All About Pump and Curve

CENTRIFUGAL PUMP
TRAINING
AESSEAL plc 2002 www.aesseal.com

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2002 AESSEAL plc Issue Doc. Ref:
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Subjects
1. What is a Pump
2. The Impeller
3. Pump Curves
4. Pressure and Head
5. Parallel and Series Pumping
6. NPSH
7. Pump Shaft

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Subjects
8. Cavitation
9. Bearings
10. Mechanical Seal Chambers
11. API Plans
12. Piping Systems
13. Motor and Shaft Alignment

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Section 1
What is a pump?

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WHAT IS A PUMP?
Most simply expressed, a

pump is a mechanical device
used to energize liquids.

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Centrifugal Pumps
80% of the pumps we deal with are

centrifugal which will be the major subject
covered in this pump training course.

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PREAMBLE
All pumps designed within the last 10 years are

almost certainly mechanical seal friendly.
International Standards such as ANSI B 73.1,

DIN 2858, ISO 5199 and API 610 8th Edition
(API682) have ensured this.

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PREAMBLE
A pump designed 20 or 30 years ago may or

may not be mechanical seal friendly.
Perhaps more importantly an older pump is

going to be installed in an older plant, with all
the associated problems.

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PUMP TYPES
Centrifugal
Mixed Flow Radial Flow Axial Flow
Single Suction Double Suction Single Suction
Self Priming Multistage Single Stage Single Stage Multistage
Open Impeller Semi-Open Impeller Closed Impeller Open Impeller Closed Impeller
Single Volute Double Volute

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In its simplest form a centrifugal pump comprises
a driven impeller in a casing. An Impeller is a
rotating device used to generate motion.
Discharge
Pump Volute/Casing
Shaft Suction
Mech. Seal Impeller
Section 2
The Impeller

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The Volute
Case

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The Volute Case
A double volute casing
- balanced radial force.
Used on large pumps. The

radial forces are balanced
due to the equal and
opposite action of the
radial forces around the
impeller.

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The Impeller
Impellers are designed in a wide variety of
shapes and the form and proportions vary
with their specific speed.

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FLOW PATH

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The Impeller
OPEN IMPELLER CLOSED

IMPELLER

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WEAR RINGS

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Impeller - End View
Liquid enters
the centre (eye) of
the impeller.
The liquid is
accelerated to a high
velocity along
the outside edge
of the vanes.

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WEAR RINGS

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The Impeller
An open impeller with
no front shroud.
Generally less efficient

than a closed impeller.
The clearance between
impeller and casing will
increase.

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The Impeller
A closed impeller with
front wear rings.
As the wear ring

clearance increases
the pump efficiency will
decrease and the rings
must be replaced.

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The Impeller
A closed impeller with
front and back wear
rings.
The use of balance

holes to hydraulically
balance the impeller will
reduce the stuffing box
pressure.

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The Impeller
BALANCE HOLES

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Section 3
Pump Curves

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265 mm 20%
60 40%
245mm
50 40%
Best Efficiency
225 mm
40 20%
85%
Head
Meters
265mm 20
245 mm 15
225 mm 10
6
KW
4
M
NPSHR
2
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour
5
0
4
Head - Meters
0
3
0
2
0
M
1
0
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour

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NPSH r (Required)
265 mm
60
50
40
Head Meters
265mm 20
15
10
6
KW
4
M
NPSHR
2
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour

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HEAD 50 Metres
265 mm
60
50
40
Head POWER abs 15KW

Meters
265mm 20
15
10
6
KW
4
NPSHr 1.9
M
NPSHR
2
CAPACITY 33 M/3
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour

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Potential Problems
If the head is only
40m instead of
50m we get extra
flow (47m3/hr) and
60
265 mm use more power
(17.5kW and require
50
more NPSHR
40 (2.8mt)
Head Meters
Can we handle the

flow? Do we have
extra NPSHA? Is
265mm 20 the motor big
15 enough?
10
6
KW
4
M
NPSHR
2
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour

