MT180e - V1.2

Teaching material
MT 180 Assembly and Maintenance

Exercise: Centrifugal Pump
10/2008
MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

All rights reserved, G.U.N.T. Gerätebau, Barsbüttel, Germany 10/2008
Teaching material
Dipl.-Ing. Klaus-Jürgen Radtke
Dipl.-Geogr. Uta Linke
Version 1.2 Subject to technical alternations
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Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technological principles of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Classification and categorisation of pump types based on operating
principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Designs and operating characteristics. . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 GUNT Practice Line kits and their usage . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4.1 Pump and system characteristics . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.3 Alteration of the operating point by restriction and
variation of speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Operating characteristics of multiple interacting pumps . . . . 20
2.4.5 Intake characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . 21
3 Basics of pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 Definition Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Reasons for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Detection of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Checking pumps and replacing common wearing parts . . . . . . . . . . 27
3.5 Wearing parts in the pumps from the GUNT Practice Line
for assembly and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.6 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.1 Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7.2 Shaft and piston rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7.3 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.4 Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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4 Technical description of the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . 46

4.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.5 Dimensions of the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.6 Parts drawing and parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Assembling and disassembling the centrifugal pump . . . . . . . . . . . . . . . . 56

5.1 Assembling the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.1.1 Assembly phase 1 – Packing gland (assembly unit 1) . . . . . 57
5.1.2 Assembly phase 2 – Bearing block (assembly unit 2) . . . . . 62
5.1.3 Assembly phase 3 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.2 Disassembling the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.1 Disassembling the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.2 Disassembling the bearing block (assembly unit 2) . . . . . . . 83
5.2.3 Disassembling the packing gland (assembly unit 1) . . . . . . . 87
6 Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Worksheet 1: Introduction to the centrifugal pump, Page 1. . . . . . . . 92
6.2 Worksheet 2: Design, function and applications of the centrifugal
pump, Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3 Worksheet 3: Identifying causes of faults, Page 1. . . . . . . . . . . . . . . 97
6.4 Worksheet 4: Sealing systems, Page 1. . . . . . . . . . . . . . . . . . . . . . . 98
6.5 Worksheet 5: Inspection of pumps, Page 1. . . . . . . . . . . . . . . . . . . 101
6.6 Worksheet 6: Servicing of pumps, Page 1 . . . . . . . . . . . . . . . . . . . 103
6.7 Worksheet 7: Repairs to pumps, Page 1. . . . . . . . . . . . . . . . . . . . . 105
6.8 Worksheet 8: Wearing parts on the centrifugal pump, Page 1 . . . . 107
6.9 Worksheet 9: Assembling the screw pump, Page 1 . . . . . . . . . . . . 109
6.10 Worksheet 10: Replacing gland packing, Page 1 . . . . . . . . . . . . . . 114
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6.11 Worksheet 11: Parts identification using the parts drawing,

Familiarisation with technical terms, Page 1 . . . . . . . . . . . . . . . . . . 117
6.12 Worksheet 12: Spare parts ordering, Page 1 . . . . . . . . . . . . . . . . . 120
7 Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.1 Worksheet 1: Introduction to the centrifugal pump, page 1 . . . . . . . 125
pump, Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.3 Worksheet 3: Identifying causes of faults, Page 1. . . . . . . . . . . . . . 130
7.4 Worksheet 4: Sealing systems, Page 1. . . . . . . . . . . . . . . . . . . . . . 131
7.5 Worksheet 5: Inspection of pumps, Page 1. . . . . . . . . . . . . . . . . . . 134

7.6 Worksheet 6: Servicing of pumps, Page 1 . . . . . . . . . . . . . . . . . . . 136
7.7 Worksheet 7: Repairs to pumps, Page 1. . . . . . . . . . . . . . . . . . . . . 138
7.8 Worksheet 8: Wearing parts on the centrifugal pump, Page 1 . . . . 140
7.9 Worksheet 9: Assembling the screw pump, Page 1 . . . . . . . . . . . . 142
7.10 Worksheet 10: Replacing gland packing, Page 1 . . . . . . . . . . . . . . 147
Familiarisation with technical terms, Page 1 . . . . . . . . . . . . . . . . . . 150
7.12 Worksheet 12: Spare parts ordering, Page 1 . . . . . . . . . . . . . . . . . 153
8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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1 Introduction
The MT 180 practice kit forms part of the GUNT learning concept for pump
maintenance, which is designed to aid education and training at trade acad-
emies and corporate training centres.
A close link between theory and practice is key to the learning content.
We offer the following products relating to the subject of pump assembly and
maintenance:
Pumps
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump
MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
Tab. 1.1 Product relating to pump assembly and maintenance
This kit includes a centrifugal pump.
Groups of two or three students working with one kit represents an optimal
way of learning.
1 Introduction 1
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The following learning content is covered:
Learning content / Exercises
Design and function of a centrifugal pump
Assembly and disassembly, including for maintenance purposes
Replacing components (e.g. seals)
Reading and understanding engineering drawings and operating instructions
Comparing different pumps

(together with an additional kit forming part of this learning concept)
Tab. 1.2 Learning content / Exercises

The teaching material includes a technical description detailing the basics of

pumps and dealing with the related maintenance.
The pump included in this kit is presented and described. Its assembly and
disassembly is demonstrated.
This section of the teaching material is intended to help tutors in preparing
their own lessons. They may, of course, select information from it at their own
discretion to use in their teaching.
The kit also includes prepared exercise sheets for the students, followed by
the relevant solutions.
The appendix includes the complete set of drawings for the pump, in the form
of an assembly drawing with parts list, and including all manufacturing draw-
ings for the individual components.
We very much hope you enjoy using this GUNT assembly practice kit, and
we wish you success in your important task of providing students and appren-
tices with an introduction to the basic principles of the technology.
1 Introduction 2
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2 Technological principles of pumps
This chapter is designed to provide basic information for the following assem-
bly and maintenance exercises from GUNT.
Code Product
MT 180 Assembly and maintenance exercise - centrifugal pump
MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump
MT 182 Assembly and maintenance exercise - screw pump
MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump
MT 185 Assembly and maintenance exercise - in-line centrifugal pump
MT 186 Assembly and maintenance exercise - gear pump
Wherever liquids are transported, produced or required to be supplied,

pumps are deployed. The demands which they must met vary widely. A vast
range of fluids has to be conveyed, from highly sensitive pharmaceuticals,
through large volumes of cooling liquid in power stations, to viscous chemical
products.
A wide variety of pumps have been developed over time for industrial
applications.
Not all pumps are mentioned in the following. Our outline presents a
structured guide to the most common types of pump.
2 Technological principles of pumps 3

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2.1 Classification and categorisation of pump types based on operating

principle
Pumps are fluid-flow machines which dictate how processes operate - that is
to say, they ensure that flow takes place within systems.
In practice, pumps are often named after the liquid they pump or their
purpose, such as milk pumps or cooling pumps. However, technicians and
fitters can more easily identify their design when they are named according
to their operating principle.
Fluid-flow machines
Machines Engines
(Machine drives a (Flowing medium
flowing medium) drives machine)
Pumps Turbines
Positive-displacement Centrifugal pumps

pumps (A gyro causes
(Medium conveyed by centrifugal forces to act
displacement device) on the medium)
Oscillating Rotating Normally priming Self-priming

Self-priming Self-priming (Not carrying gas, (Carrying gas,
(Displacement (Displacement pumping from low pumping from low
device moves device rotates in level restricted) level possible)
back and forth the pump body)
along an axis)
Piston pumps Gear pumps Centrifugal pumps Side-channel

pumps
Diaphragm pumps Screw Multi-stage
pumps centrifugal pumps
Inline pumps
Fig. 2.1 Pump types

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2.2 Designs and operating characteristics
The following table sets out the designs and operating characteristics of the
most common positive-displacement pumps.
The piston pump incorporates an oscillating piston

which is routed into a cylinder. The piston moves on an
axis. The pump body is blocked by intake and pressure
valves. A stroke gear drives the piston, which enlarges
or reduces the pump chamber on every stroke.
By enlarging the pump chamber, the pumped fluid is
drawn in by way of the intake valve. After a change of
stroke the pump chamber is reduced and the pumped

liquid is displaced by way of the pressure valve.
The diaphragm pump contains an elastomer

diaphragm which is clamped into the pump housing. The
oscillation is transferred from the stroke gear to the
diaphragm by way of a thrust rod. The fluid feeds in and
out by way of the valves, frequently executed as ball
valves.
The method of operation is the same as the piston
pump, with the diaphragm acting as the displacement
device.
The gear pump contains two opposite rotating rigid or

elastic gear wheels. The pump body is not closed off by
valves.
The liquid is pumped by the rotating gear wheels from
the intake to the delivery side in the gaps between the
teeth along the pump wall. The gear meshing and
narrow gaps between the rotor and housing minimise
the reflux.
The screw pump consists of two or more spindles with

helical splines which rotate inside a correspondingly
shaped housing. The pump body is not closed off by
valves.
The liquid is pumped axially in the free screw turns from
the intake to the delivery side.
Here too, as in the case of the gear pump, the sealing
from the delivery to the intake side is provided by narrow
gaps.

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The following table sets out the designs and operating characteristics of the
most common centrifugal pumps.
The centrifugal pump contains a rotating, enclosed

impeller with backward facing blades. The intake port is
axially aligned to the pump shaft. The delivery port is
aligned radially upwards.
The rotating impeller inside the pump body causes
centrifugal forces to act on the pumped liquid. The liquid
thrown out to the circumference of the pump by this
flows out of the pump through the delivery port.
The multi-stage centrifugal pump is similar in design

and action to the centrifugal pump. The difference is that
is features multiple impeller arranged in a row on a shaft.
The pumped liquid passes from the intake port via the
rotating impeller through a fixed guide channel to the
next impeller, and so on, until it reaches the delivery
port. The multistage impeller layout means the pump
attains higher delivery heads.
The inline centrifugal pump is similar in design and

method of operation to the centrifugal pump. Its intake
and delivery ports are along one axis however, though
here too the feed to the pump flows axially by way of an
appropriately shaped housing. The inline pump is used
in straight pipelines.

