PUMPS

1. Introduction
The basic way to classify pumps is by the energy/force required by the pump to transfer liquid and
to produce an increase in pressure.
There are two basic classifications of pumps:
That is an energy/force that is continually added to the liquid by rotating element this would be
called (dynamic).
That is an energy/force is periodically added to movable boundaries to the liquid in an enclosed
casing his would be called (displacement).
This should not be confused with the action of the moving parts in the pump either by:
1. Rotating
2. Reciprocating.
They are placed in the plant for the best requirements to:
1. To transfer liquid from one elevation of the plant to another elevation
2. Increase the flow of liquid in a process system
3. To inject a chemical liquid to another fluid in a system
4. To circulate a liquid round a process complex

2. Classification of pumps
Pumps are classified according to:
1. Dynamic or Displacement
2. Pump Type
3. Orientation
4. Operating requirements and design
Dynamic Displacement

Pump Type
Pump Type

Reciprocating Rotary

Centrifugal Radial

Piston Gear

Axial

Vane
Plunger

Other
Screw
Diaphragm

Lobe
3. Dynamic Pumps
The main types of Dynamic Pumps are:
1. Centrifugal (radial)
2. Axial

3.1 Centrifugal radial

They are the most widely used in industry and in particular the petroleum process plants.
They are adaptable and can be installed in the plant in any position and orientation that is suitable.
They use a force to move the liquid and that force is called a centrifugal force, which by
application of the design converts kinetic energy to pressure energy.
It allows very high volumetric flow rates; in addition to that it offers more power per unit of weight
compared to other types of pump and is vibration free.
Centrifugal pumps, in contrast to displacement pumps, achieve pressure to the liquid by applying
inertial forces to the liquid.
The inertial forces are transmitted to the liquid by an impeller, which by dynamic centrifugal motion
adds velocity energy through acceleration of the liquid.
The liquid flows from the impeller into a diffuser passageway where the liquid decelerates, and
velocity energy is transformed to kinetic / pressure energy.
The combination of an inlet guide vane, impeller, and diffuser or diaphragm is referred to as a
stage.
A single centrifugal stage has a relatively low-pressure ratio-making capability.
When larger ratios are desired, additional stages are added in series which then makes the pump
multi-staged in one installation.
Liquid leaves the pump with a change of direction, 90 degrees to the axis of the shaft this is the
reason for the name radial is given to that type of pump.

Theory of Operation
The theory of centrifugal pumps can be described by considering the operating principles of a
simple single-stage pump, particular reference to the following:
1. The impeller
2. The diffuser
3. The volute or diffuser casing
Sketch of Centrifugal force

Impeller
The impeller consists of blades enclosed at the back by a disc, and at the front by a cover.
This impeller is referred to as a "fully shrouded impeller".
If there is no cover, that is, if the wheel is open in the front, it is referred to as a "semi-shrouded
impeller".
If the impeller consists of radial blades without covers, that is, if the wheel is open on both sides, it
is called an open impeller.
The impeller is basically a disc with a number of blades attached to it rotates and hence
accelerates liquid from its centre, or eye, to its rim by centrifugal force.
The increase in velocity, and hence kinetic energy, acquired by the liquid is converted to potential
energy in the form of pressure in the diffuser and, finally, in the volute casing.
A simple analogy can be used when considering the impeller action on the liquid.
Imagine what happens when an object such as a stone is attached to a piece of string held in the
hand and rotated.
A force, which is termed centrifugal, tries to pull the string from the hand.
In the case of the rotating impeller, it is this force which accelerates the molecules and, from
Newton's second law, the acceleration, or velocity increase, is proportional to the force.

Type of impellers
There are three main types of impeller used in centrifugal pumps, which are; open, semi-open,
and enclosed or sometimes this is called closed.

Forces on impeller
Difference of the force acting on a single impeller and double impeller
In centrifugal radial pumps the liquid enters the suction nozzle; the liquid is drawn into the impeller.
On leaving the impeller the high velocity liquid is diffused, this causes a reduction in velocity and
an increase in pressure.
From this diffusion chamber the liquid flows out to the discharge nozzle of the pump.
There are two types of basic centrifugal pump styles, one which is called Volute and other which
is called Diffuser

Volute style of pump

Diffuser style of pump

These types of pumps can be horizontally or vertically split
Horizontal Split

Vertically Split
The most common type of centrifugal (radial) pump is the Overhung Type

The main parts of a radial overhung type pump are;

Casing with flanges attached
Shaft
Impeller
Bearings
Bearing housing
Packing or mechanical seal
Coupling
Base
Centrifugal horizontal split pump

The description of this pump is:

1. A single impeller, on a shaft supported by bearings
2. Horizontally split casing
3. Volute style Pump with double entry suction to impeller, single discharge
Multi stage pump

Impeller wear ring replacement

Casing wear ring replacement

4. Displacement pumps
Displacement pumps are used for higher pressures installations, than centrifugal but usually have
less capacity or volume than centrifugal, or in some cases they are used to measure the flow or
rate of flow.

4.1 Reciprocating pumps

Reciprocating pumps can be further divided in to three styles or types, which are Piston, Plunger,
and Diaphragm.
They have certain features, which are common:
1. They have valves, which are Suction and Discharge.
2. Their action is reciprocating, backward and forward in a horizontal stroke or up and down in
vertical stroke.
3. They must have a pressure relief valve installed in the discharge line of the pump to protect the
pump from excessive pressure and damage to the pump.

