Basic Pump Training

Fundamentals of Pump Operation

And
Design

CENTRIFUGAL PUMP FUNDAMENTALS

Pump Classification
Piston
Plunger
Reciprocating
Diaphragm

Positive
Displacement
Blow Case
Rotary

Pumps

Self Priming
Non Self Priming
Radial Flow
Mixed Flow

Single Suction
Double Suction

Axial Flow

Single Suction

Centrifugal

Single Stage
Multistage

Open Impeller
Semi-Open Impeller
Closed Impeller

Single Stage
Multistage

Open Impeller
Closed Impeller

Kinetic
Peripheral
Special

Centrifugal Pump Types

Definition of a centrifugal pump

A centrifugal pump is a machine which
converts Mechanical energy into
Hydraulic energy. It consists of a set of
rotating vanes enclosed within a casing
to impart energy to fluid through
centrifugal force.

Working principle of centrifugal pump

When impeller of a centrifugal pump whose casing &
suction piping is filled with liquid to be pumped is rotated
at a particular speed ,the liquid inside the casing is
expelled out into delivery pipe creating drop in pressure
at suction side of impeller.Then the new liquid is forced
by atmospheric or other pressure into the rotating
impeller.The impeller discharges the liquid at its periphery
at a higher velocity. The velocity is converted into
pressure energy by means of a volute or by a set of
stationary vanes called as diffuser

Mechanical Configuration

Centrifugal

Overhung Impeller

End Suction

Impeller Between Bearings

Inline

Closed Coupled

Closed Coupled

Long Coupled

Sealless
MagDrive

Sealless
MagDrive

Axial Split Case

Suspended Bowl

Cantilever

Single stage

Single stage

Multi-stage

Intermediate Support Bearings

Radial Split

Single or Multi-stage

Ring Section
Multistage

End Suction

End Suction

Mass Produced, hence low cost.

Common designs to DIN 24255 water
pumps, IS0 5199 process pumps.
Typically used for applications with
discharge branch sizes below 150 mm.
Overhung impeller design limits bearing L10
life, usually less than 25,000 Hours.
Back-pull-out facility for ease of
maintenance.

Back-Pull-Out Facility

The

spacer
coupling is
removed allowing
the whole rotating
assembly to be
removed, without
disturbing the
pipework or driver.

Axial Split Case

Axial Split Case

Designed for increased life.

Between bearing arrangement of
Impeller
Typically used for utility type
applications with discharge branch
sizes above 100 mm.
Unlike End Suction pumps, no design
standard exists for these pumps.

10

Suspended Bowl

11

Suspended Bowl

Typically used on applications where

suction lift and associated priming
problems exist.
The pump being suspended in the sump
negates the requirement for a separate
dry well.
Often utilised in industry for cooling tower
circulation duties.
Popular with water companies for transfer
duties within the water treatment process.
Used on Oil&Gas fire applications, jetty
and platforms.
12

Ring Section Multistage

13

Ring Section Multistage

Most commonly used for boiler feed

water applications in industry.
Designed for low to medium flow at
high generated heads.
Varying numbers of stages to meet
the duty condition. Often 15 stages
or more.
Complete disassembly required to
maintain any of the pumps
hydraulic components.
14

Pump Performance Parameters

15

Relevant Metric Units

Volume Cubic Metre (Sub unit - litre).

Capacity Expressed in litres per second
or cubic metres per hour.
Pressure kg/cm^2
Head rather than pressure is the
standard unit of measurement in respect
of centrifugal pumps.
Head Metre.
Head in metres = kg/cm^2 x 10 / Specific
gravity
Power - kW
16

ATMOSPERIC PRESSURE
The Pressure of the Atmosphere on the Earth
Atmospheric pressure at sea level
1.033
Kg/Cm^2.

17

Atmospheric Pressure/Elevation Chart

Altitude above sea

level

Barometric pressure
Air

Equi head of water

Feet

Meter

PSI

Feet

Meter

14.7

34

10.36

1000

305

14.2

32.8

10

2000

610

13.7

31.5

9.6

3000

914

13.2

30.4

9.27

4000

1219

12.7

29.2

8.9

6000

1829

11.8

27.2

8.29

8000

2438

10.9

25.2

7.68
18

Absolute Pressure is
sum of the available atmospheric pressure and the Gauge pressure in the
pumping system
Absolute Press(Kg/Cm^2) = Gauge Press. + Atmospheric Press.

