PUMPING EQUIPMENT

INTRODUCTION

Pumps and compressors are the mechanical equipment that produce the necessary
pressure on a fluid to make it flow at a particular velocity. Without such
equipment it would be impossible to move the large quantities of liquids and
gases about the plant. This paper will cover the fundamentals of pump
operation, their basic parts, and their proper maintenance. Compressors will
be covered in a later paper.

Before discussing specific types of pumps, let us cover the basic terms which
apply to all pumps no matter what the type.

PUMP TERMS:

1. Pump
A pump does work on a flowing liquid in one or more of the following ways:

(a) by increasing the pressure on the liquid

(b) by increasing the rate of movement of the liquid
(c) by raising a liquid to a higher elevation

There are two basic types of pumps, Centrifugal and Positive Displacement.

(a) Centrifugal

In tnis type of pump, pressure is produced on the liquid by centrifu gal

(outward) force. The pressure in the liquid is then converted within the
pump to velocity (flow).

(b) Positive Displacement

Flow is produced in this type by the positive action of a piston or

rotating part on confined liquid.

More detailed information on these types is presented later in the paper -.

2. Density
The density of a liquid is weight per unit volume of a substance. It is
usually given in terms of grammes/cm3 at a particular temperature. The
density of water is 1000kg/m% at 4 0C. Increasing the temperature of a liouio
decreases its density; decreasing the temperature usually increases its
density.

3. Specific Gravity
The specific gravity of a liquid is the ratio of its density to that of
some standard substance. For l quids, the standard is water at 4 C.
i 0

For example, the density of asoline is 750kg/m . Therefore, the

g 3

specific gravity of asoline is 750kg/m

g 3

1000kg/m 3 (water) _ .75

4. Capacity
This refers to how much liquid the pump will move in a given period of
time. Normally, the capacity of a pump is given in cubic metres per hour
m3/hr.

5. Head
The head produced by a particular pump is the height to which the pump will
raise a liquid. The head of a pump is normally given in metres. From the
topic on pressure, you will remeber that there is a relationship between the
height of a column of liquid, its specific gravity, and the pressure
exerted at the bottom of the column. Therefore, the head that a particular
pump will produce under certain operating conditions is an indication of
how much pressure, (Barg), the pump will develop.

The height locations of the pump and the level of the liquid to be pumped,
determines how high, above the level of the pump, a liquid can be pumped. In
order to fully understand this subject of head, let us look at the following
pumping systems. Assume in all these systems that the same pump is being
used and that the liquid being pumped is water.

DISCHARGE H E A D ---

30m

25rn 3/H

Fig. 1.

Note in Fig. 1. that the water in the
level. The pump is raising the liquid
Discharge Head developed by the pump,
What is the pressure on the discharge
column of water 1 metre high exerts a
(Answer. 30 x 0.1 = 3.0 berg).
suction tank and pump are at the same
30m. Therefore, we say that the
at a capacity of 25m-'/hr, is 30m.
of the pump if we are pumping water? A
pressure of 0.1 barg at the bottom.
 DISCHARGE
HEflD -
15m

25m 3/H

Fig. 2.

Because the pump in Fi g. 1. is raising 25m 3/hr of water to a height of 30m, it

does not mean that it has to be used to pump the water to this height. Look at
Fig. 2. Here instead of raising the water to 300, it is only being raised 15m
above the pump. What happened to the other. 15m of head developed (same pump as
Fig. 1.)? Remember that head is related to pressure. The 15m of water head
equals 1.5 berg or. 50% of discharge pressure of pump. The other. 15m cf head in
terms of pressure (1.5 ber g) is being taken as pressure drop across valve "A".
In any pumpin g system you will always find that part of the head developed by
the pump is consumed because of friction loss in the line, obstructions in the
line, or pumping into a vessel under pressure.

The Total Head developed by a pump will not always show up as the Discharge
Head (or pressure) on the pump. The discharge head (or pressure) you get on a
pump depends upon the levels of the pump and the surface of the liquid being
pumped. For example, lets look at Fig. 3.

Fig. 3.

