PUMP WISDOM : problem solving for operators and specialists.

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Cover Title Page Copyright Page Contents Preface Chapter 1 Principles of Centrifugal Process Pumps Pump Performance: Head and Flow Operation at Zero Flow Impellers and Rotors The Meaning of Specific Speed Process Pump Types Process Pump Mechanical Response to Flow Changes Recirculation and Cavitation The Importance of Suction Specific Speed What We Have Learned References Chapter 2 Pump Selection and Industry Standards Why Insist on Better Pumps ANSI and ISO vs. API Pumps What We Have Learned References Chapter 3 Foundations and Baseplates Securing Pumps in Place – With One Exception Why Not to Install Pump Sets in the As-Shipped Condition Conventional vs. Prefilled Baseplate Installations Epoxy Prefilled Baseplates How to Proceed If There Is No Access to Specialist Firms What We Have Learned: Checklist of Foundation and Baseplate Topics References Chapter 4 Piping, Stationary Seals, and Gasketing Pipe Installation and Support Sliding Supports and Installation Sequence Deserve Special Attention Monitoring Pipe Stress While Bolting Up Flange Leakage What to Do Prior to Gasket Insertion Spiral Wound and Kammprofile Gaskets Pipe, Hydraulic Tubing or Flexible Connections? Gusseting Concentric vs. Eccentric Reducers Vibration Problems in Piping Proven Ways to Control Piping Vibration Addressing Piping Vibration Issues Small Bore Piping Issues What We Have Learned References Chapter 5 Rolling Element Bearings Bearing Selection Overview and Windage As a Design Problem Radial vs. Axial (Thrust) Bearings Oil Levels, Multiple Bearings and Different Bearing Orientations Upgrading and Retrofit Opportunities Bearing Cages Bearing Preload and Clearance Effects Bearing Dimensions and Mounting Tolerances What We Have Learned References Chapter 6 Lubricant Application and Cooling Considerations Lubricant Level and Oil Application Issues with Oil Rings Pressure and Temperature Balance in Bearing Housings Cooling Not Needed on Pumps with Rolling Element Bearings Oil Delivery by Constant Level Lubricators Black Oil Lubricant Application As Oil Mist (Oil Fog) Desiccant Breathers and Expansion Chambers What We Have Learned References Chapter 7 Lubricant Types and Key Properties Lubricant Viscosities When and Why High Film Strength Synthetic Lubricants Are Used Lubricants for Oil Mist Systems What We Have Learned References Chapter 8 Bearing Housing Protection and Cost Justification Noncontacting Bearing Protector Seals Contacting Bearing Protector Seals How Venting and Housing Pressurization Affect Bearing Protector Seals Cost Justification Overview Advanced Bearing Housing (Bearing Protector Seal) Summary What We Have Learned References Chapter 9 Mechanical Sealing Options for Long Life Still Using Packing? General Overview of Mechanical Seals All Flush Plans Have Advantages and Disadvantages Always Obtain the Full Picture Seal Chamber Pumping Ring (Circulating Device) Technologies Lessons Apply to Many Services What We Have Learned References Chapter 10 Pump Operation Starting Centrifugal Pumps Surveillance of Pump Operation Optimum Pump Switching Interval Centrifugal Pump Shutdown Addressing Post Start-up Issues Avoiding Parallel Pump Operating Problems What We Have Learned References Chapter 11 Impeller Modifications and Pump Maintenance Maintenance Essentials Superior Maintenance Requires Upgrading Impeller Upgrading with Inducers Distance from Impeller Tip to Stationary Internal Casing Components Impeller Trimming Impeller Wear Rings Vane Tip Overfiling and Underfiling Carbon Graphite Wear Rings and Bushings What We Have Learned References Chapter 12 Lubrication Management How Bad Is Water Contamination? Avoid Solids Contamination Avoid Questionable Oil Storage and Transfer Practices Periodic Audits What We Have Learned References Chapter 13 Pump Condition Monitoring: Pump Vibration, Rotor Balance, and Effect on Bearing Life Vibration and Its Effect on Bearing Life Monitoring Methods Differ Vibration Acceptance Limits Causes of Excessive Vibration Rotor Balancing What We Have Learned References Chapter 14 Drivers, Couplings, and Alignment Driver Selection Coupling Selection and Installation Installation and Removal Alignment and Quality Criteria Consequences of Misalignment Thermal Rise and Predefinition of Growth What We Have Learned References Chapter 15 Fits, Dimensions, and Related Misunderstandings Low Incremental Cost of Better Pumps Pump Pedestals and Bearing Housings Should Not Be Water-Cooled Summary of Bearing-Related Issues Constant Level Lubricators Bearing Housing Protector Seals (“Bearing Isolators”) Motor Lubrication Summary Mechanical Seal Issues Hydraulic Issues Impeller Hydraulics Mechanical Improvement or Upgrade Options Process Pump Repair Dimensions What We Have Learned References Chapter 16 Using Failure Statistics and Root Cause Analysis Findings to Guide Reliability Improvement Efforts Mean-Time-Between Failures and Repair Cost Calculations Performing Your Own Projected MTBF Calculations Older Pumps vs. Newer Pumps Reliability Reviews Start Before Purchase Structured Failure Analysis Strategies Solve Problems The “FRETT” Approach to Eradicating Repeat Failures of Pumps Analyzing Pump Failure Data Why We Use Reliability Tools Cumulative Failure Trends Addressing Pump “Bad Actors” What We Have Learned References Chapter 17 Repair, Replace, or Modify? Repair or Replace? Repair and Spare Part Philosophies Making the Business Case for Centrifugal Pump Upgrades Payback Time Examples Example 17.1 Example 17.2 Some Final Advice on Upgrades Centrifugal Pump Hydraulic Rerates Rerate Case Study Replacing Existing Pump with an Entirely Different Model Pump What We Have Learned References Chapter 18 Centrifugal Pump Monitoring Strategies Pump Monitoring Recommendations Based on Criticality How to Use This Matrix Example 18.2: High Production Impact (Follow dashed arrows in Table 18.3) A Survey of Vibration Sensors Wireless Sensors Wired Sensors with Dynamic Outputs Wired Loop-Powered Vibration Transmitters with 4–20 mA Outputs Evaluating Sensor Information Vibration Monitoring Analysis Requirements More on Sensor Technology What We Have Learned References Chapter 19 Final Thoughts Index EULA