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Applying Variable Volume Pumping - Part II

Pumping Fundamentals To optimize system performance, the designer has a number of variations of basic primarysecondary pumping to explore
In the previous article Variable Volume Pumping Fundamentals, the concept of variable volume pumping is thoroughly developed. The example cited is a primary-secondary pumping system. Primary-secondary pumping configurations are successfully applied by thousands worldwide and is the standard approach for many design engineers. To optimize system perfor-mance, the designer has a number of variations of basic primary-secondary pumping to explore. Primary-secondary zone pumping systems Primary-secondary-tertiary pumping systems Primary variable speed pumping systems Each type of pumping system configu-ration has distinct advantages for the user or operator. There are also cautions to consider. Fundamental to all of these configurations is sound design principles. Without the proper application of the basics, the most sophisticated systems will not operate effectively. Primary-secondary zone pumping systems-A variation of the traditional primary-secondary pumping scheme is primarysecondary zone pumping (Fig. 1). This configuration is also referred to as distributive pumping. The principles of primarysecondary pumping still apply. The difference in this design is that the main distribution pump is eliminated in favor of multiple zone or building pumps. Using this approach and under the right condi-tions, pumping horsepower can be saved initially and in the future. Zones close to the chiller plant are not overheaded (over-pressurized) to meet the demands of the zones farther downstream. In large applications, pressure may also be reduced-saving pipe, valve, coil, and tank first cost. Gil Carlson of Bell & Gossett demon-strated the value of primary-secondary zone control in the early 1960s. Design considerations-Each zone pump is decoupled from the chiller pumps through a common pipe. They are, however, not decoupled from each other. Essentially, they operate in parallel. The suction and discharge of the pumps are connected through shared supply and return piping. A very small pressure drop must be maintained in the pipe shared by these pumps. This pipe includes the common pipe and the shared supply and return header (Fig. 2). The designer must be extremely careful with the selection of the pumps and the balancing of each zone. Pumps should have the same or similar pump curves. Pipe sizing-Friction loss in the shared piping dramatically effects the performance of zone pumped systems. Per ASHRAEs recommendation, friction loss no greater than 4 per 100 ft. of equivalent pipe should be followed. Friction loss must be calcu-lated at the maximum flow rate expected in the future. Pump selection-The action of pumps in the downstream zones (Pumps B and C) will affect the pump in Zone A (and vice versa), unless the distribution pipe has a very small pressure drop due to a large diameter or a very short length as shown in Fig. 2. Friction loss in the piping is based on a squared law function. The friction loss assigned to Zone Pump A must be based on the total flow in the shared pipe. Zone Pump A must overcome the added pressure drop in the shared pipe based on all of the pumps in full operation. Future loads-As loads are added in the zones, pressure drops increase in the zone piping as well as in the shared piping. Existing pumps may need to be increased in size, be replaced to meet the new resistance, or sized larger in anticipation of future conditions. Future zones-As with future load changes, future zone requirements must also be considered. Pumps must be selected with future zone character-istics in mind. The addition of an unexpected zone may require the replacement or modification of all or some of the existing zone pumps. If future zone requirements are known, the existing pumps can be selected large enough to meet future requirements. Pumping compatibility-The square law relationship between the piping system and the pumps is very important, especially when applying adjustable frequency drives to zone pumping. When the decision is made to apply zone pumping, the decision must also be made whether all of the pumps will be constant speed or use variable speed. Since the zone pumps are operating in parallel, the pumps operating curves must be compatible. The point of operation of down stream pumps will affect the performance of the upstream pumps and vice versa. Downstream users-Since each zone pump must be capable of providing enough differential pressure to transport water from the chiller plant to the loads and back to the chiller plant, each successive zone pump must be larger in horsepower even if the zone flow rates and pressure drops are similar. In a district-type system, the customer at the end of the distribution system can require pumps of

