Fall Seminar

Pump Station Maintenance

November 1, 2012
YCUA

Tim Sullivan, PE.

 Types of Pumps
Pump Selection
Pump Installation
Types of Pump Stations
10 Ways to Murder Your Pump
Operation and Maintenance
 General Pump Classification
Kinetic vs. Positive Displacement Pumps
PD Pumps will not be discussed today

Kinetic
Pumps

Vertical Centrifugal
Turbine

Overhung
Lineshaft Submersible Axial Flow Split Case Impeller
 General Pump Classification
Axial Split Case vs. Overhung Impeller
 Typical Overhung Impeller Pump Types

Frame Mounted

Close Coupled

Submersible
 Basic Overhung Impeller Types

Enclosed Semi-Open

Open
 Special Impeller/Pump Types

Vortex

Centrifugal
Screw
 Special Impeller/Pump Types

Self Priming
Trash

Chopper
Basic Considerations
Flow and head conditions (avg, min, max)
Current vs. projected future flows
Liquid being pumped (rags, grit, grease, chemical additives?)
Site constraints (space, power availability, aesthetics)
Other challenges (retrofit, forcemain network, terrain)
Important Details
Look closely at suction and discharge conditions
NPSHa > NPSHr
Potential for hydraulic transients
Pump speed (1200-1800 rpm)
Motor selection
Continuous vs. intermittent duty
Inverter duty (if VFDs are to be used)
Size motor for run-out condition
Packing vs. mechanical seals
Discuss/consider hardened materials?
Allowable Operating Region
Preferred Operating Region
Affinity Law Parabola

Best Efficiency Point

 max
friction head low wet well
min

typ
high wet well

static head
 System Curve
X X X

One Two Three

 two pumps
one pump

max

min

typ
 Common Types of Wastewater Pump Stations

Wet Well/Dry Well Pump Stations

Submersible Pump Stations
Suction Lift Pump Stations
Factory Built or Package Pump Stations
 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

Basic Considerations:
Flooding
Accessibility/Security
Grit
Safety
 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Wet Well/Dry Well

 Common Types of Wastewater Pump Stations

Submersible Pumps Consider:

National Electrical Code
Ease of pump removal
Seal failure detection
Separate valve pit
Basic Considerations
discussed previously
 Common Types of Wastewater Pump Stations

Submersible Pumps
 Common Types of Wastewater Pump Stations

Factory Built or Package Pump Stations

Suction Lift
FRP enclosure
Valves accessible
Control panel inside
 Common Types of Wastewater Pump Stations

Suction Lift Pumps

(vacuum primed)
Consider:
National Electrical Code
Suction lift capability
Dual vacuum pumps
Valves accessible
Basic Considerations
discussed previously
 Common Types of Wastewater Pump Stations

Suction Lift Pumps (vacuum primed)

 Common Types of Wastewater Pump Stations

Suction Lift Pumps (self-priming)

 Common Types of Wastewater Pump Stations

Factory Built or Package Pump Stations

Submersible
FRP enclosure
Valves accessible
Control panel inside
 Common Types of Wastewater Pump Stations

Factory Built or Package Pump Stations

Submersible
Dry pit Can
Factory Built - FRP or
steel construction
Package concrete
construction
Control panel inside
or in weatherproof
panel at grade
 Common Types of Wastewater Pump Stations

Factory Built or Package Pump Stations

 Factory Built Pump Stations

The Good
Easy to install (even your brother-in-law can do it)
Standardized design (competitive price point)

The Bad
Low price = poor quality components
System may be compact (tight quarters)

The Ugly
Can be difficult to maintain (confined space?)
Challenging to modify/upgrade in future
Can Pump Stations
Can Pump Stations
 Baseplate should be anchored and grouted to the foundation
Pump foundations should be robust (HI Std. 1.3.4)
There should be no piping strain on pump nozzles
Use good piping practices especially on suction
Provide vent valves on high spots of pump/piping
Provide suction and discharge
pressure gauges
Provide isolation
valves and (possibly)
flexible couplings
Mechanical
Displacement -
dial indicators Check pump/motor alignment (angular alignment)

Eyesight straight edge & feeler gauges

Laser Optic Check pump/motor alignment (parallel alignment)
Systems

Eyesight straight edge & feeler gauges

Seal Water System
 What do all pumping systems have in common?

All pumps require care and maintenance

Here are ten ways to Murder your pump:
#10 Overwork It #5 Stress It
#9 Starve It #4 Shake It To Pieces
#3 Poison It
#2 Drown It
#1 Neglect it
Frequent Starts
Can damage motor winding insulation
High mechanical stress during starting period

Ignoring Allowable Operating Region

Increases potential for damaging hydraulic forces, vibration and
flow separation/cavitation
Routine operation should be within Preferred Operating Region of
the curve
Less than 0.5% of a plants maintenance budget is
spent purchasing lubricants, but the downstream effects
of poor lubrication can impact as much as 30% of a
plants total maintenance costs each year.