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Other special centrifugal pump designs
The side-channel pump contains a rotating starshaped

open impeller with radially running vanes. It rotates
inside a pump housing featuring a side channel which
narrows from the inlet to the outlet.
The energy transfer acts on the medium by means of an
exchange flow of the liquid in the impeller with that in the
side channel. The side channel pump thus operates
continuously with a self-priming effect, whereas the
centrifugal pump is not self-priming.
The canned motor pump is similar in design and action

to the centrifugal pump. It is leakage-free, as it requires
no shaft seal. The drive of the canned motor pump is
located practically inside the pump housing, and the
pumped liquid flows around it.
The magnetic clutch pump is similar in design and

action to the centrifugal pump. It is leakage-free and
requires no shaft seal.
The magnetic clutch pump is driven by a non-contact
magnetic clutch. The magnet on the pump shaft is inside
the pump housing. It is separated from the magnet on
the motor shaft by a tube.

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2.3 GUNT Practice Line kits and their usage
The GUNT Practice Line kits for assembly and maintenance exercises
include the following pumps:
MT 180 – Centrifugal pump

Fig. 2.2 Toolkit with parts set and pump
Fig. 2.3 Sectional drawing of the centrifugal pump
Centrifugal pumps are in widespread use, and are primarily used to pump
fluid media. Their applications include in shipbuilding, industry and water
supply.

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MT 181 – Multi-stage centrifugal pump

Fig. 2.5 Sectional drawing of a similar multi-stage centrifugal pump
The multi-stage centrifugal pump is modular in design, and is used to pump

fluid media at higher delivery pressures. It is used in water supply and in
industry.

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MT 182 – Screw pump

Fig. 2.7 Exploded-view drawing of the screw pump
Screw pumps are primarily used to transport viscous media such as lubricat-
ing oil, plant oil, glycols and polymers. Their applications include lubrication
systems for diesel engines and transmissions, as well as in hydraulic
systems.

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MT 183 – Diaphragm pump

Fig. 2.9 Sectional drawing of the diaphragm pump
Diaphragm pumps are absolutely leakage-free and, provided appropriate

materials are selected, are particularly well suited to pumping aggressive
fluids such as acids and caustic in chemical engineering applications.
Diaphragm pumps are often used for volumetric metering, as metering
pumps.

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MT 184 – Piston pump

Fig. 2.11 Drawing of the piston pump
Piston pumps are used primarily to transport fluids at high delivery pressures
and low flow rates. Typical applications include pumping drinking water and
domestic water in residential areas, in agriculture, onboard ships and in
industry.

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MT 185 – Inline centrifugal pump

Fig. 2.13 Exploded-view drawing of the in-line centrifugal pump
In-line centrifugal pumps are a sub-category of centrifugal pumps. Inline

pumps are installed in straight pipelines. They are required in applications
including water supply, watering and sprinkler systems, and in heating engi-
neering.

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MT 186 – Gear pump

Fig. 2.15 Exploded-view drawing of the gear pump
Gear pumps are of the rotating positive-displacement pump category, and

are characterised by pulsation-free delivery at operating pressures up to
40bar. High-viscosity media such as oils, paints and adhesives can be
pumped.

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2.4 Operating characteristics of pumps
Alongside preventive maintenance, repair work forms a key part of general

service operations. Damage to pumps can be traced back to incorrect oper-
ation in more than 50% of cases.
It is advantageous for the assembly personnel to have basic knowledge of
how the pump operates and are aware of how to use the pump correctly.
2.4.1 Pump and system characteristics
The delivery capacity of a pump is indicated by the pump’s characteristic

curve. The delivery rates are measured on the test stand at the respective
delivery pressures. The pump measurement data is depicted in the form of a
characteristic curve. Usually the delivery head is given in place of the deliv-
ery pressure (as a result the characteristic curves of centrifugal pumps are
not dependent on the density of the pumped liquid).
In the case of centrifugal pumps the dependency of the delivery rate on the
head is marked: As the head rises, the delivery rate decreases significantly.
By contrast, the delivery rate of positive-displacement pumps remains virtu-
ally constant as the head rises.
Head H
Head H
Delivery Q Delivery Q
Fig. 2.16 Characteristic curve for Fig. 2.17 Characteristic curve for
a centrifugal pump a positive-displacement
pump
In the case of positive-displacement pumps, it must be ensured that the

permissible operating pressure is not exceeded. Overflow valves are
frequently used for this.

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Operation of the positive-displacement pump with the overflow valve

(partially) open is depicted in the horizontal segment of the curve (see Fig.
2.17).
The graph gives an indication of the delivery capacity of the pumps, though
it provides no information on the delivery data actually achieved.
An often cited problem when operating pumps is that the pump does not
reach the necessary pressure. Generally speaking, pumps only deliver mate-
rial; the associated pressure is caused by the system.
The system operating data can likewise be measured and depicted graphi-
cally in the system characteristic curve. As the delivery rate increases, the
system pressure - determined by practical calculation - rises.

Head H
Delivery Q
Fig. 2.18 System characteristic curve

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2.4.2 Operating point
The actual delivery data result from the interaction of the pump and the
system.
If the pump and system curves are plotted on the same diagram, the point at
which the curves intersect is the operating point.
Head H
Head H
1
Fig. 2.19 Operating point (1) of a Fig. 2.20 Operating point (1) of a
normally priming centrifugal positive-displacement pump
pump
So if the operating data do not conform to the specification, the technician

should first check and calculate the correct operation of the pump in the
system. This should be done on initial commissioning and every time the
system is modified.

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2.4.3 Alteration of the operating point by restriction and variation of speed
In practice, restriction is frequently used to set the desired delivery rate. The
flow is restricted by partially closing a valve on the delivery side of the pump.
This results in a new system curve with a steeper rise. The new operating
point 2 is the point of intersection of the new system curve with the pump
curve. Or in other words: The operating point has shifted along the pump
curve from 1 to 2.
While the delivery rate decreases as the head rises on a centrifugal pump,
the delivery of a positive-displacement pump remains constant as the
pressure rises.
Head H
Head H
1
1
Fig. 2.21 Shift in operating point from Fig. 2.22 Shift in operating point from
(1) to (2) by restriction for a (1) to (2) by restriction for a
normally priming centrifugal pump positive-displacement pump

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A common method of shifting the operating point of a pump is to vary the

speed. The speed is varied by means of an adjuster gear or a frequency
inverter. This produces a new pump characteristic curve.
The diagrams show an increase in speed from n1 to n2 for both pump types
(see Fig. 2.23 and Fig. 2.24). In the case of the centrifugal pump, the pump
curve moves upwards, while for the positive-displacement pump it shifts to
the right.
In both diagrams the operating point shifts upwards along the system curve.
That is to say, higher heads and delivery rates are produced as the speed
increases.
Head H
Head H
n2
n1 n2
n1
Fig. 2.23 Influence on the pump Fig. 2.24 Influence on the pump
characteristic of a variation in characteristic of a variation in
speed for a normally priming speed for a positive-
centrifugal pump displacement pump

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2.4.4 Operating characteristics of multiple interacting pumps
Operation of multiple pumps simultaneously in a system is quite common,

and in many cases essential in order to conform to extreme operating speci-
fications.
If multiple pumps are configured in parallel, the delivery rate is increased. If
pumps are configured in series (one behind the other), the delivery heads
are added together.
Fig. 2.25 Parallel configuration Fig. 2.26 Series configuration
The pump industry has made use of these properties and developed a
number of designs accordingly.
Multi-flow pumps achieve high delivery rates, multi-stage pumps achieve
high heads.
Fig. 2.27 Multi-flow pump, sectional Fig. 2.28 Multiple-stage pump, sectional
view and delivery principle view and delivery principle

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2.4.5 Intake characteristics of pumps
Attention must be paid to the intake characteristics of the pumps. A distinc-

tion is made between selfpriming and nonselfpriming pumps.
The normally priming centrifugal pump is a non-self-priming pump. It is not
capable of pumping a gaseous medium out of the pump body. It must always
be ensured that a liquid is fed in from a higher level, or where the feed is from
a lower level, the liquid head does not collapse, such as due to the use of foot
valves on the intake side.
Fig. 2.29 Infeed of a pump system for a normally priming pump

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Self-priming pumps include side channel pumps (see chapter 2.2, page 5).
They are capable of pumping gases. However, the pump body must always
be filled with liquid for this to happen. That is why the intake and delivery ports
on side channel pumps always point upwards.
Fig. 2.30 Intake of a pump system for a self-priming pump
Most positive-displacement pumps are self-priming. The displacement

device is able to compress the gas and displace it out of the pump body. For
this to happen, however, the pump must be partially filled with liquid, because
only wetted valves close exactly such that no reflux is possible. This also
applies to rotating positive-displacement pumps, of which the wetted gaps
restrict reflux.

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3 Basics of pump maintenance
3.1 Definition Maintenance
All pump operators should maintain their pumps in accordance with the main-
tenance and operating instructions issued by the manufacturers. Mainte-
nance is the umbrella term for inspection, servicing and repair (see Fig. 3.1).
A log book or machine file should be set up for each pump unit, indicating the
current status and the repair work carried out to date.
MAINTENANCE TO DIN 31051

Inspection Servicing Repairs
Recording and Preservation of the Restoration of the

assessment of the specified status specified status
current actual status
Measurement, Cleaning, Replacement,

Testing, Lubrication, Correction
Diagnosis Adjustment
With the system Only with Only with the system

running and at stand system stopped stopped, based on
still based on according to specific work order and
inspection instructions maintenance after careful preparation
instructions
Fig. 3.1 Maintenance
3 Basics of pump maintenance 23

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3.2 Reasons for maintenance
Pumps are required for the operations of many manufacturing systems. If the
pumps are malfunctioning, there is a risk of production outages. Appropriate
maintenance is a key factor determining the productivity of operations.
Complete replacement of the pump is possible in the event of a defect,
though it is not always essential and, especially, is not necessarily cost-effec-
tive. Carrying out preventive maintenance and servicing, as well as repairs,
is advantageous. A number of reasons are cited by way of example.
• The cost of purchasing a mid-sized industrial pump is considerable. The
annual cost of wearing parts amounts to around 10% - 20% of the
purchase price of the new pump.

