PUMP
BASICS
TOPICS THAT WOULD BE COVERED
• PUMP /PUMP TYPES
• CONSTRUCTIONAL FEATURES OF PUMPS
• DETAILS OF PUMP PARTS
• PUMP PERFORMANCE
• FACTORS AFFECTING PUMP PERFORMANCE
• AFFINITY LAWS, PARALLEL/SERIES OPERATIONS IN
PUMPS
• PUMP PRIME MOVERS
• DATA TO SEEK FOR PUMP SELECTION
DEFINITION OF
PUMP
PUMP IS A MACHINE USED TO LIFT WATER FROM A
LOWER LEVEL TO A HIGHER LEVEL.
PUMP IS A MECHANICAL DEVICE WHICH RAISES THE
ENERGY LEVELS OF VARIOUS FLUIDS BY CONVERTING
KINETIC ENERGY IMPARTED BY ITS PRIME MOVERS INTO
HYDRAULIC ENERGY.
PUMP TYPES
PUMPS ARE OF 2 TYPES – POSITIVE DISPLACEMENT AND
ROTODYNAMIC
POSITIVE DISPLACEMENT PUMPS ARE THOSE IN WHICH
LIQUID IS SUCKED AND THEN PUSHED DUE TO THE THRUST
EXERTED ON IT BY A MOVING MEMBER ,WHICH RESULTS
IN LIFTING THE LIQUID TO THE REQUIRED HEIGHT.
EXAMPLES – RECIPROCATING PUMPS, DOSING PUMPS,
PLUNGER PUMPS,SCREW PUMPS
ROTODYNAMIC PUMPS HAVE A ROTATING ELEMENT
,CALLED IMPELLER,THROUGH WHICH AS THE LIQUID
PASSES ITS ANGULAR MOMENTUM CHANGES ,DUE TO
WHICH THE PRESSURE ENERGY OF THE LIQUID IS
INCREASED.
EXAMPLES – CENTRIFUGAL PUMPS , CENTRIPETAL PUMPS
CENTRIFUGAL Vs RECIPROCATING PUMPS
CENTRIFUGAL RECIPROCATING
1 RUN AT HIGH SPEEDS ie 3000rpm+ THEY RUN AT VERY LOW SPEEDS
AND NEED SPEED REUDCING DEVICES
2 THE DISCHARGE DECREASES THE DISCHARGE DOES NOT CHANGE
WITH INCREASE IN DELIVERY HEAD WITH THE VARIATION IN DELIVERY HEAD
3 EFFICIENT FOR HEADS UPTO 60M BETTER SUITED FOR HIGH HEADS
SINGLE STAGE . SUITABLE FOR OVER 60M AND VISCOUS LIQUIDS
COLD AND CLEAR WATER ,MOSTLY
CONSTRUCTIONAL FEATURES OF PUMP
1. IMPELLER
2. CASING /CHAMBER
3. SHAFT
4. STUFFING BOX
5. BEARINGS
6. COUPLINGS
[Link]/DISCHARGE FLANGES
DETAILS OF PUMP PARTS
1. IMPELLER : It’s the most important part of the pump and
most responsible for the pump performance.
IMPELLER TYPE DEFINITION SPECIFIC SPEED EFFICIENCY REMARKS APPLICATIONS GRUNDFOS PUMP TYPES
(METRIC)
1 RADIALFLOW AXIALENTRY RADIALDISCHARGE 80-110 75-80 LOW FLOW CLEAN ,COLD CR/NB/NK/TP/CH/CHI
( CLOSED IMPELLER HIGH HEAD FRESH WATER
FRANCIS TYPE)
2 MIXED FLOW AXIALINLET PARTIALAXIAL/PARTIAL80-160 UPTO 85 MEDIUM FLOW DRAIN WATER,STORM WATER SOME AP/GEF PUMPS
( SEMI OPEN OR CLOSED) RADIALDISCHARGE MEDIUM HEAD VISCOUS LIQUIDS
3 AXIALFLOW OR OPEN AXIALENTRY AXIALDISCHARGE 110-500 85-90 HIGH FLOW SLUDGE ,SEWAGE GEF PROPELLER PUMPS
LOW HEAD PAPER PULP
IMPELLER TYPES
AXIAL ENTRY RADIAL AXIAL INLET PARTIAL AXIAL ENTRY AXIAL DISCHARGE
DISCHARGE
AXIAL OUT LET AND
PARTIAL RADIAL OUTLET
SPECIFIC SPEED OF IMPELLER
SPECIFIC SPEED IS THE TERM USED TO CLASSIFY PUMPS ON THE
BASIS OF THEIR PERFORMANCE AND DIMENSIONAL PROPERTIES .
IT IS THE SPEED IN RPM OF AN IMAGINARY PUMP GEOMETRICALLY
SIMILAR IN EVERY RESPECT TO THE ACTUAL PUMP AND CAPABLE OF
DELIVERING 75KG OF WATER PER SECOND TO A HEAIGHT OF 1M.
