Practical work # 1

Subject: Inspection, overhaul, and repair of centrifugal pumps

Purpose: Study major failures and ways to fix them during

overhauling and repair of ship centrifugal pumps.
Task: To study the design and rules of maintenance and repair of
the centrifugal pumps (CP) and possible breakdown or damage to
the parts of the CP.
All pumps are not equal! There are a wide range of pump types
because some designs are better; more efficient or more consistent or last
longer; at handling specific operating conditions or specific liquid
properties. Each application should be assessed individually, on merit,
when considering: liquid properties, allowable leakage, driver type,
installation arrangement, operating efficiency required, duty cycle,
allowable noise level, operational safety, site facilities.
1. Theoretical information: Types of centrifugal pumps used at sea:
- centrifugal pump vertical (CPV) non-self-suction (purpose:
maintenance of fire, cooling, drainage or ballast systems);
- centrifugal pump vertical (CPVS) self-suction; (purpose: sea & fresh
water-cooling systems, brine or condensate systems);
- centrifugal pump vertical (CPVS) self-suction, two-stage (fire
extinguishing & foam system maintenance);
Pump classification:

1.1. General instructions for pump maintenance before pump start-up

for ballast or other pumping make sure that the appropriate suction and
discharge are prepared for these actions, then open the corresponding
valves on the distribution box, suction & discharge, check the bypass
valve on the pump discharge. For a smooth start of the pump, if pump
equipped with bypass valve, it is need to open bypass valve (partial) to
the suction side of the pump, and as soon discharge pressure stabilized,
the bypass valve should be closed. During pump operating it is
necessary:
- to monitor the operation of both the pump and drive motor and
according to the readings of the pump gauges to maintain (change)
operation;
- adjustment the pump capacity & discharge pressure, if it is provided
constructively, change in the frequency of rotation. Centrifugal pumps
capacity or pressure regulating by throttle suction or discharge valves.
For proper pump operation and designed performance of the pump, it is
necessary to carry out preventive maintenance and repairs of the pump
components in accordance with Maker pump recommendations,
inspection or repair isolating valves, clean filters or strainers or wells in
accordance with PMS or as required.
The pump should be stopped immediately:
- if the drive motor malfunction (vibrations, noises or knocks);
- if the pump pressure on the discharge pipe suddenly drop or increase;
-if any pump part is overheated.
The pumps of the service systems, which are operated periodically,
should be inspected every 3... 5 days, external visual check, turn pump
drive or control start. This operation should include to Preventive
Maintenance System (PMS) of specific ship. During ship drydocking or
repair period or lay up in the autumn-winter period, in order to avoid
damage pump, measures should be implemented to drain water from the
pump casing and pipeline systems: the casing plugs of the pumps should
be unscrewed, divide pipeline flanges in the lowest places of the systems
, pipelines blown by compressed air.
1.2 Pump failures and corrective actions: the technical malfunctions
that occur during their operation (table.1.1).
Table 1.1 - Malfunctions and corrective actions to restore centrifugal
pumps
Malfunction Reason & Corrective action
No pumping, low or zero Suction and/or discharge
discharge pressure & pump valves are closed or partly
capacity open. OPEN valves
Suction filter or strainer, sea Clean suction filter or
chest filters, etc. are dirty or strainer of the pump
chocked
System pipeline flanges, Eliminate air suction to
pump or valve packings are pump
slack, air sucked in pump
Pump is not filled with liquid Fill up pump with liquid
Wrongly pump rotation Correct the pump rotation
Low / not enough pump Increase speed of the pump
rotation speed rotation
Boiling liquid at the pump Decrease temperature of the
suction pumping liquid or increase
pressure on the pump
suction.
Suction height is too HIGH Reduce pump suction height
Pump impeller is dirty Clean pump impeller
Leakages on the pump Eliminate leakages
suction side
Pump wearing and/or casing Renew wearing and/or casing
rings are worn out, rings, restore clearances
clearances are above the
limits
Pump impeller and/or casing Renew pump impeller and/or
are worn out casing
Continuation of the table.
1.1
Pump is not assembling Assembly pump in acc.with
correct / properly (f.e. upside Maker Manual / correct
impeller)
Increased hydraulic Restore defects on the
resistance on the discharge pressure / discharge line,
pumping line, appear clean heat exchanger,
cavitation mode. Safety increase suction pressure or
(bypass) valve is partly reduce speed (rpm) of the
open / leak pump. Clean, repair and
adjust safety (bypass) valve
in order to eliminate passing
through.
Pump vibration
Misalignment the pump Restore / adjust alignment
connection (coupling) of the (centering) of the
drive motor with pump connections (coupling) of the
drive motor with pump
Unbalancing moving parts of Balance moving parts (shaft,
the pump due to worn out or impeller, seal, coupling,
partly clogging (dirty) liquid etc.), clean pump.
flue part
Loose foundation bolts of the Re-tight foundation bolts as
pump. per Maker Manual
The pump bearings are worn Renew bearings of the pump
out (noise or abnormal
sound)
The pump drive motor load is above limit (motor overloaded)
The pump impeller is not Assemly correct and adjust
assembled or adjusted in clearances, then start pump.
casing correct (touch casing)
Start pump with OPEN Start pump at nominal speed
discharge valve or flap (non- (rpm) with closed discharge
return) valve is not installed / valve or restore operation of
equipped or stuck. the flap (non-return) valve
The pump gland packing is The pump gland packing
overtough. tightening to be adjusted as
per Maker Instruction
Axial pressure is too HIGH Adjust / ensure normal
operation of the unloading
device
The pump flowing liquid Clean pump flowing parts.
parts is DIRTHY/ chocked
Viscosity of pumping liquid Raise the temperature of the
is above the passport limit. pumping liquid.
Mechanical damages of Recondition or renew parts
impeller, shaft running
surface, mechanical seals
(scratches, dents)
Pump components temperature is above limit
Overtightening or unequal Correct tightening as per
tightening of the pump shaft Maker Instruction
gland packing
Continuation of the table.
1.1
Gland packing material is in Renew packing material
bad condition (hardened due
to age)
Gland packing material is not Restore / renew appropriate
original / wrongly quality or gland packing
purpose
Cooling water to jacket (if Provide / OPEN / clean water
available) is not provided pipelines to cooling jacket
Closed or not enough opened Completely open discharge
the pump discharge valve valve
The temperature of pumped Decrease / reduce the
liquid is too HIGH temperature of pumped
liquid.
Mechanical defects of the Renew bearing
bearing (broken separator,
balls are worn out, scratches,
etc)
The bearing is wrongly / not Assembly / install bearing
correct installed correctly
Loose bearing on the shaft or Fix / eliminate turning
in the housing. (loose) of the bearing as per
Maker Instruction
Dearty or aged (hardened) Remove grease / clean
grease of the bearing bearing, refresh with
appropriate grease.
Misalignment coupling of Alignment / centering shaft
drive motor with pump coupling.
Mechanical defects of the Recondition / repair
running surface shells or mechanical defects,
shaft sleeves (scratches, machining or build up
dents, metal detachment, running surfaces.
etc.)
Increased or reduced Restore designed (as per
clearances / gaps in bearings, Maker Manual) clearances,
misalignment (not centered) carry out centering the pump
of the pump and drive motor and drive motor coupling.
coupling
Contamination or flooding Find reason and refresh or
with water of the bearings oil clean (purify) lubricating oil
Low or High oil levels in the Correct and maintain lube oil
bearing casing level limit
Broken lubricating ring at Repair or renew lubricating
bearing with ring lubrication ring
Lubricating oil of the bearing Check Lubricating pump,
with circulating lubricants integrity of lube oil system
Pressure is reduced. (no leak), lube oil quality,
cleaning filters, inspect lube
oil pipes.
Hydraulic shocks at the pump during operation
Suction of a significant Find and eliminate defects /
amount of air to the pump retight connections, renew
suction side due to pipeline is gaskets
not integrity
The appearance of vapor Reduce / decrease the
formation. temperature of the pumped
liquid.

