Pump Maintenance Procedures
Pump upkeep is both an art and a science. The pump industry is staffed by knowledgeable veterans who are well-versed in pump maintenance processes and their nuances. But as these veterans near retirement age, it will become increasingly difficult to find experts skilled in Oil and Gas Pump Maintenance Procedures, including correct pump installation, maintenance, and operation.
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Additionally, the issue of skilled and knowledgeable employees for pump maintenance disappearing poses serious risks due to reduced maintenance funds during economic downturns. Maintenance specialists who have received the appropriate training comprehend the intricate operation of pumps and can address new problems as they arise.
Their ability to solve issues quickly and effectively helps reduce maintenance time and enhance pump performance.
The goal of Antico Pumps is to disseminate useful knowledge regarding the installation, upkeep, and use of pumping equipment.
INSTALLATION OF PUMPS
The installation of the pumps is the stage that has the biggest impact on how well they work and how much maintenance they need over time. While a poorly installed pump may need frequent maintenance and other unneeded repairs, which results in significant time and money lost, a correctly installed pump will provide years of excellent performance with hassle-free operations.
A correctly installed pump increases dependability and lowers maintenance expenses. The baseplate needs to be carefully levelled and grouted during the initial installation process. By doing this, it will be possible to prevent air from being trapped and to lay a solid foundation for the installation of the pump. A correctly balanced baseplate will help reduce vibrations caused by the pump, which will ultimately make the bearings perform more smoothly because there won't be as much hammering. This will thus increase the lifespan of bearings.
The pump should be put on the baseplate with proper alignment once it has been levelled, and only then should piping be supplied to the pump. By following these instructions, the pump's pipe loads are reduced. Pump performance can be significantly impacted by piping loads.
Inspection of pumps
It must be noted that oil is used to lubricate the majority of pumps in use, and pump manufacturers do not export pumps with oil put in the bearing frames. Just before the start of pump operation, oil is introduced. After the first 200 hours of use or then every three months after that, oil needs to be changed. Genuine details on oil type, viscosity, and grade selection can be found in the pump's maintenance manual. If the right oil is used, the pump will run more smoothly and the bearings won't burn up as rapidly.
In the second instalment of this blog series on pump maintenance, we examine the crucial phase of "Inspection" in the protocols for maintaining pumps. The majority of maintenance departments spend a significant amount of time and energy refurbishing the pump in the event that it malfunctions owing to technical errors. This method is a crucial step in the overall pump maintenance process.
INSPECTION
The pump can occasionally stop working for a number of reasons. The entire pump unit is completely disassembled and each component is examined as part of the Inspection process. Pump Casing, Impeller, Stuffing Box Cover/Seal Chamber, Shaft, Sleeve, Frame, and Thrust Bearing Housing are the parts that go through the initial inspection.
STUFFING & CASING BOX
Casing and Stuffing Box should be checked for cracks, excessive wear, and pitting first because of their susceptibility to these issues. If there are cracks, localised wear or grooving that is deeper than 3.2mm (0.125 inches), or pitting that is deeper than 3.2mm (0.125 inches), they should be replaced or repaired right away. It's also necessary to look for any imperfections on the gasket surface.
IMPELLER
The impeller sustains wear and tear damages as a result of continuous hammering. If any of the following issues are discovered, the impeller has to be replaced.
1. Vanes with cracks and damage
2. A change in the impeller's face over 0.031 inches (open design only) (0.8mm)
3. Pitting or grooving more than 0.062 inches (1.6 mm)
4. Back pump-out vanned impeller
Additionally, the impeller has to be examined for grooving, pitting, and general wear.
ADAPTER FRAME
The frame adapter should be inspected for cracks or corrosion as part of routine inspection procedures. It is important to verify the machine bores, turned fittings, and gasket surface of in frame adapter parts. These parts ought to be spotless and clear of any dust or debris.
In particular if there is a packed pump system, the shaft sleeve should be checked for any cracks or wear along the outside diameter. Any wear that is more severe than 0.062 inches (0.002 mm) can be dangerous, and the sleeve needs to be replaced very away. To make sure the sleeve fits properly on the shaft, the inside diameter of the sleeve must also be examined.
Checking for straightness should be done on the shaft sleeve. In this situation, the shaft sleeve's continued usage should be determined by the run-out threshold limit. Additionally, any shaft with an inadequate bearing fit needs to be changed. Undersized bearings can result in loose bearings, higher loads, and increased vibrations, all of which increase the risk of premature seal, bearing, and coupling failure.
TENSION BEARING
The thrust bearing must also be checked for corrosion and physical flaws like cracks and pitting. Additionally, the bearing bore must adhere to the manufacturer's intended tolerance ranges. If there are any modifications or enlargements outside the tolerance range, the Housing should be replaced. Early bearing failure might result from a bearing housing that is improperly fitted.
REASSEMBLY OF PUMP
It's time to put the pump back together after the initial cleaning and examination of the pump parts. Care should be taken during reassembly to ensure that all of the parts are clean and no debris accumulates. Any extraneous substance, including dust particles, that enters the bearing block might cause catastrophic bearing failure.
Up until recently, the majority of bearing block seals were made of lip seals and deflectors. Lip seals are convenient to install and reasonably priced, and they also provide a number of advantages. However, the shaft rapidly wears down because these seals have a very short lifespan of only 2000 hours. Due to shaft and seal wear, the bearing block's seal is inadequate, enabling debris and dust to enter.
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Oil and Gas Pump Maintenance Procedures PDF
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