Absolute Pressure =
10Kg/Cm^2(Gauge Press.)+ 1.033Kg/Cm^2 (Atm. Press.)
= 11.0333Kg/Cm^2
19

Vacuum
The full or partial elimination of Atmospheric Pressure
Atmospheric Pressure on the Moon = 0 = Full Vacuum

1 mm Hg Vacuum = 0.0136 m of Water column

20

Specific Gravity
The ratio of the weight of anything to the weight of water.

Example Specific Gravity of HCl = Weight of HCl (/) Weight of Water

= 10.0 (/) 8.34 = 1.2

21

Pressure and Liquid Height Relationship (Head)

10 m
1
Kg/Cm^2

1 Kg/Cm^2 =10 m of Water column

22

Vapour Pressure

ATMOSPHERIC PRESSURE

VAPOUR PRESSURE

The pressure pushing against atmospheric pressure on liquids at elevated

Temperatures.

23

Water Vapor Pressure Chart

24

Capacity
In a centrifugal pump, the capacity varies with the
change in total system head. The actual flow rate
achieved is directly dependent on the Total Dynamic
Head at which the pump is working.
The flow capacity of a centrifugal pump also depends
on three other factors:
Pump Design
Impeller Diameter
Pump Speed

25

Suction Head

A Suction Head exists when the liquid is taken from an open to

atmosphere tank where the liquid level is above the centerline of the pump
suction, commonly known as a Flooded Suction
26

Suction Lift

A Suction Lift exists when the liquid is taken from an open to atmosphere
tank where the liquid level is below the centerline of the pump suction.
27

Total Dynamic Head

Total Dynamic Head (TDH) = Elevation+Friction head loss+Velocity head at Delivery

28

PUMP DRAWING WATER FROM SUCTION SUMP

SITUATED BELOW PUMP CENTRE LINE
vd 2
2g
DISCHARGE TO
ATMOSPHERE

hfd

hsd
H

hss

hfs

ATMOSPHERIC
PRESSURE

TOTAL HEAD = H
2
H = ( hsd + hfd + vd ) + ( hss + hfs )
2g

vs 2
2g

29

PUMP DRAWING WATER FROM SUCTION TANK

OPEN DISCHARGE
SITUATED ABOVE PUMP CENTRE LINE
VESSEL

Vd
2g

Ps = 0
LIQUID LEVEL

hfd
OPEN SUCTION
VESSEL

Ps = 0
LIQUID LEVEL

hfs

hd

hs

Vd

hdl

hsl
Vs

hgd
hgs
Zs

Zd
PUMP DATUM

TOTAL HEAD = H = hd - hs

30

PUMP DRAWING WATER FROM SUCTION TANK

SITUATED ABOVE PUMP CENTRE LINE

CLOSED DISCHARGE
VESSEL

Vd
2g
hfd

Pd > ha
Pd

Pd
CLOSED SUCTION
VESSEL

Ps

hfs

Ps > ha
Ps

hd

hfs

hsd

hs

hs

Vd

hdl

hss
Vs

hgd
hgs

hsl
Zs

Zd
PUMP DATUM
2

TOTAL HEAD = H = ( hdl + pd + hfd + Vd ) - ( hsl - hfs + ps )

2g

31

Centrifugal Pump Components

The two main components of a centrifugal pump are the impeller and the
volute. The impeller produces liquid velocity and the volute forces the
liquid to discharge from the pump converting velocity to pressure. This is
accomplished by offsetting the impeller in the volute and by maintaining a
close clearance between the impeller and the volute at the cut-water.
Please note the impeller rotation. A centrifugal pump impeller slings the
liquid out of the volute. It does not cup the liquid.

