Pumps and their maintenance

Chapter Three
3. Example for maintenance

Screw pump ACP (IMO Co.)

3.1 Introduction

:Application
the self priming ACP screw pump is a positive displacement pump, suitable when a
constant oil flow is required. The pump is used for feeding fuel or lubricating oil in marine
or power applications such as separation systems, oil heating systems, and oil conditioning
.systems

:Design

Rotors and casing:

The ACP pump has three intermeshing screws, shaped so that they form a tight seal in
relation to each other and to the cast iron pump casing. They are lubricated by the oil
.moving through the pump
The rotors are designed to work at high speed with no vibrations or noise cased by
.imbalance
The power rotor (the central screw) is made of steel and driven by an electric motor,
.connected by a flexible coupling
The two idler rotors, made of high quality cast iron, are driven by the action of the oil that is
.pumped
Pressure Relief Valve
An integrated pressure relief valve protects the pump and motor from overloading. The
.valve opens at a pressure of 0.4 MPa (4bar)

Direction of Rotation
An ACP pump must be rotated in the specified direction and delivers the oil in one direction
.only. Arrows on the pump casing indicate the rotational and pumping directions

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 Pumps and their maintenance

:Shaft Seal

O-ring 2 Seat with hole or slot 3 Seal ring 1

Bellows unit 5 Spring 6 Stop washer 4

Working Principle

.The rotating parts of the pump consist of three helical screws enclosed in the pump casing
The threaded surfaces of the screws fit each other accurately , forming a series of enclosed
. cavities. These cavities move axially when the screws rotate
. When the cavities are filled with oil , the oil is transported from the pump inlet to the outlet
.This results in the pressure difference required for continuous feeding of the oil
When the screws rotate at a constant speed the oil is pumped at a constant flow rate.
.A relief valve is necessary to protect against harmful pressure levels

3.2 Maintenance of screw pump

Before any maintenance work, ensure that , the driver is deenergized and the
pump hydraulically isolated.

Connecting and disconnecting of electric cables must be done only by personnel

authorized to do such work.

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 Pumps and their maintenance

Changing ball bearing

Remove the power rotor from the front cover, as described under "Changing shaft
seal". Whenever the ball bearing is removed, it is recommended to exchange it for a
new one.

Dismantling and assembly of the pump can be performed on a work bench but for
working moment 2-6 and 9 we recommend to use the jaw vice of a column drilling
machine with soft jaws.

If the pumps operating temperature exceeds 60°C let the pump cool off
before any service, maintenance or dismantling work is commenced to
avoid burn injury.

Inspection
The intervals for inspection and replacement of wear parts vary greatly with the
properties of tin- pumped liquid and can only be determined by experience. Except for
the ball bearing, all internal parts of the ACE-pump are lubricated by the pumped
liquid. Pumping liquid which contain abrasive materials, or liquid that is corrosive1,
will significantly reduce service life and call for shorter service intervals. Wear in the
pump will normally show as unnormal:
• Vibration
• Noise
• Loss of capacity
• Reduction in flow/pressure
• Leakage

Inspection of shaft seal

Excessively leaking shaft seals should be changed without delay, as the leakage
normally will grow worse and there is a risk that liquids with poor lubrication
properties, (such as heavy fuel oil) will wash out the lubricating grease from the ball
bearing and there by cause additional damage. In installations where unplanned shut
downs must be avoided, it is advisable to dismantle the pump for a thorough inspection
and thereby change out shaft seal and ball bearing, every three years as a max period.
It is recommended always to have the spares included in minor spare part kit
available.

Inspection of rotors

A quick inspection of the idler rotors can be made simply by removing the rear cover. Note
that the driver must be deenergized and the pump hydraulically isolated before the rear cover
is removed.

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 Pumps and their maintenance
If a more thorough investigation is needed, proceed as under "Changing shaft seal".

All work carried out on the pump has to be performed in such a manner that risks for
personal injury are observed!

Lubrication:
The ACE-pump is fitted with an external grease lubricated ball bearing. When delivered
from Imo AB, the ball bearings in pump version Ixxx are filled with grease of type B. For
version Nxxx a high temperature grease of type C, is used. The ball bearing should be greased
while the pump is operating. Use an appropriate type of grease, as per table and a
grease gun suitable for grease nipple according to DIN 71 412 (ISO 6392).

When handling liquids that may harm skin use gloves and/or protective clothing.


When handling liquids which may involve fire hazards appropriate precautions to
avoid danger are to be taken


In case of failure for a system with elevating pressure fluid jets may cause injury and/or
damage.

Oil leakage may make the floor slippery and cause personal injury.

Summary

Despite all the care in operation and maintenance, engineers often face the
statement “the pump has failed i.e. it can no longer be kept in service”. Inability
to deliver the desired flow and head is just one of the most common conditions

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 Pumps and their maintenance
for taking a pump out of service. There are other many conditions, such as
.leakages, loss of flushing, cooling, quenching systems, etc
Also in this section we discuss the classification of pumps according to working
of them, Installation, Operation and maintenance... Due to variances of the
pumps by design, size, power and material used in making the pump there is no
general program for maintenance that why manufacturer's guide book should
by thoroughly revised in case of maintenance of pump.
Also we mention the troubles encounter the pump and the remedies of that.
Finally we illustrate the maintenance of one type of pumps (screw pump).

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 Pumps and their maintenance

Bibliography

1. Operating and maintenance Manual. ( Rayan Power Station)

 Treated water system vol. 2/2
 Sludge system vol. ½
 Fuel system (HFO units)
 Lubricating oil system (pumps vol.)
2. (‫الدليل الفني للطلمبات ) المضخات المهندس علي مصطفى فرج‬
2004 ، ‫ مطبعة المدينة‬, ‫الطبعة الوألى‬

3. Abdullah A. Ba-Wazeer , ''Short notes and Headlines In Pump''

Vol. one, 2005
4. www.cheresources.com

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