pump repair options & alternatives
TRANSCRIPT
Pump repair options &
alternatives
Presented by Bob Gaskeyof
1
My background
• Worked in a foundry and machine shop
• 27 years in aftermarket pump industry
• Worked for a Sturm Machine distributor-traveling drafting team
• Expertise with older vintage pumps
• Expertise with pump retrofits
2
My background
• Project manager on several wastewater cso deep tunnel pump repairs
• Worked in a foundry and machine shop
• Worked for a large full service pump distributor
• Currently the Pump Repair Manager with Pumping Solutions in Blue Island, IL.
3
Course Overview
• Emphasis on large water pumps typically found in fresh water, wastewater, power, steel & general manufacturing.
• Promote awareness of options to consider when faced with the decision to repair or replace pumps.
4
Goals of the course• Machining principles
• How centrifugal pumps are made
• Stabilizing your pump and motor train
• Take ownership & responsibility of your pumps
• Establishing warranty clarity
• Tracking and logging your pumps
• Application scenarios
5
Why keep older pumps running?
• Capital budgets
• Piping changes
• Foundation changes
• Pumps may not be able to be taken off line
• Build quality of older pumps-mass
6
7
8
Reasons for replacing pumps?
• Completely different technologies
• Efficiency/energy savings
• Manufacturer out of business
• Parts are obsolete
• Worn our beyond repair
• Duty point has changed
9
Pump repair considerations
10
Pump repair shop check list
11
• Crane capacity
• Press configuration/capacity
• Balancing capabilities
• Horizontal/vertical lathe capacity
• Cleaning methods
• Experience of personnel
• Engineering capabilities
• Experience repairing similar pumps
Balancer capacity
12
Balancer capacity
13
Balancer capacity
14
Balancer capacity
15
Press capacity
16
Horizontal lathe capacity
17
Vertical lathe capacity
18
Welding equipment & procedures
19
Repairs-on site inspections
• Inspect shop before repair is awarded
• Inspect pump after initial disassembly & cleaning
• Inspect pump when rotor is assemble and ready for final assembly
20
Repair documentation -establishing warranty clarity
• Repair documentation
• As found sizes
• As built sizes
• Shaft TIR
• Balance report
• Bearing housing sizes/concentricity
• Casting NDE report
• Metal certification
• Hardness report
• Alignment report
21
Repair documentation
• Accurate reports help narrow the trouble shooting process.
22
Shaft TIR
23
Balance report
24
Metal certification
25
26
Alignment report
Taking pump out of standard
• Impeller bores
• Wear ring sizes
• Pump case machining
• Design upgrades
27
Parts swapping in repairs
• Newer pumps lend themselves to a parts swapping philosophy.
• Older pumps that have been repaired and re-machined repeatedly do not lend themselves to a parts swapping philosophy.
28
All or nothing strategy
29
Evolution of pump metallurgy
• Bronze fitted pumps
• 1970’s pressure from aftermarket pump part companies.
30
Rotor stabilization
• Pump, motor (or turbine) gear box
31
Vibration analysis can expose:
• Multiple types of unbalance
• Eccentric rotor
• Bent shaft
• Multiple types of misalgnment
• Resonance
• Mechanical looseness
• Rotor rub
• Journal bearing issues32
• Rolling element bearing failure
• Hydraulic & aerodynamic forces
• Gear issues
• AC induction motor issues
• AC synchronous motor issues
• DC motor and control issues
33
Vibration analysis can expose:
• Belt drive issues
• Pulley issues
• Beat frequency vibration
• Soft foot, sprung foot & foot related resonance
34
Vibration analysis can expose:
Seal Advantages
• Seals-less drag on shaft sleeve thus saving energy
• When applied, installed with an appropriate piping plan-housekeeping
• Run dry capabilities
35
Packing Advantages
• Can help stabilize the rotor
36
Pump machining principles
• Centrifugal pumps are made up of individually machined components that mate together with register fits to form one common concentric centerline.
37
Pump part machining
• Faces must be flat, parallel & perpendicular
• Accurate sizes
• Most important-concentric common centerline
38
Application scenario #1
39
Application scenario #1
40
Application scenario #2
41
Application scenario #2
42
Application scenario #2
43
44
Application scenario #2
Application scenario #3
45
Application scenario #3
46
Application scenario #3
47
Application scenario #4
48
Application scenario #4
49
Application scenario #4
50
Application scenario #4
51
Application scenario #4
52
Application scenario #5
53
Application scenario #5
54
Application scenario #5
55
Application scenario #5
56
Application scenario #6
57
Application scenario #6
58
Application scenario #7
59
Application scenario #8
60
Application scenario #8
61
Application scenario #8
62
Application scenario #9
63
Application scenario #9
64
65
Application scenario #10
66
Application scenario #10
67
Application scenario #11
68
Application scenario #11
69
Application scenario #11
70
Application scenario #11
71
Application scenario #11
72
Application scenario #11
73
Application scenario #12
74
Application scenario #13
75
Application scenario #13
76
Application scenario #13
77
Application scenario #14
78
Application scenario #14
79
Application scenario #15
80
Application scenario #16
81
Application scenario #17
82
Application scenario #17
83
Application scenario #18
84
Application scenario #18
85
Application scenario #18
86
Application scenario #18
87
Application scenario #18
88
Application scenario #18
89
Application scenario #18
90