Mechanical seals. Operating principles

The sealing of a rotating shaft passing through a pump casing is achieved
by means of a rotating, optically flat seat, rubbing against a stationary,
optically flat, seat with a fluid film in between them, see Figure 8.16.

Figure 8.16 A simple unbalanced seal arrangement for a pump

Sealing between the rotating seat and shaft or sleeve, and the stationary
seat and gland, is usually performed by means of an elastomer such as an
"O" ring, "V" ring, etc. The primary purpose of the spring is to provide
an initial pressure between the sealing seats. One of the great advantages
of this type of sealing is that it does not cause wear to the shaft or the
sleeve. The theory as to what happens between the seat faces is
explained schematically in Figure 8.17.
Figure 8.17 Fluid distribution across seat faces and operating
pressures
The seal should be considered as drip-free but not leak-free. The very
low leakage rate, known as diffusion, will escape in the form of vapour
on the atmospheric side of the seal. The very low leakage rate, known as
diffusion, will escape in the form of vapour on the atmospheric side of
the seal.
A general and very important rule is that a mechanical seal should never
be run dry, there must always be a fluid film between the faces. Dry
running can occur even when the pump is full of liquid if the temperature
is so high that the liquid vaporizes in the stuffing box. Only specially
designed seals can be run on the vapour phase of a liquid. Dry running
seals are available for specific applications. The seal operating
conditions must be fully described and include details of the vapour
properties and the length of time the seal will operate without liquid
lubrication or cooling. At high pressures and high speeds the sliding
surfaces must be relieved so that the fluid film is kept stable. The
frictional heat must be limited at temperatures approaching the vapour
temperature. In such cases, the face pressure is reduced hydraulically.
This is done by balancing the ratio between the sealing diameter "S" and
the inner diameter of the stationary seat. The pressure between the seal
faces is thus varied according to the liquid pressure. Dependent upon the
relationship between the two surfaces "A" and "B" in Figure 8.18, the
seal is termed, balanced or unbalanced.

