Professional Documents
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Mechanical
IPCL
NC : Training Module
Module No. :
IPCLDSMEC001
TRAINING MODULE
FOR
BASICS OF PUMPS
LEARNING CENTRE
NC
Prepared by :
SUMANT KUMAR
Rev. : 01
Reviewed by : PGD
Approved by : AKS
Date : 29.10.2004
Page 1 of 54
Category :
Mechanical
IPCL
NC : Training Module
Module No. :
IPCLDSMEC001
DATE:
REV:01
SR
NO
1
SITE:NAGOTHANE
CONT
ENT
Introduction
and
classification
Definition
AUTH
OR
RESOURCES
AVAIL
ABLE
LEARNI
NG
VALIDAT
ION
TRA
INE
R
SK
Hydraulic
institute journal
Self
study
Pump handbook
by
F.POLLAK,KAR
RASIK
Pump handbook
by
F.POLLAK,KAR
RASIK
Pump handbook
by KARRASIK
Pump handbook
by F.POLLAK
Pump handbook
by F.POLLAK
Pump handbook
by F.POLLAK
Self
Study
SK
Self
Study
SK
Self
Study
Self
Study
Self
Study
Self
Study
SK
Selection of
pump
Centrifugal
Pump
Reciprocatin
g pump
Diaphragm
pump
Gear pump
Lobe pump
Pump handbook N
by F.POLLAK
Self
Study
SK
Screw pump
Vane pump
11
Maintenance
of pumps
Self
Study
Self
Study
Self
Study
SK
10
Pump handbook N
by F.POLLAK
Pump handbook N
by F.POLLAK
Pump handbook N
by F.POLLAK
KARRASIK
5
6
Prepared by :
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N
N
N
Quiz
Duration
hour
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Page 2 of 54
SK
SK
SK
SK
Category :
Mechanical
IPCL
NC : Training Module
Module No. :
IPCLDSMEC001
TABLE OF CONTENTS
SECTION
DESCRIPTION
PAGE
NO.
1
NO.
INTRODUCTION
1.1 INTRODUCTION & CLASSIFICATION
1.2 DEFINITION
1.3 SELECTION OF PUMP
1.4 STANDARDS AND CODES
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IPCL
NC : Training Module
Module No. :
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OBJECTIVE
In any industry ,various types of pumps are used to meet different requirements
of liquid handling. To understand these equipments better, it is desirable to have
basic knowledge of various types of pumps regarding their operating principle,
construction and application.
This module is prepared with a view to provide its reader basic knowledge of
various types of pumps which are commonly used in a process plant.
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IPCL
NC : Training Module
Module No. :
IPCLDSMEC001
SECTION 1
INTRODUCTION TO PUMP
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IPCL
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Module No. :
IPCLDSMEC001
APPLICATION OF PUMPS
Application of suitable type of pump for a given service is dependent on various
factors. A guideline is given in the following figure. This represents upper limits
of pressure and capacity available currently. From the figure it is evident that the
reciprocating pumps run off the pressure scale whereas the centrifugal pumps
run off the capacity scale. Upper limits of pressure and capacity of pump class
are shown in the following figure.
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IPCL
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Module No. :
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Most of the centrifugal pumps find their application in column bottom pumps,
vacuum tower separation, hydrocarbon processing, removal of sulfur and
nitrogen. They are used in steam power plants as boiler feed water pumps,
condensate circulating pumps, fuel oil systems.
pumps are used as firewater pumps and as fire water jockey pumps (Smaller
pump which maintains pressure in the distribution system during periods of low
demand).
1.2 DEFINITIONS :
Pumping is the addition of energy to a liquid to move it from one point to another.
Centrifugal pumps employ centrifugal force to develop a pressure rise for moving
a liquid.
Impeller is the rotating member in a centrifugal pump through which liquid passes
and by means of which energy is imparted to the liquid.
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Rotary pumps use gears, vanes, screws, cams etc. in a fixed casing to produce
positive displacement of a liquid.
Packing is any material used to control leakage between a moving and stationery
part in the pump.
Mechanical seals are devices mounted on the shaft of centrifugal pump to seal
the liquid in the casing.
Viscosity is property of the liquid tat resists any force tending to produce flow.
Specific gravity of a liquid is that number which denotes the ratio of the weight of
the liquid to the weight of the equal volume of water.
