C7 – PUMPS & PUMPING SYSTEMS

EVALUATION OF COMPETENCE

Function: Marine Engineering Practice at Operational Level

COMPETENCE 7

Pumps & Pumping Systems

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Operation and Maintenance of the Pumps, Piping and Pumping Systems on

board the Ship for the following:-

(1) Centrifugal Pump:

MOTOR COUPLING

MECH SEAL

SHAFT
BUSH BEARING

IMPELLER

WEAR RING

Centrifugal Pump Working Principle:

Centrifugal pump is a roto-dynamic pump applying a centrifugal action and the liquid receives
energy from the impeller and due to its continuous rotation. The fluid moves radially with
increasing velocity which is converted into pressure in the volute casing.

With the mechanical action of an electric motor or similar, the rotation of the pump impeller
imparts kinetic energy to the fluid through centrifugal force. The fluid is drawn from the inlet
piping into the impeller intake eye and is accelerated outwards through the impeller vanes to
the volute and outlet piping. As the fluid exits the impeller, if the outlet piping is too high to
allow flow, the fluid kinetic energy is converted into static pressure. If the outlet piping is open
at a lower level, the fluid will be released at greater speed.

A centrifugal pump works by converting kinetic energy into potential energy measurable as
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static fluid pressure at the outlet of the pump. This action is described by Bernoulli's principle.
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Centrifugal pumps are used for large discharge through smaller heads.

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The power required to drive a pump (Pi), is defined simply using SI units by:

Single Stage Radial Flow Centrifugal Pump

where:

Pi is the input power required (W)

ρ is the fluid density (kg/m3)

g is the standard acceleration of gravity

(9.80665 m/s2)

H is the energy Head added to the flow (m)

Q is the flow rate (m3/s)

η is the efficiency of the pump plant as a decimal

Components of a Centrifugal Pump:

Impeller: The rotation of centrifugal pump impeller causes the liquid it contains to move
radially out wards from the centre to beyond the circumference of the impeller.

Volute casing: The casing is known as volute casing because of its spiral shape. The casing
section collects the liquid, discharged by the impeller and converts velocity energy into
pressure energy

Stuffing box: Stuffing box (Gland Packing) has the primary function of protecting the pump
against leakage at the point where the shaft passes out, through the pump casing.

Mechanical seal: A mechanical seal is fitted in the seal / bearing housing (the point where the
shaft passes out, through the pump casing) preventing leakage of fluid being handled by the
pump.

Bearing: Bearing transfer the load on the shaft and provide rotary relative movement
minimizing the friction between the members. Bearing are usually roller bearing or ball bearing
if externally located (as ingress of water will cause irreversible damage to the bearing) or else
brass bush / sleeve if internally located.
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Coupling: Coupling is used to connect the pump shaft to the prime mover shaft. Mostly flange
or jaw type coupling are used. Coupling bolts are fitted with a rubber sleeve to provide a
cushioning effect on the bolts due to high starting torque and high speed of rotation.

Wear rings: To minimize the cost of pump maintenance, centrifugal pumps are designed with
wear rings. Wearing rings are replaceable rings that are attached to the impeller neck and pump
casing with a small running clearance of 0.2 mm as illustrated (Maxm allowed = 1.5 mm)
between the wear rings on the impeller and the casing. Operational wear due to corrosion and
cavitation attack results in the wear down of this component which needs to be replaced
periodically thus prolonging the life of the impeller and the casing.

IMPELLER LOCK
NUT

Capacity: The capacity of a centrifugal pump determines its performance capability in a

particular condition. Capacity of a centrifugal pump is usually given by its flow rate in liters/hr
or m3/hr.

Priming Unit: Centrifugal pumps require priming for ensuring a

satisfactory and trouble free operation. The fluid is sucked into the eye
of the impeller due to the drop in pressure across the impeller eye.
When the casing has air, the pressure drop created by air across the
rotating impeller is not sufficient to pull the fluid in the suction side.
The attached priming unit or air handling unit is used to remove the air
inside the casing during starting. Centrifugal pumps operating with the
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suction head greater than the pump impeller, do not require priming as the impeller is
always submerged in fluid due to gravity as in the case of SW pumps located in the bottom
platform and the pump is said to have a net positive suction head (NPSH).

e.g. Centrifugal pumps with priming unit: Emergency Fire pump & COP’s

Cavitations:

Cavitation is a common occurrence but is the least understood of all pumping problems. The
pump is cavitating if knocking sound and vibrations are heard when it is operating. Other signs
may be erratic power consumption and fluctuations or reductions in pump output. If continued to
be operated with the pump when it is cavitating, it will be damaged. Impeller surfaces and pump
bowls will pit and wear, eventually leading to mechanical breakdown.