The limit between balanced and unbalanced seals is determined by the

pv factor and the operating temperature. Balanced standard seals can be
used for pressures up to about 16 bar at speeds of 20 m/s. In the case of
higher pv values, hydrodynamic seals having a controlled leakage must
be used.
Surface flatness. The flatness of the seat faces must be of a very high
accuracy. The leakage is approximately proportional to the third power
of the thickness of the fluid film which normally is in the order of 0.001
mm. Flatness is normally expressed in light bands, since checking
normally takes place using an optical flat and monochromatic light,
usually sodium light. A deviation of one light band corresponds to an out
of flatness of 0.25 pm. Normal standards of flatness are better than 1 to 2
light bands with variations up to approximately 5 light bands in the case
of shaft diameters over 100 mm or in the case of special face materials.
In addition to the number of light bands the light pattern must also be
considered, see Figure 8.19. Large differences in seal tightness occur, for
example, between a spherical surface, light pattern 3, and a wavy
surface, light pattern 5. A check of seat faces is recommended as a
standard measure prior to the installation of a mechanical seal. Because
of the accuracy of mechanical seal components, any work done on seals
must be carried out in clean conditions. All components must be
thoroughly cleaned prior to assembly.
Design principles. The generation of the initial sealing pressure, i.e. the
initial face load is provided by using different types of springs. Single
springs, multiple springs, Bellville washers and wave springs are the
most common, see Figure 8.20. The drive, i.e. transmission of the torque
to the rotating seat, can when single springs are being used, be carried
out by the spring itself, separate driving elements used with other spring
types. At least two driving points are necessary in order to guarantee a
satisfactory loading of the seal faces. The top illustration in Figure 8.20
shows a seal utilising two Bellville washers to provide the axial load.
The rotating seat is positively driven by the shroud extending from the
drive collar. The next picture shows the same type of seal but the axial
load. Single springs should generally be chosen in preference to multiple
spring types. The reasons for this are that driving and face loading can be
combined in one element, that the single spring is robust and withstands
corrosion, as well as the fact that the risk for blocking is less than in the
case of small springs. In addition, the single spring is easier to handle.
The single helical spring has one major disadvantage; the spring handing
must be changed if the direction of rotation is changed. For example, a
double suction between bearings on a pump, with two stuffing boxes,
would have a different seal at each end, i.e. different springs. To
overcome this problem, many standard mechanical seals are fitted with
Bellville washers. The springs are usually inside the stuffing box in the
process liquid. Special mechanical seals can have the springs outside the
liquid on the atmospheric side.
The shape of the rotating seat varies with the method of driving,
engagement and the loading, as well as the materials of which the seal
faces are made. In order to take up any vibration in the shaft, parallel
deviations in the "O" ring grooves as well as any effects of the driving
arrangement, the stationary seat should be mounted as flexible as
possible. Figure 8.21 shows various methods of attachment. "a" is DIN
standard construction and provides the greatest flexibility.
Figure 8.20 Examples of face loading and drive

Figure 8.21 Examples of how a stationary seat can be fitted and

sealed
Temperature considerations. To achieve acceptable temperature
conditions at the seal faces, frictional heat must be dissipated to avoid
dry running due to loss of liquid between the faces. Heat dissipation
takes place by means of heat transfer through the seats and by
convection to the surrounding medium. See Figure 8.23.