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LETS CONSIDER THE PROBLEMS
ORIGINAL DESIGN
ACTUAL SYSTEM HEAD

265 mm
60
1 PAST BEF POINT
50
2 INCREASE IN FLOW
40
3 INCREASE IN POWER
4 INCREASE IN npsh Head

Meters
265mm 20
15
10
6
KW
4
M
NPSHR
2
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour
SYSTEM CURVE
Head
50 265 mm
45
40
35
30
25
20
15
10
Flooded NPSHR
5
Suction
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour
SYSTEM CURVE
Head
50 265 mm
45
40
25mm
35
30
50mm
25
20
15
Flooded 10
Suction NPSHR
5
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour
The faster a pump shaft turns the greater the head
of liquid generated. True or False?
True. In fact head varies by the square of the change

in speed. E.g. If a pump produces 10 M at 3000 RPM -
what head will it generate at 3600 RPM?
Ans. (3600/3000)2 = (1.2)2 = 1.44. 10 x 1.44 = 14.4 M

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The faster a pump shaft turns the greater the power
required to drive it. True or False?
True. In fact power required varies by the cube of the

change in speed. E.g. If a pump requires 10kW at 3000
RPM - what power will it require at 3600 RPM?
Ans. (3600/3000)3 = (1.2)3 = 1.728. 10 x 1.728 = 17.28kW

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Section 4
Pressure and Head

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The Relationship Between
Head & Pressure (Definition).
HEAD developed is dependent on the shape and the
speed of the impeller.
HEAD is totally independent of density (S.G.) of

the liquid being pumped.
PRESSURE is dependent on the density (S.G.) of the

liquid being pumped.

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Question: Will Different Density
Liquids Pump to the Same Level
(As Shown Here) or: ?
S.G.- 1.2 S.G.- 1.0 S.G.- 0.7

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Or Will They Pump to Different Levels
as Shown Here?
S.G.- 1.2 S.G.- 1.0 S.G.- 0.7

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Answer: They Will Pump to the
Same Height (Head) but Will Show
Different Pressure Gauge Readings.
H=115ft H=115ft
60 psi 50 psi 35 psi
S.G.- 1.2 S.G.- 1.0 S.G.- 0.7

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The faster a pump shaft turns the greater the volume of
liquid moved. True or False?
True. In fact volume is proportional to speed. So if a

pump produces 10 M3/Hr at 1500 RPM then it will
produce 20 M3/Hr at 3000 RPM. Conversely it will only
produce 5 M3/Hr at 750 RPM. This is known as the first
of the Pump Affinity Laws.

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Section 5
Parallel and Series Pumping

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Parallel & Series Pumping
When system requirements vary it may be
desirable to employ more than one pump.
Systems with high static head requirement should

use pumps in parallel.
Systems with low static head requirement should

use pumps in series.

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Considerations with
The second pump and seal which are operating
under Series Pumping, will be subject to higher
pressure.
Parallel Pumps must have a steep hydraulic curve
to be able to start the second pump, whilst the first
pump is running.

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Parallel Pumping
P1
Suction Discharge
P2
Series Pumping
Suction P1 P2 Discharge

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Series Pumping
Series Pumping
Suction Discharge
P1 P2

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Series Pumping
80
Series Pumping Stage 1
Differential Head (m)
60
40
20 max
min
0
0 50 100 150 200 250 300
Output m3/Hr

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Series Pumping
80 Series Pumping Stage 2
60
40
20 max
min
0
0 50 100 150 200 250 300
Output m3/Hr

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Series Pumping
80
Note Output stays the same Head increase to 120 m
Series Pumping Stage 1 and 2

120 m60
40
20 max
min
0
0 50 100 150 200 250 300
Output m3/Hr

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Parallel Pumping
Parallel Pumping
P1
Suction Discharge
P2

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80
60
40 max
duty
min
20
0
0 50 100 150 200 250 300
Output m3/Hr
System curve
80
100mm pipe
60
40 max
duty
min
20
0
0 50 100 150 200 250 300
Output m3/Hr
System curves
80
75mmpipe 100mm pipe

60
40 max
duty
min
20
0
0 50 100 150 200 250 300
Output m3/Hr
System curves
80
75mmpipe 100mm pipe

60
125mmpipe
40 max
duty
min
20
0
0 50 100 150 200 250 300
Output m3/Hr
Parallel pumping
80
75mmpipe 100mm pipe

60
125mmpipe
40 max
duty
min
20
0
0 50 100 150 200 250 300
Output m3/Hr
Pump 2 System Curve
50
40 Pump 1
30
20
M
10 8
0 M
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour Pumps in Parallel
System Curve
50
40
Pump 2
30
20
Pumps in Parallel Pump 1
M
10
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour
System Curve
50
40
30
Pump 2
Pump 1
20
M
10 8
0
0 5 10 15 20 25 30 35 40 45 50 55 60
Capacity M3/Hour
Pumps in Parallel
Section 6
NPSH

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Net Positive Suction Head
(NPSH)
The NPSH of a pump is the
differential pressure between
that at the pump suction and
the vapour pressure of the
liquid.
This is critical - cavitation.