Cause: When water enters a pump, its velocity increases causing a reduction in pressure
within the pumping unit. If this pressure falls too low, some of the water will vaporize, forming
bubbles entrained in the liquid. These bubbles collapse violently as they move to areas of higher
pressure creating the noise and vibration from the pump. The pressure required to operate a
pump without causing cavitation is called net positive suction head (NPSH). Therefore the
pressure head available at the pump inlet should exceed the NPSH required. This is specified by
the pump manufacturer, and is a characteristic of the pump

Material specifications for parts

Impeller --- Nickel Aluminum bronze

Shaft --- Stainless Steel

Wear rings --- (Renewable) Aluminum Bronze

Casing --- Bronze Casting

Shaft bearing Bush --- Bronze

Material for Salt Water pump:

Casing --- Gun metal (Bronze)

Impeller --- Ni Aluminum Bronze

Shaft --- Stainless Steel

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Centrifugal Pump Discharge Characteristics:

FACTORS RELATED TO REDUCTION IN PUMP PERFORMANCE

 The theoretical relationship between head (H) and throughput (Q) is a straight line.
 The minimum throughput occurs when the head is maximum
 Impeller blade thickness and other mechanical considerations cause shock and eddy
loses.
 Frictional losses caused by:
 Fluid contact with pump casing.
 Inlet and impact losses.
 The discharge characteristic provides important information like why throughput alters
with discharge head or back pressure. Slow rate of discharge can be explained due to:
 increasing head
 restricted pipeline
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 long discharge pipe

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 high viscosity of fluid

 storage tanks at high level
 partly opened valve on discharge line
 ingress of air in the system
 From HP/Q the power curve is obtained minimum power is consumed by pump when
there is no flow when discharge head is at its highest i.e. discharge valve closed
 Max pressure with discharge closed is only moderately above working pressure and
hence no relief valve is required.
 It will be noticed that the efficiency curve for the pump is convex which means that
maximum efficiency occurs at a point somewhere between max & min discharge head
and throughput condition.

Applications on board:
SW pumps located in the bottom platform of the
engine room with NPSH
FW pumps with NPSH where fluid flows into the
suction side due to gravity
Cargo pumps (submersible type as in FRAMO
design or equipped with priming system as in
COPT’s)
Main LO and Camshaft LO pump (submersible
type)
Emergency fire pump with priming unit.

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(2) Reciprocating Pump:

Reciprocating pumps are self priming positive displacement pumps.
Application on board these days in restricted to:
a) Engine room bilge pump gear driven with an electric prime mover
b) Steering compartment bilge pump operated by hand or pneumatic device
c) Stripping pumps in cargo pump room (steam operated)

a) Single Acting b)Double Acting

A reciprocating pump essentially consists of a piston and a cylinder where the piston is enclosed
in the cylinder. The cylinder is connected to suction and delivery pipes, each of which is
provided with a non-return or one way valve called suction valve and delivery valve
respectively. The function of non-return or one way valve is to admit liquid in one direction only.
Thus the suction valve allows the liquid only to enter the cylinder and the delivery valve permits
only its discharge from the cylinder. The piston is connected to a crank by means of a connecting
rod. The piston is equipped with ebonite rings that act as a sealing component with the cylinder.

As the crank is rotated at uniform speed by a prime mover, the piston or plunger moves to and
fro (or backward and forward) in the cylinder. When the crank rotates from e = 00 to e = 1800 the
piston which is initially at its extreme bottom (that is, it is completely inside the cylinder), moves
to its extreme top, (that is, it moves outwardly from the cylinder). During the outward movement
of the piston a partial vacuum (pressure below atmospheric) is created in the cylinder, which
enables the atmospheric pressure acting on the liquid surface in the well or sump below to force
the liquid up the suction pipe and fill the cylinder by forcing open the non return suction valve.
Since during this operation of the pump the liquid is sucked from below it is known as its suction
stroke. Thus at the end of the suction stroke the piston is at its extreme top position, the crank is
at e = 1800 (i.e. at TDC), the cylinder is full of liquid, the suction valve is closed and the delivery
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valve is just at the point of opening. During the downward (forward) stroke delivery of fluid
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takes place with the suction valve in closed position.

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Types of Reciprocating Pumps:

The reciprocating pumps can be classified according to the liquid being in contact with one side
or both the sides of the piston or plunger; and according to the number of cylinders provided.