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signifi-cantly greater horse-power than those close to the plant. Controls-Each zone operates independently and requires its own variable speed controls. It is not recommended to mix constant speed and variable speed zones in the same system. Balance-Balance is a critical factor in the design and operation of a zone-pumped system. If the system is not properly balanced, the return distribution pipe may be over-pressurized. Over-pressurization will compound the system problems. Valves can lift off their seats, resulting in hunting and poor temperature control. Primary-secondary- tertiary (tertiary) pumpingsystems-Another variation of primary-secondary pumping is tertiary pumping (Fig. 3). Secondary pumps distribute the chilled water from the central plant to the connected buildings or zones. Individual buildings or zones are decoupled from the distribution loop through a tertiary bridge. A major advantage of tertiary pumping is that the individual zones are hydraulically and thermally decoupled. This allows the designer some flexi-bility to control each zone independently, relative to differential pressure and temper-ature. Zones may be a collection of coils, air handlers, or entire buildings. This advantage is ultimately expressed in district cooling and heating systems where individual users are decoupled through the means of gasketed plate heat exchangers (GPX). When GPX are used, cross contamination of HVAC fluids may also be prevented.The operator of the distribution system is isolated from the users and is not subjected to potential excessive static pressure. Design considerations- The addition of tertiary pumps may increase the initial-connected horsepower of the system, but the level of control is increased. Under the right conditions, overall operating cost can be reduced. To optimize the performance of a tertiary-pumped system, control of the tertiary bridge modulating valve is critical. Tertiary bridge design-The same design criteria used for the secondary bridge should be followed (Fig. 4). Temperature sensor locationsProper valve control requires that temperature sensors are located at the supply water temperature to the tertiary zone, T1; return temperature to the chiller plant, T2 (a low-flow bypass is maintained across the return control valve to provide an accurate water temperature); and the supply water temper-ature from the chiller plant, T3. Proper control permits the zone to operate at the highest possible temperature without control in the zone. This maximizes the flow through each coil and control valve providing better heat transfer and valve authority. Maximizing the flow in the tertiary also reduces the amount of water from the secondary. This reduces the flow in the secondary and may result in the reduction of the number of chillers on-line in the chiller plant. Secondary pumps-Secondary pumps are selected for present flow to minimize initial horsepower. The pressure drop across the control valve of the highest head zone must be included. Consideration should be given for future flow conditions. Careful selection will permit the use of present flow pumps under future conditions. Since the secondary pumps are typically the largest pumps in the system, adjustable frequency drives and controls should be considered if economically justifiable. Tertiary pumps- Tertiary pumps are selected based on the flow and head require-ments for the zone or building load. These pumps are often low horsepower and do not need to be of variable speed unless it is economically justi-fiable. If variable speed is elected, differential pressure sensors are located across the largest, farthest load and two-way control valve. Consideration must also be given to low flow conditions. These are similar to the design parameters for primary-secondary pumping systems. Zones close to the chiller plant may operate under high distribution piping differential head. If the differential head is sufficient at all times, tertiary pumps may not be required for the nearby zones. Primary variable speed pumping systems-This type of system is not a variation of primary-secondary pumping. The concept behind primary variable speed pumping is the elimination of the secondary pumps to reduce first cost, space requirements, and maintenance (Fig.5). Constant volume is no longer maintained through the chillers. Variable system flow is directly achieved through the modulation of flow through the chillers. Primary variable speed pumping systems are especially attractive in primary-pumped retrofit situations since space may not be available for additional pumps and piping. Design considerations- Control logic and sequencing for the pumps and chillers is the heart of this type of system. With the advent of more sophisticated micropro-cessor controls, the potential problems associated with under-flowing or overflowing the chillers can be addressed. Operation of the variable speed pumps is also provided through the microprocessor control. Chillers -Multiple chillers are required to maximize the turndown capacity of the chilled water plant. With only one chiller, the low-flow range is limited to the minimum flow of the single chiller. Multiple chillers lower the minimum flow limitation. The designer must know the minimum flow requirements for each chiller. Chillers of the same size, efficiency, and manufacture simplify the control sequence.

