BASIC CENTRIFUGAL PUMPS

(BCP)

Facilitator Guide

TABLE OF CONTENTS

INTRODUCTION PAGE 1 PROCEDURE FOR CONDUCTING PROGRAMMES PAGE 2 EQUIPMENT NECESSARY PAGE 3 TRAINING OBJECTIVES PAGE 4 PROGRAMME NO.1 (BCP-1): PAGE 5 AN OVERVIEW OF CENTRIFUGAL PUMPS PROGRAMME NO.2 (BCP-2): PAGE 6 AN OVERVIEW OF SINGLE STAGE PUMP PROGRAMME NO.3 & NO. 4 (BCP-3 & 4): PAGE 7 AN OVERVIEW OF MULTI-STAGE PUMP MODEL ANSWERS TO: CRITERION TESTS EVALUATION I REPORTS BCP-1 : CENTRIFUGAL PUMPS PAGE 8 BCP-2 : SINGLE STAGE PUMP PAGE 11 BCP-3 & 4 : MULTI-STAGE PUMP PAGE 13

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INTRODUCTION The Basic Centrifugal Pumps (B.C.P.) series is aimed at providing first level instruction to such personnel as maintenance fitters, apprentices and, to a degree, for plant operators. The series comprises of three separate programmes which can be implemented virtually in any order, although it is suggested that all trainees be given the opportunity to begin at Programme No.1 (the Overview Programme). The pumps used and demonstrated in this series are predominantly SULZER originated or designed units but are typical of most popular brand names. The detail explained in a particular pump can be readily transposed for most other pumps of similar design, although it is mentioned to the trainees that specific procedures should be checked in the pump suppliers work manual, service bulletins etc. THIS SERIES COMPRISES OF THE FOLLOWING MATERIAL o Video programmes. o 1 Learner Workbook. o 1 Course Controller / Instructor's Guide. Other resources may be obtained direct from SULZER (Pump Division). TEXT BOOK: 'Pumps -Principles and Practice' from Publishers; K Myles and Associates cc . PO Box 2212, Northcliff 2115 Republic of South Africa ..

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PROCEDURE FOR CONDUCTING A PROGRAMME IMPORTANT NOTE This series has been designed purely as a TRAINING AID and in no way replaces an experienced Tutor or Instructor. SUGGESTED READING o Each learner is given a workbook. o Learner requests the loan of the relevant video. o Learner follow the instructions in the workbook, reading the relevant resource notes and viewing the relevant video. NOTE: Certain information may only appear in the resource notes (i.e. workbooks are not simply a reproduction of the video). For this reason it is very important that both trainee and instructor appreciate that the programme is based upon a "mixed media" input. The video alone do not impart all the information. o Upon completion of the tasks the Instructor must check each learner's work and sign

off the work done in the learner workbook. CRITERION TEST A learner may elect to perform the Criterion Test once all the tasks have been SUCCESSFULLY completed. SUGGESTED WORK ENVIRONMENT In order to achieve maximum benefit from each programme the training should be carried out in a properly equipped Training Centre.

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EQUIPMENT NECESSARY 1) Assortment of Centrifugal pumps, specifically end suction pumps, both 'single' and

case set 'multi-stage' units. 2) Flat and level workbench, preferably steel topped. 3) Rubber or plastic matting (for stacking parts). 4) Any 'special tools' as dictated by pump manufacturer. 5) Lifting equipment for heavier units (as necessary).

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TRAINING OBJECTIVES (OVERALL) Upon completion of this Basic series a trainee will be able to perform the following: o Describe the working principles of centrifugal pumps. o Identify popular pump types and designs. o Describe general pump maintenance procedures. o Dismantle and re-assemble a single-stage and a multi-stage pump. TRAINING AIDS REQUIRED o Tech AV BCP series video programmes. o Learner workbook BCP-1 to BCP-4. o Assorted centrifugal pumps. o Hand tools (normal fitters tools). OPTIONAL AIDS o (Obtainable via Sulzer Bros., Pump Division) o Wall charts. o Operators manuals.

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PROGRAMME NO. BCP-1 AN OVERVIEW OF CENTRIFUGAL PUMPS

OBJECTIVE At the end of this session trainees will be able to: o Describe the fundamental operating principles of typical centrifugal pumps. o Identify, by name, principal components. o Identify various pump types. o Explain typical shaft packings. o Describe the concept of 'head'. o Describe planned maintenance procedures. TRAINING AIDS REQUIRED o Learner workbook BCP-1. o Video Programme BCP-1. SUMMARY OF SUBJECT MATTER This programme provides new learners with an overview of centrifugal pumps, describing basic operating principles. It is aimed primarily at maintenance personnel and as such does not dwell too long on 'scientific data or engineering concepts'. It's main concentration is geared toward the 'should know' criteria for service personnel. Learner completes self-tests as provided in the workbook. CRITERION TEST A written test is provided in the workbook. Model answers are provided in this manual.

