.The relatively few dollars investedin new bearings may preventserious loss from downtime andpump damage. In severe or critical

services, replace the bearings ateach overhaul.

4. Check the condition of the shaft.Bearing surfaces should besmooth and free from burrs.Smooth burrs with emery cloth andpolish with crocus cloth. Shaftshoulders should be square, freefrom nicks and burrs and smooth atthe radii where smaller sectionsjoin larger sections.

Check New Bearings

Be sure the replacement bearing is ofcorrect size and type. An angularcontact bearing may be dimensionallyinterchangeable with a deep groovebearing and may fit perfectly in the pump.However, the angular contact bearing isnot suitable for end thrust in bothdirections, and will probably fail quickly.Also check to see that the shields (if any)are the same as in the original unit. Referto the pump bulletins and instruction bookfor the proper bearing to use and anynotes regarding installation.

Install Carefully

1. Oil the bearing surfaces on theshaft lightly.

2. Shielding, if any, must face in theproper direction. Angular contactbearings, on pumps where they areused, must also be oriented in theproper direction. Duplex bearingarrangements must be mountedwith the proper faces together.Mounting arrangements vary frommodel to model. Consult thebulletin and instruction book forspecific pump model.

36

3. Press the bearing on the shaftsquarely. Be sure that the sleeveused to press the bearing on isclean, free from burrs, is square cutand contacts the inner race only.

4. Press bearing firmly against shaftshoulder. The shoulder helpslocate the bearing on the shaft,support the inside race and squarethe bearing.

5. Be sure the snap rings, if used, areproperly installed, flat side againstbearing, and that the gap at theends of the ring align with the oilreturn channel in the bearinghousing to provide an open path forthe oil to travel back into thehousing. Make sure the lock nutsare tight.

6. Lubricate properly. Consult theinstruction manual for specificinformation regarding lubricationrequirements.

GREASE LUBRICATIONITT Industries grease lubricated pumpsare designed for simple foolproofmaintenance. Only one lubricant isrequired for a large variety of services.The correct lubricant is a premium ball,roller and plain bearing grease, which isoxidation resistant, has a widetemperature range and has a lithium soapbase. The oil viscosity should be 200 –250 SSU at 100°F. This wouldcorrespond to NLGI Grade 2 Grease.“Filled” greases such as those withmolybdeum, graphite, Teflon™ and otherfillers should be avoided.

This one type of grease will suffice fornearly all applications; hot and cold; wetand dry; clean and dirty.

Grease should be added to the bearingafter each 2000 hours of operation, orabout every three months. More frequentlubrication can lead to shorten bearinglife due overheating.

The normal bearing temperature dependson many variables, the ambienttemperature in the area of the unit, thetemperature of the liquid being pumped,the speed of the shaft and the amount of

air flow around the pump are only a few.It is expected that the bearingtemperature will stabilize at some levelbetween 130° and 180°F which isperfectly acceptable for a grease or oillubricated assembly. For most peopleanything above 120°F is uncomfortable totouch, so it is not unusual to have aproperly lubricated, aligned, and operatingbearing assembly which is too hot to holdyour hand on.

On the other hand, a sudden temperaturerise without a corresponding rise inambient or pumpage temperature can bea warning sign that there is somethinggoing wrong.

Figure 36

37

FLEXIBLY MOUNTED BASEPLATESThe flexibly mounted baseplate was firstused in chemical plants in the mid 1950s.At that time, special extra heavy baseswere used to provide adequate rigidity.Historically, pump and other rotatingequipment suppliers have recommendeda grouted base to provide a suitableplatform to insure a permanent means ofestablishing and maintaining alignmentbetween the rotating machine and itsdriver.

The permanent grouted base is stillrecommended for large units where flangeloads can be adequately limited, andwhere the base can be suitablymaintained. In many chemical plantsatmospheric corrodents make baseplatesand foundations expensive and difficult tomaintain. As a result, after a short time,the baseplate can deteriorate to a pointwhere it no longer is able to maintainsuitable alignment.