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Close coordination with the chiller manufacturer is highly recom-mended, especially in retrofit appli-cations. Common pipe-The common pipe is not eliminated in primary variable speed pumping. It is modified into a low-flow bypass. To ensure that minimum flow is always maintained through the chiller, a bypass with a modulating control valve is employed. As loads diminish, system flow reduces. When the system flow approaches the minimum flow requirement of the chiller, the modulating twoway valve in the bypass opens. The sum of the flow in the system plus the flow in the bypass must exceed the minimum flow requirement of the chillers. Flowmeters are installed in both the supply and the bypass to calculate the flow sequence. Primary pumps-Primary variable speed pumps are selected in a manner similar to secondary pumps in primary-secondary pumping systems. Pumps should be of equal size and designed for parallel operation. Pumps with differing flow and head characteristics do not work well together in parallel. Careful selection will permit the use of present flow pumps under future conditions. Differential pressure sensor locations-The principle method of pump control is differential pressure transmitters. As with other variable speed systems, the largest, farthest loads are usually the most critical to monitor. Sensors close to the chiller plant provide valuable information for minimizing system differential pressure during low flow conditions. Conclusion There are many ways modern HVAC systems can be pumped. Each method has its own advantages and disadvantages to the user or operator (Table 1). The designer must consider present system use, plans for the future, cost considerations, and the ability level of the operator. With more tools in the toolbox, the engineer is better equipped to make the decision, Which system is the best for my client? This article is an abridged version of a Fluid Handling Staff article that was originally published in the October, 1998 issue of HPAC magazine. Part I appeared in the January, 1999 issue of Tech Talk. 4

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Steam Control and Condensate Drainage for Heat Exchangers

Steam Systems
General Heat transfer units that use steam to produce hot water are known as indirect heaters. They are often shell and tube type heat exchangers and are generally referred to as converters, hot water generators, and instanta-neous heaters. The ASME Code for Unfired Pressure Vessels is the nationally recognized authority prescribing their construction for given temperatures and pressures. The term used varies with the heating medium and the manner of application. When these heaters use steam as the heat source they are usually called steam to water converters. In steam heated converters, the water to be heated circulates through the tubes and steam circulates in the shell surrounding the outside of the tubes. This results in condensate draining to the bottom of the heat exchanger shell as the steam gives up its latent heat. Steam to Water Heat Exchangers The operation of the shell and tube heat exchanger is as follows. Steam enters the heat exchanger shell through the top vapor opening and surrounds the outside of the tubes. As energy is transferred through the tubes it heats the water inside the tubes. The heat transfer condenses steam inside the shell forming condensate that drops to the bottom of the heat exchanger shell. The condensate flows through the bottom condensate outlet and into a steam trap. The steam pressure in the heat exchanger shell has a direct correlation to the temperature of the condensate formed in the shell. The properties of saturated steam are such that the steam temperature varies with steam pressure (See Table 1). When the latent heat of vaporization is removed, the resulting condensate will be close to the saturation temperature. Depending on the system load, slight sub-cooling may occur from the bottom of the heat exchanger and the inlet piping to the steam trap. The heat exchanger should be selected to operate at the minimum possible steam pressure. This allows the lowest possible condensate temperature to discharge from the steam trap and reduces the amount of flash steam in the return system. When heating fluids up to 200F, the heat exchanger should be selected based on 2 psig steam pressure in the shell for the most efficient system operation. This may require a slightly larger heat exchanger than one operating at higher pressure, however it will result in a smaller less expensive low pressure steam trap and a smaller steam regulating valve. The low pressure selection will also limit the maximum temperature that can occur inside the tubes, should the temperature controller fail in an open position. It is standard practice to add a fouling factor in the heat exchanger selection. This fouling factor adds additional tube surface area to assure adequate heating after normal scale and corrosion deposits on the tube surfaces. A standard .0005 fouling factor will add 20 to 25% additional tube surface area. When the heat exchanger is new and the tubes are clean and shiny, the heat exchanger will operate at lower than design pressure even at full system load. For example, a new heat exchanger designed for 15 psi steam to heat water to 160 degrees will generally heat the full system load with 0 psi steam in the heat exchanger shell. Heat Exchanger Selection The heat exchanger should be selected for operation at the minimum pressure to provide the most efficient operation. The properties of saturated steam tables show a larger amount of the latent heat is available at low pressure. Less energy remains in the condensate reducing the flash steam losses. A reasonable guide would be to select a steam pressure that has a saturation temperature approximately 30F higher than the required outlet temperature of the fluid being heated in the tubes. For fluid temperatures up to 200F, 2 psig steam is recommended. When a high steam pressure source is used, the pressure should be reduced by installing a steam pressure regulating valve or by using a combi-nation temperature pressure regulator. After selecting the heat exchanger, the next step should be planning the instal-lation. The heat exchanger should be mounted high enough to allow gravity drainage of the condensate from the steam trap into a vented gravity return line. If a gravity return line is not available, a condensate pump should be installed. The heat exchanger should be mounted with a pitch toward the condensate outlet. A minimum 1/2 inch pitch per 10 foot length should be provided. The heat exchanger should also be located such that removal of the tube bundle is possible. Steam Traps The steam trap must be capable of completely draining the condensate from the heat exchanger shell under all operating conditions. On a heat exchanger using a modulating temper-ature regulator to heat fluids under 212F, the steam pressure in the shell can be 0 psig. To assure condensate drainage, the steam trap must be mounted below the heat exchanger outlet tapping and it must drain by gravity into a vented condensate return unit. When possible, the trap should be located 15 inches below the heat exchanger outlet. The 15 inches static head to the trap inlet will provide 1/2 psig static inlet pressure to the trap when the shell steam pressure is at 0 psig. The trap should be sized based on this 1/2 psig differential pressure. A safety factor of 1.5 times the calculated full load capacity should be used to handle unusual start up loads. A float and thermostatic trap is normally the best selection for a heat exchanger. The thermostatic element quickly vents the air from the heat exchanger shell. The modulating float element provides continuous