• Holding a complete replacement pump in stock is inefficient and expensive
for many businesses. It is, however affordable, and advisable, to hold
stocks of key pump spares.
• The delivery lead times for complete pumps are usually lengthy, whereas
spares can be supplied from suppliers’ central stores at short notice.
1
Cost
Service life
Fig. 3.2 Total cost, comparison of replacement (1) and maintenance (2)
• Fig. 3.2 shows that routine maintenance of pumps (2) results in lower costs
in the medium and long term than complete replacement of pumps (1).

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3.3 Detection of faults
Many factors need to be considered in order to ensure optimised, trouble-free

operation of pumps. Nevertheless, faults will routinely occur. A number of
basic points need to be observed in order to assess faults and their causes:
• The specifications of the delivery medium need to be considered in order
to ensure long service life of the pumps. The material durability of the
pump components and seals must be ensured. The design and construc-
tion of the pump must be attuned to the specific pumping requirements.
• Most pumps are driven by electric motors. Attention must be paid to
correct dimensioning and selection.
• Incorrect electrical connections and setting the incorrect direction of

rotation are often sources of faults resulting in production problems.
• As a general rule applicable to all pumps, lengthy periods of dry running
should be avoided, as this would substantially shorten the service lives of
the shaft seal, piston seal and valves. The delivery medium provides
additional lubrication of those components. This principle is illustrated by
the example of the floating ring seal in Fig. 3.3.
Fig. 3.3 Floating ring seal with liquid film
There must always be a liquid film between the contact faces of a floating ring
seal.

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During inspection of the pump, checks should be made regularly while the
pump is running to ensure early detection of faults, focussing in particular on
the following points:
• Leakage
• Noise
• Smooth running
• Temperature
• General condition
The reasons for pump faults are many and varied.
System-related disturbances such as pressure surges should be avoided or

eliminated. Incorrectly switching system valves may stop the pumped liquid
to an extreme degree, causing overlaid liquid waves to form which result in
pressure surging as far as into the pump.
Trapped foreign bodies cause significant damage inside the pump.
Deformed shafts, destroyed bearings and valves, as well as scraping impel-
lers, are the consequences of such disturbances. Even tiny abrasive particles
will cause long-term damage to the pump and the seals.
The occurrence of cavitation is a system fault which needs to be prevented.
If the infeed line to the pump is incorrectly dimensioned, it is possible that a
vacuum will created in the intake port, causing the medium to boil. The
increase in pressure in the pump causes the boiling bubbles to implode,
thereby destroying the housing and impeller.
Fig. 3.4 Cavitation damage to a pump impeller

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3.4 Checking pumps and replacing common wearing parts
In accordance with the service intervals specified in the manufacturers’ main-

tenance instructions, which are additionally dependent on the specific oper-
ating conditions, it is advisable to check pumps about once a year.
Bearings
The operating instructions specify that the lubricant should be changed on
pumps with an enclosed gear and bearing unit.
Modern-day greased bearings are lifetime-lubricated, and merely need to be
checked for smooth running.
Shaft seals
Packing glands and floating ring seals are checked for leaks and wear.
Glands can be adjusted, if still possible. The gland packing should be
replaced after about 2000 operating hours.
The service lives of the floating ring seals are considerably longer. They are
replaced in full if worn.
Couplings
Pumps coupled to their drives by flexible couplings should be checked for
flush coupling. The power-transmitting components should be checked for
wear and replaced as necessary.

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Pump internals
The pumps should be opened and their internals checked for wear and
corrosion at the specified servicing intervals.
In the case of centrifugal pumps, as well as the shaft seal the static seal ring
must be checked and replaced if worn.
The valves of reciprocating pumps, including their sealing faces, should be
checked. Piston rings and packing should be checked for wear, and the
plungers and sleeves checked for scoring.
20
Pump internals Shaft seal
Bearing Coupling
Fig. 3.5 Pump unit with listed wearing part groups

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3.5 Wearing parts in the pumps from the GUNT Practice Line for assembly
and maintenance
It should be stated by way of preamble that, according to the state of the art
in centrifugal pumps, bearings are no longer classed as wearing parts.
MT 180 – Centrifugal pump
Housing seal Shaft seal

(gland)
Fig. 3.6 Sectional drawing of the centrifugal pump
MT 181 – Multi-stage centrifugal pump

Packing gland Housing/stage seal Floating ring seal
Fig. 3.7 Sectional drawing of a similar multi-stage centrifugal pump

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MT 182 – Screw pump

Housing seal Housing seal
Floating ring seal
Fig. 3.8 Exploded-view drawing of the screw pump
MT 183 – Diaphragm pump
Valves
Diaphragm
Oil filling Journal bearing

Fig. 3.9 Sectional drawing of the diaphragm pump
The wearing parts mentioned should be replaced during servicing.

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MT 184 – Piston pump
Piston rod seal
Valves
Oil filling Piston seal
Fig. 3.10 Drawing of the piston pump
MT 185 – Inline centrifugal pump
Housing seal Floating ring seal
Fig. 3.11 Exploded-view drawing of the in-line centrifugal pump
Wear is to be expected on the parts marked, necessitating replacement of

them.

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MT 186 – Gear pump
O-rings
Floating ring seal

Wear disc Journal bearing Housing seal
Fig. 3.12 Sectional drawing of the gear pump
Any well organised maintenance department should hold stocks of the

wearing parts on the various pumps mentioned in this chapter.

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3.6 Shutdown
In systems in which uninterrupted running of pumps is extremely important,

such as in power stations or onboard ships, replacement units are installed
fully piped-up as standby units. This allows servicing or repairs to be carried
out during live operation, by switching to the standby unit.
Fig. 3.13 Installation with standby Fig. 3.14 Single pump with stop
pump valves
In most production environments, maintenance can only be carried out during

production downtimes - that is, at partial or complete standstill. The pumps
should be integrated into the system in such a way that short-interval servic-
ing can be carried out without removing them. That is to say, they must be
easily accessible for inspection and servicing. On the pump intake side and
the delivery side stop valves should be installed.
In the case of positive-displacement pumps, the drive unit is first shut down.
Immediately after the pump stops the delivery-side valve is closed, then the
intake side is closed. If non-return valves are installed, they automatically act
as stop valves. So installed non-return valves on the delivery side, for exam-
ple, prevent possible reflux to the pump.
In the case of centrifugal pumps, the delivery-side valve is first closed, then
the drive is shut down, and then the intake side is closed.
Before opening the pump, the pump and the connected piping system must
be drained. This can be done either by way of sealing plugs or by carefully
detaching the pipe fittings.
If the pump unit is removed completely from the system for major mainte-
nance work, the safety guidelines issued by the drive manufacturers must
additionally be followed.

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3.7 Repairs
Whereas during servicing parts are usually replaced following checking and
as required, during repair complete wearing parts or defective components
are replaced after predetermined operating cycles. These cycles are either
specified by the manufacturers or they are determined by the identified
condition of parts at the various maintenance intervals.
It is advisable to schedule every second to third service as a repair operation.
3.7.1 Static seals

Flat seals and O-rings used for sealing between metal components and to
prevent escape of liquid from the pump body are replaced completely. Their
locations include at the connection fittings and on the housing covers, floating
ring seals, shaft sleeves and valves.
Procedure:
• Dismount the pump
• Remove the seals and dispose of them
• Clean the parts
• Install the new seals during reassembly
• Avoid mechanical damage. Ensure cleanliness.
Grease seals where necessary.

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Static seal
Static seals
Static seals
Fig. 3.15 O-rings in a centrifugal pump

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3.7.2 Shaft and piston rod seals
The most varied stresses on seals in pump engineering occur in the sealing
of shaft and piston rod feed-throughs. These seals must act between areas
subject to different pressures, and are subject to the demands of a wide
variety of media, as well as having to withstand additional physical strains
caused by rotating shafts or oscillating piston rods. These types of seal are
known in engineering as dynamic seals. Operators expect reliable sealing,
with minimal leakage, over a long service life. The shaft seals in particular
should be preventively replaced during scheduled repair work, because of
the extreme stresses to which they are subject.
Piston rod seal
Fig. 3.16 Example of a piston rod seal
Shaft seal
Fig. 3.17 Example of a shaft seal

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A tried and proven method of sealing shafts is by means of soft packing

glands.
This packing consists of a woven cord made principally of solid fabrics which
is inserted in the packing space between the shaft and the housing, where it
is deformed by an axial force and so moulded to the surfaces it is intended to
seal.
1 3
4
Fig. 3.18 Example of a gland Fig. 3.19 Packing gland packing
To seal the pump shaft, packing glands (1) are used. These are provided in
a wide range of materials and designs depending on the pump application.
To protect the shaft, a shaft sleeve (2) is installed. Locking rings or ancillary
glands (3) hold the packing in place. The gland press (4) compresses the
packing by way of screw fittings. Correct functioning demands careful assem-
bly and commissioning.

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Item Name
1 Washer
2 Shaft
3 Packing gland packing
4 Locking ring
5 Packing gland press
6 Stud bolt with

hexagonal nut
7 Shaft sleeve
8 Housing cover
Fig. 3.20 Packing gland of a centrifugal pump, sectional view with zoom
When packing a new gland the following points need to be considered:

• Correct choice of packing based on quality and dimensions
• Completely remove old packing residues (3)
• The shaft protective sleeve (7) must be free of surface damage
• Insert the packing (3) with offset interfaces
• Use of sharp tools will damage the gland
• Tighten the gland press (5) by screws after inserting the packing, then
slacken it slightly
• The pump shaft (2) must be loose enough to be turned slightly by hand

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• Only tighten up the gland press after a run-in time of about 20-30 minutes
with leakage of 50-100 drops per minute
• Adjust the gland to the required leakage rate of 3 drops per minute
To seal shaft lead-throughs which are subject to high stresses, floating ring
seals are the most advantageous option nowadays. They are available in a
wide range of designs, dimensions and frictional material pairings. Correctly
selected, fitted and operated floating ring seals will permit longer-lasting
operation of rotating positive-displacement and centrifugal pumps, with less
leakage, then packing glands.
3 2 4 1
Fig. 3.21 Drawing of a floating ring seal
Floating ring seals are contact seals which create a yielding seal connection
between stationary and rotating contact faces. Between the contact faces is
a film of liquid, which assumes a stable position due to the centrifugal force
occurring during rotation. The floating ring seal is sealed against the housing
by means of static elastomer seals (1). The floating ring (2) rotating with the
shaft is held axially in place relative to the counter-ring (4) fixed in the housing
by a spring (3). The contact faces thus automatically adjust axially. Even high
pressures can be controlled by means of hydraulic relief.