Figure 8.23 Heat dissipation in a mechanical seal

Each seal and combination of materials has what is called a minimum
AT in order to be able to function, see Figure 8.24. AT is the difference
in temperature between the boiling point of the liquid at the seal cavity
pressure and the actual temperature of the liquid. Usually AT should be
at least 20 ~ The seal manufacturer can provide information for each
type of duty and seal arrangement. By means of various installation
options, internal and external circulation or cooling, the available AT can
be increased., see the definitions at the beginning of Section 8.3.1.2. The
required AT of a seal can also be reduced by using materials with good
thermal conductivity or with low friction, etc. In such special cases the
AT required can be reduced to approximately 5 ~ In Figure 8.24, the
operation range of the seal is to the left of each respective speed
boundary. The liquid is water. The distance between the vapour curve
and the seal's limit is the required AT for each speed.ness
The flatness of the seat faces must be of a very high accuracy.
1.3 Damages of the pump shaft seals
Leakage pump due to damage of the shaft mechanical seal is the most
common reason out of operation order of the pump. The condition of the
shaft seal depends on factors of operating conditions, pumping media
(temperature, density, viscosity, etc.). Damage sealing the shaft is the
most common cause failure of the pump. The damage to the shaft seal
depends on the structure (type) of the seal and a pair of surface materials.
The ring seals of the shaft with a dynamic sealing ring and one surface of
the seal from the coal graphite characteristic damages are the wear and
stick of seal surfaces and the seating seals that prevent the axial
movement of the dynamic sealing ring and seal static (cover) ring. For
the end seals with surfaces of solid materials with characteristic damage
are damage caused by working without lubricant. To analyse the causes
of damage to the shaft seal and further warning of new damage is
required information about the work of the seal. On the damaged seal of
the shaft you can see what exactly was damaged, but the cause of the
damage is based on information about the pump and operation
conditions.
1.3.1 Damage due to lack of lubricant
The running of shaft seals with surfaces of solid materials depends on
the lubricant of the pumping liquid. Operating pump without lubricant
and lack of lubricant can lead to damage described below. Work without
lubricant occurs when there is no liquid in the seal area, either in the
pump as a whole, or because of insufficient ventilation, leading to a
build-up of air around the seal. Lack of a lubricating film leads to
increased friction of seal surfaces and, accordingly, quick raise
temperature. Lack of liquid, heat is exchanged through the seal - with the
temperature of many solid seal surfaces reaching few hundred degr.C
very quick. Therefore, the typical damage caused by working without
lubricant is the burning of parts, from ERDM (ethylene propylene) and
FCM (fluorocarbon) material. The damage occurs when the sealing ring
comes into contact with the hot seal surface (Figure 1.1).
Figure 1.1 - Surface damage caused by exposure to high temperature on
secondary seals from ERDM (ethylene propylene) and FCM
(fluorocarbon).
Pump shaft seal run without lubricant, the heat released during friction
can cause damage. Lack of lubricant occurs if the pumped liquid has a
very low viscosity or if the temperature of the liquid is much higher than
its boiling point at atmospheric pressure. Under such conditions, the heat
released during friction can create a very high temperature. Quick
change local heating and cooling of seal surfaces can lead to small radial
thermal cracks on seal surfaces (Figure 1.2).

Figure 1.2 - Thermal destruction of the seal surface from WC, due to
insufficient lubrication
Noise. If there is lack of lubricant or no lubricant, the sealing of the shaft
with solid surfaces can create a loud noise when pump running.
Depending on the seal design, the solid materials used and the pump
mode, the noise can be constant or periodic. When the shaft seal makes
noise, some parts of it vibrate. This can reduce the seal life / running
period due to fatigue caused by vibrations.
1.3.2 Damage due to pollution Pumped environment is often a mixture
of liquids and solids, as well as small suspended insoluble particles. The
lubricant in the seal gap is subject to large changes in temperature,
pressure and velocity. This increases the risk of accumulation sediment
in or near the seal gap / contact surface. The wedge / jam of the shaft
seal means that the axial movement of the rotating part of the shaft seal
is blocked. Mostly, the wedge occurs in ring seals, but is also observed
in the bellow seals, although the basis is a different mechanism. In the
ring seal sediment can accumulate on the shaft next to the sealing ring,
preventing its free sliding. When the temperature or pressure changes in
the system, the size of the pump parts changes, so for continuous
operation the seal must slide freely on the shaft or clutch (Figure 1.3).