Under adverse environmental conditions awell engineered flexibly mounted basecan provide an economical solution todifficult problems. The flexible mountingsystem offers the following advantages:Reduced installation costs – no tiled or

acid proof brick foundation required, nogrouting required, the pump can easily beadjusted to line up with piping. Lowermaintenance costs – uniform flangeloads will move the pump, base and motoras a unit reducing both the possibility ofcoupling misalignment and the sealproblems normally associated with excessflange loading. The raised base can beeasily hosed to remove corrosives anddebris for simplified housekeeping andlonger baseplate life. A successfulinstallation requires that the base havesufficient rigidity to permit initial alignmentand to maintain alignment over theoperational life of the equipment. Gouldsoffers the flexibly mounted basearrangement as an option on our ANSIFamily units and many other pump types.The standard cast iron or structural steelbase normally furnished on the ANSIFamily X-Series units have provedsatisfactory under actual plant conditionsup to 100 HP at 3550 RPM.

Users report that the elimination of theexpensive foundation enables them to usea standard horizontal ANSI type pump atthe same installation cost as a verticalinline unit.

Figure 37

38

IMPELLER CLEARANCEThe open impeller centrifugal pump offersseveral advantages over units equippedwith other types of impellers. It isparticularly suited to applications wherethe liquid contains abrasive solids.

Abrasive wear on an open impeller isdistributed over the diametrical areaswept by the vanes. The resulting totalwear has less effect on performance thanthe same total wear concentrated on theradial ring clearance of a closed impeller.

Because of the impeller adjustmentfeature, the open impeller permitsrestoration of nearly “new pump” runningclearance after wear has occurred withoutexpensive parts replacement.

A well designed open impeller pump willfeature a simple positive means for axialadjustment without necessity ofdisassembling the unit to add shims orgaskets.

Figure 38, with these typical instructions,shows one method employed on ITTGoulds open impeller centrifugal pumpsfor making this adjustment. Othermethods using Dial Indicators, etc, maybe used. Since the actual impellerclearance varies with pump type andtemperature, consult the specificOperating Instruction for your pump forthe proper settings. On units equippedwith mechanical seals, follow the sealmanufacturers instructions for the care ofthe seal during the impeller adjustmentprocess.

1. Loosen the jam nuts and bolts(370D) located at the bearinghousing (111).

2. Tighten the bolts (370C) evenlywhile slowly rotating shaft, until theimpeller (101) just contacts thecasing (100).

3. Snug all the bolts (370C) againstthe bearing housing (111). Looseneach bolt (370C) until a .015” feelergauge can be placed between thebearing housing and the undersideof the head of the bolt (370C).

4. Be sure the jam nuts on the bolts(370D) are loose. Tighten each bolt(370D) one flat at a time until thebearing housing is tight against thebolts (370C). Be sure all the bolts(370C and 370D) are tight. Tightenthe jam nuts on bolts (370D).

5. The rotating element andconsequently the impeller has beenmoved .015” away from the casingthus giving the required clearancebetween these two parts.

Figure 38

39

(cont'd)

PUMP VIBRATION ANALYSIS

Figure 39

Pump users have become increasinglyaware of vibration and the use of vibrationanalysis in detecting problems, predictingfailures and scheduling equipmentoutages.

The vibration analyzer shown in Figure 39is used to measure and indicate theamplitude, frequency and phase values ofvibration. Furthermore, when vibrationoccurs at several frequencies, it separatesone frequency from another so that eachindividual vibration characteristics can beidentified and evaluated.

The vibration pickup, or transducer, (A)senses the motion of the machine andconverts it into an electrical signal. Thissignal may represent the amount ofmovement, which would be displacement,the velocity at which the machine ismoving as it vibrates or the accelerationrequired to produce the particular velocity.The analyzer receives this signal andconverts it to the correspondingamplitude and frequency.

Depending on the instrument and thesettings used, the amplitude may bedisplayed in terms of peak-to-peakvibration, which would be the maximumvalues present or various methods ofaveraging such as RMS. Displacement isindicated in mils where 1 mil equals 1one-thousandth of an inch, Velocity inInches per Second and Acceleration in“G’s”.

Many machines today have graphicaldisplays for an immediate indication ofboth the amplitude and frequency of thevibration present and some have printersbuilt into them to print out the informationright on the spot. Often the units includea down loading feature so that theinformation collected may be saved on aPC or disk for later analysis.

Most instruments are equipped with adevice to indicate frequency which gives adirect readout of the predominantfrequency of the vibration. Otherinstruments have tunable filters (C) whichallow scanning the frequency scale and

40

(cont'd)

reading amplitudes at any particularfrequency.