DISCHARGE
H E A D

25m 3/H

0632L VI - 3
In this case, the pump is raising 25m 3/hr of water only 25m above the pump.
However, isn't it also "sucking " the water. 5m up to the pump from the tank? We
would say once again that the pump develops a Total Head of 30m (25 + 5) but
only the 25m (or. 25 x .01 = 2.5 barg) of the total is the Discharge Head of the
pump. The 5m that the pump is raising the water is called the Suction Lift.
Water can be suction lifted by any pump a maximum of 10m. Why? Because a column
of water. 10m high exerts a pressure at the bottom equal to atmospheric pressure
1 bara.

D
H C HA

30m

Fig. 4.

Lets look at one more pumping system, thats shown in Fig. 4. In this case, the
pump is raising 25m-/hr, of water. 30m above the pump. However, is not 15m of
this Discharge Head produced by the water in the tank on the pump suction? If you
opened bypass "A", without the pump even runnin g, would not the water gravitate
from the tank up 15m towards tank "B"? This head is called the Suction Head on
the pump. The pressure on the discharge of the pump in this case is 3.0 barg
(3 x 0.1). When pumping liquids that vaporise easily, it is necessary to have a
certain minimum positive pressure (head) on the suction of the pump. The minimum
Suction Head for any pump must always be greater than the vapor pressure exerted
by the liquid at the pumping temperature. If it is not, vapor binding of the
pump will result. Normally the term Net Positive Suction Head is used to specify
the suction conditions for a pump. This term means nothing more than the
difference between the Suction Head on the pump and the vapor pressure of the
liquid at the pumping temperature.

0632L VI - 4
 CLASSIFICATION OF PUMPS

The following chart shows the broad classification of pumps.

Positive
Displacement Reciprocating

Pi imos

Rotary

Kinetic

Centrifugal

F i g . 5.
We will concentrate primarly on centrifugal and rotary pumps in this paper as
Special
these are the most common types used in our plant.

CENTRIFUGAL PUMPS

Centrifugal force is certainly nothing new. It is the same force that David
used when he slew the giant Goliath in the Bible story.

We are putting this force to many uses today. For example, we use it to spin
clothes dry in some modern washing machines. By high speed rotation, water is
forced out of the clothes. The cyclotron is another modern device which puts
this force to work in the splitting of atoms.

A simpler example is the bucket of water we swung around in circles when we

were young. Centrifugal force kept the water in the bucket even when we swung
it over our heads. If we were to make a small hole in the bucket and then swing
it rapidly, a stream of water would be thrown for some distance. We would then
have a very simple centrifugul pump.
1. Theory of Operation

All centrifugal pumps are similar in operation.

THROUGH THIS
DISCHARGE.
OPENING AT
HIGH PRESSURE

4
INTO THIS VOLUTE..
3
AND IS THROWN
CARRIES THE LIQUID OUT EY CENTRI-
FUGAL FORCE

F i g 6.

1. Liquid is drawn into the suction inlet.

2. It fills the spaces between the impeller vanes and is then thrown
out by the turning impeller.

3. The moving liquid is collected in the casing or volute.

4. Then it is carried out to the dischar ge line.

Remember as the liquid leaves the impeller, more liquid is drawn in through
the suction line. If we have no liquid in the pump in the first place, the
pump will not prime itself. Therefore, always prime the pump when starting.

(a) Main Pump Parts

One of the most important advanta ges of the centrifugal pump is that it has
so few moving parts. Aside from the bearings, the only moving part is the
main pump rotor.

However, all rotors consist of the basic parts:

1. Shaft
2. Shaft Sleeve
3. Impeller
4. Impeller Wear Ring
5. Case Wear Ring
The case wear ring is not part of the rotor. It is slipped over the impeller
rings before the pump is assembled. In the next few pages, we are going to
assemble a centrifugal pump. We will show how the wear rings function while the
pump is in operation.

An assembled pump consists of rotor, casing and bearings. The pump is bolted
together and the bearing covers are secured in place.

The case rings are now locked in the casing; the impeller rings are fixed to
the impeller. When the casing top is bolted down, the case rings should not
touch the impeller rings. You can. check this by turning the shaft -by hand.
nA321 VI - 6
The rotor should turn freely with no rubbing or binding.