According to the first basis of classification the reciprocating pumps may be classified as:

(i) Single acting pump.

(ii) Double acting pump.

If the liquid is in contact with one side of the piston or plunger only, it is known as single acting
pump. Thus as shown in fig a the single acting pump has one suction and one delivery pipe and
in one complete revolution of crank there are only two strokes-one suction and one delivery
stroke. On the other hand if the liquid is in contact with both the sides of the piston or plunger, it
is known as double acting pump. As shown in fig b the double acting pump has two suction and
two delivery pipes with appropriate valves, so that during each stroke when suction takes place
on one side of the piston, the other side delivers the liquid. In this way in the case of a double
acting pump in one complete revolution of the crank there are two suction strokes and two
delivery strokes.

According to the number of cylinders provided the reciprocating pumps may be classified as:

(i) Single cylinder pump

(ii) Double cylinder pump
(iii) Triple cylinder pump
(iv) Duplex double acting pump
(v) Quintuplex pump

Function of an air vessel: -

An air vessel provided in a reciprocating pump acts like a flywheel of an engine.

Other functions of an air vessel:-

1. Reduces the possibility of separation and cavitations.
2. Allows pump to run at high speed without shock.
3. Suction head can be increased by increasing the length of pipe below air vessel.
4. Large amount of power is saved due to low acceleration head.
5. Uniform velocity in discharge. 9
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Material Specification:
Reciprocating Pump:
Piston -- Forged steel
Piston rod -- Nickel
Valve body -- Brass / Bronze
Water end cylinder -- Cast Steel
Cylinder Liner -- Brass / Bronze
Rings -- Ebonite
Valve plate -- Stainless steel

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(3) Screw Pump: Screw pumps also fall in the category of rotary positive displacement pumps.
Screw pumps are different from other rotary pumps because of the axial flow of the fluid
through their pumping elements. The fluid in screw pumps moves between the screw
threads and are displaced axially as the screws rotate and mesh.

Due to the axial flow pattern and low internal velocities, the screw pumps have certain
advantages in applications where churning and agitation of fluid is highly objectionable or not
desired as in the case of LO circulation. The inter-meshing of the screw threads on the rotors
and the very fine clearances with the surrounding casing creates a seal between the pumps inlet
and outlet.

Due to the rotation of the screws and its axial movement cavitations pockets are formed in the
helices of the screw. As the screw moves the pockets also move axially and act similar to a
piston moving in one direction, while the fluid is moved axially from inlet to outlet.

Application on board: Sludge pump, Main Engine LO pump, Cargo Oil pumps.

Screw Pump X-sectional sketch

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Material TOP VIEW X-SECTION

Screws in a casing Forged Steel
Screw shaft HG Carbon Steel
Casing Bronze
Bearing Roller type (open)
Thrust Bush White Metal INLET
CASING

OUTLET

SCREW PUMP FOR CARGO WITH GAS TIGHT BULKHEAD SEAL

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(4) Gear pump: Though the construction, shape and design of gear, vane and globe pumps are
a bit different, they fall under the same category of rotary positive displacement pumps. The
working of all these pumps is based on the same principle, i.e. pumping of the liquid with the
help of rotating elements. The rotating elements can be gears, screws or vanes.

A gear pumps rotating assembly consists of two gears, a driving gear and a driven gear.
Pumping in a gear pump takes place when the driving gear meshes with the driven gear to form
cavities that moves the fluid. The cavities are the clearances between the gears or lobes and the
body of the pump. The mating surfaces of the gears meshing provide continuous sealing
between the inlet and outlet ports.

As the rotation of the pump continues, movement of the cavities progresses, moving the fluid
along the way. After some time, a point is reached where the seal between the captured fluid
and the outlet part of the pump is broken. At this point of time the vanes, gears or lobes, forces
the volume of the captured fluid out of the pump. A continuous cycle takes place due to the
simultaneously opening of new cavities at the inlet port. This leads to a continuous flow of
liquid though the suction and discharge ports.