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condensate drainage equal to the system condensing rate. Failure to provide complete condensate drainage will lead to poor temperature control and possible water hammer. Any lift in the condensate return piping after the trap discharge requires a positive pressure to develop in the heat exchanger shell to provide condensate drainage. For this to occur, condensate must back up in the heat exchanger shell until enough tube surface is covered by condensate to build a positive steam pressure. When the positive steam pressure develops to move the condensate through the steam trap and up the vertical return line, over heating can occur on the tube side of the heat exchanger due to the positive steam pressure remaining in the shell. This results in a wide range of outlet fluid temperatures from the heat exchanger. A lift in the return line as shown above should be avoided on heat exchangers using a modulating control valve. A lift or back pressure in the steam trap return piping can flood the heat exchanger shell and cause severe water hammer as steam enters the flooded shell. The resulting water hammer can damage the steam trap, the steam regulating valve, the heat exchanger tubes and cause the gasket in the heat exchanger and trap to fail. Trap Installation The trap should be located below the heat exchanger shell to allow free flow of condensate into the trap. A strainer complete with a screen blow down valve should be installed ahead of the steam trap. A shut off valve should be provided in the trap discharge return line to isolate the unit for service. Unions should be provided to allow trap service or replacement. The return line from the trap discharge should be pitched into a vented condensate return unit. Vacuum Breakers Most steam to water heat exchangers provide a tapping in the shell to allow installation of a vacuum breaker. The vacuum breaker allows air to enter the shell when an induced vacuum occurs. Failure to install a vacuum breaker will allow the heat exchanger shell to operate at a negative pressure which may cause condensate to be held up in the shell. During light load, the heat exchanger will have a layer of steam at the top and air under the steam to provide just the right amount of heat. The vacuum breaker should be mounted on a vertical pipe 6 to 10 above the topping to provide a cooling leg. This protects the vacuum breaker from dirt and extreme temperatures. Steam Regulator The choice of the temperature regulating valve includes self contained temperature regulators, pilot operated regulators and pneumatic regulators. The steam inlet pressure to the regulator must be higher than the required heat exchanger operating pressure to allow flow. The available steam pressure should be at least two times the heat exchanger operating pressure to provide modulation of the regulator for good temperature control. This will also provide the smallest size steam regulator. The steam regulator should be sized based on the maximum lb./hr. of steam required by the heat exchanger. To properly size the regulator, the available inlet steam pressure and the heat exchanger design operating pressure must be known. The steam regulator should not be oversized. Oversizing the regulator may cause the temperature to overshoot and the regulator will hunt more than a properly sized regulator. The steam regulator is normally smaller than the connecting inlet and outlet steam piping. Regulator InstallationA steam drip trap should be installed in the steam piping ahead of all steam regulating valves. Failure to install a drip trap will allow condensate to collect in the steam piping ahead of the regulator. As the regulator opens, the mix of condensate and steam passing through the regulator may cause water hammer that can destroy the diaphragms or bellows used to operate the regulator. A steam strainer should also be installed ahead of the regulators to prevent dirt from entering the valve. Dirt can deposit on the valve seat and not allow it to close tight. The steam strainer should be installed with the screen pocket horizontally. Installation with the screen down, as commonly piped for water service, will allow a condensate pocket to form in the steam line. This condensate pocket can carry into the main valve and cause water hammer or sluggish operation. Shut off valves, pressure gauges, a manual bypass and unions should be installed to allow proper servicing of the valves and strainers. When possible refer to the manufacturers installation manual for proper installation. The temperature sensing bulb should be installed as close as possible to the heat exchanger outlet. It is important that the full length of the temperature sensing bulb be inserted in the system piping. Any portion of the bulb installed in a no flow area will reduce the accuracy of temperature control. When the sensing bulb is installed in a separable well, heat transfer compound must be installed between the well and the sensing bulb to aid heat transfer. The tube side of the heat exchanger should have a continuous running recir-culation pump to provide continuous flow past the sensing bulb. A minimum 20% recirculation should be provided. Pilot operated regulators with a pressure pilot require a downstream pressure sensing line. The pressure sensing line connection should be connected in a non-turbulent area downstream of the main valve; a min-imum 10 pipe diameters downstream of the main valve is recommended. The steam pressure sensing connection can also be connected directly to the heat exchanger shell. Condensate Coolers When heat exchangers operate at high pressure, consideration should be given to the addition of a condensate cooler. The justification will depend on the size of the heat exchanger and the actual number of hours per day the unit will be in operation. With a condensate cooler, the discharge from the steam trap on the steam heat exchanger outlet is piped through a water-to-water heat exchanger. A second trap is then installed on the discharge of the water-to-water heat exchanger to maintain saturation pressure and prevent flashing and water hammer from occurring in the condensate cooler. A separate thermostatic trap is installed to allow direct air venting of the steam heat exchanger into the vented return line downstream of the condensate cooler. The water-to-water heat exchanger design differs from a steam heat exchanger. The water-to-water heat exchanger has internal baffles to direct the water flow across the tubes to improve heat transfer. Water-to-water heat exchangers are externally distin-guishable as the shell inlet and outlet tappings are the same size; steam heat exchangers have a large vapor opening in the top of the shell and a smaller condensate outlet in the bottom. The fluid in the condensate cooler tubes may be the inlet water to the steam heat exchanger tubes. When the initial temperature of the fluid is too high to cool the condensate below 212F, a separate fluid may be heated. Preheating domestic hot water or preheating boiler make up water are two possibilities. This article is reprinted from Fluid Handlings Steam Team Bulletin FHD-206.

