PUMP

BASICS
 TYPES OF PUMPS
 CENTRIFUGAL
– Low pressure
– High flow
– flow changes when pressure changes

 POSITIVE DISPLACEMENT
– High pressure
– Low flow
– Flow does not change when pressure changes

2
7/23/2010
 TERMINOLOGY
 CENTRIFUGAL
– MOVING AWAY FROM CENTER

 CENTRIFUGAL FORCE
– INERTIA OF A BODY REVOLVING AROUND A
CENTER POINT

3
7/23/2010
CENTRIFUGAL FORCES
IMPELLER ROTATION

4
7/23/2010
 CENTRIFUGAL PUMP DESIGN
 SPLIT CASE
– Initial design
– Horizontal shaft
– Top & bottom halves of casing for maintenance
– Large amount of floor space

 END SUCTION
– Less floor space
– Suction and discharge at right angles

5
7/23/2010
SPLIT CASE HORIZONTAL

6
7/23/2010
VERTICAL SPLIT CASE

7
7/23/2010
END SUCTION UNITS

8
7/23/2010
 END SUCTION
 CLOSE COUPLED UNITS
PUMP IS ASSEMBLED ON MOTOR
SHAFT
 FRAME MOUNTED UNITS
ASSEMBLY INCLUDES PUMP,
MOTOR, BASE, COUPLING & OSHA
COUPLING GUARD

9
7/23/2010
END SUCTION CLOSE-COUPLED

10
7/23/2010
END SUCTION

11
7/23/2010
 12
7/23/2010
 MULTI-STAGE PUMPS
 MULTIPLE IMPELLLERS ON SINGLE SHAFT
 AXIAL FLOW, NOT RIGHT ANGLE
 VERY HIGH DISCHARGE PRESSURE
– LIKE PUTTING SINGLE-IMPELLER PUMPS IN
SERIES
 FLOW DOES NOT CHANGE
– PUMPS IN PARALLEL CHANGES FLOW NOT
PRESSURE
 EXAMPLES:
– LINE SHAFT TURBINES
– SUBMERSIBLE TURBINES 13
7/23/2010
VERTICAL TURBINE

14
7/23/2010
VERTICAL TURBINE IMPELLER ASSEMBLY

15
7/23/2010
SUBMERSIBLE PUMP-MOTOR
ASSEMBLY

16
7/23/2010
CENTRIFUGAL PUMP
COMPONENTS
 SHAFT ASSEMBLY
 Connects pump to motor
 Can be direct-coupled
 Same shaft for pump and motor
 frame-mounted
 Motor shaft and pump shaft mechanically coupled
 alignment must be maintained
 shaft sleeve
 fits over shaft
 protects shaft where shaft passes thru pump casing
 bearings
 supports & holds spinning shaft in place
 radial bearings prevent side-to-side movement
 thrust bearings prevent up & down movement from
water pressure against impeller 18
7/23/2010
 PUMP ASSEMBLY
 Volute
 Portion of casing that directs water as it enters and leaves the impeller
 X-sectional area increases, velocity decreases, pressure increases
 piping
 Diameter suction side > diameter discharge side
 4 fps suction side velocity
 7 fps discharge side velocity
 Prevent air pockets in suction side piping
 Slope horizontal runs up towards pump
 Use eccentric reducers with flat side on top
 NEVER use pump to support piping
 Wear rings
 prevent water from recirculating back thru pump from discharge to
suction side of impeller
 close tolerance between pump & impeller to as little as 0.010”
 Become worn from friction & are replaceable 19
7/23/2010
Wear Ring

20
7/23/2010
 SEALS
 Plugs hole where shaft enters pump body
 Keeps water in & air out of pump
 Stuffing box
 Part of pump casing where shaft passes through
 Contains several rings of packing
 Want rings staggered to allow distribution of lubricating/cooling water
 Packing gland
 Metal ring on top of stuffing box
 Used to put pressure on packing to minimize water leakage
 Seal water
 Used to cool & lubricate the rings of packing
 Can come from low pressure side (suction) of pump if sufficient pressure
 Otherwise pipe from discharge side (high pressure) of pump
 Need air gap if mixing potable & nonpotable water
 Lantern ring
 Used to direct water from seal water piping to the inside of the stuffing box
where the rings of packing are located around the shaft sleeve
 Metal ring with holes
 Water circulates around the outside of ring & passes thru the holes to get to
the packing 21
7/23/2010
 22
7/23/2010
Packing & Glands

