SUBJECT : Rules of thumb for pumps 2-7 I you want te know a pumps capabilities, the rules ae simple. Look atthe manufacturer's published pump curve. The problem is that you do not always have the curve available, Pump companies tet their pump te determine its performance, they have no need for general guide lines or "rules of| thumb.” ‘Over the years I've accumulated many of these rules to help me estimate pump performance. Here area few of them: PUMP Basics ‘+ How to estimate the shut off head of a pump (inch sizes) © AC1750 rpm, Shut off head= Diameter ofthe impeller squared © At3500 rpm, Shut off head= Diameter ofthe impeller squared x 4 «For ather speeds you ean use the formula: Shut Of Head =D? x (new rpm / 1750)? + Bstimating metric head isa litle bit more involved, but it sill works ‘Measure the shaft in mm. (as an example: 250 mm ) ‘Mark off two places. (2,5) ‘Square the number. (6,25) For 1450 rpm, multiply by 3 (18,75) ‘Add 10 % for the answer in meters. (21 meters ) NOTE: For 3000 1pm, you'd multiply by 12 instead of 3. Although you can estimate shutoff heed with these formulas you cannot estimate the pump capacity. you'll ned the pump curves for tht. ++ The pumps best efficiency point (B.E.P.) is between 80% and 85% of the shut of head, At this point there is litle to.no radial thrust on the impeller. Also the "power in” is closest to the "power out” + The L*/D# ratio should be below 60 (2.0 in metic) to prevent excessive shaft bending. To calculate it for end suction centrifugal pumps ‘© L= length of she shaft from the center of te inboard bearing tothe ceater of the impeller (inches or millimeters), Caution: do not use centimeters, the numbers will ome out wrong. ¢ D=diameter ofthe shaft (under the sleeve) inthe stuffing box area (inches or millimeters) Do not use centimeters. + ‘Since most shaft materials havea similar modulus of elasticity, changing shaft materials will not prevent shaft bending when you operate off of the BE. Lowering the L“D4is the only logical and efficient solution, When pump manufacturers diseuss operating off of the BE. they relate problems tothe heat that will build up in a minimum flow condition and ignore the problems with shaft bending. + A double suction pump cae run with 27% less N.P.S.H. or at @ 40% faster speed without cavitating, + Ifyou double the speed ofa pump youll get twice the capacity, four times the head and it will take eight times the horsepower to doit [A stainless ste! shaft bas only a stall portion of the conductivity of a carbon steel shaft. This is very important when you're pumping at Clevated temperatures because we do not want to transmit the high temperatute back tothe bearing ol T'you double the speed of pump you'l get almost four times the shaft whip, wobble or run out and eight times the weer. ‘Multistage pumps reduce efficiency 2% to 4% instances, an inducer can lower Net Positive Suction Head Required by as much as $0% ‘paper stock, modify the curves for head, capacity, and effcieney as follows! #01725 far 6% slock + 01825 for 5.5% stock > 0.90 for 5% 2 0.94 for 45% 0.98 for 4% LO for 3.5% or less + Open impeller clearance settings are determined by the purnp manufacturer and normally run between 0,008" and 0.015" (0,2 to 0,5 mm) You lose 1% of the pumps capacity foreach 0.002" (0,08 mm) you miss this setting. ‘+ Wear ring clearances are very similar to impeller clearances, but you lose 1% pump capacity foreach 0.001" (0,025 mm) of wear. Atypical clearance would be 0.003 inchiinch diameter with 0.010 inches (0,3 mm) minimum clearance for wear rings less than two inches (50 mm.) in ‘ouside diameter. + Bearing, grease or lip seals have a design life of less than 2000 hours. In a constantly running pump this would be only 83 days. These seals will also darnage the expensive shafl and place a stress point atthe maximum bending moment arm, Substitute non fretting labyrinth seals, or positive face seals in these locations. Its a good idea to install them in electric motors also to prevent moisture from entering and damaging the ‘motor windings and bearings + Dornot use a vent on the top ofthe bearing ase, At shut down the outside moisture will enter the hearing housing through this vent. Let the ‘moisture attempt to enter the ease through the labyrinth seals instead, They will do a better job of directing the moisture tothe external drain hole Ifyou install positive face seals you can forget about this problem. ++ The axial clearance in a bearing is ten times the radial clearance, This is the