Figure 1.3 - Scheme to block the axial motion of the rotating seal
surface
If the rubber bellow seal is operated at temperatures close to the
allowable maximum for the seal, the inner surfaces of the compensator
begin to stick to the shaft, which leads to a wedge. This also applies to
elastomers seals, such as FCM, have properties to stick to stainless steel.
The wedge cannot always be detected during the damage inspection, as
the seal has often already been disassembled.
Expanding the seal gap. Some suspensions and solutions can cause
growths from sediments on seal surfaces. Since these sediments cover
only part of the seal surfaces, the seal gap is opened, leading to a leak
through the seal of the shaft, started the small leak, but the more liquid
gets into the seal gap, the more intense the leakage becomes. At the same
time, the formation of precipitation will accelerate, as the temperature on
the surface of already fixed sediments will increase (see Figure 1.4).
Figure 1.4 - Sediments on the surface of the seal, material coal graphite
Clogged. If the pumped liquid contains a large number of suspended
particles and fibers, the seal may be damaged due to deposits or
accumulations of particles and fibers on springs, compensators, seal
frames or seal rings. The rate of subsidence is affected by the type of
fluid being pumped and the flow parameters around the seal.
Particles and sediments. Small amounts of particles on seal surfaces
cause increased wear and tear, especially when a pair of materials are
used to combine hard/soft surfaces. In such cases, small particles can
penetrate into a softer seal surface and then work on a hard surface as a
grinding tool.
Getting an outsider particle into the gap between seal surfaces causes an
increase in the degree of leakage until the particle is ground and washed
away. For example: - human hair has a thickness of 50... 100 microns,
while the seal gap operating under normal operating conditions is only
0.3 microns thick. Thus, human hair 60 microns thick is 200 times
thicker than a normal seal gap. The degree of leakage is proportional to
the thickness of the seal gap erected in the third degree. That is, if human
hair gets stuck between the seal surfaces, the degree of leakage will be in
2003 to 8,000,000 times the degree of leakage through the seal of the
shaft with clean seal surfaces (without hair).
The seizing occurs when two seal surfaces are stuck or partially stuck to
each other. The grip damage causes the seal to damage if the seizing is
higher than the engine turning torque. It can also cause mechanical
damage to seal parts. The seizing can be caused by some of reasons. The
tendency to seize have seals with a combination of two solid materials in
the surfaces. The main causes of seizing are sediments on the surfaces of
the seal from the pumped liquid or corrosion of seal surfaces. The
seizing is possible only in the seals of the pump shaft with the start/stop
mode. The period during which seal rings are glued can be from a few
hours, depending on the fluid being pumped. At high temperatures, the
process is accelerated.
1.3.3 Damage due to chemical and physical impact. All parts of the
shaft seal material to be sufficiently resistant to the chemical and
physical factors of the affecting environment to work throughout the
service life as designed. Increased temperatures and excessive chemical
or mechanical loads shorten the life of the seal. The proper sealing is
provided in certain ranges of temperature and loads; if the limits are
exceeded, there is damage and quick destruction. In this case, parts of
elastomers can have many different damages, such as gas sinks, cracks,
cavities or discoloration. In some cases, destruction can only be
determined by measuring physical properties. Unacceptable chemical
and/or temperature exposure lead to the complete destruction of the seal.
Swelling is an increase in volume and a decrease in stiffness due to the
absorption of solvent. The increase in volume depends on the type of
sealing ring material, type and concentration of the solvent, as well as
the temperature and duration of exposure. In some cases, the swollen
rubber part can double in volume. The work of many types of shaft seals
largely depends on the geometry of rubber parts. Therefore, even minor
changes in size can be critical. The decrease in hardness is due to
changes in the mechanical properties of rubber. The most common
material of THE EROM demonstrates a high degree of swelling when
exposed to mineral oil, and the swelling occurs regardless of the
concentration of oil in the water. However, the lower the concentration,
the longer the seal will work.
Other types of sealing ring material also swell under the influence of
some fluids. As stated above, swelling is only one sign of
incompatibility with the pumped liquid. Also, the effect of pumped
liquid on the sealing ring can be determinate as changes in physical
properties such as strength on rupture, relative lengthening and hardness.
Increased temperatures and duration of exposure create more aggressive
conditions. The physical properties of the end seal may change as a
result of aging. Typically, aging affects characteristics such as strength
on rupture and hardness. Divides two main categories of aging:
- aging in storage;
- atmospheric aging.
Aging in storage is essentially a decomposition of the material as a
result of oxidation. Sources of oxidation, in addition to the most obvious
- oxygen, are heat, light, internal and external mechanical load or
voltage, and actively oxidizing metals.
In contrast to aging in storage, atmospheric aging occurs as a result of
ozone exposure. At the same time, the mechanism of influence is
significantly different. If the rubber is exposed to any load, then the
result is atmospheric cracking, in which cracks appear on the rubber,
located perpendicular to the direction of elongation. This is clearly seen
on the surface of old bicycle or car tires - deep concentric cracks are
formed in places where the tire is most deformed during operation.
Explosive decompression is appeared on the surface of polymeric parts
in the form of bloating, surface pit or potholes. When the pumped liquid
has high gas phase partial pressure, the gas can penetrate the rubber. If
the pressure drops and the rubber-absorbed gas cannot release at the
same rate at which the pressure is lowered, the internal pressure becomes
excessive. If this pressure exceeds the strength of the material, there is an
explosion caused by decompression. Therefore, elastomers with high gas
solubility and low mechanical strength are affected to explosive
decompression.
Corrosion. As a rule, the surfaces of the end seal are made of composite
materials. To prevent selective corrosion, all components of the material
must be resistant to the pumped liquid. For example, corrosion of
cemented tungsten carbide is due to the effect on the metal binder. As a
result of this impact, mechanical properties, including wear resistance,
deteriorate. When the metal binder disappears, the surface will become
matte. In addition, selective corrosion of the binder can cause tensions
that lead to cracks in the seal rings (Figure 1.5).

Figure 1.5 - Selective corrosion of cemented tungsten carbide. The phase

of the metal binder is corrosion, which has reduced resistance to wear
On the surfaces of seals from other materials in places where the phase
of the binder was treated to corrosion, there may be severe erosion. For
example, in stainless steel pumps, tungsten with a cobalt binder corrodes
in running water. Corrosion sometime occurs on the metal seal parts in
stainless steel pumps, as the metal seal parts are usually made of a higher
stainless-steel grade than other metal parts of the pump.
Wear. Since the thickness of the lubricant is comparable to the
roughness of the surface, the seal surfaces will always wear out a little.
Normal wear is so small that the seal can work for many years (Figure
1.6). In some cases, wear can cause problems, but often seals function
perfectly when worn up to 0.5... 1.0 mm if the axial flexibility of the seal
ring still exists. Deep scratches on the surface of the seal from the
pumping liquid indicate that the particles from the pumped liquid has
penetrate into the seal gap. Deep scratches from the atmosphere indicate
that solid deposits have formed in the places where the lubricants
evaporate.