32

Liquid Power

Liquid Power is a measure of the useful work

done on or by a liquid in unit time.
Liquid kW = lit/sec x metres head x s.g.
102
Liquid kW = m3/hr x metres head x s.g.
367

33

Absorbed Power & Efficiency

Absorbed Power is the power input to

the pump shaft. (Brake Power).
Efficiency = Ratio of liquid power and
absorbed power.
Efficiency% = Liquid kW x 100
Input KW
Absorbed Power = Liquid kW x 100
Efficiency %

34

Example

A Pump is selected to deliver water (s.g

1.0) at 100 lit/sec @ 50 metres head.
Calculate the absorbed power based on
an efficiency of 75%.
Absorbed Power = 100 x 50 x 1.0
102
= 49.01 (Liquid kW)
0.75 (Eff.
fraction)
= 65.35 kW
35

Important Considerations
Absorbed Power

Duty conditions often vary.

Absorbed power should be
calculated based on the worst case
scenario.
Stated pump efficiencies are subject
to tolerances.
Examples being ISO9906 or BS5316
Pump efficiency will deteriorate
between major overhauls.
36

Sizing the Driver

Good engineering practice, is to allow a

margin of power in hand, when selecting a
driver.
A 10% margin in hand is the industry
norm.
This is over and above the worst case
operating condition.
An increased margin in hand is
recommended for small pumps, as
mechanical seals in particular, can absorb
a disproportionate amount of power.
37

Driver Input Power

By dividing the absorbed power by

the motor efficiency (fraction), you
will arrive at the driver input power.
Overall pump set efficiency is the
ratio of the energy delivered by the
pump and the input energy to the
driver.

38

Changing the performance of a

pump

39

Pump Performance vs Impeller

Diameter

The performance of a centrifugal pump

can be varied by changing the impeller
diameter.
Common rules of affinity apply between
the diameter and flow, head and power:

40

Changes in Impeller Diameter

41

Change in Impeller Diameter

An Example

A pump has the following characteristics:

Q = 6 l/s
Impeller dia = 165mm

H = 25m
Speed = 2950rpm

Calculate the head, flow and power if the

diameter is reduced to 155mm.

42

NPSH and CAVITATION

43

NPSH
(NET POSITIVE SUCTION HEAD)
NPSH= Ha-hvp-hst
Ha= atmospheric pressure in mwc
hvp= vapour pressure
hst= Total suction lift/ suction head
NPSH(A) : NPSH AVAILABLE IS A FUNCTION OF THE
SYSTEM.
NPSH(R) : NPSH REQUIRED IS THE FUNCTION OF PUMP
DESIGN
FOR SATISFACTORY PUMP OPERATION
NPSH(A) > NPSH(R)
44

Net Positive Suction Head Required

(NPSHR)
The net positive suction head required is a
function of the pump design at the
operating point on the pump performance
curve.

45

NPSHr

This is a function of the pump inlet design

Every pump has its own NPSHr
characteristics, which will be detailed by
the manufacturer
NPSHr varies with the type and size of
pump
NPSHr increases with both flow and
speed
The NPSHa must always be greater than
the NPSHr
46

Net Positive Suction Head Available (NPSHA)

The net positive suction head available is a function of the pump suction
system.
The Net Positive Suction Head is the absolute total suction head in meters.
The NPSH available in a flooded suction system is:
Atmospheric Pressure (- ) Vapor Pressure (+) Liquid Height (-) Friction in
the Suction Line.

47

The NPSH available in a suction lift system is:

Atmospheric Pressure (-) Vapor Pressure (-) Liquid Ht. (-) Friction in the
Suction Line.

48

Ways to improve NPSHA:

1) Increase suction pipe size.
2) Reduce suction lift by installing pump
closer to liquid source.
3) Reduce liquid temperature to reduce
vapour pressure.

49

NPSHA CALCULATIONS
1) CASE No. 1 : PUMP DRAWING LIQUID FROM A SUMP OPEN TO ATMOSPHERE

DATA :
a) SUCTION LIFT

3 M.

= 3 meters

b) FRICTION LOSSES IN
SUCTION PIPE LINE,
FOOT VALVE, STRAINER

= 1 meter

c) TEMPERATURE OF WATER = 21C

d) VAPOUR PRESSURE

= 0.25 meters

e) ATMOSPHERIC PRESSURE = 10.00 meters

TOTAL SUCTION LIFT = hs = hss - hfs
= -3-1
= - 4 meters
NPSHA

= ha hs - hvp
= 10 - 4 - 0.25
= 5.75 meters

50

NPSHA CALCULATIONS
1) CASE No. 2 : PUMP DRAWING WATER FROM TANK, LOCATED ABOVE
PUMP CENTRE AND OPEN TO ATMOSPHERE.

