Proper calibration is a vital, yet often overlooked, aspect of efficient operation in industrial pumping systems. While accurate calibration is a must for horizontal pumps, vertical pumps also have this need, although it may not be widely known.

What is Pump Alignment And Why is it Important?

Pump alignment is the process of ensuring that the pump shaft is aligned with the motor shaft centerline. Its importance includes:

Increase efficiency: Proper alignment optimizes energy transfer and improves pumping system efficiency.

Reduce wear: Misalignment increases vibration and stress on bearings, seals and couplings, accelerating component wear.

Extend life: Proper alignment reduces stress and extends pump and motor life.

Reduce maintenance: Good alignment reduces maintenance needs and reduces failure rates.

Save energy: Misalignment results in additional energy consumption and increases operating costs.

Do Vertical Pumps Require Alignment?

Yes, vertical pumps require calibration, unlike horizontal pumps. Some people believe that vertical pumps are self-calibrated due to their vertical orientation, which is a misconception and can lead to inefficient operation. Vertical pumps must ensure that the pump shaft is vertical and the motor shaft is aligned with the pump shaft. Miscalibration can lead to mechanical stress, reduced efficiency and premature equipment failure.

Challenges with vertical pump calibration include foundation settlement, where natural soil movement or structural changes can cause uneven foundation settlement, which can affect pump calibration, especially if the installation is imprecise or the pump weight moves over time.

Thermal Expansion: Pump components such as the pump housing, motor shaft, and piping expand and contract at different rates with temperature fluctuations, which can cause misalignment that can accumulate over time and affect pump performance.

Pipeline Stress: Improperly installed or poorly supported piping can exert uneven forces on the pump, causing shifting or misalignment, especially when pressure is applied by the weight of the piping and the forces generated by fluid flow.

Improper Installation: Proper installation is critical to long-term reliability. Errors during the installation phase, such as aligning the motor and pump shaft or securing the pump to the foundation, can cause alignment issues, and even minor misalignments can accelerate wear and eventually lead to mechanical failure.

Wear: Vertical pumps wear over time, and bearings, seals and other moving parts degrade, which can cause minor misalignments. Regular maintenance and monitoring are required to identify and correct them in time to avoid inefficient operation or failure.

What Are The Signs Of Misalignment In Vertical Pumps?

Regular inspections and maintenance are essential to identifying alignment issues with vertical pumps before they become a problem. Ensuring that your pump is properly aligned not only keeps it running efficiently, but it also extends its life and improves reliability, thereby avoiding unnecessary repairs and downtime. Here are some signs that may indicate that your vertical pump is misaligned:

Increased vibrations: If your pump vibrates unusually during operation, it could be a sign of misalignment.

Increased noise: A misaligned pump may produce louder or different sounds than usual.

Increased energy consumption: If your pump's energy consumption suddenly rises without a corresponding increase in output, misalignment could be to blame.

Fast wear of seals or bearings: Frequent failure of these components could be a sign that your vertical pump is misaligned.

Excessive temperatures: Misalignment can cause extra friction, which can increase the temperature of the pump or motor.

Leaks: Misalignment can subject seals to uneven pressure, causing leaks to occur.

Unusual wear of couplings: Rapid or unusual wear of the coupling between the pump and motor could mean there is an alignment problem.

Tianjin Kairun Pump Co., Ltd

Although vertical and horizontal pumps have different alignment requirements, alignment is critical to the proper operation and maintenance of both. Regular alignment checks and adjustments should be incorporated into the pump maintenance process to ensure optimal performance, energy efficiency and equipment life.

Tianjin Kairun Pump Industry Co., Ltd. understands the importance of proper pump alignment for the efficient operation of pumping systems. As a leader in pump manufacturing, we focus on pump research and development, manufacturing and modification. Our team of experts can provide customized solutions to meet your specific pumping needs and provide technical guidance on the correct alignment of vertical pumps. To avoid misalignment affecting pump performance, please contact our customer service department (catherine@kairunpump.com) to learn how we can help you optimize the operation of your vertical pump and ensure its long-term efficiency.

References

1. Pump Systems Matter. (2021). "The Importance of Pump and Motor Alignment." 

2. Hydraulic Institute. (2020). "Pump Alignment Best Practices."

3. Bloch, H. P., & Budris, A. R. (2013). "Pump User's Handbook: Life Extension." Fairmont Press.

4. Karassik, I. J., Messina, J. P., Cooper, P., & Heald, C. C. (2008). "Pump Handbook." McGraw-Hill Education.

5. Nelik, L. (2019). "Centrifugal and Rotary Pumps: Fundamentals with Applications." CRC Press.

6. American National Standards Institute. (2016). "ANSI/HI 9.6.4-2016: Rotodynamic Pumps for Vibration Measurements and Allowable Values." Hydraulic Institute.

7. Forsthoffer, W. E. (2017). "Forsthoffer's Rotating Equipment Handbooks: Pumps." Elsevier.