23
7/23/2010
END SUCTION FRAME MOUNTED PUMP ANATOMY

24
7/23/2010
 MECHANICAL SEALS
 Replaces packing rings inside the stuffing box
 Includes 2 highly polished seal faces
 One face is inserted in a gland ring
 Gland ring replaces the packing gland
 Other seal face is attached to the rotating shaft
 Held in place on shaft with a locking collar
 Collar includes a spring-loaded assembly that pushes
the 2 seal faces together when pump not running
 Seal water (same criteria as for packing seals)
 When pump running seal water forces 2 seal faces
apart
 This closes gap & keeps water in & air out
Insufficient seal water pressure or no pressure will
result in seal faces rubbing against each other & seal
failure 25
7/23/2010
 26
7/23/2010
MECHANICAL SEAL

27
7/23/2010
 PUMP
HYDRAULICS
 TERMINOLOGY
 FLOW RATE
 HEAD
 NPSH (NET POSITIVE SUCTION HEAD)
 PUMP EFFICIENCY
 MOTOR RPM
 HP (HORSEPOWER)
 ELECTRICAL PHASES

29
7/23/2010
 FLOW RATE
THE VOLUME PER TIME OF
WATER TYPICALLY
MEASURED AS:

 GPM (GALLONS PER MINUTE)

 GPH (GALLONS PER HOUR)
 GPD (GALLONS PER DAY)
30
7/23/2010
 Pressure & Head
 Pressure is a force based on weight per unit area
 Measured in pounds per square inch, lbs/in²
(psi), or pounds per square foot, lbs/ft²
 Pressure is exerted on the bottom of a container
and is not related to the volume of the container
or the size of the base
 Pressure is only dependant on the height of the
fluid in the container
 The height of the fluid in a container is referred
to as head, which is a direct measurement in feet
& is what exerts the pressure
31 31
7/23/2010
PRESSURE VS FEET OF HEAD

32
7/23/2010
Relationship between Pressure & Head
 Weight of water is 62.4 pounds per ft3
 7.48 gal/ft3 x 8.34 lbs/gal = 62.4 lbs/ft3

1 ft 1 ft3

1 ft
1 ft
33 33
7/23/2010
 Pressure & Head
Imagine a cube of water 1ft x 1ft x 1ft. Then, the surface
area of any one side of the cube will contain 144 in² (12in
x 12in = 144 in²). The cube will also contain 144 columns
of water one foot tall & one inch square.

Weight = 62.4lbs/144in² 1 in
1 in
= 0.433lbs/in² or
= 0.433 psi

Therefore, 1 foot of head 12 in

= 1ft 0.433psi
= 2.31 ft/psi

So, 1ft = 0.433 psi, and 34 34

1psi = 2.31 feet 7/23/2010
 Remember these
conversion factors
 PSI x 2.31 = FEET
Example:
43.3 PSI x 2.31 FT/PSI = 100 FT

 FEET x 0.433 PSI/FT = PSI

Example:
100 FT x 0.433 PSI/FT = 43.3 PSI
35
7/23/2010
 PRESSURE GAUGES

 PSI = POUNDS PER SQUARE INCH

 PSIG = PSI GAUGE

 PSIA = PSI ABSOLUTE

36
7/23/2010
 Gage vs Absolute Pressure
 PSIG common type of pressure within plant environment
Does not include effects of atmospheric pressure
 Patm = 14.7 psi = 33.9 ft = 34 ft (at sea level)

 maximum practical lift of a pump at sea level

PSIG = 0 means system is at atmospheric pressure

PSIG < 0 considered a vacuum for the system (still some
value below atmospheric pressure)
 until PSIG < -14.7 psi pressure due to atmosphere
 PSIA pounds per square inch absolute
Usually used to describe a vacuum
Includes atmospheric pressure
PSIA = 0 means no pressure in system
PSIA < 0 absolute vacuum
37 37
 PSIA = PSIG + Patm 7/23/2010
CHANGES IN ATMOSPHERIC
PRESSURE WITH HEIGHT

38
7/23/2010
 Energy and Head
Energy in water has 4 forms:
 elevation head, EH
 measured in feet as height above datum
 pressure, P in psi
 pressure head, PH in ft = P x 2.31 ft/psi
 velocity, V in fps
 velocity head, VH in feet = V2/2g
 g = gravitational acceleration = 32.2 ft/s2
 head loss, HL measured in feet
 caused by turbulence, friction
 creates heat energy which is lost from system
 increases with smaller pipe diameter, higher flow,
rougher pipe walls 39
7/23/2010
 Static Suction Lift TDH
 Fluid level suction side below eye of pump impeller
 TDSL = static suction lift + VHs + HLs
 TDDH = static discharge head + VHd + HLd
 TDH = SSL + VHs + HLs + SDH + VHd + HLd