Figure 1.6 - Normal wear on the surface of the seal from tungsten
carbide
1.3.4 Damage due to incorrect installation Sometimes damage to end
seals occurs due to improper installation and operation. Examples are:
not centered shaft, the installation of the cover ring is not perpendicular
to the shaft, incorrect mounting length, etc. Position and width of traces
of wear on the cover seal ring showing the failure of centering the shaft
and seal.
If the width of the worn-out area same on the slip surface of the opposite
seal ring, the shaft seal is well centered and has no deviations (Figure
1.7).
If the sliding footprint on the cover ring is wider than the rotating surface
of the slip, this indicates a strong deviation from the shaft axis (Figure
1.8). Another possible cause is the unbalance of the rotating parts. The
different depth of the seal wear marks indicates that the seal is assembled
tilted to shaft (Figure 1.9)
Figure 1.7 – Correctly Figure 1.8 – Shaft seal
centered shaft seal with radial deviation
If the "seat" of the seal is tilted, there is excessive wear and tear of the
rotating surface. The wear and tear of the rotating surface is
accompanied by axial scratches on the inside surface (Figure 1.10) if the
cause is the movement of the shaft or clutch relative to the seal. It can be
axial movement of the shaft due to vibration or not alighned of the
stationary "seat" ("seat” or cover ring is not perpendicular to the shaft).

Figure 1.9 – Not the same Figure 1.10 - Wear of the

depth of wear marks on rotating surface at the
the "seat of cover ring" point of contact with the
due to the wrong shaft
installation
Axial movement caused by the vibration or tilt of the "seat of cover ring"
can cause the shaft or clutch to wear under the rotating seal surface.
Friction seals on the shaft damage the shaft protective layer, leading to
corrosion (Figure 1.11).
Figure 1.11 - Corrosion of the shaft under the rotating part of the
seal as a result of the axial movement of the shaft
Assembling. When the end seal is mounted on a rotating shaft, the axial
motion of the shaft should not exceed the flexibility of the shaft seal. The
axial motion of the shaft, exceeding the allowable flexibility of the
rotating part of the end seal, can cause an increase in seal wear or
irreversible damage to individual parts of the shaft seal.
Installation. Many of the shaft seals have a standard mounting length.
This allows you to replace one type of seal with another with improved
performance for these conditions. But even if the two seals have the
same mounting length, the sliding surfaces can be placed at different
levels. Using the components of two different seals, the compression of
the seal may be insufficient or excessive as a result.
Damage due to changes in working conditions. During pump
operating conditions may differ slightly from those for which the pump
was designed. Changing operating conditions can affect the performance
of the seal. These are: - pressure in the seal chamber; temperature in the
seal chamber; pumped liquid; rotation speed; size of the shaft seal. If
these parameters do not meet the operating conditions, this may result in
the shaft seal being damaged. The pressure on the side of the pumped
liquid should be within the corresponding seal design, seal materials and
pumped liquid. When the pressure of the liquid on the shaft seal exceeds
the maximum for the seal, it can lead to increased friction of the seal
surfaces and damaging of secondary seals.