Net positive suction head required is the energy needed on the suction side of
the pump to fill the pump to the discharge valve during operation.
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3. Mode of operation :
intermittent ? Criticality of the pump in service, which will decide upon the
stand by equipment.
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Following guidelines can be adapted for selection of any type of pump in general
:
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In recent times, many stringent clauses are included in the project standard
looking into the safety and environmental issues, which are assuming significant
importance worldwide.
A Quick check of existing pump standards will reveal that there are a number of
them. The list includes:
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SECTION 2
BRIEF DESCRIPTION OF VARIOUS
TYPES OF PUMPS
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Now, let us discuss various other parameters that are specified for a pump
independent of pump types:
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main reason for using head instead of pressure to measure a centrifugal pump
energy is that the pressure from a pump will change if the specific gravity of liquid
changes, but the head will not change. Since any centrifugal pump can move a
lot of different fluids, with different specific gravities, it is simpler to discuss pump
head than its pressure.
The key idea is that the energy created by the centrifugal force is kinetic energy.
The amount of energy given to the liquid is proportional to the velocity at the
edge or vane tip of the impeller. The faster impeller revolves or the bigger the
impeller is, then the higher will be the velocity of the liquid at the vane tip and the
greater the energy imparted to the liquid.
Capacity
Capacity means the flow rate with which liquid is moved or pushed by the pump
to the desired point in the process. Quantity of flow is defined as the amount of
liquid passing through the pump in unit time. It is measured in m3/hr.
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Power
The work performed by a pump is a function of the total head and the weight of
the liquid pumped in a given time period. Pump input or brake power is the
actual power delivered to the pump shaft and pump output or the hydraulic power
is the liquid power delivered by the pump and is expressed in KW.
Efficiency:
Efficiency of the pump takes into account all the losses in the system. When
specifying a pump, the rated point should be at or to the left of the best efficiency
point. Efficiency is expressed as
NPSH
The satisfactory operation of a pump requires that the vapourisation of the liquid
being pumped does not occur at any condition of operation. This is so desired
because when a liquid vapourises, its volume increases very much.
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When the pressure at the impeller eye goes down below the vapour pressure of
the fluid at which liquid begins to boil at the existing temperature, the liquid will no
longer remain in the state of liquid but in vapour state. These air bubbles are
carried along till they meet a region of higher pressure where they collapse
damaging pump internals. This phenomenon is called cavitation.
Specific speed
Specific speed is a non dimensional design index that identifies the geometric
similarity of pumps. It is used to classify pump impellers as to their type and
proportions.
Specific speed identifies the approximate acceptable ratio of the impeller eye
diameter D1 to the maximum impeller diameter D2 in designing a good impeller.
In British system,
Ns:500 to 5000 D1/D2>1.5:Radial flow pump
Ns:5000 to 10000;
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A typical single stage , overhung process type pump is the heart of the
process industry.A centrifugal pump essentially consists of an impeller with
vanes,surrounded by a volute casing.impeller is mounted firmly on shaft
,which is supported by two bearings,which in turn is supported in the bearing
housing. Impeller rotates with close clearance with the casing.Stuffing box
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prevents leakage of the process fluid from the impeller area to the
atmosphere.At the other end of the shaft ,coupling is fitted which takes drive
from the primemover such as electric motor or turbine.
STATIONARY COMPONENTS:
CASINGS
Pumps with volute casings are generally called as Volute pumps in which the
casing section collects the liquid discharged by the impeller and converts
velocity energy into pressure energy. Volute increases in area from its initial
point till it encompasses the full 360 deg.around the impeller and flares out to
the discharge opening.The wall dividing initial section and the discharge
nozzle of the volute is called the tongue of the volute.
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eliminates radial loads . This design consists of two 180 deg. Volutes ,a
passage external to second joins the two volutes into a common discharge.
atmospheric, the chamber prevents leakage out of the pump. Both refer to a
chamber, either integral with or separate from pump case housing that forms
the region between the shaft and casing where sealing media are installed.
When the sealing is achieved by means of packing, the chamber is reffered
as stuffing box. The seal chambers and stuffing boxes are also provided with
cooling or heating arrangement for proper temperature control.