SPECIFIC SPEED IN METRIC UNIT IS GIVEN BY:
Ns = 3.65XNX Q 1/2
H 3/4
N – Speed in rpm
H – head in meters ( per stage)
Q – Discharge in m3/sec
CASING/CHAMBERS
CASING IS A RECEPTACLE FOR ENCLOSING THE IMPELLER BOTH AT THE
SUCTION AND DELIVERY ENDS SO AS TO FORM A PRESSURE VESSEL.
CASINGS ALSO PROVIDES SUPPORTING AND BEARING MEDIUMS FOR THE
SHAFT AND IMPELLER ASSEMBLY.
VOLUTE CASING DIFFUSER CASING
1 UNSYMMETRICALLAYOUT SYMMETRICALLAYOUT
2 SIMPLE CONSTRUCTION COMPLICATED DUE TO STATIONARY
IN SINGLE STAGE PUMP VANES IN SINGLE STAGE PUMP
3 RADIALTHRUST AT PART LOADS NO APPRECIABLE RADIALTHRUST
AND OVER LOADS BUT HIGH AXIALTHRUSTS ARE THERE
THRUST SHARPLY INCREASES AS
HEAT INCREASES
4 QH CHARACTERISTIC IS MODERATE DROOPING AND OVER LOADING TYPE QH
AND NON OVERLOADING TYPE UNSTABLE OPERATIONS AT PART LOADS
STABLE OPERATION AT PART LOADS
5 MOSTLY HORIZONTALAND SINGLE VERTICALTYPE AND MULTISTAGE
STAGE TYPE
SHAFT
SHAFT IS A COMPONENT THAT CARRIES ALL THE ROATATING PUMP PARTS
AND ALSO PROVIDES POWER TO THE IMPELLER.
THE SHAFT HAS TO WITHSTAND THE ROTATING TORQUE ,AXIAL AND
RADIAL THRUST.
SHAFT MATERIAL IS SELECTED CONSIDERING THE FOLLOWING:
1. CRITICAL SPEED
• ENDURANCE LIMIT
• CORROSION RESISTANCE
• NOTCH SENSITIVITY
STUFFING BOX
The Purpose Of A Stuffing Box Is To Seal Off The Space Around The Rotating
Shaft Where It Passes Through The Delivery Casing Of The Pump.
Gland Packing And Mechanical Seal Are Commonly Used In Pumps
Mechanical Seal Or Shaft Seal Has A Stationary Part /Face Which Matts With
The Rotating Face Very Smoothly Under Pressure Exerted By A Spring Which
Gets Its Energy Partially By Precompression Given Manually And From
Pressure Energy Of The Liquid.
Seal Types O Ring, Bellow Or Cartridge Are Commonly Used In Grundfos
BBUE – BELLOW TYPE SEAL WITH CARBON vs TC SEAL FACES AND EPDM
ELASTOMER.
AUUV – O RING SEAL WITH TC Vs TC SEAL FACES AND FKM ELASTOMER .
HQQK – CARTRIDGE SEAL WITH SiC Vs SiC SEAL FACES AND KALREZ
ELASTOMER.
BEARINGS
Bearings Are The Mediums Which Keep The Shaft Or Rotor In Correct
Alignment With Its Stationary Parts Under The Action Of Axial And
Radial Thrusts.
Bearings Which Are Designed To Take Radial Thrust Only Are Called
Line Bearings And Those Designed For Axial Thrust Are Called Thrust
Bearings
Types
1. Bush Bearings
2. Antifriction Bearings
We Use Antifrictional Bearings In Our NB/NK Pumps. In The CR ,These
Bearing Come In The Motor
Antifrictional Bearings – Ball Or Roller Types.
COUPLINGS
COUPLINGS ARE DEVICES USED FOR CONNECTING PUMP WITH
THE PRIME MOVER. ITS MECHANICAL EQUIVALENT OF A FUSE
COUPLINGS ARE OF 2 TYPES
1. RIGID
2. FLEXIBLE
A COUPLING THAT CONNECTS TWO SHAFTS SOLIDLY FOR
POWER TRANSMISSION IS A RIGID COUPLING. EX: SLEEVE AND
CLAMP COUPLINGS
A FLEXIBLE COUPLING ALLOWS FOR EASY ASSEMBLY AND
DISMANTLING , WITHOUT DISTURBING THE SHAFTS . THEY ARE USED
FOR POWER TRANSMISSION BY MEANS OF MECHANICAL JOINT
WITHOUT SLIP IN MOTION.