ExxonMobil Case Study

Lubrication
Reduces friction between two surfaces
Mitigates wear (loss of metal)
Decreases heat generation at moving elements
Lubricant does not last forever
Moisture, dirt and heat degrade lubricants with time
Adhere to manufacturers lubrication schedules
Keep good records
Net Positive Suction Head
Make sure NPSH(R) is less than NPSH(A)
Typical conditions that increase NPSH(A):
Lowering the shut off level in the wet well
Clogged suction line or partially closed valve
Audible cavitation is a strong indicator of a serious problem
Collapse of vapor cavities causes erosion of the impeller and
other internal components
Operating at Shutoff Head
If pump is operating near shutoff, a problem exists
Partially closed valve
Clogged discharge line
Surcharged conditions upstream
Pump will overheat since water is circulating within volute
Condition must be corrected immediately to prevent damage to
the pump and motor
Unusual Grit Quantities or Sizes
If excessive grit is normal pumps should be constructed of
hardened (Ni-Hard) materials or glass lined
If unusual grit is detected in the wet well look upstream for
collapsed pipes or erosion around manholes
Periodic manhole/wet well cleaning can detect problems and
protect the pumping system
Piping Misalignment
External stress at inlet and discharge nozzles can cause
distortion of bearing frames and pump casings
This condition may occur during installation or through thermal
expansion or differential settlement
Make sure that heavy valves and piping are supported
independent from the pump suction and discharge nozzles
If thermal expansion and/or differential settlement is anticipated
or detected, provide rubber expansion joints in piping
Vibration
There are numerous potential sources of vibration
Pumps operating outside of the AOR
Machine imbalance or shaft misalignment
Resonance with natural frequency of system
Vibration may be unavoidable but can be mitigated
Start with proper selection (operate near BEP)
Set up with good balancing and alignment
Provide proper pump and piping support
Securely anchor pump base plate to strong foundation
Corrosive Fluids
Not typically encountered in municipal wastewater
Intermittent industrial discharge or spills may occur
Metal salts (ferric chloride) can be extremely damaging to pump
metal components
Coordinate with IPP personnel to report detection of low pH
The presence of corrosive fluids will also cause damage to sewer
and forcemain piping so must be corrected immediately
Seal Leakage Management
Seal water from the packing gland or mechanical seal should be
carried away from the pump, especially the rotating elements
Make sure that gland is adjusted to minimize leakage (about a
drop of water every second is adequate for cooling)
The stuffing box drain pipe should be directed to a floor drain or
hub and maintained in flowing condition
Properly install packing to maintain backpressure on the pump
casing/shaft interface
Promptly replace failed mechanical seals
Manufacturer Recommended Service
Closely follow the preventive maintenance practices outlined in the
pump O&M manual including operational check-ups
Take careful note of any abnormal sound or vibration and take
action to promptly correct any problems
Check motors and rotating elements of pumps for higher than
normal temperature, using a thermometer at least quarterly
Visually inspect pumps and motors for coating failure and
oxidation and reapply protective coatings/paint as necessary
 Pay close attention to 4 areas:
Selection (as discussed previously)
Installation (as discussed previously)
Operation
Repair & Maintenance
 Monitor pump flow rate
Dont throttle the suction
Dont run it dry
Dont run at excessively low flow/high flow
VFD Keep within POR
Alternate pumps
Do not cycle pumps
Observe flushing/cooling water
Visit your pumps routinely (daily or weekly)
Look/Listen/Feel/Smell
 Perform manufacturer recommended PMs
Take care when dismantling
Examine all metal to metal fits and recondition with care
Always use new gaskets, O-rings & lip seals
Check the clearances & run out of all shafts, sleeves and
wear rings/plates
Keep equipment clean, dry and painted
Inspect stuffing box and pump casing for corrosion
Inspect impeller and internal wear components for
corrosion, erosion and cavitation
Keep good records of inspections and repairs
Check all electrical connections & components
Keep Records of the
critical data about
your equipment:
 Have Supplier Annotate O&M Manuals
Review for completeness (must include all
components)
Have them identify the PM for all components
Request O&M Manual in the P.O.
 Utilize O&M Manuals During Training
Have them point out the page
Have them revise as required
Request Additional Training 8 hours at a later date
Request Training in the P.O.
 Safety First
Lock Out Tag Out
Short Circuit Coordination Study (SC/CS)
Arc Flash
 Infrared Camera
Tighten Lugs
Clean Contacts
Adjust Electro-mechanical Components
 Located at Pump/Equipment
Corrosion
GAC Air Conditioning
Questions/Comments?

Thanks,
Tim Sullivan, P.E.