Once a pump is primed, a film of liquid separates the wear rings. So long as
the pump remains filled with liquid, there will be no metal-to-metal contact
within the pump. Result - no excessive wear of the moving parts.

We have so far discussed in general terms the basic parts of centrifugal

pumps. Actually the basic parts in a centrifu gal pump, depending on the job to
be done, can be made up of a combination of the following specific parts.

IMPELLERS - can contain what are called open or closed impellers. A closed
impeller is more efficient than an open impeller. However, it will foul, and
become damaged very easily if any solids get into the impeller. An open
impeller should always be used when pumping liquid that contains any solids.

CASINGS - There are essentially two types of casing arrangements used on

centrifugal pumps, horizontally split and vertically split.

NO. OF SUCTIONS - Centrifugal pumps have either single or double suctions.

Double suctions are used when very high pumping capacities are required.

NO. OF STAGES - Most of the centrifu gal pumps within the plant are single stage
pumps, that is they contain a single impeller. However, we also have what is
called multi-stage centrifugal pumps. These are pumps that have a number of
impellers on a sin gle shaft. In these pumps, the discharge from one im peller
goes to the suction of the next impeller and so on. By passing throu gh successive
impeller sta ges, it is thus impossible to develop very hi gh pressures.

PERFORMANCE CHARACTERISTICS

The two mein things you are interested in with any pump here - how much will
it pump, and what pres sure will it develop? In a centrifugal pump, a certain
total centrifugal force (ener gy) is imparted to the liquid. This total force
(energy) can then be converted into two kinds of energy, velocity (capacity)
or head (pressure). If you want to get maximum capacity m 3/hr out of a
particular centrifu gal pump, you will have to be satisfied with a low discnarce
head, or the opposite. In other words, ,when you speak of the capacity of a
centrifugal pump as being so many m }/hr, this is its capacity at a sin gle
discharge head.

Actually for a particular centrifugal pump, you can draw what is called a
Capacity-Head curve. A typical one is shown in Fig. 7

12

2.3 4.6 6.4 9.2 11.5 13.8

C A P A C I T Y - m3/ H
Fig. 7
This curve tells you how many m 3/hr the pump will deliver at a certain
discharge head, or how much discharge head the pump will develop at a certain
capacity. For instance, Tthe above pump will pump 35 m 3/hr against discharge
head of 70 metres at 45m )/hr., it will develop a discharge head of only 50
metres. Concerning the head developed by a centrifugal pump, there is one very
important point you should especially remember. A centrifugal pump with a given
impeller, speed, and size will develop the same head in metres no matter what
the liquid or specific gravity. (Obviously, we are not considering liquids
with a high viscosity or consistency when making this statement. Also, the
kilowatts required is not constant).

Consider two columns of liquid both 3Q high - one of water density 1.0 and
the other gasoline density .75.
Fig 8.

3Gm

T
WATER GA54L! N
The pressure at base of water column is:

30(1) = 3.0 bard

10

The pressure at base of gasoline column is:

30 (.75) = 2.25 bard

10

Suppose some white balls are a light liquid, such as gasoline, specific
gravity .75, and black balls are water, specific gravity 1.0. Since the
impellers are revolving at the same speed, both balls will leave the impeller
with the same velocity. They will travel the same distance or be thrown to the
same height. Therefore, the head in meters will be the same.
 Now place a tin in the path of the balls. It is plain to see OUTLET
that the black or
RETURN
heavy balls LINE to.exert a greater pressure on the can than the white
are going
I or light ones. In other words, the discharge pressure of the pump will be
greater for water than for gasoline even though both liquids are pumped to the
LANTERIJ _________
show total head in metres of liquid.
n
same height in metres. For this reason, most manufacturers performance curves

GLAND
RING________________
. i i i -----------------------.........J///!.

