Operator's Guide to Centrifugal Pumps

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What Every Reliability-Minded Operator Needs to Know
Operators Guide to Centrifugal Pumps is specifically written for process operators who regularly deal with centrifugal pumps, addressing principally those variables and factors under their control, while keeping design theory and mathematics to a minimum. Some topics covered in this book are:

1. Importance of equipment reliability and what role operators play in this mission.

2. Centrifugal pump operating characteristics

3. Mechanical seals and their related seal flush plans

4. What operators should know about electric motors

5. Lubrication basics

6. Troubleshooting basics

7. How to start a pump reliability program

Operators Guide to Centrifugal Pumps: What Every Reliability-Minded Operator Needs to Know can be used as a self-paced, self-taught short course or as a companion to a "live" prepared short course for both inexperienced and seasoned operators. It can also serve as a handy field guide.

What We Like About This Book: Robert Perez has worked in the petrochemical industry for 30 years and knows this topic from a practitioners standpoint. He has included a lot of useful lookup tables, recommendations and guidelines. It includes a useful Field Troubleshooting Matrix and his 10 step process to reliability success.

Author:  Robert X. Perez
Published:  2008
Format:  Paperback
Pages:  194

The most preventable types of centrifugal pump failures are lubrication related failures. With sufficient attention to details, lubrication failures should be rare events. Operators play a key role in maximizing the lubricants useful life through their vigilance.

The lubricants and sealing methods available today have greatly improved the reliability of sump type lubrication systems. All centrifugal pumps require lubrication of their radial and axial bearings in order to maintain the rotor’s position relative to the casing and ensure reliable operation.
Table Of Contents:  

The Operator's Mission

    Reliability Tracking
    MTBR Data from Across the Industry
    Other Tracking Tools
    Bad Actors

Centrifugal Pump Primer—Part I

    Why use centrifugal pumps?
    Head versus Pressure
    Centrifugal Pump Performance
    System Curves
    Bernoulli’s Principle Explained

Centrifugal Pump Primer—Part II

    The Best Efficiency Point
    The 40/60/80 Rule of Thumb (for low flow operation)
    System Curves Revisited
    Cavitation Defined
    Ways to Avoid Cavitation

Centrifugal Pump Primer—Part III

    Pump Design Considerations
    Basic Centrifugal Pump Construction
    Centrifugal Pump Types
    Pump Suction Arrangements
    Sealless Pumps
    Pump Drivers

How to Protect Your Mechanical Seals

    Seal Chamber Venting
    Seal Flush Plans
    Stuffing Box Pressure
    API Flush Plans
    Detailed Operating Guides for 12 Common Flush Plans

Motors 101 for Operators

    Motor Bearings
    Motor Overload
    Electrical Safety

Pump Lubrication in a Nutshell

    Types of Lubrication
    Grease Lubrication and Greasing Tips
    Splash Lubrication
    Oil Mist Lubrication
    Closed Loop Lubrication Systems
    Lubrication Responsibilities

10 Ways to Protect Your Pumps

    Ten Ways to Positively Affect Pump Reliability
    The Pitfalls of Parallel Pump Operation
    Pump Design and Installation Problems Operators Should Look Out For

How to Start-up a Centrifugal Pump

    Avoiding Early Pump Failures
    Start-up Procedures for Common Centrifugal Pump Situations
    Why Detailed Start-up Procedures are Important

Introduction to Field Troubleshooting

    Common Symptoms
    Common Causes
    How to Use a Field Troubleshooting Matrix
    Troubleshooting Example

The Road to Reliable Pumps

    Ten Proven Steps to More Reliable Pumps

Illustrated Glossary of Centrifugal Pump Terms
Glossary of Electric Motor Terms
Basic Centrifugal Pump Formulas

It’s important for reliability professionals to have easy access to a rather extensive library of technical books.  There are certainly more than a dozen different pump books sitting on my shelves and they all cater to different but overlapping audiences.  If, until very recently, I might have had doubts about needing any additional ones, it turns out I would have been wrong.

With his OPERATOR’S GUIDE TO CENTRIFUGAL PUMPS, Robert X. Perez fills a very significant gap.  Subtitled “What Every Reliability-Minded Operator Needs to Know”, this book was specifically written for process operators who regularly deal with centrifugal pumps.  It optimally addresses the various variables and factors under the operators’ control and keeps design theory and mathematics to a minimum.

I was impressed by the relevance of the topics covered by Robert Perez, an experienced engineer who devoted the better part of his career to interfacing with process operators.

By the time the reader reaches the end of this text, he or she will have acquired a clear understanding of how to operate and monitor process pumps. Three handy appendixes are also contained in the book; they will answer questions that arise in the field.

This multi-faceted book can be used as a self-paced, self-taught short course or as a companion to a "live" prepared short course for both inexperienced and seasoned operators. It can also serve as a handy field guide after completion of the course.

The author set out on a mission to add value.  He wanted this book to provide the latest generation of operators with a body of knowledge that is relevant, complete, and practical in any industrial setting.  Perez also wanted the text to be useful for years to come - I firmly believe he has accomplished this goal.  Your facility will benefit from this clear, extremely well-written narrative, the many illustrations, and the various experience-based checklists.

Review by: Heinz P. Bloch, P.E.

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