The strobe light (D) is used to determinethe phase of the vibration which can be ofgreat value when dealing withcomplicated vibration signatures and indepth analysis. The strobe can be madeto flash at the predominant frequency ofthe vibration or at any frequency settingusing an internal oscillator to fire it.

A reference mark on a rotating partviewed under the strobe flashing at thevibration frequency may appear as asingle mark, multiple marks and eitherstationary or rotating. The number ofmarks viewed and whether they arerotating or stationary is useful indetermining the source of the vibration.The relationship between the location ofthe mark on the part and where it isilluminated by the strobe can bedetermined and that information can beused when balancing rotating parts.

The first step in vibration analysis is todetermine the severity of the vibration,then, if the vibration is serious, a completeset of vibration readings should be takenbefore attempting to analyze the cause.Figure 40 is a severity chart based onamplitude, frequency and velocity. Figure41 is a general guide for centrifugalpumps as published by the HydraulicInstitute.

Figure 40

Figure 41

41

(cont'd)

The severity of vibration is a function ofamplitude and frequency; however, itshould be noted that a change in severityover a period of time is usually anindication that the condition of themachine is deteriorating. This change isoften more important than the actualvibration values themselves. Vibrationlevels in the “slightly rough” or “rough”ranges that do not change with timemaybe be perfectly acceptable. Theopposite is also true; a machine thatexhibits vibration in the “Very Smooth”area but moves to the “Very Good” area ina short period of time may be very closeto failure.

Complete pump vibration analysisrequires taking vibration readings at eachbearing in three planes (horizontal,vertical and axial). Readings at the pumpsuction and discharge flanges may alsobe useful in some cases.

After all data has been tabulated, it can beanalyzed to determine the most likelycause or causes of the vibration.Figure 42 lists the most common causesof vibration and the identifyingcharacteristics of each.

By analyzing the tabulated vibration datawith the reference to the identificationchart, one or more causes may be found.Each possibility must be checked, usuallystarting with the most likely cause oreasiest or least expensive to correct.

For example, assume that axial vibrationis 50% or more of the horizontal or verticalvibration and the predominant frequencyis the same as the RPM of the pump. Thechart indicates the most probable cause ismisalignment or a bent shaft. Couplingmisalignment is probably the mostcommon single cause of pump vibrationand is one of the easiest to check. If,after checking, the alignment is found tobe within acceptable limits, then aninspection for excessive flange loading iswarranted. Flange loading beyond thelimits allowed can cause distortion andmisaligment inside the pump leading tohigher than expected vibration levels. Ifthat inspection does not reveal the sourcethen the next step is to check for a bentpump shaft.

Cavitation in a pump can cause seriousvibration. Vibration caused by it usuallyappears at random frequencies but it ismost often identified by a loud cracklingnoise in the suction area of the pumprather than by any characteristic vibration.Vibration at random frequencies can alsobe caused by hydraulic disturbances inpoorly designed suction or dischargesystems.

Vibration analysis, while a relatively newfield, has rapidly gained acceptance inindustry as a valuable tool in preventiveand predictive maintenance and as ageneral troubleshooting tool.

42

(cont'd)

Figure 42

PUMP MAINTENANCE RECORDS PAY DIVIDENDSToo often plant records of pumps are littlemore than an inventory record foraccounting and insurance purposes listingnot much more than the pump size andmanufacturer. In other plants,maintenance records may be kept as partof a pump lubrication schedule. In eithercase complete pump records could bekept with very little additional effort. Withthe wide spread use of PC’s in industryand the development of inexpensive DataBase programs more and moreorganizations are going to MaintenanceTracking Systems in an effort to reducedowntime, lost production andmaintenance costs. Completemaintenance records, filed in an

accessible location, are invaluable indiagnosing pump failure, in ordering repairparts and in establishing lubrication andmaintenance schedules. In addition thesemaintenance record cards are helpful indetermining a pump’s suitability for newrequirements due to process changes.Notations of pump failures and the repairsrequired may be used to define theoptimum period of any given pump beforecomplete inspection and overhaul isrequired. If a unit has been on an annualoverhaul program and the pumpMaintenance record indicates that nofailures have occurred over a period ofyears, perhaps a longer period betweeninspections would be warranted.

