PRE- COMMISSIONING
& COMMISSIONING OF PUMP
a.
Check the base frame installation, foundation,
tightness of foundation bolts and leveling.
b.
Check the tightness of fasteners of pump and
motors.
c.
Ensure the pump is aligned and it is within the
morms.
d.
Check cable connection of motor and check the
power supply is on line.
e.
Check the lubrication of the pump viz grease,oil
. ensure correct oil/grease is filled as instructed in the pump vendor manual.
f.
Check the pump strainer and find the mesh
condition. Clean if necessary.
g.
Ensure the motor is checked for no load
condition and cross check the correctness of electrical connections, motor fan
and earthing.
h.
Ensure the fan is not touching with fan cover by
rotating motor shaft manually 3 to 4 times by pump operation direction. Check
rotation of the pump by kick start. Don’t operate for more than 1 minute during
first start.
i.
Ensure the tank is neat and clean and it should
have any foreign materials like welding rod. PCC pieces, metal pieces etc.
j.
Ensure the water/process liquid is filled in the
tank with no leakage. (hydro test of the tank to fluid leakage to be finished before
this filling)
k.
Prime the pump if it is negative suction, for
positive suction open suction valve and flush the lines before connecting to
pump suction. Connect suction line to pump after ensuring no forein matters
present in the tank.
l.
Check free rotation of pump coupling by hand.
(electrical power to be switched off before doing this activity)
m.
Check the direction of NRV fixed in the delivery
line. Check gland cooling water line connection with pump if applicable. Open
gland cooling water prior to start up of pump and adjust cooling water flow as
per vendor manual.
n.
Ensure suction valve of tank and particular pump
is open and start the pump. Open the delivery valve slowly and check whether
pump is transferring water by reading the pressure gauge and /or flow meter
installed at the discharge of the pump. Check if motor signal available in
panel/PLC/DCS as applicable. Arrest any leakage in the piping and valves. If
the leakage found in suction or discharge, stop the pump and attend the
leakage. Run the pump for 6 hrs for observation and check the gland leakage,
current, vibration and heat, oil leval for geared motor, flow & pressure
every hour.
TROUBLE SHOOTING OF PUMP
|
EQUIPMENT
|
PROBLEM
|
CAUSE
|
REMEDY
|
|
pump
|
Abnormal noise
|
Bearing failure.
Rubbing of rotary parts.
Spider failure.
Loose base bolts.
|
Change the bearing.
Avoid the rubbing.
Change the spider
Tighten them and check the alignment.
|
|
|
Too hot
|
Poor lubrication.
High friction between
Rotary parts
|
Lubricate properly.
Reduce the friction
|
|
|
More vibration
|
Loose fittings. No proper support on piping or tension in piping.
Misalignment of couplings.
|
Tighten the fittings.
Support piping and remove the tension.
Re align it and check the love joy bush
|
|
|
Frequent leak in the stuffing box
|
Poor quality of gland ropes improper size of the ropes groove in the
shaft sleeve
|
Use right quality ropes.
Choose correct size.
Change the sleeve.
|
|
|
Oil seal damage is frequent
|
Poor quality groove in the path of the shaft.
|
Go for good brand.
Fill the groove by metalizing and machine it to the right size or
shift the seating area of the oil seal on the shaft if space permits.
|
|
|
Mechanical seal failure
|
Impeller may be worn out
In sufficient flow of cooling water.
Improper gland alignment.
|
Check the diameter of the impeller and change if necessary.
Open/check cooling water valve. Change the seal and align gland
properly.
|
|
|
Poor efficincy
|
Clearance in between impeller and casing may be more RPM of the prime
mover may be less
|
Adjust the clearance.
Choose the right prime mover.
|
|
|
Pump is tripping often
|
Over load due to :
Bearing might have gone.
Misalignment.
Shaft may be bent.
Foreign particle clogged in the casing.
|
Change the bearing.
Realign it
Replace with new shaft.
Remove it.
|
|
|
Pump is running but not pumping
|
Low level or no level of the liquid.
Drawing air in the suction or stuffing box.
Choke in the suction line.
Wrong direction of rotation.
|
Maintain the level.
Remove the air lock or avoid the air suction.
Prime the pump.
De choke the line.
Change the electrical connection.
|