reason proper installation isso critical. I the bearing is over ‘compressed the bearing balls will distort and rol instead of spin causing excessive heat and premature failure. The temperature a the bearing race ofa properly installed bearing is atleast 10 degrees Fahrenheit (5° C) higher than the oi sump temperature + The life of bearing ol is directly related to its temperature. The rule of thumb used by the SKF Bearing Company, is thatthe service life of an oil is estimated to be 30 years at 30 degrees Centigrade (86° F) and it's life is eut in half for each 10 degree Centigrade (18 F) temperature increase. This corresponds to © Alife of 3 months at 100 C. (212 F.) © A life of 6 months at 90 C, (195 F.) © Alife of 12 months at 80. (176 F.) ‘These numbers assume that the lubricating ol is nol being contaminated by water from one oral ofthe Following sources: + Packing leakage ‘+ The water hose used to wash the packing leakage away from the pump area, ‘+ Aspiration, as moisture laden air enters the bearing case ‘An automobile engine running at 1750 rpm. would cover about 100,000 miles (160,000 kilometers) every 2000 hours (83 days in the life of a ‘constantly running pump ). Auto manufacturers recommend changing their automatic transmission oil every 25,000 miles (40,000 kilometers) APPLICATION ep cyetacr 2 3+ Use Centerline pump designs when the pumping teraperature exceeds 200 degrees Fahrenheit (100° C). Tis design will allow the wet end of the pump to expand in two directions instead of from the feet up, destroying the wear rings. Try to buy pumps with a Suction Specific Speed (SSS) below 8,500 (10,000 metric) Do not buy pumps with a $SS over 12,000 ( metric 16,500) unless youte pumping hot water or mixed hydrocarbons. Ifyou have a douile suction pump you can divide the SSS number by 2 + Do not specify a pump with the largest impeller available. Give yourselt an additional 5% or 10% you might need it ‘+ The maximum viscosity a centrifugal pursp can handle would be a product similar to 30 weight oil at room temperature ‘+ Usea variable speed pump i your head is mainly system head, Circulating hot or cold water would be typical applications. I'you have a high static or pressure head, as is the ease with a boiler feed pump, the variable speed will not be of much help in keeping you on of near the best cfficieney point Pumps piped in series must have the same capacity (impeller width and speed) ‘Pumps piped in paralle! must have the same head (impeller diameter and speed ) Use a rotary postive displacement pump if your capacity is going to be less than 20 gpm. (4,5 cubic meters per hour) ‘A centefugal pump can handle 0.5% sit by volume. At 6% it will probably become air bound and stop pumping, Cavitation can occur with any amount of ait ‘+ Use double volute pumps any time your impeller diameter is 14 inches (355 mm) or greater. They should also be used on long shaft vertical ‘pumps to prevent excessive shaft movement that will cause problems with the packing, seals, bearings and eritcal dimensions ‘+ A Vortex pump is 10% to 15% less efficient than a comparable size end suetion centrifugal pump. ‘+ The A.PL. (American Petroleum Institue). sixth edition tates: High energy pumps, defined as pumping to a head greater than 650 feet (198 ‘meters) and more than 300 horsepower (224 KW) per stage, require special consideration to avoid blade passing frequency vibrations and low frequency vibrations at reduced flow rates PIPING ETC ‘+ There should be at least 10 diameters of pipe between the suction ofthe pump and the frst elbow. This is especially critical in double ended pump designs asthe turbulent inlet flow ean eause shal thrusting, and subsequent bearing problems, + Substituting a globe valve for a gate valve ina piping system is similar to adding another 100 feet (31 meters) of piping tothe system. On the discharge side ofthe pump this will cause the purnp to run off ofits B.EP. wit a resultant shaft bending. On the suction side ofthe pump it will probably eause Cavitation + Afler the pump and motor have been aligned, dowel both the pump and the motor to the base plate Be sure to dowel only the feet closest to the ‘coupling, allowing the outboard ends to expand with temperature changes. + Check impeller rotation after installing the pump. Do not assume it will tum in the correct direction. I've heard about two speed pumps with the second speed wired backwards, They will drive you crazy because the pump will often meet its head requirement but not the eapacity