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Fig. 3.22 Floating ring seal
Procedure for replacing the floating ring seal on a centrifugal pump shown
below:
• Shut down the pump
• Open the pump cover (1)
• Slacken the impeller nut (2)
• Detach the impeller (3) from the shaft
• Remove the floating ring (4) from the shaft
• Pull the counter-ring (5) out of the housing using a suitable implement
• Assemble in the reverse order of removal
4
1
3
5
2
Fig. 3.23 Example of replacing a floating ring seal on a centrifugal pump

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In view of the wide range of floating ring seal designs and pump versions,
methods of removal and fitting vary. The principle illustrated here is that appli-
cable to the most frequently used centrifugal pump.
The piston rod sealing in oscillating motions of the piston rods and plungers
of the piston pumps is achieved by using packing glands, lipped rings,
grooved rings (1) and conical rings held in support rings (2). The design and
materials must always be selected to match the given operating conditions.
Spring-loaded (3) seals, for example, offer uniform pre-tension, low friction
and so longer service lives.
3 1 2
Fig. 3.24 Drawing of a piston rod seal
The method of removal and fitting depends on the specific pump version and
design. The manufacturers’ fitting instructions are useful in this context, and
should be followed.

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The same is true of the piston seals. Replacing piston rings and piston
sleeves forms part of the essential scheduled repair routine. Some design
variants are shown in Fig. 3.25.
Piston with hemp stricks Piston with leather/rubber Piston with metal seal
sleeves rings
Fig. 3.25 Examples of piston seals

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3.7.3 Valves
Positive-displacement pumps such as reciprocating pumps and diaphragm

pumps seal off the delivery space by means of intake and delivery side
pressure valves. They open due to the resultant pressure difference on every
stroke and close due to their intrinsic mass or by additional spring force.
The valves of the smaller diaphragm pumps, used as metering pumps in the
chemical industry, are executed as ball valves. Owing to the more precise
effect achieved, twin ball valves are often installed. They are replaced by
simply unscrewing the valve unit out of the housing.
Fig. 3.26 Twin ball valve of a diaphragm pump
The valves of the piston pumps may be executed as weight or spring-loaded

disc valves.
The sealing faces are mostly metallic, and correspondingly sensitive.
After being individually removed, the discs are replaced. The valve seats are
checked and re-milled or lapped as necessary. In the case of valves with an
additional elastomer sealing disc, only the disc needs to be replaced, and the
smooth running checked.

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Weighted with conical Spring-loaded with flat Spring-loaded with flat seat
seat seat and seal ring
Fig. 3.27 Examples of disc valves
3.7.4 Spare parts ordering
Maintenance work should generally be carried out on a routine basis in

accordance with the maintenance instructions and safety rules laid down by
the manufacturers. Key parts should be replaced at the maintenance inter-
vals indicated in the operational or machine log. Arrangements should be
made for parts to be procured from the supplier in advance.
Every pump has a rating plate affixed to it by the manufacturer. The rating
plate indicates the manufacturer’s name, the pump model and serial number.
The data is often also imprinted on the housing, so the information is still
available even if the rating plate comes off. Based on this information, the
exact technical and material specification can be identified.

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Fig. 3.28 Example of a housing with imprinted model and serial number
The details shown in Fig. 3.29 need to be quoted to the supplier when order-
ing spares, so as to ensure the correct parts are supplied:
1. Pump model
2. Serial number
3. Part name
4. Item number on parts list
Fig. 3.29 Information for spare parts ordering, e.g. identified from rating plate, parts
drawing or parts list

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4 Technical description of the centrifugal pump
4.1 Description
Fig. 4.1 Centrifugal pump
Centrifugal pumps are one of the most common types of pumps. They are
compact and relatively simple in design.
The medium is conveyed by centrifugal force generated by the rotation of the
pump impeller, or gyro. Standard pumps are – as the term suggests –
standard items. As a result they are relatively cheap to purchase and main-
tain.
Centrifugal pumps are primarily used to pump water and other fluid media.
Their applications include in shipbuilding, industry and water supply.
Centrifugal pumps can be supplied in a wide variety of designs, depending
on the requirements they must meet. The pump described here in the MT 180
practice kit is a bearing block version.
4 Technical description of the centrifugal pump 46

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4.2 Mode of operation
An impeller (4) is caused to rotate by way of the shaft (5) of the centrifugal
pump. The blades of the impeller face backwards and rotate. This causes
centrifugal forces to act on the pumped liquid. The pumped liquid is forced to
the outer circumference of the spiral housing (2).
The fast-flowing liquid is slowed in the spiral housing, which expands. As a
result, the kinetic energy generated by the rotating impeller is converted into
static pressure energy. The pumped liquid flows out of the pump’s delivery
port (7). Additional liquid is continuously fed in by way of the intake port (8).
7 5
Item Name
2 Spiral housing
4 Impeller
5 Shaft
7 Delivery port
8 Intake port
Fig. 4.2 Flow path inside the centrifugal pump

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Inside the pump, a portion of the flow - dependent on the counterpressure -

always flows back from the higher pressure level to the impeller inlet.
The direction of pumping is not reversible. The pump reaches its nominal
delivery in clockwise rotation (viewed in the direction of the drive shaft).
The centrifugal pump is non-self-priming. It must not be run dry, so as to
prevent wear and preserve the sealing.
Fig. 4.3 Action of the impeller

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4.3 Layout
The layout of the centrifugal pump is shown in the sectional drawing. The
pump consists of the following main components:
• Bearing block (1)
• Spiral housing (2)
• Housing cover (3)
• Impeller (4)
• Shaft (5)
• Packing gland (6).
The pump is usually driven by an electric motor which is linked to the shaft by
a flexible coupling.
The shaft is guided radially and axially in the bearing block by two radial ball
bearings.
An enclosed radial impeller is mounted on the front end of the shaft. It rotates
inside the spiral housing, which expands as far as the delivery port.
The intake port is aligned axially to the impeller. The delivery port aligned
radially upwards on the spiral housing.

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2 4 3 6 5 1
Item Name Item Name
1 Bearing block 4 Impeller
2 Spiral housing 5 Shaft
3 Housing cover 6 Packing gland
Fig. 4.4 Sectional drawing with main components of the centrifugal pump

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4.4 Technical data
Pump model: 32/125 No. 308370

Power consumption max. 1.1 kW
Max. capacity: 19 m3/h
Max. head: 22 m
Impeller diameter: 130 mm
Speed: 2900 rpm
Intake port: DN 50
Delivery port: DN 32
Housing and impeller made of grey cast iron

Shaft seal: Packing gland packing Ramilon
Head
Speed: 2900 rpm
Diameter
of impeller
Fig. 4.5 Characteristic map

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4.5 Dimensions of the centrifugal pump

Fig. 4.6 Dimensions

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4.6 Parts drawing and parts list

Fig. 4.7 Parts drawing, sheet 1

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Pos. Quan- Unit Item Article code/norm Remark

tity
1 1 Piece Bearing block MT180.10.01.001 EN-GJL-200
2 1 Piece Spiral housing MT180.10.01.002 EN-GJL-250
3 1 Piece Housing cover MT180.10.01.003 EN-GJL-250
4 1 Piece Impeller MT180.10.01.004 EN-GJL-200
5 1 Piece Shaft MT180.10.01.005 X20Cr13
6 1 Piece Packing gland press MT180.10.01.006 EN-GJL-200
7 2 Piece Bearing cover MT180.10.01.007 EN-GJL-200

8 1 Piece Shaft sleeve MT180.10.01.008 X2CrNiMoN22-5-3
9 1 Piece Washer MT180.10.01.009 X2CrNiMoN22-5-3
10 1 Piece Locking ring MT180.10.01.010 CuZn28
11 1 Piece Flat seal MT180.10.01.011 Centellen WS3820
12 2 Piece Radial ball bearing DIN 625-6303
13 1 Piece Featherkey ISO 2491-A-6x6x22 X2CrNiMoN22-5-3
15 1 Piece Splash ring 24x50x4
16 4 Piece Packing gland packing Ramilon 4586 Spick
17 5 Piece Sealing plug with flat seal DIN 910-G3/8“A St
18 1 Piece O-ring 20x1,5 Perbunan

19 1 Piece Hexagonal cap nut DIN 917-M16 CuAl10Ni
20 4 Piece Stud bolt DIN 939-M10x30 8.8
22 4 Piece Hexagon head screw ISO 4017-M8x15 8.8
23 6 Piece Hexagonal nut ISO 4032-M10 8
24 1 Piece Spring ring DIN 128-B16
25 1 Piece Corrugated spring 42x51x0,5 K2 L&M
26 5 Piece Sealing plug with flat seal DIN 7603-24x17x2 Klingersil C4400
27 2 Piece Washer ISO 7090-12 200 HV
Tab. 4.1 Parts list

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5 Assembling and disassembling the centrifugal pump
5.1 Assembling the centrifugal pump
The process of assembling the centrifugal pump is divided into three sec-
tions:
• Assembly phase 1 – Packing gland (assembly unit 1)
• Assembly phase 2 – Bearing block (assembly unit 2)
• Assembly phase 3 – Pump
Tools:
• Puller
• Combination wrench, size 13
• Soft hammer
• Screwdriver
• Socket wrench, size 24
• Jigs 1 and 2.
5 Assembling and disassembling the centrifugal pump 56

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5.1.1 Assembly phase 1 – Packing gland (assembly unit 1)
10
Item Name
6
3 Housing cover
6 Packing gland
16 press
10 Locking ring
16 Packing gland
packing
Fig. 5.1 Drawing of the packing gland (assembly unit 1)
23
27
Item Name
23 Hexagonal nut
27 Washer
Fig. 5.2 Packing gland, fully assembled (assembly unit 1)

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23, 27
10
16
Item Name
3 Housing cover
6 Packing gland press
10 Locking ring
16 Packing gland packing
23 Hexagonal nut
27 Washer
Fig. 5.3 Parts required for assembly

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Procedure for assembling the packing gland (assembly unit 1)
Housing cover
(item 3)
Packing gland packing

(item 16)
Locking ring
(item 10)
Packing gland packing

(item 16)
Packing gland press

(item 6)
Hexagonal nut
with washer
(items 23, 27)
Packing gland
(assembly unit 1)

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Assembly procedure for packing gland (assembly unit 1)
NOTICE
For the assembly exercises the supplied
dummies should be used in place of the gland
packing.
Fig. 5.4 Dummies for gland packing
Assembly procedure:
• Shape a gland pack (16) into a ring and stuff it into the housing cover (3).
• Slot the locking ring (10) into the housing cover (3).
• Stuff the other three gland packs (16) into the housing cover. The
abutment of each must be at a 90° offset.