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GLAND PACKING
To stop the pumped fluid from escaping along the shaft, one method of
sealing is a packed gland. Rings of packing material are fitted in a packing
box and they fit around the shaft sleeve. Harder shaft sleeve is fitted for the
purpose of good wearing properties and a means of replacing a normally
wearing surface without having to replace the shaft.
BEARING HOUSING
The bearing housing encloses the bearing mounted on the shaft. The
bearings keep the shaft or rotor in correct alignment while stationery parts
under the action of radial and transverse loads. The bearing housing also
includes an oil reservoir for lubrication, constant level oiler, jacket for cooling
by circulating cooling water.
ROTATING COMPONENTS
IMPELLER
The impeller is the main rotating part that provides the centrifugal acceleration
to the fluid. They are often classified in many ways:
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*Mixed flow
WEAR RINGS
Closed impellers require wear rings. Wear rings provide an easy and economical
renewable leakage joint between impeller and casing. As the wear rings wear
,the leakage loss increases and pumping efficiency goes down causing heat and
vibration .But, if the clearances are too tight, then both the both the impeller and
casing wear rings might seize resulting in jamming the pump. This is specifically
true for hot service pumps. Commonly used material for wear rings is 11-13% Cr
steel series, with casing wear ring material hardness more than the impeller wear
ring material hardness by about 50BHN to prevent galling. API 610 provides
guidelines on these clearances.
SHAFT
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SHAFT SLEEVE
Pump shafts are usually protected from erosion , corrosion and wear at the seal
chambers, leakage joints, internal bearings and in the waterways by renewable
sleeves.
MECHANICAL SEAL
A mechanical seal has a rotating face and a stationary face. Means such as
bellows , wedges and O rings are used to seal the rotating face against the shaft
sleeve. O-rings are normally used to seal the stationary face to the casing. One
face with the springs is held stationary in most of the cases and other face
rotates. Both the faces are matched so they fit together perfectly.
Stationary face is many times made of carbon and rotating face of silicon
carbide.
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The pump suppliers try to match the system curve supplied by the user with a
pump curve that satisfies these needs as closely as possible. A pumping system
operates where the pump curve and the system resistance curve intersect. The
intersection of the two curves defines the operating point of both pump and
process. However, it is impossible for one operating point to meet all desired
operating conditions.
system resistance curve shift left and so does the operating point.
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losses in a system in a graphic form and, since friction losses vary as a square of
the flow rate, the system curve is parabolic in shape. Hydraulic losses in piping
systems are composed of pipe friction losses, valves, elbows and other fittings,
entrance and exit losses, and losses from changes in pipe size by enlargement
or reduction in diameter.
The pump
performance curve also shows its efficiency (BEP), required input power (in
BHP), NPSHr, speed (in RPM), and other information such as pump size and
type, impeller size, etc.
It is generated by tests
This point is
sometimes called the run-out point. The pump curve is relatively flat and the
head decreases gradually as the flow increases. This pattern is common for
radial flow pumps. Beyond the run-out point, the pump cannot operate. The
pump's range of operation is from the shut-off head point to the run-out point.
Trying to run a pump off the right end of the curve will result in pump cavitation
and eventually destroy the pump.
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In a nutshell, by plotting the system head curve and pump curve together, you
can determine:
1. Where the pump will operate on its curve?
2.
What changes will occur if the system head curve or the pump
performance curve changes?
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linkage. Direct-acting pumps have a plunger on the liquid (pump) end that is
directly driven by the pump rod (also the piston rod or extension thereof) and
carries the piston of the power end. Indirect-acting pumps are driven by means of
a beam or linkage connected to and actuated by the power piston rod of a
separate reciprocating engine.
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pistons are driven by the crosshead drives. Rod and piston construction, similar
to duplex double-acting steam pumps, is used by the liquid ends of the low
pressure, higher capacity units. The higher pressure units are normally singleacting plungers, and usually employ three (triplex) plungers. Three or more
plungers substantially reduce flow pulsations relative to simplex and even duplex
pumps.
Power pumps typically have high efficiency and are capable of developing very
high pressures. They can be driven by either electric motors or turbines. They
are relatively expensive pumps and can rarely be justified on the basis of
efficiency over centrifugal pumps. However, they are frequently justified over
steam reciprocating pumps where continuous duty service is needed due to the
high steam requirements of direct-acting steam pumps. In general, the effective
flow rate of reciprocating pumps decreases as the viscosity of the fluid being
pumped increases because the speed of the pump must be reduced. In contrast
to centrifugal pumps, the differential pressure generated by reciprocating pumps
is independent of fluid density. It is dependent entirely on the amount of force
exerted on the piston.
