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long period standby pump

02/22/2011 4:47 AM

hi all

as you know in many plants there are 2 or 3 pumps in parallel.. one of them online and the others are in standby mode somtime for long periods.. months.. so im wondering

1-what are the adverse impacts on centrifugal pumps and its components if we dont operate the pump for long time period?

2 what should we do to increase the reliability and avialability of this standby centrifugal pump?

3 what are the checks, tests and actions should done to this dtandby centrifugal pump and its components to ensure its avibility when it needed?

4- finally do u suggest any paper or book talk about this?

best regards

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#1

Re: long period standby pump

02/22/2011 4:58 AM

<...do to increase the reliability and avialability of this standby centrifugal pump?...>

Simply swap the duty at intervals so that the other pump runs.

However, it is not good practice to make the run hours of the duty pump and the standby pump the same: there is every chance that they will both wear out at about the same time, making replacement of the worn pump fraught with risk that the facility will shut down prematurely due to a similar failure in the second pump.

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#2

Re: long period standby pump

02/22/2011 6:39 AM

Standby pumps shall be available for un-interrupted operation in case running pump breaks down. Some times it may so happen that when tried to start stand by pump, found it it has problem. When stand by pump is not operated for long time, some times problems may arise due to corrosion, electrical or instrumentation related. So in my opinion it is advisable to swap the pump once in a week. For bigger pumps (run by HT motor), the change over period can be adopted as 15 days or a month depending on size.

"there are 2 or 3 pumps in parallel.. one of them online and the others are in standby mode sometime for long periods" If there are 3 pumps in parallel..only one of them online then select one of the standby pump for hibernation. Blank its suction, discharge and bypass line flanges, drain the liquid, dry all internals and electrically isolate it. Revive it only when you really require. It will prolong pump life by reducing damages caused by corrosion and aging of seal parts with contact of liquid.

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#3

Re: long period standby pump

02/22/2011 9:47 AM

With critical systems, boiler fill pumps, turbine lube pumps, chemical process pumps, ect. where we use multiple pumps , we utilize an "Alternator Panel".

This panel will alternate between the two lead pumps for each operation. If a third (or even fourth) pump is utilized, the third (or fourth) pump will be exercised at a ratio predetermined based on the frequency of use/duration of the two lead pumps. Pumps can also be set up in a lead/lag configuration between the pumps.

The assumption is correct that the lead pumps may wear out around the same time (I have on rare occasions seen this) but most likely not. In either case you still have back up pumping capability.

There are many manufacturers of these panels. They are quite versatile and can be set up to virtually any lead/lag/exercise configuration and number of pumps.

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#4

Re: long period standby pump

02/22/2011 10:06 AM

I agree with these comments. They are really useful.

thanks

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#5

Re: long period standby pump

02/22/2011 11:03 AM

Excellent comments so far. Just to add:

One of the adverse effects of leaving the standby pump idle for long periods is something called 'false-brinelling' of the bearings. This is caused by vibration from the duty pump causing the bearing balls or rollers in the standby pump to impact continuously on the same spot on the races, and it can result in rapid bearing failure if the standby pump is started after a long period of being idle. This alone is a good enough reason to recommend, as previous posters have, that the standby pump should be operated (intermittently).

If any additional pumps are hibernated, as pritam suggests, our old O&M manuals (for chemical process pumps) would have recommended that the pumps be turned by hand (if possible) a few revs every month or so. I'm not sure if this is really necessary, or if it is a relic of the days of gland-packing when these manuals were compiled. But it's worth checking your pump O&M manuals, or the pump manufacturers recommendations if not in the manuals. You might find this useful as well:

http://effective-maintenance.com/Documents/Dutystby.pdf

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#6
In reply to #5

Re: long period standby pump

02/23/2011 7:03 AM

Yep. Been there. Two monster pumps on the same skid frame, side-by-side, with vibration mountings between the skid frame and the floor, and not between the pumps and the skid frame. When the standby pump was eventually started after several weeks running on the duty pump, the row was horrendous!

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#7
In reply to #6

Re: long period standby pump

02/23/2011 7:19 AM

That must have been quite a noise, and quite a surprise! I've never actually seen or heard the result on pumps, only heard about it. But I experienced a similar phomenon on the head-bearing of a friends motorbike in Canada. The damn thing only ever went in a straight line, so the head bearings had taken a set and didn't like being turned from the straight ahead position. That bike was a pig to drive on anything but straight roads.

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