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Fig. 5.5 Assembling the gland packing
• Slot the gland press (6) into the housing cover (3).
• Attach the gland press (6) lightly to the housing cover by the washer (27)
and hexagonal nut (23).

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5.1.2 Assembly phase 2 – Bearing block (assembly unit 2)
1 12 25
14
7
22
15
Item Name Item Name
1 Bearing block 14 Featherkey
5 Shaft 15 Splash ring
7 Bearing cover 22 Hexagon head screw
12 Radial ball bearing 25 Corrugated spring
Fig. 5.6 Drawing of the bearing block (assembly unit 2)

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Fig. 5.7 Bearing block, fully assembled (assembly unit 2)

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22
7
14
15 5 25 12
Item Name
1 Bearing block
5 Shaft
7 Bearing cover
12 Radial ball bearing
14 Featherkey
15 Splash ring
22 Hexagon head screw
25 Corrugated spring

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Procedure for assembling the bearing block (assembly unit 2)
Bearing block
(item 1)
Radial ball bearing

(item 12)
Bearing cover
(item 7)
Hexagon head screw

(item 22)
Radial ball bearing

(item 12)
Shaft
(item 5)

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Corrugated spring
(item 25)
Bearing cover
(item 7)
Hexagon head screw

(item 22)
Splash ring
(item 15)
Featherkey
(item 14)
Bearing block
(assembly unit 2)

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Assembly procedure for bearing block (assembly unit 2)

• Drive the radial ball bearing (12) with the jig 2 and the soft hammer into the
front seat in the bearing block (1).
Fig. 5.9 Driving in the radial ball bearing
• Attach the bearing cover (7) by the hexagon head screws (22) to the front
bearing seat in the bearing block (1).
Fig. 5.10 Attaching the bearing cover

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• Drive the radial ball bearing (12) with the jig 1 and the soft hammer onto
the rear seat of the shaft (5).
Fig. 5.11 Driving in the radial ball bearing
• Drive the shaft (5) with the jig 1 and the soft hammer from the rear into the
bearing block and the front bearing.
Fig. 5.12 Driving in the shaft

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• Place the corrugated spring (25) against the rear bearing.

Fig. 5.13 Inserting the corrugated spring
• Attach the bearing cover (7) by the hexagon head screws (22) to the rear
bearing seat in the bearing block (1).
• Push the splash ring (15) onto the front part of the shaft.
Fig. 5.14 Pushing on the splash ring

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• Insert the featherkey (14) into the rear keyway of the shaft.
Fig. 5.15 Inserting the featherkey

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5.1.3 Assembly phase 3 – Pump
17, 26 4 18 A 8 B
2 19 24 13 9 11 23
Item Name Item Name
A Assembly unit 1 13 Featherkey
B Assembly unit 2 17, 26 Sealing plug with flat seal
2 Spiral housing 18 O-ring
4 Impeller 19 Hexagonal cap nut
8 Shaft sleeve 23 Hexagonal nut
9 Washer 24 Spring ring
11 Flat seal
Fig. 5.16 Drawing of the pump

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Fig. 5.17 Centrifugal pump, fully assembled

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B
23
11
24
13
4
19
9
8 18 A 17, 26
Item Name Item Name
A Assembly unit 1 13 Featherkey
B Assembly unit 2 17, 26 Sealing plug with flat seal
2 Spiral housing 18 O-ring
4 Impeller 19 Hexagonal cap nut
8 Shaft sleeve 23 Hexagonal nut
9 Washer 24 Spring ring
11 Flat seal

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Procedure for assembling the pump
Bearing block
(assembly unit 2,
(item B)
Shaft sleeve
(item 8)
Packing gland
(assembly unit 1,
(item A)
O-ring
(item 18)
Washer
(item 9)
Featherkey
(item 13)
Impeller
(item 4)

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Hexagonal cap spring

with spring ring
(items 19, 24)
Flat seal
(item 11)
Spiral housing
(item 2)
Hexagonal nut
(item 23)
Sealing plug
with flat seal
(items 17, 26)
Centrifugal pump

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Assembly procedure for pump

• Push the shaft protective sleeve (8) onto the front part of the shaft.
Fig. 5.19 Pushing on the shaft sleeve
• Carefully push assembly unit 1 – packing gland (A) over the shaft and
against assembly unit 2 – bearing block (B).
Fig. 5.20 Assembling the packing gland (A)

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• Push the O-ring (18) over the shaft against the shaft sleeve (8).
Fig. 5.21 Pushing on the O-ring
• Push the washer (9) over the shaft against the O-ring and shaft sleeve.
• Insert the featherkey (13) into the keyway of the shaft.
Fig. 5.22 Inserting the featherkey

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• Mount the impeller (4) onto the shaft.

Fig. 5.23 Assembling the impeller
• Screw the hexagonal cap nut and spring ring (19, 24) onto the thread of
the shaft.
• Place the flat seal (11) against assembly unit 1 – packing gland.
Fig. 5.24 Inserting the flat seal

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• Attach the spiral housing (2) by the hexagonal nut (23) to assembly unit 2
– bearing block.
Fig. 5.25 Attaching the spiral housing to the bearing block
• Fit the four sealing plugs with flat seals (17, 26) into the tapped hole of the
spiral housing (2).
Fig. 5.26 Fitting the sealing plugs

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5.2 Disassembling the centrifugal pump
Tools:
• Puller
• Soft hammer
• Screwdriver
• Socket wrench, size 24
• Jig 2.
5.2.1 Disassembling the pump
• Unscrew the four sealing plugs with flat seals (17, 26) from the tapped hole
of the spiral housing (2).
• Unscrew the hexagonal nut (23) from the stud bolts of the spiral housing
(2).
• Detach the spiral housing (2) from assembly unit 2 – bearing block (B).
Fig. 5.27 Disassembling the spiral housing

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• Remove the flat seal (11) from assembly unit 1 – packing gland (A).
• Detach the hexagonal cap nut and spring ring (19, 24) from the shaft using
the socket wrench. Brace the impeller with the screwdriver when doing so.
Fig. 5.28 Detaching the hexagonal cap nut and spring ring
• Detach the impeller (4) from the shaft.

• Remove the featherkey (13) from the keyway of the shaft.
• Detach the washer (9) from the shaft.
• Carefully release and remove the O-ring (18) from the shaft sleeve (8)
using the screwdriver.
Fig. 5.29 Releasing the O-ring

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• Detach assembly unit 1 – packing gland (A) from the shaft and assembly
unit 2 – bearing block (B).
• Remove the shaft sleeve (8) from the shaft.
Fig. 5.30 Centrifugal pump, disassembled

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5.2.2 Disassembling the bearing block (assembly unit 2)
• Remove the featherkey (14) from the rear keyway of the shaft (5).
• Detach the splash ring (15) from the shaft (5).
• Detach the hexagon head screws (22) from the rear bearing seat in the
bearing block (1) and take off the bearing cover (7).
• Detach the corrugated spring (25) from the rear bearing.
Fig. 5.31 Removing the corrugated spring

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• Carefully drive the shaft (5) out of the bearing block (1) to the rear using
the soft hammer until the rear bearing is exposed.
Fig. 5.32 Driving out the shaft
• Place the puller over the radial ball bearing (12). Press the hook arms
evenly onto the bearing. Turn the adjuster thread against the shaft end.
Detach the bearing from the shaft by carefully turning the adjuster thread.
Fig. 5.33 Detaching the radial ball bearing

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• Detach the hexagon head screws (22) from the front bearing seat in the
bearing block (1) and take off the bearing cover (7).
• Carefully drive the shaft, together with the front radial bearing, out of the
bearing block (1) towards the front using the soft hammer.
Fig. 5.34 Removing the shaft
• Drive the radial ball bearing (12) off of the shaft using the jig 2 and the soft
hammer.
Fig. 5.35 Driving out the radial ball bearing

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Fig. 5.36 Bearing block, disassembled

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5.2.3 Disassembling the packing gland (assembly unit 1)
• Detach the hexagonal nut and washer (23, 27) from the stud bolts of the
housing cover (3).
• Remove the gland press (6) from the housing cover (3).
• Lever the gland packing (16) out of the housing cover using the screw-
driver.
Fig. 5.37 Removing the gland packing
• Pull the locking ring (10) out of the housing cover.