Application on board: Oil transfer pumps

DRIVE GEAR

 This is a positive displacement pump

 It is usually motor driven directly coupled
 These pumps are efficient and smooth running and are best suited to pump viscous oil
 These are used for purifiers feed, pressurized supply of FO to ME, Boiler & DG’s,
Gearbox lubrication systems, fuel oil transfer etc
 Lubrication is provided by the oil passing through
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 Spring loaded relief valves are fitted on the discharge side and are adjusted to regulate the
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delivery pressure

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Material
 The rotor and shafts are integrally forged of nitralloy steel. They are hardened all over and
ground finished after hardening.
 Casing and bearing housings are made of close grained cast iron.
 The shafts of the pumps are supported in bearings of
a) White metal b) Needle roller c) Bronze bush bearings

(5) Other Pump Types:

Semi Rotary Hand Pump: Semi Rotary Portable Hand Pump (also available with pneumatic
motor) is suitable for the handling of clear and light liquids such as water, petrol, diesel and all
fuels etc. It can handle hot liquids - up to 80°C (176°F) safely.

Portable type : On board transfer of lube oil stored in drums.

Fixed type: DG lube oil priming pump

Diaphragm Pump: These kind of pumps are portable type and air supply is required to operate
them as illustrated in sketch to transfer light fluids. This kind of pump is a compulsory
requirement in the SOPEP equipment list.

Troichoid Pump: This type of pump is similar to a gear pump in operational theory but used
for smaller applications and generally mounted and keyed onto the main prime mover.

On board applications i) DG rocker arm lube oil pump

ii) DO supply pump for incinerators.

HAND PUMP DIAPHRAGM (WILDEN) PUMP TROICHOID PUMP

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(6) Lapping of valve/valve seat: Grinding pastes are used for controlled removal of metal by
grinding and lapping. From the very fine used for the adjustment of bearings to the very rough
used for large metal removal. Fuel valves overhaul, exhaust valves overhaul, Gate valve
overhaul all use lapping pastes.

Grinding Paste

Lapping paste or grinding paste is basically is a mixture of a uniform size of hard particles in
some lubricant base. The lubricant base can be oil based like grease or water soluble lubricant.
The hard particles used are carborandum, aluminum oxide, silica or silicon carbide, glass,
boron carbide, etc.

Lapping pastes are used for a small amount of metal removal or controlled removal and is used
basically for close mating of surfaces, for removing rust and brightening of the metal surface
for the lapping of the exhaust and the inlet valves of engines, for repairing the seat of the globe
valves, for the overhaul of reciprocating compressor valves. The lapping paste is graded from
extra coarse to extra fine, depending upon the size of the abrasive particles.

Correct Methods of Lapping

Lapping done on a face plate having a very even surface finish or by lapping the two sealing
surfaces with each other. When lapping without a guide the alignment of the hand should be
proper. The exposed metal should give a uniform polished look and the quality of the lapping
can be made out by the patterns. Any stray scratches on the lapped surface should be avoided.

Role of Oil in Lapping Paste

Oil or grease is used as a base in the grinding paste and is in a measures amount. Some people
like to use additional lubricant during lapping process. The abrasive particles of the lapping
paste is washed away if extra lubricant is added. During lapping if you want fast removal of the
metal you must lap till the effort of the lapping reduces. Thereafter you must remove the old
lapping paste and put new one. The lessening of the effort indicates that the abrasive particles
have broken down. If sufficient care is not taken during this time then metal to metal contact
would take place and the seat would be spoiled.

(7) Pipe bending:

Pipe Bending Methods

The standard Methods for bending pipe, tube and structural’s include: ram bending, rolling,
mandrel bending, rotary-draw and heat-induction.

Ram pipe bending, is a method that which forces a die against the section of tube, pipe or
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structural where the bend is wanted. The die will push against the sidewall of the material and
force it to bend between other, opposing dies on the other sidewall. This will force the pipe to
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conform to the contours of the die. Used in large diameter projects.

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Roll pipe bending, draws pipe, tube or other material through a series of spool-like rollers to
apply pressure to the pipe as it goes through them. The rollers positions are progressively
changed for each pass during operation until the desired radius is met. This method allows for
more gradual bending and less distortion on the pipe or tube being bent. We use this process for
many smaller diameter pipe & tube projects.

Mandrel Bending uses a machine where a fixed mandrel is inserted within a tube or pipe. The
bending is done in the pipe just beyond the mandrel. When used properly, the mandrel
maintains the size and structure of the pipe diameter better than ram bending, for specific
materials or applications.

Heat Induction uses high heat to allow for softening of the metal, which allows for the
bending operation.

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(8) Different type of Valves

Globe Valves:

A globe valve is so named because of its globular appearance and because some valves of the
past had hemispherical shaped valve plates inside. However today globe valves with the shape
of a circularly cut flat valve plate to hemi spherical shaped valve plate are available in the
market. The shape of the valve plate depends on the application, the manufacturer’s design, and
the control required. Globe valves are used extensively in industry and very frequently in the
marine field. They are very popular due to the following characteristics:

 They have a long service life.