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A Working Mans Guide to Servicing Centrifugal Pumps

Maintenance Tips
A pump is a wonderful thing when operating properly. You never give it a second thought. But when its not running properly, you hear about it right away. People on the receiving end are not getting heat, cooling, process fluids, etc., and theyre quick to let you know, usually very loudly. So here are some service procedures for centrifugal pumps that will help keep your customers in hot water and you out of it. But before we launch into the actual service, a few words about safety. After all, being rushed to the emergency ward doesnt make the job go any quicker. When working on any type of equipment, safety should always be your first concern, and centrifugal pumps are no exception. You need to follow the proper procedures set-up at your shop. There are several areas with which to be particularly concerned. First, make sure the pump can be taken out of service. It may be providing services that are extremely important. Removing a pump from service thats providing chilled water to the operating suite at a hospital without permission, for example, will not earn you that

bonus you deserve. Before you even start, youll want to remove power to the equipment. All shops have some type of lock-out/tag-out procedure. Follow them completely; all the way through tag removal. This is absolutely necessary, because if you occasionally forget to remove your tags, someone else will get in the habit of removing them for you, usually while youre still working on the equipment. Make sure you remove all sources of power. Some motors, such as at hospitals, also have an emergency power source. Isolate that source from the pump too. More will be mentioned as we go through the servicing proce-dures. Were not quite ready yet to start disas-sembling our pump. To ensure that the whole process runs smoothly, lets take a few steps before proceeding. It would be nice to have an exploded diagram of the pump before we begin. One reason for this is so well know where to put all the extra parts we have left over when were done. They have to go somewhere. Manufacturers dont usually add parts that dont have any function. An exploded diagram like the one shown in Figure 1 is especially helpful. It not only illustrates the pump, it also gives us the proper part names. Therefore, if we need to order a replacement, we know what to call it besides a thing-amuh-jig. Bell &Gossett and some other manufacturers have made these diagrams available over the Internet. Just check their websites and youll be surprised at all the information that can make your job easier. You will even find valuable service instructions. Points of Service Were going to look at the three main areas for service. They are: lubrication seal replacement alignment. Lubrication is probably the single most important step in a maintenance program to keep a pump running without problems. Obviously, the manufacturers recommendations as to the type of lubricant and proper lubri-cation intervals are the best place to start. Its a starting point; not the final word. The reason I say that is the manufacturer doesnt know how his equipment is being used. How its used will affect how much you lubricate it. A couple of factors that affect the lubri-cation schedule are how often you run, or dont run the pump. What type of environment is it in? Is it hot, dirty, and dusty? Or is the pump lucky enough to reside in a cool, dry, location? You can see that the answer to, How often should I lubricate a pump? is, it all depends. Not much of an answer. So heres where experience comes into play. The more you know about the system, the better youre able to protect it. If youre lacking in experience, dont worry, you have something else to rely on: common sense. To help you determine a lubrication schedule, check your records to see how the system is performing. What have you done in the past to maintain the system? Where have you been successful, or unsuccessful in the past? If you dont know, you dont have a good set of records. So now, you need to start a log. There are a few things you want to put in that log: suction pressure, discharge pressure, how the pump is running (Hot? Noisy?), when was it lubricated? Youre going to lubricate the bearings on occasion. Generally there are two types of bearings: sleeve bearings and ball bearings. Everything about them is different. One of the best ways to determine when to lubricate either type is based on how hot theyre running. If you have a way to measure the temperature, great. If not, youll want to err on the side of lubricating them too often. After all, the cost of grease or oil is small compared to the time and cost of replacing the bearings. Lets start with the ball bearings. Before you start pumping grease into the grease fitting, check to see if theres a plug in the grease relief hole. If there is, remove it. You dont want to pump new grease into the bearings with no way of removing the old grease. Too