• Press the last gland pack (16) to the housing cover.
Fig. 5.38 Packing gland, disassembled

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6 Tasks
Tasks / Exercises Subject
Worksheet 1 Introduction to the centrifugal pump
Worksheet 2 Design, function and applications
Worksheet 3 Identifying causes of faults
Worksheet 4 Sealing systems
Worksheet 5 Inspection
Worksheet 6 Servicing
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembling the centrifugal pump
Worksheet 10 Replacing the gland packing
Worksheet 11 Parts identification using the parts drawing
Worksheet 12 Spare parts ordering
6 Tasks 88
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Parts drawing and parts list

6 Tasks 89
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6 Tasks 90
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tity


Fig. 6.3 Parts list
6 Tasks 91
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6.1 Worksheet 1: Introduction to the centrifugal pump, Page 1
Objective:
To obtain an overview of the design and function of the centrifugal pump.
Exercise:
You are provided with an assembled pump. Disassemble the pump so that
all the component parts are laid out before you.
6 Tasks 92
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Worksheet 1, Page 2
Pick up the pump drawings and the parts list. Locate the components in the
drawing. Refer to the parts list to find out the correct names of the
components.
6 Tasks 93
10/2008
Worksheet 1, Page 3
You are now familiar enough with the overall design of the pump to be able
to answer the following questions:
1. How is the lead-through of the free end of the shaft sealed on this pump?
2. Does a centrifugal pump have a predetermined direction of rotation? Or

are clockwise and anti-clockwise both possible?
3. Can you explain the basic operating principle of a centrifugal pump?
4. Take a look at the materials on the parts list. For which media might the
pump be suitable?
6 Tasks 94
10/2008

pump, Page 1
Objective:
To explain the design of the pump. To understand and describe its method of
operation and usage.
Exercise:
1. Describe the design of the pump. Use the drawings
2. Name the five key components.
6 Tasks 95
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Worksheet 2, Page 2
3. Explain the method of operation of the pump. Explain the delivery

principle.
4. Where is the centrifugal pump used?
6 Tasks 96
10/2008
6.3 Worksheet 3: Identifying causes of faults, Page 1
Objective:
To identify or suspect likely causes of faults in response to specific mal-
functions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table on the left. Note down
your assumptions in the right-hand section of the table. You can exclude
system-related disturbances.
Fault Suspected cause
Excessive amount of medium emerging

from the shaft end
Running noise has markedly increased
The usually generated pressure difference

between the inlet and outlet is no longer
being attained. The pressure difference is
much less than normal.
The pump housing has a much higher

surface temperature than normal
The current consumption of the drive motor

has increased significantly compared to
normal operating conditions
Medium is leaking from the housing cover
6 Tasks 97
10/2008
6.4 Worksheet 4: Sealing systems, Page 1
Objective:
To divide sealing systems into basic categories and identify them based on
the example of the centrifugal pump.
Information: Sealing systems found in pumps are categorised as follows:
Sealing systems
Static seals Dynamic seals

(seals subject to stationary (seals subject to
stress) motion)
6 Tasks 98
10/2008
Worksheet 4, Page 2
Exercise:
1. Here you see the sectional drawing of the pump.
In the sectional drawing, mark the static seals as S and the dynamic seals
as D.
What respective functions do they perform?
6 Tasks 99
10/2008
Worksheet 4, Page 3
When you have identified the sealing systems used in the centrifugal pump,
move on to the following exercise.
2. Describe the design and method of operation of a shaft seal based on the
floating ring principle.
3. Take a look at a shaft seal which applies the packing gland principle and
describe it.
6 Tasks 100
10/2008
6.5 Worksheet 5: Inspection of pumps, Page 1
Objective:
To know what the term “inspection” involves, and to draw up an inspection
plan/protocol.
Exercise:
1. What does the term “inspection” mean in the context of technical mainte-
nance?
Mark the statements you consider to be true or false in the Yes or No
column of the following table as appropriate.
Activity Yes No
The current actual status of a pump is recorded and assessed
Components such as impellers or seals are replaced as a

preventive maintenance measure
Shaft bearings are lubricated and couplings re-aligned
Entire pump units are replaced
An inspection is always carried out with the system stopped
During an inspection operating data of the pump system are

measured (read) and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair
Inspection is a routine operation in machinery and plant

maintenance
6 Tasks 101
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Worksheet 5, Page 2
When you have established what the term “inspection” means, move on to
the following exercise.
2. Imagine you were talking about a large-sized centrifugal pump which is of
key importance to the operations of a refinery.
Let’s also assume that this large pump is similar in design to the small
pump from our MT 180 practice kit.
Draw up an inspection plan by mean of which an inspection can be
documented.
Inspection plan
Pump: Performed by:
Serial no.: Date:
Item Comments
6 Tasks 102
10/2008
6.6 Worksheet 6: Servicing of pumps, Page 1
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technical main-
tenance?
Activity Yes No
Components such as impellers,

shaft seals and other seals are replaced as a preventive
maintenance measure
The object of servicing is to record and assess the current actual

status of a pump
Servicing of a pump is a routine operation, carried out at

predetermined intervals
A service is usually carried out with the system stopped
Servicing can be seen as equivalent to preventive repair
During a service, packing glands are repositioned, couplings

adjusted or oil fillings changed for example
Servicing is always carried out when damage to a pump is

identified
6 Tasks 103
10/2008
Worksheet 6, Page 2
When you have established what the term “servicing” means, move on to the
following exercise.
2. Do you think that routine servicing is useful and necessary for the centrif-
ugal pump from our MT 180 practice kit?
Give reasons for your decision.
3. Let’s assume that two centrifugal pumps with the classic differing shaft
seals are being used in a water supply system.
What servicing operations need to be carried out on the packing gland type
shaft seal and on the floating ring seal type?
6 Tasks 104
10/2008
6.7 Worksheet 7: Repairs to pumps, Page 1
Objective:
To know what is meant by the term “repairs” in this context and to draw up a
preventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technical main-
tenance?

Activity Yes No
In repair operations, parts which have been in use for a lengthy

period of time, such as impellers and seals, are replaced
Repairs are carried out when damage has occurred to the pump
Repairs may also be carried out as routine and preventive

maintenance measures to prevent damage and stoppages from
occurring in the first place
Preventive maintenance can prevent a pump from failing
Repairs are normally carried out with the system stopped
If servicing is carried out on a regular basis, repairs are not needed
6 Tasks 105
10/2008
Worksheet 7, Page 2
When you have established what the term “repairs” means, move on to the
following exercise.
2. Let’s assume that our centrifugal pump is a key component in a water
supply system, whereby a failure of the pump would shut down the entire
system.
In view of this, the pump is inspected and serviced at regular intervals.
In order to ensure the safest possible operation, the plant management
also decides to carry out routine preventive repair work on the unit.
Draw up a repair assignment to detail and document the work required.
Use the drawings.
Inspection assignment
Pump: Performed by:
Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Parts to be checked:
6 Tasks 106
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6.8 Worksheet 8: Wearing parts on the centrifugal pump, Page 1
Objective:
To identify the wearing parts on the centrifugal pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them.
6 Tasks 107
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Worksheet 8, Page 2
2. Of what materials are the wearing parts of the centrifugal pump made?
Enter the wearing parts from the previous page in the table with their
material data or standard designations.
Wearing part Material

6 Tasks 108
10/2008
6.9 Worksheet 9: Assembling the screw pump, Page 1
Objective:
To structure the assembly process. To identify which assembly units and
phases can be compiled before the overall assembly is carried out.
Exercise:
You have laid out all the component parts of the screw pump in front of you.
Your task is to assemble the pump.

To do so, you will first put together individual assembly units. Then combine
the assembly units in assembly phases to produce the overall system.
1. Collect the components from which you can compile assembly units and
phases. Name the assembly units and phases.
Use the drawings.
•
Item Name
6 Tasks 109
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Worksheet 9, Page 2
Item Name
Item Name
6 Tasks 110
10/2008
Worksheet 9, Page 3
2. When you have put together the various assembly units, the next step is
to assemble the pump.
In doing this, set out the procedure in a structure as shown in the
schematic diagram.
Depict the pump assembly phase through to completion of the fully
assembled pump.
Bearing block
(item 1)
Parts x, y, ...
Parts x, y, ...
Centrifugal pump
6 Tasks 111
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Worksheet 9, Page 4
Procedure for assembling the centrifugal pump
Assembly unit 2
(item B)
6 Tasks 112
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Worksheet 9, Page 5
Centrifugal pump
6 Tasks 113
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6.10 Worksheet 10: Replacing gland packing, Page 1
Objective:
To plan and carry out the replacement of gland packing on the centrifugal
pump.
Exercise:
1. Your task is to replace a gland pack on the centrifugal pump.
Set out your method in the pre-compiled work plan. Use the drawings.
6 Tasks 114
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Worksheet 10, Page 2
Work plan
Name: Centrifugal pump – Replacing gland packing
Deadline: Performed by:
Order no.: Date:
Opera- Procedure
tion Tools
Disassembly
6 Tasks 115
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Work plan
Order no.: Date:
Opera- Procedure
tion Tools
Assembly
Estimated time required: _____ min
6 Tasks 116
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Familiarisation with technical terms, Page 1
Objective:
To allocate items from a parts list to a parts drawing.
Exercise:
You are provided with a parts drawing on which the item numbers are not yet
entered. Refer to the supplied parts list.

Enter the item numbers from column 1 of the parts list in the boxes on the
drawing.
6 Tasks 117
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6 Tasks 118
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6 Tasks 119
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6.12 Worksheet 12: Spare parts ordering, Page 1
Objective:
To place a spare parts order.
Exercise:
You are going to carry out a repair, and need replacement parts for your
centrifugal pump.
Select three parts and place orders for them.
Use the documents provided.
Spare parts order for pump:
Part:
6 Tasks 120
10/2008
7 Solutions
Tasks / Exercises Subject
Worksheet 1 Introduction to the centrifugal pump
Worksheet 2 Design, function and applications
Worksheet 3 Identifying causes of faults
Worksheet 4 Sealing systems
Worksheet 5 Inspection
Worksheet 6 Servicing
Worksheet 7 Repairs
Worksheet 8 Wearing parts
Worksheet 9 Assembling the centrifugal pump
Worksheet 10 Replacing the gland packing
Worksheet 11 Parts identification using the parts drawing
Worksheet 12 Spare parts ordering
7 Solutions 121
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Parts drawing and parts list

7 Solutions 122
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7 Solutions 123
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tity