43

Vibration Identification Chart

Cause Amplitude Frequency Phase Remarks

Unbalance Largest in radialdirection.Proportional tounbalance.

1 X RPM Single referencemark

Misalignment ofcoupling orbearings and bentshaft

Axial directionvibration 50% ormore of radial

1 X RPMnormally

Single, double, ortriple

Easily recognizedby large axialvibration.Excessive flangeloading cancontribute tomisalignment.

Bad anti-frictionbearings

Unsteady Very high.Several timesRPM.

Erratic Largesthigh-frequencyvibration near thebad bearing.

Mechanicallooseness

2 X RPM Two referencemarks. Slightlyerratic

Check grouting andbaseplate bolting.

Bad drive belts Erratic or pulsing 1, 2, 3, & 4 XRPM of belts

Unsteady Use strobe light tofreeze faulty belt.

On other pumps, the records may indicatefrequent failures. This may suggest thatsemi-annual inspections and repairs arerequired. It may also suggest that there isa need to take a closer look at this unit.Something may be wrong with the unititself, its assembly, the application, theoperation or the installation.

The chronological notation of pumprepairs can be used to develop a properspare parts inventory and may, in somecases reduce inventory and the costsassociated with it. Frequent replacementof a part subject to abrasive wear mayindicate a different material selectionwould be more economical.

Simple maintenance records for eachpump, in both primary and secondaryservice, are much less expensive thantrial and error solutions.

44

ITT INDUSTRIES / FTC OFFERS A COMPLETE LINE OFPUMPS TO MEET EVERY INDUSTRIAL NEED

45

ANSI Process

Model 3196

This is the original ANSI pump that hasbecome the standard of the industry. Over600,000 installations attest to the remarkableperformance of the 3196.

Abrasive Slurry

Model SRL

SRL rubber lined pumps are designedspecifically for handling abrasive and corrosiveslurries found in the mining and mineralprocess industries, and in pulp and paper,aggregate, pollution control and chemicalapplications.

Magnetic Drive

Model 3298

The 3298 is designed specifically to handlemoderate to severe corrosives with or withoutsolids. As a sealless design, it’s an effectivealternative to pumps with mechanical sealproblems. Meets strictest EPA regulations.

In-Line ANSI Process

Model 3996

For corrosives, abrasivesand high temperatures.Fully open impeller, backpull-out design, heavyduty construction. Fieldalignment not required.

46

Splitcase Double Suction

Model 3420

For a wide range of industrial, municipal,marine services .. cooling tower, raw watersupply, booster, fan pump, high/low lift, firepump, pipelines.

Paper Stock Process

Model 3180

All customer requirements were consideredin the design of this paper stock/processpump. The result is a true world class pumpline. . .a product without compromise.

Vertical Industrial

Model VIT (Turbine)

A wide rangeof hydraulicconditionsallows meetingrequirements ofvirtually everypump service.These pumpsare designed tomeet customuser specifi-cations.Model VICcan-type turbinemeets API-610specifications.

Model VIC (Can-type)

Vertical Sump and Process

Model 3171

Vertical industrial pumps forwide range liquid handlingcapabilities. For drainageand general sump, tankunloading and transfer,process circulation,outside tank mounting,high temperatureservice.

47

ISO Lined Sealless

Model Richter PCK

The ICK is designed to handle moderate tosever corrosives, providing excellent service ina variety of process plants worldwide.

Multi-Stage

Model 3600

Advanced design with proven operating history.Axially split, with many enhanced features thatmake it an extremely reliable, highperformance, pump well suited to a wide rangeof services.

General Industry

Model 3355

Goulds Model 3355 is a multi-stage ring sectionpump designed for high-pressure servicesincluding: boiler feed, reverse osmosis, showerservice, pressure boosting, plus much more. Itsmodular design and multiple configurationsmake it ideal for your system.

API-610 (8th Edition) Process

Model 3700

High temperature and high pressure processpumps designed to meet the requirements ofAPI-610 (8th Edition). Centerline support forhigh temperature stability, maximum rigidity.Tangential discharge for maximum hydraulicefficiency.

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49

NOTES

50

© 2002 Goulds Pumps PRINTED IN U.S.A.Form # BRCARE 9/2002

Visit our website at www.gouldspumps.com