Table of Contents. Introduction...xv Knowledge Areas...1. Chapter One Pump Types, Rotodynamic Positive Displacement...

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1 Table of Contents Introduction...xv Knowledge Areas...1 Chapter One Pump Types, Rotodynamic Positive Displacement...2 Chapter Two Pump System Components, Prime Movers Piping Valves End-use Equipment Pump System Overview...6 Chapter Three Pump System Component Interactions, Piping Prime movers Valves End-use Equipment System Curves...9 Chapter Four Standard Pump System Operating Procedures, 11 vii

2 viii Table of Contents Chapter Five Benefits of Pump System Optimization, Efficienc Life Cycle Costs Other...16 Chapter Six Factors that Impact Pump Efficiency and Reliability, Design Review and Operation Rotodynamic Pump Operating Regions Rotodynamic Pump Net Positive Suction Head Allowable Nozzle Loads Pump Suction Piping and Intake Design Material of Construction Pump Antifriction Bearings Pump Sleeve Bearings Bearing Housings, Seals, and Lubricants Mechanical Seals Improper Installation and/or Maintenance...42 Chapter Seven Factors that Affect Pump System Reliability and Efficiency, Improper Mechanical Seal System Design Drivers Motor Temperature Motor Cooling Gearboxes and Gearing Pump Piping...45

3 Table of Contents ix Chapter Eight Elements of Life Cycle Costing, Introduction Initial Cost (C ic ) Installation and Commissioning (Start-up) Cost (C in ) Energy Cost (C e ) Operating Cost (C o ) Maintenance and Repair Cost (C m ) Downtime and Loss of Production Cost (C s ) Environmental Cost, Including Disposal of Parts and Contamination from Pumped Liquid (C env ) Decommissioning and Disposal Cost, Including Restoration of the Local Environment (C d )...53 Chapter Nine Basic Pump Maintenance Practices, Introduction Preventive Actions Predictive Actions Periodic Efficiency Testing...56 Chapter Ten Piping and Instrumentation Diagrams, 59 Chapter Eleven Isometrics, 61 Chapter Twelve Process Flow Diagrams, 63

4 x Table of Contents Chapter Thirteen Engineering Drawings, Introduction Anatomy of a Drawing...65 Chapter Fourteen Key Plant Personnel (Positions) Needed on an Assessment Team, Personality Traits Standard Roles and Expectations...71 Chapter Fifteen Roles and Responsibilities of an Assessment Team, 73 Chapter Sixteen Field Measurement Parameters and their Acceptable Ranges, Field Measurements of Fluid and Electrical Parameters Acceptable Performance Range...76 Chapter Seventeen Hydraulic and Electrical Formulae, Net Positive Suction Head Available (NPSHA) Affinity Rules Motor Load and Efficienc...80 Chapter Eighteen Measuring Devices and their Requirements and Proper Applications, Pressure Flow Input Power...84

5 Table of Contents xi Chapter Nineteen Common Operating Problems and Errors, Improper Equipment Operation...85 Chapter Twenty Pump and Motor Performance Curves, Pump Selection Chart Pump Manufacturer s Published Curve Certified Performance Curve Motor Performance Curve...90 Chapter Twenty-One System Curves, Operating Duty Point...93 Chapter Twenty-Two Parameter Estimation Methods, 97 Chapter Twenty-Three Data Collection and its Relationship to Reliability, 99 Chapter Twenty-Four Reliability Metrics, Reliability Availability Average Cost per Repair Annual Repair Cost per Installed Horsepower Installed Cost per Horsepower per Machinery Type Material Multiplier...102

6 xii Table of Contents Chapter Twenty-Five Currently Available Equipment and Technology, 103 Chapter Twenty-Six Industry Best Practices, 105 Chapter Twenty-Seven Basic Financial Analysis, Look Beyond Energy Savings Attach Dollar Values to Nonenergy Benefit Life Cycle Costing Chapter Twenty-Eight Utility Rate Structures and Incentives, 111 Chapter Twenty-Nine Principles and Techniques of Prioritizing Solutions, 113 Chapter Thirty Elements and Layout of a Pump System Assessment Report, 117 Chapter Thirty-One Presentation Techniques, 119 Chapter Thirty-Two Techniques for Assisting Clients/Customers in Aligning Goals and Strategies with Assessment Recommendations, 121

7 Table of Contents xiii Chapter Thirty-Three Implementation Strategies, Tasks Throughout the Entire Assessment Process Tasks During an Assessment Tasks After an Assessment Chapter Thirty-Four Commissioning, Obtain Management Participation in a Closeout Meeting Implementation Appendix A Glossary, 129 Appendix B References, 141 Appendix C External Links, 143 Appendix D Index, 145 List of Figures 1.1 Pump types matrix: rotodynamic and positive displacement Sleeve bearings Undesirable effect of an elbow mounted directly on suction flang Flow as a function of time operating curve Duration curve of the fl w Continuous level control P&ID... 60

8 xiv Table of Contents 11.1 Isometric diagram Title block Revision block Methods of denoting changes Datum elevation for various pump designs at the eye of first-stage impeller Example of speed variation affecting rotodynamic pump performance Example of impeller diameter reduction affecting rotodynamic pump performance Pump selection chart Pump manufacturer s published curve Certified performance curve Motor performance characteristics Operating duty point at H pump = H syst for a rotodynamic pump Operating duty point at H pump = H syst for a positive displacement pump Causes of production losses in refine ies Best potential MTBR improvement paybacks List of Tables 6.1 Estimated or mean time between repair, in years... 18