Start-up and shut down procedures June 2008
OBJECTIVE When you complete this module, you will be able to: • Ope Operate rate// sta starrt up up the the pu pumps mps • Shut down the pump
PUMP OPERATION Pumps are generally selected for a given capacity and head when operating at rated speed. Positive displacement pumps cannot operate at any greater flows than rated except by increasing their speed, nor can they operate at lower flows except by reducing their speed operation or bypassing some of the flow back to the source of of supply.
PUMP OPERATION Cont’d On the other hand, centrifugal pump can operate over a wide range of capacities, from near zero flow to well beyond the rated capacity. Because a centrifugal pump will always operate at the intersection of its head-capacity and system head curve, the pump operating capacity may be altered either by throttling the pump discharge (hence altering the system head curve) or by varying the pump speed (changing the pump head-capacity curve)
PUMP OPERATION Cont’d This makes the centrifugal pump very flexible in a wide range of services and applications that require the pump to operate at capacities and heads differing considerably from the rated conditions. There are, however some limitations imposed upon such operation by hydraulic, mechanical, or thermodynamic considerations.
WHAT SHOULD I PREPARE BEFORE OPERATING/ COMMISSIONING THE PUMP? 1. Pump data sheet 2. Pump Curve 3. Inst Instal allat latio ion n Oper Operati ation on & Maint Mainten enanc ancee (IOM (IOM)) Book Book 4. Tools Tools : Gene Genera rall tools tools (W (Wre rench nch,, All Allen en keys keys,, etc etc)) & special tool (impeller wrench) 5. Inst Instrum rumen entat tatio ions ns : Vibro Vibrome mete ter, r, Ther Thermo mome mete ter, r, Tachometer, Pressure gauge, etc 6. Alat Alat-2 -2 safe safety ty : Saf Safet ety y sho shoes es,, helm helmet et,, gemb gembok ok hita hitam m
P P E E B B T T A A P P H H B B D D N N A A D D A A E E H H
FLOW
Ns = 1000-2000
P E B T A P H B D N A D A E H
FLOW
Ns = 2000 - 4000
P E B T A P H B D N A D A E H
FLOW
Ns = 4000 - 6000
P E B T A P H B D N A D A E H
FLOW
Ns = 6000 – 10,000
Pre start up checks 1. Pump and and Motor Motor prope properly rly secure secured d to the base plate 2. All faste fastene nerr tighte tight ened ned to the correct correct torques 3. Coupling oupling gua g uard rd in i n pla pl ace and not n ot rubbin r ubbing g 4. Shaft haft rotation rotation check check (c. (c.w. w. viewe viewed d from the moto mo torr end for ANSI ANSI pump pu mps). s). Generall nerally y an arrow rro w on the pump casing or bea bearing rin g housing hou sing indica ind icate tes s the corre cor rect ct rota ro tatio tion n
Pump um p and and Motor oto r pro p roperly perly se s ecured cu red to the t he base base plate plate
Coupling guard & shaft rotation
Pre start up checks cont’d 5. Shaft align li gnment ment che ch eck 6. Impe mp elle ll er cle cl earance setting setti ng (no (nott appli pp licable cable for new new pump) pump ) 7. Shaft seal seal prop pr ope erly rl y inst in sta alle ll ed 8. Seal support system system opera operationa tionall (if (if any) any) 9. Bea Bearing ri ng lubr lu bric ica ation ti on
ANGULAR ALIGNMENT
PARALLEL ALIGNMENT
Seal & the flushing system
Bearing lubrication
Bearing housing cooling system
Cooling system
Pre start up checks cont’d 10. Beari Bearing ng housi ho using ng cool co oling ing syst s yste em operatio operational nal (if any) ny ) 11. Support uppo rt leg leg cooli c ooling ng for cente centerli rline ne mounting mounti ng optio opt ion n Operation Operationa al (if any) 12. Heating ti ng// cool co olin ing g for fo r ja j ack cke eted casing/ casin g/ cove cov er operati operation ona al (if any) ny ) 13. Pump um p ins i nstr trumentation umentation is ope op erationa ration al (if any any)) 14. Pump um p is i s pri p rimed med 15. Rota ot ation ti on of o f sha sh aft by ha h and
Instrumentations
Pump Start - up 1. Open pen suction suction valve valve to full f ull open open positio po sition n 2. Open pen discharge discharge valve valve a slight sligh t amount amount 3. Make certa certain in the pump is i s prime prim ed
(1)
(2)
4. All cooling, cool ing, hea heating, and flush line lin es must be sta st arte rt ed and regul ated 5. Start tart driver driver (typica (typically, lly, the electric lectric motor) 6. After After pump is running, adjust the discharge discharge valve valve slowly slow ly until u ntil the desir desire ed flow fl ow is re r eached ched
Pump Start - up 7. For pumps equippe equipped d with mecha mechanica nicall sea seals, check check for seal seal le l eakage : there t here shoul sho uld d be b e none no ne 8. For pump with shaft shaft packing, packing, observe observe the lea leakage kage from the stuffin g boxe bo xes s and adjust adjust the sea sealing liquid liqui d valve valve for pro per per flow fl ow to t o ensur ensure e the lubrica lubri catio tion n of t he packi packing. ng. If If the th e packi packing ng is i s new, do not n ot tigh t ighte ten n up on the gland gland imme imm ediately, diately, but let let the t he packi packing ng run r un in in befor before e reduc reducing ing the lea leakage kage throug thr ough h the th e stuffi stu ffing ng boxes. Note Not e : (1) For Mixe Mix ed and Axi al Flow pumps pum ps,, open the discharge dis charge valv valve e fully. (2) For Se Self Priming pumps p umps,, fill fil l in the primi ng chamber chamber with wit h liquid liq uid
Priming the Pump Many process pump applications have pumps connected to a tank above ground, called flooded suction, and discharge into another tank at higher level or pressure.
Horizontal Pump
Sump Pump
Vertical Turbine Pump
Self Priming Pump
The casing filled with an initial prime liquid to entrain the air contained in the suction line Sump Filling
Priming Tank
Pump Shutdown Shutdo hu tdown wn pro p roce cedu dure re shou sh ould ld be b e the th e revers reverse e of the t he start-up start-up proc p roce edure dur e •
Slowly low ly close clo se the discha dis charge rge valve valve for small pumps pum ps
•
Shutdown hutd own the driver
•
Close los e the th e suct su ction ion va v alve
The end
TEST
1. Why do we need pump data sheet when we are assigned to do pump start-up/ commissioning?
2. Why do we need Pump curve when we are assigned to do pump start-up/ commissioning?
3. How is the discharge valve position? Why?
4. How is the discharge valve position? Why?
5. How is the discharge valve position? Why?
6. How is the discharge valve position? Why?
7. How is the discharge valve position? Why?
8. When you start the pump, what is the position of the suction valve ? a. Fully opened b. Slightly opened c. Slightly closed d. Fully Closed
9. How do you control the capacity of centrifugal pumps?
10. Checking the motor rotation is very important before starting the pump. Incase we do not have documents that showing the motor rotation, what should we do?