1.12 – Damaged sealing rings by HIGH pressure

1.4 Centrifugal pump maintenance.
1.4.1. The dismantling and assembly of support mechanisms and
equipment should be carried out in time in accordance with Preventive
Maintenance Plan and in a technological sequence provided by the
Manual instructions, technical conditions for repair or guidance on the
repair of this mechanism.
1.4.2. When inspecting the parts of the pumps, it is necessary: - to
identify possible defects of shaft necks in the area of seals and sliding
bearings (scratches, bullies, etc.), as well as to check the condition of the
shafts of pumps, ball bearings, their landing in the pump casing and on
the shafts; check pump foundations, and piping; check freeing rotation of
shafts in bearings; check the pump – drive motor coupling, the condition
of the valves and gauges.
When assembling and overhauling of the pump should avoid excessive
tension of connecting pipelines and tightening foundation bolts. The may
lead to misalignment coupling, additional pump wearing or damaging.
1.4.3. When inspecting centrifugal pumps, it is necessary to check the
condition of surfaces and input edges of the blades of working wheels. -
temperature bearings, seals, al. Engine, noises and vibrations
1.4.4 Service during operation. During the pump, it is necessary to:
- to monitor the readings of the control gauges (the arrows of the gauges
in the normal operation condition of the pump and pipelines have small
smooth vibrations without throws; significant fluctuations the arrow of
the gauge indicate the presence in the air pump throws in the readings of
the amperemeter at the calm readings of the rest of the devices indicate
problems inside the pump: seizing in bearings, impeller-casing wearing
ring, mechanical seal);
- monitor the grease of bearings and their temperature (max temperature
less than 70 degr.C);
- monitor the condition of the shaft seal (their heating should not exceed
60 degrees Celsius) and the flow of liquid to hydraulic shutters (if any) If
in a healthy condition, the slings must pass continuously separate drops
of water;
- time by time depends of operation condition carry out de-aerating
pump casing through designed valve opening.
- if the pump run for a long time, additional grease or lube oil to the ball
bearing as per Maker Manual may be required.
1.4.6. Annual inspection and repair. (Inspection and overhaul /
examination in accordance with Preventive Maintenance Plan).
With intensive operation of centrifugal pumps (4500 - 60000 hours per
year) should be carried out an annual inspection / maintenance of the
following perts of the pump:
- rubber and plastic sleeves of bearings;
- the sleeves of sealing impellers in two-stage pumps;
- the shaft seals (as a rule, a change packings is required);
- pump & drive motor flexible coupling (usually, required renewal of
rubber inserts);
- Device to switch pump mode from parallel to sequentially water supply
(two stage pumps).
It is forbidden to perform maintenance operations during the pump,
which can lead to an accident.
1.5 Maintenance of centrifugal pumps of the Wartsila L20 engine
(Fig 1.13)
1.5.1 Device. The centrifugal pump is driven by gear connection at the
free end of the engine. The shaft is made of acid-resistant steel, impeller
6 and the rest of the parts are cast-iron. The shaft is set in two ball
bearings 8 and 10, which are lubricated by spray of oil coming through
the holes in the bearing hull. Shaft 16 seal prevents oil from leaking and
at the same time protects against dirt and leaking water. The gear 12 is
attached to the shaft by conical ring elements 13. When the screws are
14 tightened, the rings create pressure between the gear and the shaft.
Due to friction, the force from the gear is transferred to the shaft of the
pump. The water side of the pump is equipped with a mechanical seal of
the shaft. Ring 4 rotates with the shaft and seals it together with the ring
seal. The spring presses the rotating ring to the stationary ring 3, which
seals the hull by means of ring seal 7. Probably leaks through seals water
and oil can drain via hole 18.
1.5.2 Service. Routine maintenance work, such as dismantling the
impeller or renewal a mechanical seal, can be done without the entire
pump being removed from the engine.
Figure 1.13 - Wartsila L20 centrifugal pump: 1 - cover clamp; 2 -
sealing ring; 3 - ring; 4 – shaft seal; 5 - bolt; 6 - working wheel; 7 -
sealing ring; 8 - bearing; 9 - shaft; 10 - bearing; 11 - bearing cover; 12 -
drive gear;13 - tapered rings; 14 - bolt; 15 - hard drive; 16 - seal; 17 -
sealing ring; 18 - "control" hole
The pump is to be inspected or overhauled as per intervals according to
the engine maintenance manual or if the coolant or oil leaks
immediately. Periodically check that the control hole 18 clean.
a) Disassembly and assembly of the working wheel:
- remove the pump cover, unscrew the cover clamp 1 and the screws of
fastening;
- unscrew the screw 5 fixing the impeller;
- remove the working wheel with the help of a puller;
- when assembling a impeller tighten the screws with a moment, 85-5
nm;
- make sure that the ring seal 2 and the reverse valve ring seals on the
cylinder block are not damaged and are in their seats when the pump
cover is installed. Check correct assembling of pump;
- Install the cover clamp 1 and tighten the screws.
b) Disassembly and assembly of mechanical sealing of the shaft:
- remove the working wheel according to paragraph (a) above;
- carefully remove all the details of the seals. The sealing rings are very
fragile / delicate. Special care is required not to damage the sealing
surfaces, as a small scratch can loss the sealing;
- completely replace the seal if it leaks or its sealing surfaces are
damaged by corrosion, uneven or worn out. Avoid touching the sealing
surfaces with your fingers. Do not lubricate with mineral oil when
installing a seal - use liquid soap or water.
Some seal parts are made of rubber that is not suitable for use with
hydrocarbon oils. Any fading or alteration of the color of the rubber parts
of this seal has no effect on its functioning;
- pay attention to the fact that the seal does not depend on the direction
of rotation;
- assemble the parts in the appropriate order and install the impeller
according to the pos. (a) above. Do not forget to install a thin washer
between the spring and the ring seal.
c) Renewal bearings and sealing the shaft:
- remove the pump from the engine;
- disassemble the working wheel and mechanical seal according to the
paragraphs (a) and b) above;
- unscrew screws 14 and remove the pressure plate 15;
- remove the gear without using any tool. If removing the gear is
difficult, you can knock with a soft hammer (friction ring elements 13
are released along with the gear). Using a puller may damage the shaft
(longitudinal risks);
- release the stop ring bearing 11 and remove the shaft and bearing;
- check seal 16 and bearings for the wearing and damage. If the seal
leaks, disassemble seal with a suitable brass instrument;
- remove the bearings. Press the bearing acting to inner ring; - to inspect
the shaft wearing and damage;
- lubricate new seal and insert it, pressing to the edge;
- grease and press the bearing for its inner ring with a suitable pipe
(fig.1.14 A);
- rotate the shaft according to figure 1.14 B;
- grease and press the bearing over its inner ring with a suitable pipe (fig.
1.14 B);
- rotate the casing according to fig.1.14C and grease the outer surfaces of
bearings with oil. Press the shaft into the case on the inner and outer
rings of the bearing with a suitable pipe or correction.
Figure 1.14 - Mounting bearings
Figure 1.14 - Mounting bearings