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much grease can be just as harmful as too little grease. You want to keep pumping new grease in until you start to see all the old grease come out. Youre done greasing that bearing, but do you want to put the grease plug back in? Many people will simply throw the relief hole plug away for fear the next person will forget to remove it before they start to pump in grease. In fact, some manufacturers wont even thread the hole to keep the plug from getting jammed in the hole. For sleeve bearings youre going to want to add oil. Not just any oil, mind you. Once again, use what the manufacturer recommends. This will be a non-detergent oil. Theres an important reason for this. Oil evaporates - detergent doesnt. As the oil evaporates, the concentration of the detergent becomes stronger. You can see that each time you replenish the oil, you add even more detergent to the oil. Once the oil is added, it is absorbed by a wick that deposits it where its needed, between the sleeve bearing and the shaft to maintain a thin film of oil between the two. The wick has an important job. Therefore, youll want to inspect it. If its scored or burnt, replace it. If it feels waxy, it can no longer do its job effectively. The most likely reason for disassembling a pump is to replace the seals. Even if seal replacement isnt your reason for disassembly, its a good idea to replace the seal while you have the pump apart. That seal kit you bought contains all the parts you need. Replace the whole thing and not just an individual part. When you remove the seal, put on your detectives hat. Ask yourself why the seal wore the way it did. Were there grooves in the seal? This could be a sign of a high concentration of suspended or dissolved solids. Suspended solids less than 10 microns will get between the two seal faces. Maybe you need to choose a seal that is more tolerant of these solids. Maybe you need to determine if theres a way to remove these solids from the system. Your chemical concentration may be too high. A seal has two highly polished surfaces mated up to each other. Sure, no liquid is suppose to leak between the two surfaces, but it does -it has to. The thin film of liquid between the two surfaces heats up due to friction. The heat is then removed when the liquid evaporates. You never see that evaporation because its extremely small. But, like the oil in the sleeve bearing, the chemicals are left behind. They can then cause grooving in the seal. If you find that youre replacing seals often, perhaps you need to look at the type of seal youre using. If you cant remove the high concentration of chemicals, perhaps you need a seal that is more tolerant of the high concentration. Other factors that will affect seal selection are pH levels and temperature. The last word on seals is that theyre most often damaged during their installation. Be especially careful when putting the seal in. Dont touch its surface with dirty hands. Use soapy water to slide the seal on the shaft, since petroleum products may affect the seal. Try not to chip the seal when placing it on the shaft. And dont run the seal dry. Open the service valves to flood the pump cavity before running the pump. As you disassemble the pump, youll have to deal with gasket surfaces. Whenever youre dealing with a gasket surface, be careful not to scratch these machined surfaces. It may cause a leak path. And always use new gaskets when putting the pump back together. Keep It Straight Alignment is a concern for flexibly coupled pumps. The couplers job is to transmit power from the motor shaft to the pump shaft. It can also take up minor misalignment. The key word here is minor. Exactly how much has been determined by the coupler manufacturer based on several factors, so use their recommendations. How you check alignment is basically determined by rpm. The lower the rpm, the less sophisticated a method you can use. At 1,750 rpm you can get away with aligning the shafts with just a straight edge and taper gauges. At 3,500 youll want to use a dial indicator. For higher rpm and greater accuracy, you may need a laser. Check that the pump and motor shafts rotate around the same axis. This means you have to check the parallel and angular alignment as in figures 2 and 3. To change these alignments, youll have to place or remove shims from under the motor and move the motor from side to side. After youve placed shims under the motor, tighten the motor down to check alignment again. Its always better to use fewer, larger shims than a larger number of thin shims. After youve placed the pump in service, recheck the alignment when the pump reaches its operating temperature. Obviously, theres a lot to cover when servicing a centrifugal pump. Here, weve just touched on some of the main areas of concern. Along with that, my final advice is to use common sense and be methodical when working so as to not damage the pump - or yourself. This article is an abridged version of a Little Red Schoolhouse Staff article that originally appeared in the March, 1999 issue of Contracting Business.