Total Static Head

Static Discharge Head

Static Suction
Lift Pump CL

40 40
7/23/2010
 Static Suction Head TDH
 Fluid level suction side above eye of pump impeller
 TDSH = static suction head + Patm – VH – HL
 TDDH = static discharge head + VHd + HLd
 TDH = SDH - SSH + VHs + HLs + VHd + HLd

Total Static Head

Static Discharge Head

Static Suction Head

Pump CL
41 41
7/23/2010
 NET POSITIVE SUCTION HEAD, NPSH
 NPSH is the total energy available to move water
into the volute and the eye of the impeller
 At sea level NPSH = 1 atm = 14.7 psi = 34 ft
 However, this energy is reduced by:
– static suction lift (biggest factor)
– velocity head, VH to get water moving
– head loss, HL
– Vapor pressure (based on temperature)
 Portion of water evaporates when placed under
a vacuum (at the eye of impeller)
 NPSHR = net positive suction head required
42
 NPSHA = net positive suction head available 7/23/2010
 Net Positive Suction Head, NPSH
 For suction lift condition
NPSH = Patm – Pv – static suction lift – HL

 For suction head condition

NPSH = static suction head + Patm – Pv – HL

43
7/23/2010
Vapor Pressure vs Temperature
Temperature, o F Vapor Pressure, feet
32 0.204

59 0.565

68 0.774

100 2.17

150 8.56

200 26.45
44 44
7/23/2010
 45 45
7/23/2010
 Total Dynamic Head, TDH
 Total energy in feet required to move water from fluid level
suction side to fluid level discharge side
 combination of EH, VH and HL of suction and discharge lines
 VH discharge side > VH suction side due to reduced diameter of
discharge piping
 Total dynamic suction lift, TDSL
 fluid level suction side below eye of impeller
 TDSL = static suction lift + VH + HL
 Compare to net positive suction head, NPSH – energy reqd to
move water into volute or impeller eye
 available NPSH = P atm – P v – static suction lift – HL
 Check pump curve to compare available vs required NPSH
 Total dynamic suction head, TDSH
 fluid level suction side above eye of impeller
 NPSH = static suction head + Patm – Pv – HL
 pump choice ok if static suction head ≥ NPSH required 46
 TDSH = static suction head + Patm – VH – HL 7/23/2010
 47 47
7/23/2010
 48 48
7/23/2010
 MECHANICAL POWER
• EXPRESSED AS HORSE POWER

• THE AMOUNT OF WORK REQUIRED TO LIFT ONE

POUND TO THE HEIGHT OF ONE FOOT IS DEFINED
AS 1 FT-LB

• ONE HORSE POWER IS THE THEORETICAL POWER

REQUIRED TO LIFT 33,000 POUNDS TO A HEIGHT OF
ONE FOOT IN ONE MINUTE

• 1 HP = 33,000 FT-LB/MINUTE
• 1 HP = 550 FT-LB/SECOND

49
7/23/2010
 ELECTRICAL POWER
 MEASURED IN HP, WATTS (W) OR
KILOWATTS (KW)

 1,000 W = 1 KW = 1.34 HP or

 1 HP = 746 W = 0.746 KW

50
7/23/2010
 ELECTRICAL POWER
 SINGLE PHASE: 115 OR 230 VOLT AC
CONSIST OF THREE LEGS (HOT, NEUTRAL &
GROUND. NORMALLY REQUIRES A
STARTING CIRCUIT (RELAYS AND
CAPACITORS)

 THREE PHASE: 208/230/460 VOLT AC

CONSIST OF THREE HOT LEGS & A
GROUND. POSSIBLE TO REVERSE
ROTATION BY CHANGING ANY TWO
LEADS. BALANCING PHASE IS IMPORTANT
TO LIFE.