Ex: PIN AND BUSH TYPE, LOVEJOY , DISC TYPE COUPLINGS
PUMP PERFORMANCE FLOW Q, M3/hr
SUCTION PRESSURE – KSC
DISCHARGE PRESSURE -KSC
DIFFERENTIAL PR,KSC =
(DISCHARGE PR + or – SUCTION
PR)
- For Suction head condition
+ for suction lift conditions
HEAD = (DIFF PR X 10 )/SG , M
Q H g D
P
1
1 9.81 1000
P 3600 2.72
1
m3 / h H m 2.72
P kW
1000
Power Curve
P1 – MOTOR INPUT FROM THE MAINS
P2 – MOTOR SHAFT OUTPUT
P3 – PUMP INPUT
P4 – PUMP OUTPUT
P1 H
P4
P2
P Q
P3
P2
Q
P4 P1= P2 x Motor h
POWER CURVE - II
1 : Duty point with poor H 1
H 2
2 : Duty point with good H 0
0 Q
%
0
0 Q
Example: LP 100-125/137
P1
P2
P3 Capacity: 130 m³/h
Head: 16 m
P4
130m3 / h 16m H 2.72
P4 : 5.65kW
1000
130m3 / h 16m H 2.72
P2 : 7.53kW
H
P4
0.75 1000
130m3 / h 16m H 2.72
P1 : 9.07 kW
0.83 0.75 1000
P Q
P2
P1= P2 x Motor h
FACTORS AFFECTING PUMP
PERFORMANCE
1. SPECIFIC GRAVITY
2. ALTITUDE
3. VISCOSITY
4. TEMPERATURE
5. VAPOUR PRESSURE
6. PERCENTAGE OF SOLIDS
[Link] OF THE PUMP
NPSH
What is NPSH ?
Net Positive Suction
Head
0
0 Q
H
0
0 Q
Loss NPSH is usually stated in metres
9
NPSH
The NPSH Value of a Pump is the minimum absolute pressure that
has to present at the suction side of the pump to avoid cavitations.
The NPSH value is measured in (m) and depends on the flow, when
flow increases, the NPSH value increase as well, resulting in
cavitation.
Vapour pressure and calculation of suction lift
Temp., [ °C] Pressure, H [m] Hs: Safety [1-2 m]
100 Hv: Vapour pressure
10.0
9.0
Hf: Friction loss, suction pipe
8.0 Hb: [pipe and foot valve]
90
7.0 Barometric NPSH
pressure
6.0
5.0
80 4.9
4.0 H
70
3.0
60 2.0
50
1.0
40
30 0.5
20
10 0.0
PUMP DRAWING LIQUID FROM A SUMP OPEN TO ATMOSPHERE
NPSH - Calculations
To system
PUMP
1 mt
3 mts
5mts
# Suction Lift - 3 Mts.
# Friction Loss - 1 Mts.
# T emp. of Water - 21 ºC
CALCULAT ION:
Vapour Pressure (hvpa) @ 21 ºC = 0.253 (from the table)
NPSHa = ha - hsl - hfs - hvpa
10.2 - 3 - 1 - 0.253 = 5.947 mts
AFFINITY LAWS
n x Qx Speed n is proportional to
flow Q
n Q
2
H x Qx Head H is proportional to flow
H Q in second power.
3
Px Qx Input power is proportional to
flow Q in third power
P Q
Changing Impeller Diameter
d1 216
Q2 H
d 2 d1 d 2 193
Q1
40
d 2 216
50
d 2 193 0
0 Q2 Q1 Q
Warning
Consult manufacturer (Grundfos) for accurate data
Effects of Variable Speed
n1 = 2900
H
n1 x (Q2/Q1) = n2
2900 x (12.5/25) = 1450 10
n2 = 1450
2
H1 x (Q2/Q1) = H2 2.5
2
10 x (12.5/25) = 2.5
1.2
3
P1 x (Q2/Q1) = P2
1.2 x (12.5/25) 3 = 0.15 0.15
12.5 25 Q
Pump with Change-Pole Motor
Example of construction:
> 1 pump with 2 and 4 poles
1. 2.
H
1450
2900
2900 rpm.
1450 rpm.
Q
Parallel Operation of Similar Pumps
Q
Theoretic:
Double flow [2 x Q]
Same head [1 x H]
Series Operation of Pumps
H
Theoretic:
Double head [2 x H]
Same flow [1 x Q]
Q
PRIME MOVERS OF A PUMP
PRIME MOVERS ARE POWER TRANSMISSION DEVICES TO IMPEL /PROPEL
THE PUMPS.
TYPES OF PRIME MOVERS USED IN PUMP APPLICATIONS
1. ELECTRIC MOTORS – INDUCTION MOTORS
2. DIESEL ENGINES
3. STEAM /GAS OR HYDRAULIC TURBINES
4. STEAM ENGINES
DATA TO SEEK FOR PUMP
SELECTION
• Media or Liquid to be pumped.
• Concentration of the liquid ,%( for ex acetic acid/HCL/H2SO4)
• Solid content ,if any.
• Particle size ,mm
• TDS
• Flow/Capacity of Pump ,m3/hr or USGPM OR LPS
• Head, m or ft
• Suction pressure ,Discharge pressure ,Kg/cm2
• Suction head or Suction lift condition
• Temperature of the Pumping [Link] C.
• Specific gravity or Density of the liquid.
• Viscosity of the liquid, Cp/Cst.
• NPSHA, m or ft