when the second speed cus in. Youll also notice excessive noise at this time. + Use eccentric reducers rather than concentric reducers atthe pump suction. Concentric reducers will rap air. Be sure the evcentrie reducer isnot installed up side down, “+ Suction piping should be atleast one size larger than the suction flange a the pump, + Vortexing can occur if any ofthe following conditions are present; © Low liguid levels Liquid level falling greater than 3 PLsec. (I Meter see.) There isa large concentration of dissolved gases in the liquid. High outlet velocities in pipes leaving vessels. Generally greater than 10 fetisec. (3 metersise.) Liquids near thei vapor point, High circulation caused by asymmetrical inlet or outlet conditions. Inlet piping too close tothe wall or bottom of the tank, Consult the Hydraulic Insitste Manual ora similar publication for recommended clearances, © Inarmixer, the liguid level must bea least one and one half diameters ofthe blade, above the blade ‘TROUBLESHOOTING ‘+ Cavitation damage on the trailing edge ofthe impeller blade means © The NPS. available is too lov. © Aris entering atthe pump suction «© ‘There is liquid turbulence at the pump suction, ‘+ Cavitation damage on the leading edge ofthe impeller blade indicates internal recirculation. Check the Suction Specific Speed number to see if its below 9000 (10,000 metic) Higher numbers mean that the problem is with the impeller shape or adjustment. Tae problem was created when the pump manufacture tried to come up with to0 low a N.P.S.H. Required + Cavitation damage just beyond the cutwater, onthe easing and tip of the impeller blade, indicates the impeller blade is too close to the cutwater, ‘This learance should be at least 4% of the impeller diameter up toa 14 inch (356 mm, impeller, and 6% greater than 14 inch (356 mm.) Some self priming pump manufacturers want a maximum clearance of 1/8" (3 mm) and, as a result, often experience this problem. A repain substituted impeller is often the cause ofthe problem in anon self priming pump. ‘+ Water in the bearing oil will reduce bearing life 48%, The water enters from packing leakage, wash dawn hoses, and aspiration caused by the temperature cooling down in the bearing casing after shutdown and moisture laden ar entering the bearing case, A 6% water content in the oil will reduce bearing life by as much as 83 + The mass ofthe pump concrete foundation must be 5 times the mass ofthe pump, base plate, and other equipment that i being supported, or vibration will occu, + Upto 500 horsepower (375 KW), the foundation must be 3 inches (76 mm.) wider than the base plate all around. Above S00 horsepower (375 KW) the foundation should be a minimum of 6 inches (150 ram.) wider. + Imaginary lines extended downward 30 degrees to either side ofa vertical through the pump shaft, should pass through the bottom ofthe foundation and not the sides. + The bearing oil level should be atthe center ofthe lowest most ball ofa stationary bearing. The preferred choice for bearing lubrication would bean ol mist system with positive face sealing atthe bearings, if you could solve the emission problem. + Pipe from the pump suction flange tothe pipe rack, not the olber way around, + Make sure eccentric reducers are not installed upside down atthe pump suction. The top ofthe reducer should go straight into the suetion ange + Valve stems, T Branches and elbows shouldbe installed perpendicular to the pump shaft, not at right angles. ‘+ Do not use packing in any pump that runs under a vacuum, as air will enter the system through the pump stuffing box.. These applications include Pumps that it Fiquid. © Pumps that take their suction from a condenser or evaporator. ep year 2 2 edor«© Any pump that takes its suction from a negative pressure, Heater drain pumps area typical application. + Besure too vent the stuffing box ofa sealed, veticel pump back tothe suction side ofthe pump or ait will become trapped in the stuffing box. ‘The vent must he located above the lapped seal faces. + Ifthe specific gravity of the purnping liquid should increase, due to temperature, there is a danger of overloading the motor and therefore ‘motors having sufficient power should be used. The same overloading power will occur ifthe pump is run too fa to the right of ts B.E.P. This is very common problem because of the great numberof oversized pumps in existence. For information about my CD with over 600 Seal & Pump Subjects explained, click here, Link to Me Nally home page ep cyetacr 2