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PROGRAMME NO. BCP-2 AN OVERVIEW OF SINGLE STAGE PUMP OBJECTIVE At the end of this programme trainees will be able to dismantle, check and re-assemble an end-suction type, single-stage, centrifugal pump of popular manufacture. TRAINING AIDS REQUIRED o Learner workbook BCP-2. o Video programme BCP-2 . o 1 x Single stage and suction pump ( 80/200). SUMMARY OF SUBJECT MATTER This programme first overviews the principal parts / components of a volute type pump. The procedures for dismantling are then demonstrated. An inspection of parts is next overviewed and the pump is re-assembled. The primary instructional value of this programme is to demonstrate an acceptable procedure for dismantling and re-assembly. Resource notes in the workbook enhance and supplement the information provided by the video. CRITERION TEST o Part one -a short theoretical test. o Part Two -practical in training workshop. Model answers provided plus criterion check list for evaluation purposes.

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PROGRAMME NO. BCP-3 AN OVERVIEW OF MULTI-STAGE PUMP

OBJECTIVE At the end of this programme trainees will be able to dismantle, check and re-assemble an end suction, case set, multi-stage centrifugal pump. TRAINING AIDS REQUIRED o Learner workbook BCP-3. o Video programme BCP-3 Part One and BCP-3 Part Two. o A multi-stage pump. SUMMARY OF SUBJECT MATTER This programme begins by over viewing the basic operating principles of a multi-stage pump in the workbook (non-video sequence). Practical demonstration is provided for the dismantling procedure video BCP-3 Part One and an inspection of parts / components is overviewed. Procedure for assembly pump is demonstrated video BCP-3 Part Two. CRITERION TEST This is very much a practical test. Evaluation is conducted according to criteria on the learner mark sheet.

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MODEL ANSWERS CENTRIFUGAL PUMPS -OVERVIEW (BCP-1)

CRITERION TEST

INSTRUCTIONS The following questions should be answered without reference to any study aids. QUESTION 1 What is the primary purpose of a centrifugal pump? ANSWER: To provide the means of moving liquid/fluids from one place to another. QUESTION 2 What two functions are performed by the impeller? ANSWER: (1) It energises fluid. (2) It creates the suction or vortex to draw fluids in. QUESTION 3 Label the part names indicated on the pump illustrated below. ANSWER: A =Impeller E = Gland Cover B =Impeller Shaft F = Volute / Casing C =Bearing Bracket G = Packings D =Bearing H =Gland / Follower QUESTION 4 What is the purpose of a 'wear ring'? ANSWER: To provide a replaceable means of reducing impeller to casing clearances. QUESTIONS 5 What do packing rings do? ANSWER: Prevent the entrance of air into the pump. QUESTION 6 What is used, on some pumps, to prevent the packing rings from damaging the impeller shaft? ANSWER: A 'wear sleeve' . QUESTION 7 Why is it necessary to ensure that fluid or water is present at the gland? ANSWER: To lubricate and exclude air. QUESTION 8 What is the function of a Lantern ring? ANSWER: To provide a channel to distribute liquid to the shaft / seal area.

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QUESTION 9 What can sometimes be used instead of soft packings? ANSWER: A mechanical seal QUESTION 10 What classification (i.e. type) of pump has only one impeller and casing? ANSWER: Single stage: QUESTION 11 What type of pump has a 'double entry' impeller? ANSWER: Horizontal split type. QUESTION 12 What important factor must be considered when a pump is coupled to its drive unit? ANSWER: That the pump and drive unit are aligned perfectly. QUESTION 13 What is 'SUCTION LIFT' or 'STATIC SUCTION' ? ANSWER: The term given where a pump has to draw liquid from below the level of the pump. . QUESTION 14 What is the term given to the height, above pump level, that the liquid has to be raised? ANSWER: Static delivery head. QUESTION 15 What does the term 'FLOODED SUCTION' mean? ANSWER: That the supply liquid, to the pump, is above the level of the pump. QUESTION 16 What features in a pump system can increase friction losses? ANSWER: Pipe bends, valves, pipe walls. QUESTION 17 What is meant by the expression 'priming' a pump? ANSWER: Ensuring that the suction line and pump casing is full of liquid before a pump is started up. QUESTION 18 What function does a 'foot valve' perform? ANSWER: Prevent fluid from running back out of the pump via the suction line.