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capacity range, and the necessity of check valves in the suction and discharge
nozzles. An example of a diaphragm pump is shown in Figure 20.
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There are two types of gears used in gear pumps in addition to the simple spur
gear. One type is the helical gear. A helix is the curve produced when a straight
line moves up or down the surface of a cylinder. The other type is the
herringbone gear. A herringbone gear is composed of two helixes spiraling in
different directions from the center of the gear. Spur, helical, and herringbone
gears are shown in Figure 15.
The helical gear pump has advantages over the simple spur gear. In a spur gear,
the entire length of the gear tooth engages at the same time. In a helical gear,
the point of engagement moves along the length of the gear tooth as the gear
rotates. This makes the helical gear operate with a steadier discharge pressure
and fewer pulsations than a spur gear pump.
The herringbone gear pump is also a modification of the simple gear pump. Its
principal difference in operation from the simple spur gear pump is that the
pointed center section of the space between two teeth begins discharging before
the divergent outer ends of the preceding space complete discharging. This
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There are many variations in the design of the screw type positive displacement,
rotary pump. The primary differences consist of the number of intermeshing
screws involved, the pitch of the screws, and the general direction of fluid flow.
Two common designs are the two-screw, low-pitch, double-flow pump and the
three-screw, high-pitch, double-flow pump.
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Positive displacement pumps deliver a definite volume of liquid for each cycle of
pump operation. Therefore, the only factor that effects flow rate in an ideal
positive displacement pump is the speed at which it operates. The flow
resistance of the system in which the pump is operating will not effect the flow
rate through the pump. Figure 21 shows the characteristic curve for a positive
displacement pump.
The dashed line in Figure 21 shows actual positive displacement pump
performance. This line reflects the fact that as the discharge pressure of the
pump increases, some amount of liquid will leak from the discharge of the pump
back to the pump suction, reducing the effective flow rate of the pump. The rate
at which liquid leaks from the pump discharge to its suction is called slippage.
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Positive displacement pumps are normally fitted with relief valves on the
upstream side of their discharge valves to protect the pump and its discharge
piping from over pressurization. Positive displacement pumps will discharge at
the pressure required by the system they are supplying. The relief valve prevents
system and pump damage if the pump discharge valve is shut during pump
operation or if any other occurrence such as a clogged strainer blocks system
flow.
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SECTION 3
MAINTENANCE OF PUMPS
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Measure the depth of the tread on your automobile tires, record the
distance driven on the tires, and if you do not change your driving habits,
you can accurately predict the life remaining.
Do the same thing with the shoes you are wearing and you will come up
with a similar result.
These are items that tend to "wear out" so life to date is a valid measurement.
The problem with centrifugal pumps is that seals and bearings account for over
90% of premature pump failures and neither of these items ever "wears out".
Seals should run until the sacrificial carbon face has worn away, but a close look
at used seals will demonstrate that wear is actually a minor problem. In excess of
85% of mechanical seals leak with plenty of wearable face still visible.
Bearings do not "wear out" like mechanical seals. They have a predictive fatigue
life that is based on load and cycles. Properly loaded they could last a hundred
years, but like seals, they experience a very high premature failure rate. All of
this means is that the measurements you are taking today are no indication of
what is going to happen tomorrow. It is like trying to predict an automobile
accident. There are precautions you can take, but accidents still happen.
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If your blood pressure is too high you could get a stroke. (insertion)
A loss of oil pressure means shut off the engine and react immediately.
(scram)
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Pumps also "scram" and give "insertion" signals", unfortunately vibration analysis
indicates that destruction has already started (scram). Let's look at some of the
"insertion" signals:
The stuffing box temperature is increasing. If it gets too hot you are going to have
a problem. You had better correct the condition if you do not want to experience
a premature seal failure. What can happen if the stuffing box temperature gets
too hot?
The product can change state. It can stop being a lubricant and quickly
become a destructive solid or vapor:
o
It can crystallize and interfere with the moving parts of the seal.
It can cause the product to build a film on the faces (hot oil as an
example) and sliding components, making them inoperable.
