What is a Split-Case Pump?
A split-case pump is a type of centrifugal pump that has two separate casing halves, that are bolted together. This design allows for easy access to the internal parts and maintenance without disassembling the entire pump. The impeller is located in the center and rotates inside the casing, which creates a fluid flow by centrifugal force. Split-case pumps are commonly used in commercial and industrial applications, such as HVAC systems, municipal water systems, and oil refineries. They are designed to handle high-flow volumes at low to medium head pressures.
A Split-Case centrifugal pump is a type of machine used to pump liquid at a variety of rates. The device consists of two halves, which are separated by the diameter of the shaft running through the center. This allows for efficient pumping and reduces wear and tear on the machine’s moving parts. Split-Case Pumps can be configured to provide variable speeds or constant speed, depending on the application’s needs.
Types of Split-Case Pumps
There are several types of split-case pumps:
1. Single-stage, horizontally split-case pump: This is the most common type of split-case pump. It has a single impeller and a horizontally split casing.
2. Multistage, horizontally split-case pump: This type of split-case pump has multiple impellers in series and a horizontally split casing.
3. Vertical split-case pump: A vertical split-case pump has a vertically split casing and can be single or multi-stage.
4. Axially split-case pump: An axially split-case pump has a casing that is split axially (along the shaft axis) and can be single or multi-stage.
Advantages and Disadvantages.
Advantages of split-case pumps:
2. Easy maintenance: The split-case centrifugal pump design of these pumps allows for easy access to the impeller and other internal components, making maintenance easier and less time-consuming.
3. Reduced noise and vibration: Since the impeller is mounted on a shaft that is supported by bearings on both ends, split-case pumps generate less noise and vibration than other types of pumps, reducing unwanted noise pollution.
4. Versatility: Split-case centrifugal pump can be used for a wide range of applications, including water supply systems, HVAC systems, industrial processes, and firefighting.
Disadvantages of split-case pumps:
1. Size and weight: Split-case pumps tend to be larger and heavier than other pump types, making installation and transport more difficult and costly.
2. Limited pressure capacity: Despite their high flow rate capabilities, split-case pumps have limited pressure capacity compared to other pump types, making them unsuitable for high-pressure applications.
3. Higher initial cost: These pumps are more expensive than other types of pumps due to their complex construction, which may not be cost-effective for some smaller projects.
4. Water leakage: Split-case pumps are susceptible to water leakage around their seal areas, which can result in increased maintenance costs over time.
Common Applications of Split-Case Pumps
Split-Case pumps are mainly used in the industrial sphere, particularly for applications involving higher pressures or longer operating times.
1. HVAC Systems: Split-case pumps are commonly used in heating, ventilation, and air conditioning systems for circulating water and other fluids.
2. Municipal Water Treatment Plants: These pumps are often used in municipal water treatment plants for distributing drinking water, fire protection, irrigation and water circulation.
3. Industrial Manufacturing: Split-case pumps are also used in industrial manufacturing applications such as chemical processing, mining, power generation, and paper mills.
4. Agriculture: These pumps are extensively used in the agricultural sector for irrigation and water distribution, ensuring proper crop growth and yield.
5. Oil and Gas Industry: Split-case pumps are widely used in the oil and gas industry to circulate and transport fluids such as crude oil, natural gas, and refined petroleum products.
6. Wastewater Treatment: In wastewater treatment plants, these pumps move sludge and other wastewater materials from one treatment unit to another.
7. Mining: In mining applications, split-case pumps are used for dewatering operations, transporting slurries, and pumping water from mining pits.
8. Fire Protection: Split-case pumps are used in fire protection systems to provide reliable and continuous water supply for firefighting.
Base Materials Used for Split-Case Pumps.
Top manufacturers of split-case pumps include Grundfos, Flowserve, Sulzer, KSB, and Ebara.
Base materials used for split-case pumps include:
1. Cast iron: This material is commonly used for split-case pump casings as it is durable, cost-effective, and can withstand high pressures.
2. Bronze: Bronze is often used for the impellers of split-case pumps as it has good corrosion resistance and is well suited for handling seawater, acidic liquids, and other corrosive fluids.
3. Stainless steel: Stainless steel is frequently used for the shaft and other components of split-case pumps that are exposed to corrosive or abrasive fluids as it is highly resistant to both corrosion and wear.
4. Carbon steel: Carbon steel is used for certain parts of split-case pumps, such as the frame, as it is strong and robust, making it an excellent choice for heavy-duty applications.
5. High-temperature alloys: In some cases, split-case pumps may need to handle high-temperature liquids, in which case high-temperature alloys such as Inconel or Hastelloy may be used for their superior heat resistance.
Split case horizontal pump
A split case horizontal pump is a type of centrifugal pump where the casing is split into two halves along the horizontal plane. This allows for easy access to the internal components of the pump, such as impellers and shafts, without the need to dismantle the entire unit.