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Available, NPSHa
Case 1
Positive Suction
from an open tank.

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Available, NPSHa
Case 2
Suction lift from
an open tank.

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Available, NPSHa
Case 3
Suction from a closed
tank and temperatures
greater than ambient.

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(NPSH)
The available NPSH of the

suction line must be
calculated.
The available NPSH must be

greater than the required
NPSH.

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To Increase the NPSH a.
Raise the suction tank (or level in the tank).
Lower the pump.
Increase the pressure in the suction tank.
Cool the liquid to reduce vapor pressure.
Modify the suction piping. - Increase pipe diameter -
reduce the length - change fittings - modify valve type -
reduce number.

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To Decrease the NPSH r.
Increase the eye of the impeller.
Install a suction inducer in the pump.
Use a pump with a double suction.
Use slow speed pump with larger
impeller.
Use a number of lower capacity pumps
in parallel.
Install a booster pump.

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The Pump Shaft
Shaft Deflection
The capability of the shaft to handle the
various loads without excessive radial
movement becomes very important.
Industry standards = 0.002 (0.05mm)
How would you measure this?

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The Pump Shaft
L
Slenderness Ratio =
D4
Keep the ratio low and

keep the pump running.

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Section 8
Cavitation

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Cavitation
Higher
Liquid Pressure
Pressure
Implodes
Bubbles
Vapour
Low Pressure
Creates Bubbles Pressure

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Cavitation
The effects on a mechanical seal are:
1) Face popping i.e. unstable fluid film.
2) Mechanical damage - quite often on the O.D. of the

rotary.
3) Dry running
4) Leaching of the carbon.

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Cavitation
- The effects on a mechanical seal are as a result of
the pump vibration:
1) Unstable fluid film.
2) Mechanical damage - quite often on the O.D.

of the rotary.
3) Dry running
4) Mechanical damage - due to vibration.

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Other Factors Confused with
Cavitation
Air Entrainment - air already in the
product before it reaches the pump -
similar damage to cavitation.
Suction Recirculation - occurs at very
low flows - damage mid-way along
vane.
Discharge Recirculation - occurs at low
flows - damage at impeller tip and cut
water.

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Avoiding Cavitation
NPSH a (Available) > NPSH r (Required).
NPSH a = System
NPSH r = Pump

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Cavitation
The effects on a mechanical seal are as a result of the
pump vibration:
Bearing Arrangement

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Bearing Arrangement
Pump bearings accomplish three important functions:
1. Locate the rotating element.
2. Allow the shaft to rotate.
3. Absorb all the radial and axial loads.

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Bearing Arrangement
Single row, deep
groove ball bearing.
Most commonly used

as a radial bearing,
however, can handle
axial thrust loads on
light duty pumps.

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Bearing Arrangement
Single angular
contact bearing.
Designed to support
a heavy thrust load in
one direction only.

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Bearing Arrangement
Tandem angular
contact bearings.
Designed to support a
heavy thrust load in
one direction only. The
load being distributed
evenly.

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Bearing Arrangement
Back-to-Back angular
contact bearings.
either direction but by
one bearing at a time.

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Bearing Arrangement
Face-to-Face angular
contact bearings.
either direction but by
one bearing at a time.

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Bearing Arrangement
Always change the

bearing before installing
a new mechanical seal!

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Section 10
Mechanical Seal Chambers

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Stuffing Box Design
Typical stuffing box cross sections would be 5/16''
(8mm) on 1 3/8'' (35mm) shaft and 3/8'' (10mm) on
shaft above 1 3/8'' (35mm).

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Stuffing Box Design

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There is a large selection and it will depend on

the application as to which to use.

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Stuffing Box Design
Typical clearances that

you can expect when a
mechanical seal has
been fitted would be
0.040 (1mm) on 5/16
(8mm) cross section
and 0.060 (1.5mm) on
a 3/8 (10mm) cross
section.