 They can control the flow of the fluid passing (though not much, and for a finer degree of
control, control valves with special valve profile must be used).
 They can be kept open any degree from full open to full close.
 Very little valve lift is required to attain full flow (unlike gate valves).
 A change in direction of the fluid flow can be done (unlike gate valves) in angular valves.

In a globe valve the fluid to be controlled always flows from below the valve seat, so as not to
pressurize the stuffing box and the gland packing. The globe valves are used for specific
applications where stringent shutoff requirements exist. They normally use metal-to-metal
seating surfaces, but sometimes use soft-seating like PTFE or other composition materials
forming the sealing boundary.

Different Parts of the Globe Valve

 Wheel nut: This is the nut at the top of the wheel and it helps to retain the wheel on the
spindle or the stem. It often has a plain washer beneath it.
 Hand wheel: It is provided to open and close the valve. The bigger the wheel, the less
effort is required to operate the valve as the torque applied is more. This is the reason
wheel spanners are used onboard ships, as the longer the arm, the more the torque.
 Yoke nut: It has internal threads and the stem or the spindle of the valve has
corresponding external threads. When the spindle is turned by the wheel handle, the stem
rises or falls thus opening or closing the valve.
 Gland bolt: These are used to tighten the gland flange and the gland bush, thus in turn
compressing the gland packing and stopping leakage along the stem of the valve. In ships
generally a stud with nuts are used as they are easier to access and maintain.
 Gland flange and gland bush: They are provided to compress and keep the gland
packing in place. Sometimes they are combined together and form one piece.
 Gland Packing: They are cut as per the size of the stem and put end to end, there should
be no gap between the ends otherwise the fluid may leak out. The packings are staggered
so that the cut portion may not lie over each other and provide an easy channel to pass
through. Several packing material can be used depending on the applications like PTFE,
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graphite ribbons, etc.

 Bonnet: This is the top portion of the valve and it has an opening for the stem to pass
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through.

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 Bonnet bolt: The bolts are used to tighten the bonnet against the body and compress the
gasket in between, thus effectively sealing against leakage.
 Back seat: removable and replaceable part for maintaining clearances, and guiding the
stem, and reducing leakage
 Gasket: It is made of a compressible, oil proof, chemical proof, and heat proof material
and put in between the bonnet and the valve body, to stop leakage along the metal faces.
 Stem: It is also called the valve spindle and is connected at one end to the valve seat (in a
screw lift valve) and other side has the wheel. It is threaded on the upper part.
 Disc: Also called the valve disc, its lower end is correctly machined and sits on the valve
seat. The valve and the valve seat have face to face contact and must be true to each other
to stop the flow.
 Seat: Also called the valve seat, it is sometimes a replaceable insert
 Body: Also called the valve body, it is the housing.

Diagram of Globe valve

Globe valve has a bulb like body with a valve seat, which can have a screw-down plug or a disc
acting as valve. The surfaces of valve and valve seat are made up a hard alloy of cobalt and
chromium with cobalt as the principal ingredient. The seat is secured into the valve chest with a
help of light interference fit and grub screw. A spindle or stem with square or vee threads above
and below the stuffing box is used. The spindle is held in the valve disc by a nut. Stuffing box
is fixed with an appropriate gland around the spindle in order to prevent leakage.

Not all types of globe valves can handle the change in direction of the fluid flow. The globe
valve that allows a reverse flow is known as an angle valve. In the reverse flow, the flow is
from under the valve seat and thus the valve is not subjected to higher static pressure when the
valve is closed. The disc is guided on the seat with the help of the piston or a stem which is
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attached to a wheel handle outside the valve.

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Types of Globe Valves

Globe valves are distributed into two types on the basis of the disc attached to the spindle. They
are:

 Screw-lift type - If the disc is attached to the spindle

 Screw down non return valve - If the disc is not attached to the spindle.

The Screw Down non return valves is generally used in bilge systems to prevent back flooding,
as feed check valves or as boiler stop valves. In both the types of valves a guiding vane or
guides are required in order to keep the valve concentric with the seat when it is in the open
position. The greatest lift that a valve can achieve is one-quarter of a bore. For this reason it is
essential that the stem is of a length greater than that of the lift.

Non return valves or the free lifting valves are generally fitted in the compartments having
bilge suction lines. They are used to prevent flooding in case of damage due to collision.

Working:

A normal globe valve is operated with the help of a hand wheel which is attached to the stem.
Anti-clockwise rotation of the hand wheel moves the stem over the threads, lifting the valve
from its seat and thus opens the valve. Clockwise rotation results in the reverse process.