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QUESTION 19 When shutting down a pump, what should be done before switching the power off? ANSWER: Close the delivery valve. QUESTION 20 What must be done. to prevent accidental starting of a pump whilst you are working on it? ANSWER: The main switch must be locked out. QUESTION 21 Describe how to correctly start up a pump. ANSWER: Ensure delivery valve is closed, start pump, fully open valve slowly. QUESTION 22 What parts of a pump will become damaged or worn owing to abrasive materials in the pumped fluid? ANSWER: Impeller wear rings, wear sleeves, packings / seals.

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MODEL ANSWERS BASIC CENTRIFUGAL PUMPS· SINGLE STAGE (BCP·2)

CRITERION TEST You have now completed the training exercises. Now without reference to this workbook or the video attempt the criterion test that follows. INSTRUCTIONS PART 1 • THEORY Answer the following questions: QUESTION 1 What 'category' bearings must be fitted to a pump? ANSWER: C3 QUESTION 2 Which openings, passages etc. must be cleared or cleaned during an overhaul? ANSWER: Impeller balance holes, lantern ring, lantern I seal feed passage. QUESTION 3 Which components should normally be replaced during an overhaul? (List 4) ANSWER: 1) Wear Rings. 2) Wear Sleeves. 3) Packings. 4) Gaskets I Seals. PART 2 • PRACTICAL EXERCISE 1) Ask your Instructor I Course Controller for a single stage, end suction pump to work on. 2) Perform a full dismantling, inspecting and reassembling procedure on it. NOTE: You may refer to the manufacturers manual only (if available) during the practical exercise. 3) Ask your Instructor I Course Controller to check your work upon completion.

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CRITERION TEST - BCP-2 EVALUATION - CHECK SHEET / REPORT

ITEM CRITERIA YES NO

1) THEORY All questions answered correctly.

2) DISMANTLING

Workpiece and work area clean.

No damage to parts during operation.

3) CLEANING All faces / critical surfaces cleaned up.

All passages, drillings, balancers open.

4) ASSEMBLING

Oil and/or anti-seize used on fitted parts.

Impeller and sleeve fitted correctly.

Gland assembly correctly fitted.

Bracket to volute gasket installed.

Pump turns freely by hand.

WORK CHECKED: ______________________________________________________________ CAPACITY: ___________________________________________________________________ CRITERION OBTAINED

YES NO

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MODEL ANSWERS CRITERION TEST - MULTI-STAGE (BCP-3&4)

EVALUATION - CHECK SHEET / REPORT

LEARNER: ____________________________________________________________________ TEST DATE: ___________________________________________________________________ ITEM CRITERIA YES NO

PREPARATION Pump and work area clean.

Pump set up onto flat guide strips.

Pump safety clamped.

DISMANTLING Correct (size and fit) tools used.

Correct sequence of dismantling followed.

Jacking screws used where applicable.

Scale or corrosion sanded down (shaft area).

Parts properly stacked (on non concrete surface).

INSPECTION /

REPORT

Shaft checked for damage and run out.

Bearings checked for damage and shaft fit.

Wear sleeves checked for damage.

Neck bush checked for damage / clearance.

Counter disc checked for damage / bore clearance.

Balancing disc checked for damage / wear.

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ITEM CRITERIA YES NO

Casings checked for damage / blockages.

Impeller wear rings checked for wear / clearance.

Diffusers / overflow piece checked for damage, threads, sleeve fit.

Impeller checked for damage.

Stuffing box checked for erosion.

Bearings / Brackets checked for damage, cleaned out.

Tie bolts checked and cleaned.

SUB ASSEMBLING New gaskets and ‘o’ rings obtained.

Working area cleaned thoroughly.

Guide rails set up correctly.

SUCTION CASE Large wear ring correctly installed / anti-seize.

Neck bush correctly installed.

Case set up and clamped securely to rails.

STAGE CASES Large wear ring correctly installed / anti-seize.

Overflow pieces correctly installed and secured.

Small wear rings correctly installed.

Diffusers installed correctly.

DISCHARGE CASE Counter disc installed correctly / anti-seize.

Counter disc ‘o’ ring renewed.

Jacking screw holes plugged.

Diffuser installed.

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ITEM CRITERIA YES NO

ALIGNMENT Throttling bush installed.

Radial clearance checked around the throttling bush.

Minor adjustments effected by tightening the tie bolts.

Balancing disc installed correctly and keys.

Threaded sleeve installed and secured end float checked.

Concentricity of wear faces (wear rings) checked (balancer closed).

N.D.E. bracket fitted correctly - new gasket.

Finger installed.

Gland installed.

CHECKS

Pump rotates freely - by hand.

T-mark made on shaft.

WORK CHECKED: ______________________________________________________________ CAPACITY: ___________________________________________________________________ CRITERION OBTAINED

YES NO