Diaphragm Pump
A Diaphragm usually made from a flexible material, this pump is used for chemical injection air
works one side of the diaphragm and the spring returns the diaphragm back.
The length of stroke can be adjusted or the speed varied, therefore the rate of flow can be
controlled.
Sketch of internal parts

Plunger Pump
Plunger pump crank end

Plunger pump valve end

4.2 Rotary Pumps
There are three main styles or types of rotary pump which are commonly used in process plants,
they are;
1. Screw
2. Lobe
3. Gear
They also have some features, which are different from the other types of displacement pump,
and some same
1. Rotary pumps do not have valves (suction or discharge).
2. Rotary pumps need closer clearances from the rotating part to the casing.
3. Rotary pumps are more constant in there flow delivery
4. They must have a pressure relief valve installed in the discharge line of the pump to protect the
pump from excessive pressure and damage to the pump.

Gear Pump
The most common form of gear pump is two intermeshing gears.
One driven and one idle, in close fitting casing.
The liquid being pumped is picked by the teeth of the gears and continues to rotate; thus the liquid
is trapped in the spaces between the gear teeth and the pump casing.
The liquid is carried this way to the discharge side; it cannot leak back to the suction side by the
close clearance between the gears meshing.
Lobe Pump
The lobe is similar to the gear pump except the pump has lobes not gears: the principle of
operation is the same.
The close fitting clearance is between lobe tips on each revolution and the lobe tips and the
casing.

Screw Pump
Screw pump is another version of the previous two examples of rotary pumps; instead of
intermeshing gears this pump has intermeshing screws.
One driven and one idle but to assist this process there is also two gears to make this uniform,
liquid is trapped in the spaces between the screw and the casing.
The liquid cannot return to the low-pressure side because of the oncoming screw, so is forced out
towards the discharge side.

Single screw
Double screw

5. Sealing Devices
Sealing devices stop or reduce the amount of liquid that leaks from the pump, there is various
types of sealing devices and types.

5.1 Lip Seal

Very common and can be found in many pumps, its main function is to stop leaks along the shaft,
wither that be oil or process.
It is usually pressed on to the bearing housings of pumps, again to seal the oil in the housing and
stop oil leaking along the shaft also to stop foreign particles or dirt entering the bearing housing
and contaminating the oil.
5.2 Packing
Packing on the pump is also very common, it can be found on every type of pump that requires a
seal round the shaft of the pump.

Sketch of two packing arrangements

Mechanical Seal & Bill of Material

6. Bearings
Bearings are very important to a pump, the support the Shaft or Rotor; they allow the shaft to
move freely.
They need lubrication to move freely to reduce the force of friction that wants to stop this.
There are many types of bearings; the main types are Ball, Roller, Sleeve or Sleeve/Journal
bearing and pad radial or thrust type.

Lubrication is required:
1. To reduce wear in the machined parts So that pumps can operate smoothly
2. So that unnecessary stress is not put on the pump bearings
3. To operate pumps efficiently, have a longer operating life between maintenance
Sketch of ball bearings, single and double
Common types of bearing
Tapered roller

Sleeve or journal bearing

Troubleshooting Guide for pumps
Centrifugal Pumps
Trouble Possible Causes
Pump not primed
Liquid not being pumped Air in pump
Mechanical blockage
Mechanical defects
Pump overloads driver Liquid to high viscosity
Driver defect
Packing to tight
Stuffing box overheats Packing not lubricated
Incorrect packing installation
Incorrect oil level
Misalignment
Bearings overheat or war
rapidly Cooling insufficient
Bearings to tight
Plunger Pumps
Trouble Possible Causes
Suction lift to high
Air pocket in suction lines
Failure to deliver liquid Pump not in rated speed
Valves or packing leaking
Pump not primed
Gas or Vapour in Line
Pump not to rated speed
Failure to deliver
discharge Mechanical defects
pressure Pump not filling in suction
line because of high viscosity
oils
Pressure higher than the
Pump overloads driver pump is rated
for.
Remedies
Prime pump
Check for air
Check for any blockage
Check, packing, bearings, etc
Check liquid viscosity
Check bearings of driver
Adjust packing
Lubricate packing
Check packing
Check oil level
Check alignment
Check that bearings are being
cooled or is there a
blockage
Check the clearance of bearings
Remedies
Modify the pump layout
Purge the lines/prime the pump
Check the RPM
Overhaul valves / packing
Prime the Pump
Purge the Line
Check the RPM
Repair mechanical defects
Change the oil viscosity or decrease
by increasing the
temperature
Decrease the delivery pressure
 Gear Pumps
Trouble Possible Causes Remedies
Relief Valve faulty Check relief valve/ calibrate
Excessive clearance
between Check wear of gears and
Not enough head and or flow rate
gears and bushing
casing
Excessive end clearance Axial adjustment of Rotor
Liquid leaks along Shaft Mechanical seal failure Replace Seal or overhaul
Noise Vibration Cavitation Check suction pressure

Diaphragm Pumps
Trouble Possible Causes Remedies
Oil pressure valve set to low Calibrate oil max pressure
Insufficient head and /or
Air in the oil system Calibrate oil min pressure
flow rate
Leakages from piston seal Replace or tighten the seal
Contamination of pumped
Leaking Diaphragm Replace diaphragm
product by oil

Piston Pumps
Trouble Possible Causes Remedies
Suction line not filled Prime the line
Pump loses suction after
Gas or vapour in line Purge the line
starting
Air in line Purge the line
Pressure higher than the
Decrease the delivery
pump is rated
pressure
for.
Pump overloads driver
Viscosity of liquid being
pumped is to Decrease the viscosity
high
Pump fails to deliver liquid at Check for mechanical
Mechanical defects
pressure defects