DATA :
1) HEIGHT OF WATER LEVEL IN SUCTION TANK,
ABOVE THE CENTRELINE OF THE PUMP

= 4 meters

2) FRICTION LOSSES IN SUCTION PIPE SYSTEM = 1.2 meters

( PIPE LINE VALVE & FITTINGS )

4 M.

3) TEMPERATURE OF LIQUID :

= 21C

4) VAPOUR PRESSURE OF THE LIQUID :

= 0.25 meters

5) ATMOSPHERIC PRESSURE :

= 9.00 meters

METHOD :
SUCTION HEAD, hs = hss - hfs
= + 4 - 1.2 meters
= 2.8 meters OF WATER (SUCTION HEAD)
NPSHA

= ha hs - hvp
= 9.00 + 2.8 - 0.25
= 11.55 meters

51

NPSHA CALCULATIONS
1) CASE No. 3 : PUMP DRAWING WATER FROM A CLOSED VESSEL UNDER VACUUM
600 mm OF Hg VACUUM

DATA :
1) VACUUM IN VESSEL

= 600 mm of mercury

2) LIQUID TEMPERATURE

3) LIQUID LEVEL ABOVE PUMP CENTRE =

10.2 M.

40C
10.2 meters

4) FRICTION LOSSES IN SUCTION

PIPE lLINE SYSTEM

1 meter

5) VAPOUR PRESSURE

0.49 kg / cm2

6) SP. GRAVITY OF LIQUID

0.72

METHOD :

10 x 1
= 13.89 meters of liquid
0.72
10 x 0.49
=
= 6.81 meters of liquid
0.72
= 600 mm of Hg
600
13.6
=
x
= 11.33 meters of liquid
1000
0.72
13.6 is specifie gravity of mercury )

ha =
hvp
Ps
( ...

hs = hsl - Ps - hfs
= 10.2 - 11.33 - 1
= - 2.13 meters of liquid ( suction lift exists )
NPSHA

= ha hs - hvp = 13.89 - 2.13 - 6.81 = 4.95 meters

52

NPSHA CALCULATIONS
1) CASE No. 4 : PUMP DRAWING LIQUID UNDER PRESSURE FROM A CLOSED TANK.
0.5 kg / cm 2
PRESSURE

0.2 M.

DATA :
1) PRESSURE IN CLOSED VESSEL
2) ATMOSPHERIC PRESSURE AT INSTALLATION
3) LIQUID LEVEL IN A VESSEL ABOVE THE
PUMP CENTRE LINE
4) FRICTION LOSSES IN SUCTION
PIPE LINE SYSTEM
5) VAPOUR PRESSURE OF LIQUID
6) SP. GRAVITY OF LIQUID

= 0.5 kg / cm 2
= 0.9 kg / cm 2
= 0.2 meters
=

1.5 meters

=
=

0.45 kg / cm2
0.8

METHOD :

10 x 0.9
= 11.25 meters of liquid
0.8
10 x 0.45
hvp =
= 5.625 meters of liquid
0.8
10 x 0.5
Ps =
= 6.25 meters of liquid
0.8
ha =

NOW
hs = hsl + Ps - hfs
= 0.2 + 6.25 - 1.5
= 4.95 meters of liquid ( suction head exists )
NPSHA

= ha hs - hvp
= 11.25 + 4.95 - 5.625
= 10.575 meters

53

To Avoid Cavitation
NPSH Available

NPSH Required

MENU

54

MENU

55

Effects of Cavitation
1. Noise
2. Damage to the pump
3. Reduced pump performance

56

Cavitation

Cavitation is the occurrence of

cavities/bubbles forming in a liquid.
Cavitation is evident by a cracking
type noise and often measurable
vibration, which is either intermittent
or continuous.
This distinct noise is as a result of
cavities forming in low pressure areas
at the pumps and then collapsing as
the pressure increases.