In a non return valve, there is no stem attached to the valve. The valve opens and closes
according to the pressure of the fluid. When the pressure of the fluid becomes greater than the
pressure of the valve, the valve lifts off its seat. There is no reverse flow allowed in this type of
valve.

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Gate Valves:

The gate valves are so called because they actually have a gate or a gate shaped wedge inside
the valve that is controlling the flow of the working fluid. Though used extensively in marine
field it is the most abused type of valve. The gate valve should not be used for controlling the
fluid flow or for throttling the flow as it can damage the valve due to the high velocity of the
fluid when the valve is only slightly open. They should not be used in places where you need to
control the flow as in the suction and discharge side of pumps. They are normally used in
applications where a minimum restriction to the flow of fluid is a design requirement and only
an On-Off type of control is required.

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Butterfly Valve:

Butterfly valves consist of a gate hinged on its centre and will turn through 90 degrees only.
The valve is operated by the handle fixed on the central hinge. The circular gate will close
agains a rubber seat on the inner surface of the valve body. They are commonly used in the
ballast and bunker lines where the valves are located inside the tank, or in the duct spaces and
are hence remotely operated from a control station.

Reducing Valves:

If it is necessasry to provide steam or air at a pressure less than that of the boiler or compressed
air reservoir, a reducing valve is fitted. This will maintain the down stream pressure with in
defined limit over a range of flow,despite any changes in supply pressure.

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Working: The spring load causes the valve to open,this is balenced by the reduced steam
pressure p2 acting on the area of the top of the valve,A2 as this area is constant,any decrease in
outlet pressure will allow the valve to open and any increase will close it.

The area of the under side of the valve and that of the piston are equal, A1 , both these area are
exposed to the inlet steam pressure P2 and so the loads on them will be equal and
opposite,therefore they will balance.

Relief Valve:

Excess pressure is avoided in pipe systems by the use of relief valves. The valve disc is held
closed by a spring arrangement on the stem. The spring compression can be adjusted to enable
the valve to open at the appropriate pressure. Boiler safety valves are a special case of relief
valve.

Valve must be able to release all the steam the boiler can produce without the pressure rising by
more than 10% over a set period. Spring-loaded valves are always fitted on board ship because
of their positive action at any inclination. They are positioned on the boiler drum in the steam
space. The ordinary spring loaded safety valve is shown in Figure.

The valve is held closed by the helical spring. Whose pressure is set by the compression nut at
the top. The spring pressure, once set, is fixed and sealed by a Surveyor. When the steam
exceeds this pressure the valve is opened and the spring compressed. The escaping steam is
then led through a waste pipe up the funnel and out to atmosphere. The compression of the
spring by the initial valve opening results in more pressure being necessary to compress the
spring and open the valve further. To some extent this is countered by a lip arrangement on the
valve lid which gives a greater area for the steam to act on once the valve is open. A manually
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operated easing gear enables the valve to be opened in an emergency. Various refinements to
the ordinary spring-loaded safety valve have been designed to give a higher lift to the valve.
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(9) Types of gaskets, gland packing, mechanical seal, sealing ring.

Types of gaskets:

 General purpose joints used in sea water line, fresh water line, low temperature line.
 Neoprene rubber used in sea water and low pressure line.
 Teflon joint used in high pressure pipe connection.
 Reinforced steam joint used in steam line, steam condensate line, F.O. line.

Types of Gland Packing

There are many different types of gland packing depending on the type of applications such as
for valve stem sealing, centrifugal pump shaft sealing, reciprocating pump shaft sealing, static
duties like hatches sealing and pressure vessels manholes sealing etc. The gland packing are
made from the following basic substances and are a combination of these basic materials and
are sometimes reinforced with metal wires for extreme conditions.

 Jute
 Flax
 Hemp
 Cotton
 PTFE
 Wrapped metal foils
 Graphite fiber
23

 Carbon fiber
 Glass fiber
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 Poly acryl nitrile fibers

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C7 – PUMPS & PUMPING SYSTEMS

All the gland packing are a combination of the above mentioned basic materials. The packing
made of a combination of graphite, carbon, glass, etc. are used for harsh applications whereas
gland packing made of materials like Jute, flax, hemp, and cotton are used for light applications
like sea water, potable water etc.

