pump repair options & alternatives
TRANSCRIPT
![Page 1: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/1.jpg)
Pump repair options &
alternatives
Presented by Bob Gaskeyof
1
![Page 2: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/2.jpg)
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
![Page 3: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/3.jpg)
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
![Page 4: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/4.jpg)
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
![Page 5: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/5.jpg)
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
![Page 6: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/6.jpg)
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
![Page 7: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/7.jpg)
7
![Page 8: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/8.jpg)
8
![Page 9: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/9.jpg)
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
![Page 10: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/10.jpg)
Pump repair considerations
10
![Page 11: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/11.jpg)
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
![Page 12: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/12.jpg)
Balancer capacity
12
![Page 13: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/13.jpg)
Balancer capacity
13
![Page 14: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/14.jpg)
Balancer capacity
14
![Page 15: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/15.jpg)
Balancer capacity
15
![Page 16: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/16.jpg)
Press capacity
16
![Page 17: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/17.jpg)
Horizontal lathe capacity
17
![Page 18: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/18.jpg)
Vertical lathe capacity
18
![Page 19: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/19.jpg)
Welding equipment & procedures
19
![Page 20: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/20.jpg)
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
![Page 21: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/21.jpg)
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
![Page 22: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/22.jpg)
Repair documentation
• Accurate reports help narrow the trouble shooting process.
22
![Page 23: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/23.jpg)
Shaft TIR
23
![Page 24: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/24.jpg)
Balance report
24
![Page 25: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/25.jpg)
Metal certification
25
![Page 26: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/26.jpg)
26
Alignment report
![Page 27: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/27.jpg)
Taking pump out of standard
• Impeller bores
• Wear ring sizes
• Pump case machining
• Design upgrades
27
![Page 28: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/28.jpg)
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
![Page 29: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/29.jpg)
All or nothing strategy
29
![Page 30: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/30.jpg)
Evolution of pump metallurgy
• Bronze fitted pumps
• 1970’s pressure from aftermarket pump part companies.
30
![Page 31: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/31.jpg)
Rotor stabilization
• Pump, motor (or turbine) gear box
31
![Page 32: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/32.jpg)
Vibration analysis can expose:
• Multiple types of unbalance
• Eccentric rotor
• Bent shaft
• Multiple types of misalgnment
• Resonance
• Mechanical looseness
• Rotor rub
• Journal bearing issues32
![Page 33: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/33.jpg)
• 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:
![Page 34: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/34.jpg)
• Belt drive issues
• Pulley issues
• Beat frequency vibration
• Soft foot, sprung foot & foot related resonance
34
Vibration analysis can expose:
![Page 35: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/35.jpg)
Seal Advantages
• Seals-less drag on shaft sleeve thus saving energy
• When applied, installed with an appropriate piping plan-housekeeping
• Run dry capabilities
35
![Page 36: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/36.jpg)
Packing Advantages
• Can help stabilize the rotor
36
![Page 37: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/37.jpg)
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
![Page 38: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/38.jpg)
Pump part machining
• Faces must be flat, parallel & perpendicular
• Accurate sizes
• Most important-concentric common centerline
38
![Page 39: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/39.jpg)
Application scenario #1
39
![Page 40: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/40.jpg)
Application scenario #1
40
![Page 41: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/41.jpg)
Application scenario #2
41
![Page 42: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/42.jpg)
Application scenario #2
42
![Page 43: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/43.jpg)
Application scenario #2
43
![Page 44: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/44.jpg)
44
Application scenario #2
![Page 45: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/45.jpg)
Application scenario #3
45
![Page 46: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/46.jpg)
Application scenario #3
46
![Page 47: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/47.jpg)
Application scenario #3
47
![Page 48: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/48.jpg)
Application scenario #4
48
![Page 49: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/49.jpg)
Application scenario #4
49
![Page 50: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/50.jpg)
Application scenario #4
50
![Page 51: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/51.jpg)
Application scenario #4
51
![Page 52: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/52.jpg)
Application scenario #4
52
![Page 53: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/53.jpg)
Application scenario #5
53
![Page 54: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/54.jpg)
Application scenario #5
54
![Page 55: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/55.jpg)
Application scenario #5
55
![Page 56: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/56.jpg)
Application scenario #5
56
![Page 57: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/57.jpg)
Application scenario #6
57
![Page 58: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/58.jpg)
Application scenario #6
58
![Page 59: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/59.jpg)
Application scenario #7
59
![Page 60: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/60.jpg)
Application scenario #8
60
![Page 61: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/61.jpg)
Application scenario #8
61
![Page 62: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/62.jpg)
Application scenario #8
62
![Page 63: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/63.jpg)
Application scenario #9
63
![Page 64: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/64.jpg)
Application scenario #9
64
![Page 65: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/65.jpg)
65
![Page 66: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/66.jpg)
Application scenario #10
66
![Page 67: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/67.jpg)
Application scenario #10
67
![Page 68: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/68.jpg)
Application scenario #11
68
![Page 69: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/69.jpg)
Application scenario #11
69
![Page 70: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/70.jpg)
Application scenario #11
70
![Page 71: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/71.jpg)
Application scenario #11
71
![Page 72: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/72.jpg)
Application scenario #11
72
![Page 73: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/73.jpg)
Application scenario #11
73
![Page 74: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/74.jpg)
Application scenario #12
74
![Page 75: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/75.jpg)
Application scenario #13
75
![Page 76: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/76.jpg)
Application scenario #13
76
![Page 77: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/77.jpg)
Application scenario #13
77
![Page 78: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/78.jpg)
Application scenario #14
78
![Page 79: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/79.jpg)
Application scenario #14
79
![Page 80: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/80.jpg)
Application scenario #15
80
![Page 81: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/81.jpg)
Application scenario #16
81
![Page 82: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/82.jpg)
Application scenario #17
82
![Page 83: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/83.jpg)
Application scenario #17
83
![Page 84: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/84.jpg)
Application scenario #18
84
![Page 85: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/85.jpg)
Application scenario #18
85
![Page 86: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/86.jpg)
Application scenario #18
86
![Page 87: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/87.jpg)
Application scenario #18
87
![Page 88: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/88.jpg)
Application scenario #18
88
![Page 89: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/89.jpg)
Application scenario #18
89
![Page 90: Pump repair options & alternatives](https://reader030.vdocuments.net/reader030/viewer/2022020701/61f719ae6691bf27c51a4112/html5/thumbnails/90.jpg)
Application scenario #18
90