Fig. 7.3 Parts list
7 Solutions 124
10/2008
7.1 Worksheet 1: Introduction to the centrifugal pump, page 1
Objective:
To obtain an overview of the design and function of the centrifugal pump.
Exercise:
You are provided with an assembled pump. Disassemble the pump so that
all the component parts are laid out before you.
7 Solutions 125
10/2008
Worksheet 1, Page 2
Pick up the pump drawings and the parts list. Locate the components in the
drawing. Refer to the parts list to find out the correct names of the compo-
nents.
7 Solutions 126
10/2008
Worksheet 1, Page 3
You are now familiar enough with the overall design of the pump to be able
to answer the following questions:
1. How is the lead-through of the free end of the shaft sealed on this pump?
By a packing gland.
2. Does a centrifugal pump have a predetermined direction of rotation? Or
are clockwise and anti-clockwise both possible?
The centrifugal pump has a predetermined direction of rotation. The direc-
tion of pumping is not reversible. The pump reaches its nominal delivery in
clockwise rotation (viewed in the direction of the drive shaft).
3. Can you explain the basic operating principle of a centrifugal pump?
An impeller rotates inside the pump body. This causes centrifugal forces
to act on the pumped liquid. The pumped liquid is thrown out to the circum-
ference of the pump and flows out of the pump through the delivery port.
4. Take a look at the materials on the parts list. For which media might the
pump be suitable?
The pump is used to transport non-aggressive, fluid media, such as water.
7 Solutions 127
10/2008

pump, Page 1
Objective:
To explain the design of the pump. To understand and describe its method of
operation and usage.
Exercise:
1. Describe the design of the pump. Use the drawings

The pump is usually driven by an electric motor linked to the shaft by a
flexible coupling.
The shaft is guided radially and axially in the bearing block by two grooved
ball bearings.
An enclosed radial impeller is mounted on the front end of the shaft. It
rotates inside the spiral housing, which expands towards the delivery port.
The intake port runs axial to the impeller. The delivery port is aligned
radially upwards on the spiral housing.
The shaft is sealed by a packing gland.
The housing is sealed by flat seals.
2. Name the five key components.
Bearing block, spiral housing, impeller, shaft, packing gland.
7 Solutions 128
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Worksheet 2, Page 2
3. Explain the method of operation of the pump. Explain the delivery

principle.
An impeller is caused to rotate by way of the shaft of the centrifugal pump.
The blades of the impeller face backwards and rotate. This causes centrif-
ugal forces to act on the pumped liquid. The pumped liquid is forced to the
outer circumference of the spiral housing.
The fast-flowing liquid is slowed in the spiral housing, which expands. As
a result, the kinetic energy generated by the rotating impeller is converted

into static pressure energy. The pumped liquid flows out of the pump’s
delivery port. Additional liquid is continuously fed in by way of the intake
port.
4. Where is the centrifugal pump used?
Centrifugal pumps are in widespread use, and are deployed primarily to
pump water and other fluid media. Their applications include in shipbuild-
ing, industry and water supply.
7 Solutions 129
10/2008
7.3 Worksheet 3: Identifying causes of faults, Page 1
Objective:
To identify or suspect likely causes of faults in response to specific mal-
functions while the pump is operating.
Exercise:
Try to find the causes of the faults listed in the table on the left. Note down
your assumptions in the right-hand section of the table. You can exclude
system-related disturbances.
Fault Suspected cause
Excessive amount of medium emerging Shaft seal worn

from the shaft end
Running noise has markedly increased Bearing damaged

Foreign bodies in the pump
Impeller scraping on housing
The usually generated pressure difference Speed has decreased

between the inlet and outlet is no longer Motor defective
being attained. The pressure difference is
Wrong direction
much less than normal.
Impeller defective
The pump housing has a much higher Impeller scraping on housing

surface temperature than normal Shaft deformed
Pump pumping against closed gate valve
The current consumption of the drive motor Motor is defective

has increased significantly compared to Pump pumping with no counterpressure
normal operating conditions
Foreign bodies in the pump and internals
scraping
Medium is leaking from the housing cover Housing seal defective
7 Solutions 130
10/2008
7.4 Worksheet 4: Sealing systems, Page 1
Objective:
To divide sealing systems into basic categories and identify them based on
the example of the centrifugal pump.
Information: Sealing systems found in pumps are categorised as follows:
Sealing systems
Static seals Dynamic seals

(seals subject to stationary (seals subject to
stress) motion)
7 Solutions 131
10/2008
Worksheet 4, Page 2
Exercise:
1. Here you see the sectional drawing of the pump.
In the sectional drawing, mark the static seals as S and the dynamic seals
as D.
What respective functions do they perform?
The static seals seal the housing.
The dynamic seals seal the shaft feed-through.
D
S
7 Solutions 132
10/2008
Worksheet 4, Page 3
When you have identified the sealing systems used in the centrifugal pump,
move on to the following exercise.
2. Describe the design and method of operation of a shaft seal based on the
floating ring principle.
Floating ring seals are contact seals which create a yielding seal connec-
tion between stationary and rotating contact faces. Between the contact
faces is a film of liquid. The centrifugal force occurring during rotation
causes the liquid film to assume a stable position.

Static elastomer seals seal the floating ring seal from the housing. The
rotating floating ring is held by a spring axial to the counter-ring fixed in the
housing.
3. Take a look at a shaft seal which applies the packing gland principle and
describe it.
Packing glands are used to seal the pump shaft.
The gland packing is a woven cord mainly made of solid fabrics. It is
deformed in the packing space between the shaft and the housing by an
axial force and so pressed onto the surfaces being sealed.
A sleeve is fitted to protect the shaft. Locking rings or ancillary glands hold
the packing in place. The gland press compresses the packing by way of
screw fittings.
7 Solutions 133
10/2008
7.5 Worksheet 5: Inspection of pumps, Page 1
Objective:
To know what the term “inspection” involves, and to draw up an inspection
plan/protocol.
Exercise:
1. What does the term “inspection” mean in the context of technical mainte-
nance?
Activity Yes No
The current actual status of a pump is recorded and assessed X
Components such as impellers or seals are replaced as a X

preventive maintenance measure
Shaft bearings are lubricated and couplings re-aligned X
Entire pump units are replaced X
An inspection is always carried out with the system stopped X
During an inspection operating data of the pump system are X

measured (read) and entered in an inspection plan
An inspection can be seen as equivalent to preventive repair X
Inspection is a routine operation in machinery and plant X

maintenance
7 Solutions 134
10/2008
Worksheet 5, Page 2
When you have established what the term “inspection” means, move on to
the following exercise.
2. Imagine you were talking about a large-sized centrifugal pump which is of
key importance to the operations of a refinery.
Let’s also assume that this large pump is similar in design to the small
pump from our MT 180 practice kit.
Draw up an inspection plan by mean of which an inspection can be
documented.
Inspection plan
Pump: Performed by:
Serial no.: Date:
Item Comments
Pump Capacity
Delivery pressure
Leakage
Noise
Smooth running
Temperature
General condition
7 Solutions 135
10/2008
7.6 Worksheet 6: Servicing of pumps, Page 1
Objective:
To know what is meant by the term “servicing”.
Exercise:
1. What does the term “servicing” mean in the context of technical main-
tenance?
Activity Yes No
Components such as impellers, X

shaft seals and other seals are replaced as a preventive
maintenance measure
The object of servicing is to record and assess the current actual X

status of a pump
Servicing of a pump is a routine operation, carried out at X

predetermined intervals
A service is usually carried out with the system stopped X
Servicing can be seen as equivalent to preventive repair X
During a service, packing glands are repositioned, couplings X

adjusted or oil fillings changed for example
Servicing is always carried out when damage to a pump is X

identified
7 Solutions 136
10/2008
Worksheet 6, Page 2
When you have established what the term “servicing” means, move on to the
following exercise.
2. Do you think that routine servicing is useful and necessary for the centrif-
ugal pump from our MT 180 practice kit?
Give reasons for your decision.
Yes! During servicing, the condition of the wearing parts is checked and
the parts are replaced as necessary. For the centrifugal pump from
MT 180 the parts are the packing gland and the housing seal.
3. Let’s assume that two centrifugal pumps with the classic differing shaft
seals are being used in a water supply system.
What servicing operations need to be carried out on the packing gland type
shaft seal and on the floating ring seal type?
Packing glands must be repositioned depending on the leakage rate. Their
general condition must be checked and they must be repacked as neces-
sary.
Floating ring seals do not have to be adjusted. Their condition must, how-
ever, be checked at every service interval and they must be preventively
replaced depending on how important they are.
7 Solutions 137
10/2008
7.7 Worksheet 7: Repairs to pumps, Page 1
Objective:
To know what is meant by the term “repairs” in this context and to draw up a
preventive maintenance plan.
Exercise:
1. What does the term “repairs” mean in the context of technical main-
tenance?

Activity Yes No
In repair operations, parts which have been in use for a lengthy X

period of time, such as impellers and seals, are replaced
Repairs are carried out when damage has occurred to the pump X
Repairs may also be carried out as routine and preventive X

maintenance measures to prevent damage and stoppages from
occurring in the first place
Preventive maintenance can prevent a pump from failing X
Repairs are normally carried out with the system stopped X
If servicing is carried out on a regular basis, repairs are not needed X
7 Solutions 138
10/2008
Worksheet 7, Page 2
When you have established what the term “repairs” means, move on to the
following exercise.
2. Let’s assume that our centrifugal pump is a key component in a water
supply system, whereby a failure of the pump would shut down the entire
system.
In view of this, the pump is inspected and serviced at regular intervals.
In order to ensure the safest possible operation, the plant management
also decides to carry out routine preventive repair work on the unit.
Draw up a repair assignment to detail and document the work required.
Use the drawings.
Inspection assignment
Pump: Performed by:
Serial no.: Date:
Procedure Comments/Status
Parts to be replaced:
Gland packing (16)
O-ring (18)
Housing seal (11)
Flat seal (26)
Parts to be checked:
Housing components
Impeller
Bearing
Shaft
7 Solutions 139
10/2008
7.8 Worksheet 8: Wearing parts on the centrifugal pump, Page 1
Objective:
To identify the wearing parts on the centrifugal pump.
Exercise:
1. Mark the wearing parts on the pump drawing and name them.
Seal Housing seal Gland packing
O-ring
7 Solutions 140
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Worksheet 8, Page 2
2. Of what materials are the wearing parts of the centrifugal pump made?
Enter the wearing parts from the previous page in the table with their
material data or standard designations.
Wearing part Material
Gland packing (16) Ramilon 4586, Spick

O-ring (18) Perbunan
Housing seal (11) Centellen WS3820
Flat seal (26) Klingersil C4400
7 Solutions 141
10/2008
7.9 Worksheet 9: Assembling the screw pump, Page 1
Objective:
To structure the assembly process. To identify which assembly units and
phases can be compiled before the overall assembly is carried out.
Exercise:
You have laid out all the component parts of the screw pump in front of you.
Your task is to assemble the pump.