The split case centrifugal pump design also typically results in a more balanced hydraulic design, which improves pump efficiency and reduces wear on the components. These pumps are commonly used in industrial and municipal applications, such as water supply and irrigation, HVAC systems, and chemical processing.
Split case horizontal pumps can handle a wide range of flow rates and pressures, and are known for their reliability and long service life. They are available in various materials, including cast iron, bronze, and stainless steel, to suit different applications and fluid types.
Horizontal split case pump parts
1. Pump casing – houses the impeller and other components
2. Impeller – rotates and creates a flow of fluid
3. Shaft – transmits power from the motor to the impeller
4. Bearings – support and guide the rotating shaft
5. Mechanical seal – prevents leakage between the pump casing and the shaft
6. Seal housing – houses the mechanical seal
7. Stuffing box gland – seals the shaft where it exits the pump casing
8. Motor frame – supports the electric motor
9. Coupling – connects the pump shaft to the motor shaft
10. Baseplate – supports the pump and motor
11. Suction nozzle – connects to the piping system and draws in fluid
12. Discharge nozzle – connects to the piping system and expels fluid
13. Bolts – secure the pump casing to the baseplate
14. Gaskets – provide a seal between pump components
15. Wear rings – reduce metal-to-metal contact and prevent damage to the impeller and casing
16. Spacer coupling – allows for easy maintenance and replacement of mechanical seals
17. Relief valve – protects the pump from over-pressurization
18. Pressure gauge – measures the pressure at the pump discharge
19. Flow meter – measures the flow rate of the fluid
20. Drain plug – allows for draining of the pump and piping system during maintenance.
Agriculture, Irrigation, Water supply systems, HVAC, Fire protection, Industrial processes, Power generation, Oil and Gas, Mining, Chemical processing, and many others.
Split case centrifugal pump
The impeller of a split-case centrifugal pump is mounted on a shaft that is supported by bearings located outside the pump casing. When the pump is in operation, the impeller spins and creates a centrifugal force that moves the fluid through the pump’s volute or casing.
Split-case centrifugal pumps are commonly used in applications where high flow rates and high pressures are required, such as in water supply and distribution systems, irrigation systems, and industrial applications. They are generally more efficient than end-suction centrifugal pumps and can handle larger volumes of fluid.
Casing in centrifugal pump
Here are the top 10 root causes and troubleshooting methods for split casing pumps:
- Low flow rate or no flow: This can be caused by a clogged impeller or suction strainer, a closed or partially closed discharge valve, or a damaged impeller or casing. Troubleshooting methods include inspecting and cleaning the impeller and suction strainer, checking the discharge valve position, and inspecting the impeller and casing for damage.
- Low pump head: This can be caused by a worn or damaged impeller, a low suction pressure or vacuum, or a clogged suction strainer. Troubleshooting methods include inspecting the impeller for wear or damage, checking the suction pressure or vacuum, and cleaning or replacing the suction strainer.
- Excessive vibration: This can be caused by misalignment of the pump and motor, loose or damaged pump components, or cavitation. Troubleshooting methods include checking and correcting the alignment of the pump and motor, inspecting and tightening all pump components, and adjusting the pump speed or impeller diameter to prevent cavitation.
- Bearing failure: This can be caused by improper lubrication, excessive vibration, or a worn or damaged bearing. Troubleshooting methods include checking and adjusting the lubrication system, checking and correcting any sources of excessive vibration, and inspecting and replacing worn or damaged bearings.
- Leakage at the pump seal: This can be caused by worn or damaged seals, improper installation or adjustment of the seal, or excessive pressure or temperature. Troubleshooting methods include inspecting and replacing worn or damaged seals, checking and adjusting the seal installation and adjustment, and reducing the pressure or temperature if necessary.
- Excessive noise: This can be caused by cavitation, improper installation or alignment, or worn or damaged pump components. Troubleshooting methods include adjusting the pump speed or impeller diameter to prevent cavitation, checking and correcting the installation or alignment, and inspecting and replacing worn or damaged pump components.
- Overheating: This can be caused by a blocked or restricted cooling system, excessive pump speed or power, or improper lubrication. Troubleshooting methods include inspecting and cleaning the cooling system, reducing the pump speed or power, and checking and adjusting the lubrication system.
- Corrosion or erosion of pump components: This can be caused by exposure to corrosive or abrasive fluids, improper material selection, or poor maintenance practices. Troubleshooting methods include selecting the appropriate materials for the fluid being pumped, improving maintenance practices, and inspecting and replacing corroded or eroded pump components.
- Electrical problems: This can be caused by faulty or damaged electrical components, improper wiring, or improper electrical grounding. Troubleshooting methods include inspecting and replacing faulty or damaged electrical components, checking and correcting the wiring, and ensuring proper electrical grounding.
Impeller damage: This can be caused by solids or debris in the fluid, excessive vibration, or improper handling or installation. Troubleshooting methods include inspecting and cleaning the fluid for solids or debris, checking and correcting any sources of excessive vibration, and handling and installing the impeller properly.
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