_______ II"'
I N i . / ! //.

PACKING

INLET IMPELLER
Fig 10. 1. This valve closes 5. And liquid fi lls this end of the
cylinder
2. As the steam p
moves t h i s piston to the l e f t 6.
Through t h i s o en valve

3. performance
Actually the overall This valve opens characteristics
and l i q u i d 7. From theof
suction line
centrifugal pumps are
flows
given in the form of i n t o the
three discharge
curves on the same plot. An example is shown in
line 8. On the return stroke of the
piston each valve chan ges
4. The pressure of l i q u i d i n position. The liquid is
the discharge l i n e s closes then forced from the r i o h t
th i s valve hand chamber i n t o the dis-
/0 0 30 char ge l i n e .

% EF FI C. Meters
60 24
Head Capacity

BRAKE ,
6c 1 &- HORSE-
POWER

q0 - 12-
Buna N = 120°C

Teflon = 230°C 2.

Asbestos = 4000C

(NOTE: Pumps equipped with mechanical seals may require cooling in cases
other than those listed above. However, they are special applications and
should be specified in the seal design).
2. 3
External steam is used from time to time on leaky material seals in light
CAPACITY
hydrocarbon service. - m 3/H
The reason for its use is to melt ice formations on the
seal components and restore the seal balance. If the leakage is not corrected in
a short time, the continued use of steam will only overheat the seal and the
hydrocarbon, and aggravate the seal operation.

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VII ----1113
VVI 20
12
16
19
07
11
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PUMP LUBRICATION

Centrifugal pump shafts must turn at high speeds in order to produce high
pressures. The rotating shaft is supported by ball bearings to permit high
speed without vibration. A ball bearing consists of four parts.

Outer race - fits into bearing house, does not turn

Inner race - fits on shaft, turns shaft

Balls - located between outer and inner races, balls roll in these races

Retainers - located between races, serve to keep balls separated and

spaced evenly

Bearing parts are very carefully ground and fitted together. The bearings are
assembled in air-conditioned rooms and are kept perfectly clean. The care of
bearings should not end at the manufacturer's plant. We should treat them as
carefully as he does. We can then expect good service from our bearings.

Ball bearings seldom wear out if treated properly. Bearings are designed to
operate with a fine film of lubricant surrounding each ball. As a result, the
balls could roll for years and not show any wear. We know this because we have
had ball bearings in continuous service for more than ten years in other plants.

The close fit of bearings means smooth operation; but it also means trouble if
dirt enters the bearing house. One little piece of dirt can do enough dama ge to
destroy the entire bearin g.

Bearings are made of steel and may become rusty in a wet atmosphere. Take
care to keep moisture out of bearing housings.

Remember to keep bearings clean:

- Use only clean oil or grease

- Keep the lubricant in a clean, covered container

- Prevent foreign matter from entering bearing houses

The right amount of lubricant is very important. The most common type of oil-
lubricating bearing housing has a constant level oil cup connected to it.

Be sure to fill this cup when necessary. As long as we can see oil in the
cup, we know that the bearings will automatically get the right amount.

The second type of bearing housing has a sight glass which shows the oil
level. In this type we add oil through a filler cup until the correct level
appears in the glass. A ring turning on the shaft splashed oil to the
bearings.

In either of the two types oil level can cause serious damage. A bearing
without oil soon overheats and expands. The expanding bearing acts very much
like a brake. The resulting friction can cause the bearing to become red hot.
Result: destruction and possible fire.

Grease lubricated bearings also require periodic lubrication. Since we can't

see the "grease-level", we must lubricate at re gular intervals. 0632L VI - 23

Whether we use grease or oil, too much lubricant is almost as bad as not
enough. A high level causes crowding and overheating of the bearings. You
would never put eight quarts of oil in your automobile, so why over-lubricate
your pumps?

Let us review the lubrication practices which should be applied to all of our
pumps.

1. Using Mobil specified grade lube oil in all centrifugal pumps and Mobil
grease in all centrifugal pump motors.

2. Making daily visual inspection of the oil sight glass and drawing an oil
sample from the bearing housing once weekly on each pump to check for oil
color. Mobil oil is a bright clear yellow. When the slightest
discoloration or cloudiness is observed, the oil should be changed.

The importance of the latter rule cannot be overemphasised since even the best
oil will damage bearings when it becomes contaminated. In actual plant
experience, oils in service under wet and gaseous operating conditions have
become fouled, in one day's time.

0632L VI - 24