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Troubleshoot Pumps Using Pump Curves and Gauge Readings

Maintenance Tips
A manufacturers pump performance curves contain data that can help hvac technicians analyze a pumping instal-lation. Pump curves also help identify the systems operating point, find reasons for a system not performing, and even determine a pumps impeller size. After designing a pump, the manufac-turer usually produces a number of units for testing. The tests are necessary to establish how the pump will perform. The data collected often includes water flow operating against various system resistances, brake horsepower required, efficiency, and the net positive suction head required for proper operation of the various diameter impellers allowable in the pump volute. This data is analyzed and then plotted and published as the pump operating characteristics. The pump curve then shows how the pump will perform with varying head or flow requirements. (See Fig. 1). In the real world it isnt unusual for a pumps nameplate to be missing. Because the information on a nameplate is so important (it usually includes manufacturers name, pump model, size, impeller diameter, head and flow for the duty point), its frequently removed for safe keeping. Unfortunately, at times its so well safeguarded that it cant be retrieved. Or, perhaps its just painted over. Either way, the information on it isnt available. To identify the pump and re-establish the nameplate data, the manufacturer must be determined. Most pumps are fabricated of castings and most of these have casting part numbers and markings on them which identify the pump manufacturer. Once the pump manufacturer is known, the type or model and size can be determined with the help of published liter-ature or a phone call. Since larger pumps generally have a family of impeller sizes which can be used with a given pump body, at this point the impeller diameter is unknown. A simple procedure using a pressure gauge and the pumps curves will identify the impeller size in the pump. Identifying Impeller Size Close the pump discharge valve and take the suction and discharge pressures. This is the dead-head condition. Reopen the discharge valve and reset it to the position it was in prior to closing, if it was used to balance the flow. The algebraic difference between the discharge pressure and the suction pressure is the head being generated by the pump. Convert this to feet of water head and determine the correct impeller from the no flow point on the pump curve. As an example: P discharge = 20.5 psi P suction = 4-in. of Hg vacuum (a negative pressure) But, the curves are dimensioned Head, feet of water therefore, the gauge pressures must be converted. To convert pressure in psi to head in feet of water multiply psi by 2.31 and divide by the specific gravity of the fluid being pumped. The specific gravity of water is 1. One inch of Hg is equal to 0.491 psi. Therefore: P discharge = 20.5 psi x 2.31 ft. of water per psi / (divided by) 1 = 47.4 ft. of water P suction = 4 in. Hg x 0.491 psi per in. Hg = -1.96 psi x 2.31 ft of water per psi/1= -4.5 ft. of water Pump head = P discharge - P suction = 47.4 - (-4.5) ft. of water Algebraically subtracting a minus is a plus, so: Pump head = 47.4 + 4.5 ft. of water = 51.9 ft. of water. Locating this head, 52 ft., at 0 gpm flow on the pump curve in Fig. 1, shows the pump impeller diameter to be 7 in. The system operating point can also be determined by using gauge readings. Take the suction and discharge pressures while the system is operating with the discharge valve in the normal open position. Again convert these into feet of water and subtract (algebraically) the suction pressure from the discharge pressure. This is the head of the pump at the operating flow. Follow the head line from the zero flow axis out to where it intersects the previously identified impeller characteristic curve. The flow at that point is the systems operating flow. Example: After determining the pumps impeller diameter to be 7 in., gauge readings of the pump taken while it operated were: P discharge = 17.5 psi P suction = 4 in. Hg (vacuum) Convert the gauge readings for the fluid being pumped to feet of water: P discharge = 17.5 psi x 2.31/1 = 40.5 ft. of water P suction = 4 in. Hg x 0.491 psi per in Hg = -1.96 psi x 2.31 ft. of water per psi/1 = -4.5 ft. of water Pump head = 40.5 - (-4.5) ft. of water = 45.0 ft. of water The pump head of 45.0 ft. intersects the 7 inch diameter characteristic curve at 55 gpm, which then is the system operating flow. Being able to fully identify a pump, determine the installed impeller size and the system operating point are of great use in troubleshooting. As an example: The 2 hp base-mounted pump in Figure 2, when pumping water, regularly trips its circuit breaker. The nameplate specifies an 81/ 2-in. diameter impeller with a duty point of 51 gpm at 74 ft. of