To do so, you will first put together individual assembly units. Then combine
the assembly units in assembly phases to produce the overall system.
1. Collect the components from which you can compile assembly units and
phases. Name the assembly units and phases.
Use the drawings.
• Assembly unit 1 – Packing gland
Item Name
3 Housing cover
6 Gland press
10 Locking ring
16 Gland packing
23, 27 Hexagonal nut with washer
7 Solutions 142
10/2008
Worksheet 9, Page 2
• Assembly unit 2 – Bearing block

Item Name
1 Bearing block
5 Shaft
7 Bearing cover
12 Radial ball bearing
14 Featherkey
15 Splash ring
22 Hexagon head screw
25 Corrugated spring
• Assembly phase – Pump assembly

Item Name
A Assembly unit 1
B Assembly unit 2
2 Spiral housing
4 Impeller
8 Shaft sleeve
9 Washer
11 Flat seal
13 Featherkey
17, 26 Sealing plug with flat seal
18 O-ring
19 Hexagonal cap nut
23 Hexagonal nut
24 Spring ring
7 Solutions 143
10/2008
Worksheet 9, Page 3
2. When you have put together the various assembly units, the next step is
to assemble the pump.
In doing this, set out the procedure in a structure as shown in the
schematic diagram.
Depict the pump assembly phase through to completion of the fully
assembled pump.
Bearing block
(item 1)
Parts x, y, ...
Parts x, y, ...
Centrifugal pump
7 Solutions 144
10/2008
Worksheet 9, Page 4
Procedure for assembling the centrifugal pump
Assembly unit 2
(item B)
Shaft sleeve
(item 8)
Assembly unit 1
(item A)
O-ring
(item 18)
Washer
(item 9)
Featherkey
(item 13)
Impeller
(item 4)
7 Solutions 145
10/2008
Worksheet 9, Page 5
Hexagonal cap spring

with spring ring
(items 19, 24)
Flat seal
(item 11)
Spiral housing
(item 2)
Hexagonal nut
(item 23)
Sealing plug
with flat seal
(items 17, 26)
Centrifugal pump
7 Solutions 146
10/2008
7.10 Worksheet 10: Replacing gland packing, Page 1
Objective:
To plan and carry out the replacement of gland packing on the centrifugal
pump.
Exercise:
1. Your task is to replace a gland pack on the centrifugal pump.
Set out your method in the pre-compiled work plan. Use the drawings.
7 Solutions 147
10/2008
Work plan
Order no.: Date:
Opera- Procedure
tion Tools
Disassembly
1 Unscrew hexagonal nut (23) from stud bolts of spiral Combination

housing (2) and detach spiral housing (2) from assembly wrench, size 13
unit 2 – bearing block (B)
2 Remove the flat seal (11) from assembly unit 1 – packing
gland (A)
3 Detach the hexagonal cap nut and spring ring (19, 24) Socket wrench,
from the shaft using the socket wrench. Brace the size 24, screwdriver
impeller with the screwdriver when doing so.
Detach the impeller (4) from the shaft
4 Remove the featherkey (13) from the keyway of the shaft
and detach the washer (9) from the shaft
5 Detach assembly unit 1 – packing gland (A) from the
shaft and assembly unit 2 – bearing block (B)
6 Detach the hexagonal nut and washer (23, 27) from the Combination
stud bolts of the housing cover (3) and remove the gland wrench, size 13
press (6) from the housing cover (3)
7 Lever the gland packing (16) out of the housing cover Screwdriver
using the screwdriver
8 Pull the locking ring (10) out of the housing cover
9 Press the last gland pack (16) to the housing cover
7 Solutions 148
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Work plan
Order no.: Date:
Opera- Procedure
tion Tools
Assembly
10 Shape a gland pack (16) into a ring and stuff it into the
housing cover (3)
11 Slot the locking ring (10) into the housing cover (3)
12 Stuff the remaining three gland packs (16) into the
housing cover. The abutment of each must be at a 90°
offset
13 Slot the gland press (6) into the housing cover and attach Combination
it only lightly to the housing cover by the hexagonal nut wrench, size 13
and washer (23, 27)
14 Carefully push assembly unit 1 – packing gland (A) over
the shaft and against assembly unit 2 – bearing block (B)
15 Push the washer (9) over the shaft against the shaft
sleeve and insert the featherkey (13) into the keyway of
the shaft
16 Mount the impeller (4) onto the shaft and attach it to the Socket wrench,
shaft by the hexagonal cap nut and spring ring (19, 24) size 24
17 Place the flat seal (11) against assembly unit 1 – packing
gland
18 Attach the spiral housing (2) by the hexagonal nut (23) to Combination
assembly unit 2 – bearing block wrench, size 13
Estimated time required: 30 min
7 Solutions 149
10/2008

Familiarisation with technical terms, Page 1
Objective:
To allocate items from a parts list to a parts drawing.
Exercise:
You are provided with a parts drawing on which the item numbers are not yet
entered. Refer to the supplied parts list.

Enter the item numbers from column 1 of the parts list in the boxes on the
drawing.
7 Solutions 150
10/2008
MT 180
7 Solutions
3 18 10 16 8 6 15 12 25 5 14
19 24 17 26 13 4 9 11
ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP
151
10/2008
22
7
1
21
27 23
23 20
2
7 Solutions 152
10/2008
7.12 Worksheet 12: Spare parts ordering, Page 1
Objective:
To place a spare parts order.
Exercise:
You are going to carry out a repair, and need replacement parts for your
centrifugal pump.
Select three parts and place orders for them.
Use the documents provided.
Spare parts order for pump:

Model: 32/125
Serial no.: 308370
Part:
1 set of gland packs Item 16
1x housing seal Item 16
1x O-ring Item 18
7 Solutions 153
10/2008
8 Index
A
Assembly phase 1 – Packing gland . . . . . . . . . . . . . . . . . . . . . . . . 57, 87
Assembly phase 2 – Bearing block . . . . . . . . . . . . . . . . . . . . . . . . . 62, 83
Assembly phase 3 – Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 80
C
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 8, 29, 46, 56
Centrifugal pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
Characteristic curve, pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Characteristic curve, system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
D
Diaphragm pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 11, 30
Dimensions of the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Dynamic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F
Floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
G
Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14, 32
H
Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
I
Inline centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13, 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Intake characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Multi-flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multiple-stage pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Multi-stage centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 9, 29
8 Index 154
10/2008
O
Operating point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
P
Packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 49
Parallel configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts drawing centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Parts list centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 12, 31
Piston rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 41
Piston seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Positive-displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 14
Pump characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pump, multi-flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump, multi-stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
R
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 34
Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
S
Screw pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 10, 30
Seals, dynamic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Seals, floating ring seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Seals, packing gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 49
Seals, static . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Series configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Standard centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Static seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
T
Technical data of the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . 51
V
Valves in pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Index 155
10/2008
9 Drawings
Name Drawing number
Assembly drawing MT180.00.01.000
Parts list MT180.00.01.000S
Bearing block MT180.10.01.001
Spiral housing MT180.10.01.002
Housing cover MT180.10.01.003

Impeller MT180.10.01.004
Shaft MT180.10.01.005
Gland press MT180.10.01.006
Bearing cover MT180.10.01.007
Shaft sleeve MT180.10.01.008
Washer MT180.10.01.009
Locking ring MT180.10.01.010
Flat seal MT180.10.01.011
Bearing block, unmachined cast part MT180.16.01.001
Spiral housing, unmachined cast part MT180.16.01.002
Impeller, unmachined cast part MT180.16.01.004
9 Drawings 156

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Teaching material

MT 180 Assembly and Maintenance

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

Version 1.2 Subject to technical alternations

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

2 Technological principles of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Operating characteristics of pumps . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Basics of pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

4 Technical description of the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . 46

5 Assembling and disassembling the centrifugal pump . . . . . . . . . . . . . . . . 56

5.1 Assembling the centrifugal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

6.11 Worksheet 11: Parts identification using the parts drawing,

7.5 Worksheet 5: Inspection of pumps, Page 1. . . . . . . . . . . . . . . . . . . 134

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

MT 180 Assembly and maintenance exercise - centrifugal pump

MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182 Assembly and maintenance exercise - screw pump

MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump

MT 185 Assembly and maintenance exercise - in-line centrifugal pump

MT 186 Assembly and maintenance exercise - gear pump

Tab. 1.1 Product relating to pump assembly and maintenance

This kit includes a centrifugal pump.

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

The following learning content is covered:

Learning content / Exercises

Design and function of a centrifugal pump

Assembly and disassembly, including for maintenance purposes

Replacing components (e.g. seals)

Reading and understanding engineering drawings and operating instructions

Comparing different pumps

Tab. 1.2 Learning content / Exercises

The teaching material includes a technical description detailing the basics of

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

2 Technological principles of pumps

MT 180 Assembly and maintenance exercise - centrifugal pump

MT 181 Assembly and maintenance exercise - multi-stage centrifugal pump

MT 182 Assembly and maintenance exercise - screw pump

MT 183 Assembly and maintenance exercise - diaphragm pump

MT 184 Assembly and maintenance exercise - piston pump

MT 185 Assembly and maintenance exercise - in-line centrifugal pump

MT 186 Assembly and maintenance exercise - gear pump

Wherever liquids are transported, produced or required to be supplied,

2 Technological principles of pumps 3

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

2.1 Classification and categorisation of pump types based on operating

Positive-displacement Centrifugal pumps

Oscillating Rotating Normally priming Self-priming

Piston pumps Gear pumps Centrifugal pumps Side-channel

Fig. 2.1 Pump types

2 Technological principles of pumps 4

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

2.2 Designs and operating characteristics

The piston pump incorporates an oscillating piston

stroke the pump chamber is reduced and the pumped

The diaphragm pump contains an elastomer

The gear pump contains two opposite rotating rigid or

The screw pump consists of two or more spindles with

2 Technological principles of pumps 5

MT 180 ASSEMBLY AND MAINTENANCE EXERCISE: CENTRIFUGAL PUMP

The centrifugal pump contains a rotating, enclosed

The multi-stage centrifugal pump is similar in design