Mechanical Seal: Mechanical seals are pump components located at the point (Seal & Bearing
housing with an ID = shaft diameter) where the shaft enters the casing. It consists of a rotating
carbon element and a fixed ceramic element forming a leak proof sealing assembly held in
contact (mated) with each other by a spring housed in a carrier. It is important that mechanical
seals contact surfaces are lubricated (generally an oil cup is provided on the housing) and seal
housing cooled. They must not run dry and care must be taken to prevent ingress of foreign
matter between the seal element surfaces.

The carbon seal and ceramic seals are of very precise in design and kept in complete contact
with each other by the force of the fluid acting upwards and the spring which elongates under
operational conditions as the direction of spring axis is opposite to the direction of rotation of
the prime mover.

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(10) PMS routines for Pumps:

1) Gland packing (if applicable) to be tightened gently when leakages are seen.
2) Periodical replacement of gland packing required.
3) Bearings are to be greased regularly.
4) Mechanical seal lube oil to be topped up.
5) Check motor amperage while the pump is running (Megger readings = 3 monthly)
6) Feel motor for vibration and check for abnormal noise.
7) EO to regularly grease motor bearings.
8) Record suction and discharge pressure when vessel on light load (ballast) condition and in
full load condition as variations will be observed due to change in NPSH. So will be the
case where tide variations will influence the performance of the pump with vessel in port.
9) Check the coupling bolts / foundation bolts regularly and replace if required.
TOTAL OVERHAUL OF PUMPS:
Ensure the pump and its associated system is immobilized in all respects with standby
system in use. Relevant manuals and spares are available on board to complete the
overhaul
CENTRIFUGAL PUMPS:
 Dismantle Pump for overhaul on schedule and check wear rings (upper and lower)
measure clearances
 Check sleeve (bush) bearing for wear.
 Check shaft for trueness on lathe.
 Keyway and keys to be checked for cracks.
 Replace wear rings and sleeve bearing if required (Max Clearance = 0.2 mm)
 Renew gaskets and o-rings when assembling the pump.
 Use new gland packing or mechanical seal
 Ensure impeller and shaft are properly secured by the locking nut
 Check pumps shaft freeness by rotating with hand.
 When first trying out make sure amperage of the pump is within allowed limits
RECIPROCATING PUMPS:
 Ensure all line filters are kept clean
 Air ingress in the suction line to be regularly checked & eliminated
 Lubrication / Greasing of moving parts to be correctly maintained
 Check condition of piston rings & replace if required.
 Check piston rod is straight and true.
 Check valves, springs and valve seat when assembling.
 Make sure the valves are locked in place with lock screw and cap nut when assembling
 Check motor & pump drive gears and associated bearings for wear & tear.
 Make sure motor-pump alignment / locking arrangement is correct when assembling
 Relief valves and pressure gauges to be in checked for correct working
ROTARY PUMPS
 Line filters to be kept clean
 Lubrication of bearings and moving parts to be correctly maintained
 Pressure / Amperage to be monitored
 Checks for abnormal noise / vibrations to be carried out
25

 Complete overhaul as per manufacturer’s recommendation – considering clearances and

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bearing / lip seal condition

GME AND BS TRAINING COURSE MATERIAL

C7 – PUMPS & PUMPING SYSTEMS

PIPELINE DRAWING ANNOTATIONS

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(11) Sketch the layout of Ballast Pumping System.

AUX SERVICES

AUX SERVICES

TO BE BLANKED IF INCORPORATED

BALLAST PUMPING LINE DIAGRAM

EMERGENCY BILGE SUCTION SYSTEM:

The schematic drawing shows a section where Emergency Bilge Suction Valve is incorporated.
It has a bell mouth section above the floor plate and is put in use only when water level in the
engine room bilges has reached an alarming level due to heavy ingress of water caused by some
unforeseen circumstances. The valve is also provided with an extended spindle with bevel gear
arrangement in order to operate the same from a higher platform if required.

In such an event the valve which is normally in shut position is opened and water from the
engine room bilge is pumped overboard using the largest circulating sea water pump (Main sea
water pump or Ballast pump) in the machinery space to which it is connected as shown in the
sketch.

(12) Sketch the layout of Fuel Oil Transfer, Service and Bunkering System.

Refer C6 & C10 respective sections.

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(13) Sketch of a Hydrophore System used on board a ship.

GME AND BS TRAINING COURSE MATERIAL

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CHARGE AIR

RELIEF
VV +
VENT

ALL VALVES IN THE SYSTEM TO BE OF NON RETURN TYPE

28

(14) Learn Starting and Stopping Cargo Oil Pumps Turbines.