51
7/23/2010
 Pump and Motor Efficiencies
 motor or wire HP, MHP = electrical energy in HP
supplied to motor; motor efficiency determines brake HP

 brake HP, BHP = mechanical energy in HP supplied to

pump shaft from motor; pump efficiency determines water
HP

 water HP, WHP = mechanical energy in HP transferred

to water by pump
Motor, Pump,
MHP % efficiency BHP % efficiency WHP

52
7/23/2010
 Horsepower Requirements
 Water HP – energy transferred to water by pump
 HP = (Q, gpm x 8.34 #/gal x TDH, ft)/33,000 ft-
#/min
 WHP = (Q x TDH)/3960

 Brake HP – energy transferred to shaft of pump

from shaft of motor
 Brake HP = WHP/Effpump

 Motor or Wire HP – energy required in electrical

input to the motor
 Motor or Wire HP = BHP/Effmotor
 used to calculate cost of pump operation 53
7/23/2010
 PUMP
CURVES
 Pump curve characteristics
 Head Capacity curve – curve A
– Shows relationship between head in feet
and capacity, or flow in gpm
 Brake horsepower curve – curve B
– Indicates power in horsepower required for
pump to meet head and flow conditions
from curve A
 Efficiency curve – curve C
– Provides efficiency of the pump 56
7/23/2010
 Affinity Laws
 Impeller diameter and pump speed (rpm) for pump
curve must match impeller diameter and speed of
pump
 Can use affinity laws to compensate for changes in
diameter
– Q2 = Q1 x D2/D1
– H2 = H1 x (D2/D1)2
– HP2 = HP1 x (D2/D1)3
 For changes in speed
– Q2 = Q1 x RPM2/RPM1
– H2 = H1 x (RPM2/RPM1)2
59
– HP2 = HP1 x (RPM2/RPM1) 3 7/23/2010
 Shut-Off Head
 The maximum amount of head or pressure a
pump can develop
 Flow drops to 0 when a pump reaches shut-
off head
 Pump curve NOT valid if pump can not
generate rated shut-off head
– Could be due to worn impeller or worn
wear rings
– Could also be due to pump running at lower
rpm than rating 60
7/23/2010
MECHANICAL SYSTEMS
OPERATION &
MAINTENANCE
(O&M)
 MAINTENANCE &
TROUBLESHOOTING
MOST OF THE TIME THE PART THAT
FAILED IS SELDOM THE ROOT
CAUSE OF THE FAILURE. UNTIL YOU
CORRECT THE ROOT CAUSE, REPEAT
FAILURES WILL OCCUR.
 MAINTENANCE &
TROUBLESHOOTING
 PACKING & GLANDS
 MECHANICAL SEALS
 BEARINGS
 SHAFTS
 SUBMERSIBLE WELL SYSTEMS

63
7/23/2010
 64
7/23/2010
Packing Problems

65
7/23/2010
 MECHANICAL SEAL
COMMON FAILURES
 RUN-DRY
 DEAD HEADING
 TEMPERATURE
 ALIGNMENT
 VIBRATION
 PARTICULATE / ABRASIVES
 CHEMICAL INCOMPATIBILITY

66
7/23/2010
 67
7/23/2010
 68
7/23/2010
BEARINGS

69
7/23/2010
RADIAL, AXIAL, & THRUST
LOADS

70
7/23/2010
 BEARING MAINTENANCE
• LUBRICATE PER MANUFACTURERS
RECOMMENDATIONS
• SEALED OR SHIELDED BEARINGS
ARE FACTORY LUBRICATED AND
RATED FOR 10,000 HOURS & UP
• OVER GREASING IS NOT
RECOMMENDED.
• BE AWARE WHEN PLACING ON
SHAFT OF CREATING FLATS SPOTS
71
7/23/2010
 COMMON FAILURES
 LACK OF LUBRICATION /
TEMPERATURE
 DIRT
 IMPROPER INSTALLATIONS (FLAT
SPOTS)
 FATIGUE
 VIBRATION

72
7/23/2010
 STATIC JOINTS
COMMON FAILURES
 NO PIPE SUPPORT
 OVER-TORQUEING BOLTS
 IMPROPER ALIGNMENT (BASES &
SUPPORTS)

73
7/23/2010
 HYDRAULIC
COMMON FAILURES
 CAVATION WEAR
 SYSTEM DESIGN
 PARTICULATE MATTER
 SYSTEM ADD-ONS

74
7/23/2010
 COUPLINGS
COMMON FAILURES
 MISALIGNMENT
 IMPROPER SIZING (HP VS. RPM)
 FATIGUE

75
7/23/2010
GENERAL START UP OF PUMPS

76
7/23/2010
SUBMERSIBLE PUMP TROUBLESHOOTING

77
7/23/2010
 78
7/23/2010
 79
7/23/2010
 80
7/23/2010
QUESTIONS?