Fig. 1.14 - Mounting bearings

- install a stop ring bearing 11 (Figure 1.15). Fix the screws with
mastics;
- before installing the gears should be cleaned and smeared all
contact surfaces;
- set in place gear and friction rings 13. Friction rings should easily
stand in place and should not seize;
- install pressure plate 15 in place;
- tighten the screws and check the correct position of the gear;
- tighten the screws to the point of 35-3 nm;
 Figure 1.15 - Drive gear editing: 11 - bearing stopper; 12 -
drive gear; 13 - conical rings; 14 - bolt; 15 - hard drive
- install the impeller and mechanical seal according to the points (a) & b)
above.
2. How to do the job
- 2.1. Prepare data during preparation: study the design features, the
purpose and principle of the blade pumps. Check design of seals.
- 2.2. Learn safety instructions when working with a plumbing tool.
- 2.3. Get acquainted with the workplace and find out the location,
purpose and device of equipment, appliances and tools, the contents of
regulatory documents. Prepare the tools for work.
- 2.4 Disassemble the centrifugal pump: before disassembling, the pump
should be disconnected or isolated from the suction and discharging
sides. The electric motor to be disconnected from the power supply. The
pump liquid (water, oil, etc.) to be drained through the lower drain hole.
The coupling motor-pump to be released depend in way depend of
design. The pump lubricating systems, water supply for cooling and
seals to be disconnected. Disassembling sequence, depending on the
design of the pump, may differ.
For single-stage pumps, the cover of the suction side, the lid of bearings,
to be disassembled on the first. Depending on the type of the shaft seal
removes the seal cover or securing arrangement the end seal. After that,
the working wheel is removed and pull out the shaft with the bearings.
All the removed parts are washed and examined to detect defects. At
once defective parts of the pump have been repaired or renewed, balance
check of shaft assembling is carried out, the pump should be assembled
in reverse sequence.
Assembled to foundation pump coupling to be centered to drive motor.
The dismantling of the pump with two-way suction is carried out in the
consistency. First disassembling coupling, then the seal parts depend of
design (packings or mechanical seal). Next to be dismounted the bearing
cover is then removed pump casing. Bearings to be removed as per
design of the pump, and clearances / gaps, condition to be checked. The
next step is the impeller to be disassembled.

Figure 1.16 - Central pump sketch:1 - wheel, 2 - shaft, 3 - front disc, 4

- rear disc, 5 - blades, 6 - bearings, 7 and 8 - seals, 9 - liner, 10 - spiral
pull, 11 - pressure patch
2.5 The pump parts should be inspected & examined for defects and
wearing. The results of the inspection to be recorded and written to
Overhaul report accordingly. Depend of the technical condition parts of
pump to be reused or renewed, the pump to be assembled as per Maker
Manual.
3. Report
3.1 The Centrifugal pump design to be described;
3.2 Using the pump instructions make Maintenance and Overhaul Plan.
3.3 Describe the sequence of operations to disassemble and assemble the
Centrifugal Pump. Indicate the tightening moments of the main threaded
connections.
3.4 Describe main faults of the Centrifugal Pump and how to fix them.
3.5 Complete Overhaul and Inspection Report of the Centrifugal Pump
with description defects, inventory renewed and reused parts.
3.6 Answer and be ready for self-control questions below mentioned.
4. Self-control questions:
4.1 Typical damages of the Centrifugal Pumps.
4.2 Materials of the Centrifugal Pump parts.
4.3 Operation Instruction for Centrifugal Pump: before start preparation,
start, stop, and lay-up of the pump;
4.4 What action to be carried out by Watch Engineer during the
Centrifugal Pump operation.
4.5 Instruction for mounting rolling bearings (best experience practice)?
4.6 How to assemble the seals of Centrifugal Pump shafts?
4.7 Safety precaution during maintenance of the Centrifugal Pump.

Literature 1. Cherkassky V.M. Pumps. Fans. Compressors. - M.,

Energy, 1977, p. 143 - 151.
2. Ravens V.F., Artykov A.P. Ship hydraulic machines. - L.,
Shipbuilding, 1976, p. 24-25.
3. Blinov I.S. Handbook of the technologist of the mechanical assembly
shop of the ship repair plant. - M., Transport, 1979, p.593