Some seal faces can be damaged by high heat. Plated materials and filled
carbons are two such examples. Voids in some carbon faces can expand
causing pits in the lapped faces
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What could be causing this high heat? If you take no corrective action one of the
above will occur.
A loss of flushing fluid. There are multiple reasons why this could happen
and I am confident you can think of many of them.
Loss of cooling in the stuffing box cooling jacket because the circulating
water was "hard" and has deposited an insulating layer of calcium on the
inside of the cooling jacket.
The seal is running dry because the stuffing box was not vented in a
vertical application.
The seal was installed incorrectly. There is too much spring load on the
faces.
The open impeller adjusting technique can over compress some seal
designs.
The stuffing box is running in a vacuum because the supply tank is not
vented properly or cold weather is freezing the tank vent.
Water hammer, pressure surges and cavitation will all alter seal face
loading.
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Module No. :
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O-rings and other elastomer designs to extrude and jam the sliding
components.
If you are monitoring temperature and pressure in the stuffing box area you will
note the changes mentioned and depending upon your knowledge of the above,
you will have time to react before seal failure occurs.
An increase in the bearing case oil temperature is significant because the life of
bearing oil is directly related to the oil temperature. Lubricating oil has a useful
life of thirty years at thirty degrees centigrade (86F) and its life is cut in half for
every ten degree centigrade (18F) increase in temperature. You can figure the
temperature in the bearing is at least ten degrees centigrade (18F) higher than
the oil sump temperature. At elevated temperatures the oil will carbonize by first
forming a "varnish like" film that will turn into a hard black coke at these higher
temperatures. It is these formed solids that will destroy the bearing.
What is causing these elevated temperatures? There are a number of
possibilities:
Some one is cooling the outside of the bearing casing causing the outside
diameter of the bearing to shrink, increasing the load.
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Category :
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IPCL
NC : Training Module
Module No. :
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The bearing is over lubricated. The oil level is too high or there is too
much grease in the bearing.
The shaft is overloaded because the pump is operating off of the B.E.P.,
misalignment, unbalance, etc.
If you monitor pump suction and discharge pressure and coordinate this
information with flow and motor amperage readings you can come up with a lot of
useful information such as:
You can estimate where you are in respect to the B.E.P. and know if the
shaft i deflecting, or is about to deflect.
You will know when the impeller needs adjusting or the wear rings need
replacement.
You can spot poor operating practices if you have a chart recorder
installed, instead of pressure and temperature gages.
You can tell if the tank you are pumping from is losing the proper level or if
the suction lines are clogging.
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It goes without saying that constant monitoring is the most sensible answer to
predictive maintenance. It is the same logic you use with your automobile. You
believe that the extra expense of installed gauges is a cheap investment for
longer engine life.
There is nothing wrong with vibration analysis (an E.K.G. is still part of taking a
physical) but do not substitute it for sensible monitoring. The "scram " is too
expensive in this very competitive world of ours.
To properly maintain these pumps, there are three areas that should be
addressed. This includes the lubrication, seal replacement and alignment.
Proper Alignment
Proper alignment is another area that needs to be addressed. Alignment is more
critical in higher rpm applications. Use a dial indicator if your pump is running at
3,500 rpm. For those of you running at 1,750 rpm a straight edge and taper
gauges will do the trick.
Replacement of Seals
The last area of maintenance is the replacement of seals. Whenever you replace
the seals make sure that you replace all the items and not just one part. Inspect
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Module No. :
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the seals and try to determine why they wore the way they did. If there are
grooves in the seals, this could indicate that there is a high level of suspended or
dissolved solids that need to be addressed.
Be very careful when you replace the seals. Do not touch them with dirty hands
and be especially careful not to damage them when placing them on the shaft.
Also be careful not to scratch any of the machined surfaces that will result in a
leak path.
Reliability
Efficiency
Crop loss
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REACTIVE MAINTENANCE
Maintenance is performed only when it has failed and you are required to
act immediately.
PREVENTATIVE MAINTENANCE
PREDICTIVE MAINTENANCE
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Power consumption
Module No. :
IPCLDSMEC001
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Date : 29.10.2004
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Module No. :
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REFERENCES:
1. PUMP HANDBOOK
BY F.POLLOCK
2. PUMP HANDBOOK
BY KARRASIK
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