57

Effects of cavitation

Cavitation leads to loss of

capacity/efficiency.
Material wastage, in the form or
heavy pitting.
Bearing, seal and in severe cases
foundation failure.

58

Common Causes of cavitation

Insufficient NPSHa.
Turbulence or acute velocity
changes local to the pump inlet.
Operating condition in respect of
HQ curve.
Internal Recirculation
Blockage in suction strainer

59

PROPERTIES OF WATER

60

SG vs Temperature

61

Vapour Pressure vs Temperature

62

BASIC PUMP SELECTION

63

The Q/H Curve

The performance of a pump is
generally depicted on a Q/H curve.
This normally shows the following
properties of the pump:

Flow vs Head
Flow vs Efficiency
Flow vs NPSHr
Flow vs Power

64

Typical Q/H Curve

65

Operating Range

66

Minimum Safe Continuous Flow

Every pump has a

minimum safe flow
below which it should
not be operated
This flow is normally
governed by the
temperature rise
within the pump, but
can also be affected
by cavitation and
vibration
67

Minimum Safe Continuous Flow

Power loss = absorbed power water power

All this power is transformed into heat
Bearing friction and radiation heat losses are
negligible, and can be ignored
Typically mscf is 20-30% of BEP

Temp. rise, t =
1-e xH
427e Sh

e= pump efficiency
heat

H= pump head

Sh = specific

Minimum flow needs to be considered in

variable speed applications or when operating
different pumps in parallel
68

Impeller Geometry

Impeller geometry dictates the

performance characteristics of the
pump.
Specific speed is a theoretical
classification of impeller types.
Specific speed is primarily of use to
pump designers, but is also useful
for classifying pump types.

69

Specific Speed

70

Radial Flow Designs

Liquid enters the impeller at the hub

and flows radially to the periphery.
Radial flow impellers develop high
head at relatively low flow rates.
Typical examples are End Suction
and some Axial Split Case pumps.

71

Mixed Flow Designs

The flow enters axially and is

discharged in both an axial and radial
direction.
These designs develop higher flows
at medium heads/pressures.
This design is associated with larger
End Suction and Suspend Bowl
Pumps.

72

Francis Vane Designs

Liquid enters at the hub axially and

is discharged radially through to
the periphery.
This is an intermediate design
between radial and mixed flow.
Many axial split case and medium
to large End Suction pumps
incorporate this design.

73

Axial Flow

Often referred to as Propeller pumps.

Flow enters the impeller axially and is
discharge axially.
This design develops high flows at low
heads
Strictly speaking these are not
centrifugal pumps, however these
pumps are usually manufactured by
centrifugal pump manufacturers.
Nearly always Suspended Bowl or
submersible type pumps.
74

Characteristic Curves

STABLE Q/H CURVE

UNSTABLE Q/H CURVE

75

Characteristic Curves

76

SYSTEM DESIGN

77

Friction Loss

To ensure flow in a system, a head of liquid must be

provided to overcome resistance.
Resistance is dependent upon:
-

The area in contact with the liquid

The smoothness and regularity of the surface
The flow velocity
The mode of flow (laminar or turbulent)
The liquid viscosity

Losses are generated by all system components:

Pipes
Valves
Bends & fittings
Process Equipment (heat exchangers, filters etc.)
78

Factors affecting Friction Loss

Flow velocity
Pipe diameter
Number of pipes parallel mains
Pipe material
Pipe age
Type of fitting
Liquid viscosity
Velocity/diameter and pipe materials have a
major effect on pump selection and power
requirements
79

Friction Calculations
Darcy-Weisbach (1845)
- requires friction coefficient
Laminar

f = 64/Re
(Re<2300)
Turbulent f = Moody
Diagram

Hazen Williams (1905)

- requires C value
Typically

120 to 150

Colebrook White (1939)

- requires ks value
Typically

0.03 to 0.6mm

D = Int. Diameter (m)

S = Hydraulic Gradient (m/m)
v = kinematic viscosity (m2/s)
V = velocity (m/s)
80

The System Curve

Relates Flow to head

Comprises static and friction losses
Takes account of any varying static
Incorporates common main losses,
including process equipment
Generally excludes station losses
associated with individual pump suction
and delivery pipework
Pump curve can be added
81

System Head Curve

To Calculate a System Head Curve several points must
be chosen to calculate friction losses on both the
suction and discharge sides of the pump at various
flow rates.
The static suction head/lift and the static discharge
head remain constant.