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head. Gauge readings at shutoff are 12 psi suction pressure and 46 psi discharge pressure. When the 3-way valve is fully open to the coil, the suction pressure is still 12 psi and the discharge pressure is 44 psi. When the 3-way valve is fully open to the bypass, the suction pressure is still 12 psi, but the discharge pressure is 40 psi. Whats the problem? Whats the solution? First, you must analyze the pump readings. Shutoff head is (discharge pressure -suction pressure) x 2.31 = (46 psi - 12 psi) x 2.31 = 78.5 ft. of water The 78.5 ft. at shutoff and the pump curve (Fig. 1) confirms the impeller diameter as 81/ 2 inches. With the 3-way valve fully open to the coil: Pump head = (44 psi - 12 psi) x 2.31 = 74 ft. of water The intersection of 74 ft. of head and the 81/ 2-in. impeller curve on Fig. 1 indicates a flow of 51 gpm. The horsepower required is 13/4. With the 3-way valve open to the bypass, the pump head is calculated as follows: Pump head = (40 psi - 12 psi) x 2.31 = 64.7 ft. of water. The intersection of 64.7 ft. of head and the 81/2 inch impeller curve on Fig. 1 indicates a flow of 80 gpm. The horse-power required is 21/ 3. The problem - too much flow because the resistance to flow in the bypass circuit is too low. The solution - increase the resistance in the bypass circuit by 9.3 ft. of water (74 -64.7) so the resistance through the bypass circuit is the same as the resistance through the coil. The flow and the horse-power will then be reduced to the same as that flowing through the coil, eliminating breaker trips. Understanding the information provided on the pump curves by the pump manufacturer and taking some simple gauge readings are of great help in analyzing pumped system problems. This article is an abridged version of a Little Red Schoolhouse Staff article that originally appeared in the November, 1998 issue of Contracting Business.

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Bell & Gossett Offers New Coupling Guards

Whats New
Bell & Gossett has introduced a new line of ANSI and OSHA-Compliant Coupling Guards that offer increased protection and conform to the specific requirements of ANSI B15.1, section 8 and OSHA 1910.219. Engineered to provide personnel with the highest possible level of safety and protection from rotating equipment, the guards are available in numerous sizes to cover all B&G frame mounted centrifugal pumps. The new guards feature slotted viewing windows for easy inspection and are also available in easy-toinstall change-out kits for units already installed in the field. The coupling guards are now standard on all Series VSC/VSCS, Series HSC and Series 1510 centrifugal pumps from Bell & Gossett. For more information, please mark #1 on the enclosed reply card or contact your local Bell & Gossett representative.

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