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GME AND BS TRAINING COURSE MATERIAL

C7 – PUMPS & PUMPING SYSTEMS

SCHEMATIC DIAGRAM OF CARGO PUMPING SYSTEM

BULK HEAD
GLAND

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C7 – PUMPS & PUMPING SYSTEMS

GAS
TIGHT
BULK
HEAD
GLAND

PUMP
SHAFT

STANDARD COPT INSTALLATION

Preliminary Checks:
 Check the oil level in the Turbine sump and in the Governor.
 Start the pre lube oil pump and check that the lube oil pressure reaches 0.5 kg/cm2.
 Ensure that Cooling Water is open to the lube oil cooler.
 Start the Vacuum Condenser S.W. cooling pump & ensure that cooling water is open to
the vacuum condenser and to the air ejector condenser (generally common line).
 Drain all the steam lines to be opened and check that the INLET valve to the turbine is
SHUT and that the EXHAUST (OUTLET ) valve is FULLY OPEN
 Open the warm up steam valve and gland steam valve and adjust the steam pressure to
between 0.1 ~ 0.3 kg/cm2
 Open steam to the air ejector and check that the vacuum is being developed.
 Turn the turbine with the turning bar to ensure that it is free.
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Starting COPT Plant:

1. Ensure that the boiler is firing on "tanker mode or continuous mode" and on high
pressure setting, generally 15 ~ 16 bar.

2. Ensure that the turbine is on preheat and sufficiently warmed up, (steam should be
coming out of all drains) and pre lube oil pump is on with a pressure of 0.5 ~ 0.8 kg/cm2

3. Open the steam inlet valve of the corresponding COPT fully and close the warm up
valve. Open the steam master control valve a little so that the turbine runs at about 50~100
rpm. known as rolling rpm.

4. Check for any vibration or any other abnormality.

5. Once steam is observed from the drains close all the drains. Check the vacuum pressure.

6. Try out the Emergency Stop and check that the turbine comes to stop.

7. Reset and gradually restart the turbine and slowly raise the rpm to about 800 rpm check
for any noise and vibration. Check that the pre lube oil pump cuts out as the system pressure
should reach 1.5 ~ 2.0 kg/cm2 at this corresponding speed.

8. After checking all the parameters and everything found satisfactory the turbine control is
to be handed over to CCR and the rpm can be raised as per requirement up to a maximum of
1200 ~ 1400 which is the normal working rpm.

Stopping COPT plant:

1. From the CCR the speed of the turbine is brought to the minimum ~ 500 rpm and
controls taken over to ECR.

2. Gradually shut the steam master control valve of the plant.

3. Check that the turbine rpm falls and that the pre lube oil pump cuts in. Pre lube oil
pump should cut in when the system pressure drops to 0.5 kg/cm2.

4. Shut the steam valve to the air ejector and the gland steam to all the turbines. Open the
steam drains of all turbines shut the steam inlet valve on the individual turbines.

5. Pre lube oil pump must be run for at least 2 hours after stopping.

6. Cooling water to the lube oil cooler to be on for 2 hrs after stopping.

7. Immobilize plant completely by putting off power supply to control panel.

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COPT OVERSPEED TRIP DEVICE

Safety Alarms & Trips for COPT’s:

 Over Speed set at 10% above normal operating rpm.

 Low lube oil pressure alarm & trip
 High Steam Exhaust pressure alarm & trip.
 Low vacuum in steam condenser alarm & trip
 High condensate level in the condenser alarm
 Sump oil level low alarm
 Lube oil temperature high alarm & trip
 Low IG pressure in tanks.
 Steam inlet pressure low / high alarm

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Pump Casing temperature high - trip

 Pump Shaft Bearing temperature high – trip
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 Turbine Bearing temperature high – trip

GME AND BS TRAINING COURSE MATERIAL

C7 – PUMPS & PUMPING SYSTEMS

SCHEMATIC DIAGRAM OF STEAM SYSTEM FOR COPT’s

Steam from Boiler

COPT System Steam Isolating Valve

Steam Inlet

Turbine Turbine Turbine Turbine Turbine

I II III W/B T/C

Steam Exhaust

Cascade
tank

EJECTOR STEAM

SW~ IN In
VACCUM CONDENSOR

SW~ OUT

Out

Condensate Pump 33
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C7 – PUMPS & PUMPING SYSTEMS

COLOR CODE FOR PIPELINES

(14) Learn Oil Pollution Control Methods and knowledge of Oily Bilge Separator and its
functions.

Refer Competency 10, Question no 1

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GME AND BS TRAINING COURSE MATERIAL