82

SYSTEM HEAD CURVE

ESTABLISHES PUMP
CONDITIONS

VE
CUR
FRICTION

HEAD IN METRES

EM
SYST

TOTAL STATIC
HEAD

CAPACITY IN l / sec.

CAPACITY IN l / sec.

ARTIFICAL SYSTEM CURVE

OPERATING POINT
OPERATING POINT

C2
HEAD IN METRES

HEAD IN METRES

SYSTEM HEAD CURVE

H2

C1

H1

SYSTEM HEAD
CURVE

FRICTION HEAD + V 2
2g

TOTAL STATIC HEAD

Q2
CAPACITY IN l / sec.

Q1
DESIRED FLOW

83

Variable Speed Pump

The performance of a centrifugal pump

can be varied by changing the speed.
Common rules of affinity apply between
the speed and flow, head and power:

84

Change in Pump Speed

85

Change in Pump Speed - An Example

A pump has the following characteristics:
Q = 6 l/s

H = 25m

Power = 3.1kW

Speed = 2950rpm

Calculate the head, flow and power if the

speed is reduced to 2870rpm.

86

INSTALLATION FACTORS

87

Foundations

Civil structure.
Foundations in reinforced concrete.
Sufficiently Substantial to:
Absorb Vibration
Form a permanent rigid support
Be at least 1.0 - 1.5 x weight of the pump set.

88

Foundations Continued

Minimum foundation depth (m):

= W (Total Pumpset weight Kg)
2400 x B x L
2400 (kg/m3) = concrete density
B (m) Base plate width
L (m) Base plate length
Ensure that the foundation is wider and
longer than the base plate
Dynamic foundation loadings should be
sort from the pump manufacturer.
89

Baseplates

Often overlooked by specifiers.

Poor baseplate design is one of the most
common cause of premature failures
Distortion, vibration, resonance, soft feet,
misalignment etc. etc.
Rigid channel, box section or cast iron
bases are preferred.
Motor jacking screws greatly assist with
on site alignment.
Sufficient free surface area must be left
available for grouting.
90

Alignment

A pump & driver must be in alignment to ensure

satisfactory vibration free operation.
Misalignment will result in premature bearing
and mechanical seal failure.
This is the responsibility of the installer.
Typically final alignment should be within
0.05mm.
Pump & driver should be level, under no strain
from connecting pipe work.
Laser alignment technique is preferred method.
91

Angular & Parallel Alignment

92

Pump Station Pipe work, Valves &

fittings

Valves are required in a typical

installation for:

Isolation.
To prevent back flow through the pump.
To control/regulate flow
To prevent over pressurisation.

93

Pump Station Pipework, Valves &

fittings
Support all pipework and avoid loading the
pump nozzles.
Open circuits require suction strainers.
Fittings are required to connect pipes of
different diameters and change the direct of
pipework.
The correct sizing and positioning of these
components is important.
Suction pipework arrangements are
particularly susceptible to poor practice.
94

Suction Pipework

Flow velocities should be kept low.

Under 1.5 m/sec.
Formula for flow velocity in pipes:
V = L/sec x 1273.2
d2
Keep suction pipework simple.
Minimise the use of bends & fittings.
Avoid any potential for air locking.

95

Avoidance of air pockets

96

Bends in Suction Pipework

97

Discharge Pipework Valves & Fittings

Not so critical, however poor practice will

result in head losses, noise and vibration.
Keep velocities under 4.0 m/sec.
Fit taper increasers to pump discharge
connections.
NRV & Isolation valves should be
upstream of the taper handling flow at the
lower velocity.
Support all pipework.
98

Thank You

99