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Tapered bore seal

chamber with vortex
breaker.
Self-venting, non
clogging and increased
cooling.

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Parallel Bore Large
Cross Section

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Taper Bore

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Taper Bore Large

Cross Section

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Taper Bore Large Cross Section

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Section 11
API Plans

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API Plans
Within API 610 and 682 is the concept of plans, these are
merely layouts, P & IDs (Piping and Instrumentation
Diagrams) for different installations created to standardise
on the differing ways of supporting mechanical seals to
provide a stable fluid films at the seal faces.

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01 02 11 12 13
21 22 23
51 61 62
31 32
41
SINGLE CARTRIDGE SEAL

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01 02 11 12 13
21 22 23 53 54 61 62
31 32
41
PRESSURISED DUAL CARTRIDGE SEAL

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Plan 01
Integral (internal) recirculation from pump discharge to seal.

Recommended for clean pumpage only.

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Plan 11
From pump discharge
Recirculation from pump discharge through a flow control orifice to the

seal.

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Plan 21
From pump discharge
Recirculation from pump discharge through a flow control orifice and

cooler, then into to the seal chamber.

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Plan 23
Recirculation from a pumping ring in the seal chamber through a cooler

and back into the seal chamber.

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Plan 32
Optional
Flush is injected into the seal chamber from an external source.

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Plan 53A
Circulation is by an internal pumping ring.

Reservoir pressure is greater than the process pressure being sealed.

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Plan 53B (A.K.A. 53 Modified)
Pre-pressurised bladder accumulator provides pressure to the

circulation system. Flow is maintained by an internal pumping ring. Heat
is removed from the circulation system by an air-cooled or water-cooled
heat exchanger.

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Plan 54
Pressurised external barrier fluid reservoir or system. Circulation is by

an external pump or pressure system. Reservoir pressure is greater
than the process pressure being sealed.

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Plan 62
Exterior source providing a quench. The quench may be required to

prevent solids from accumulating on the atmospheric side of the seal.
Typically used with a close-clearance throttle bushing.

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Section 12
Piping Systems

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Piping Systems
The suction side of a pump is more important than

the discharge pipework.
Problems on the suction side, can be the source of

ongoing and expensive difficulties which may never
be traced back to that area.

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Piping Systems
When a pump is running, the liquid must arrive at the

impeller eye with sufficient head and the even laminar
flow necessary for reliable operation, this depends largely
on the suction piping design.

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Piping Systems
Suction Reducer - Which

is correct?

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Piping Systems
As the suction pipework is

generally one size larger
than the pump suction
nozzle then an eccentric
reducer is used. It should
always have the flat side
at the top.

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Piping Systems
The pump suction piping must also be free of air pockets.

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Piping Systems
Piping Elbows
Elbows must be located

as far away from the
pump as possible.
The length of the straight inlet line = 5 to 10 times

the pipe diameter.

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Piping Systems
The concentric increaser
is used on the discharge
side of the pump and is
normally bolted straight to
the discharge flange of
the pump.

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Piping Systems
All pipe connections must be accurately aligned

before the bolts are tightened and all piping, valves
and associated fittings should be independently
supported without strain being imposed on the pump.

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Section 13
Motor and Shaft Alignment

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Motor & Shaft Alignment
Coupling Alignment Basics
The pump shaft and the drive shaft must rotate

on a common axis.

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Better Alignment = Fewer Failures
The last function performed before pump start-up

should be a final alignment check.

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Motor low (pump high) Divergent pump/motor (vertical)
Motor to one side of pump Divergent pump/motor

(horizontal)

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Countless studies from all over the world have

come to the same conclusion.
The Better the Alignment the Better the
Savings, Safety and Environment.

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The older the plant the more likelihood of motor

and shaft misalignment. Check how (or if) the
alignment is being carried out.
Poor Alignment = Premature Seal Failures

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RCA
Last serviced Weather Conditions
Air Traffic Plane Crash Fuelling
Communications Pilot

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CENTRIFUGAL PUMP

AESSEAL plc 2002 www.aesseal.com

AESSEAL plc 2002 www.aesseal.com

AESSEAL plc 2002 www.aesseal.com

AESSEAL plc 2002 www.aesseal.com

Most simply expressed, a

AESSEAL plc 2002 www.aesseal.com

80% of the pumps we deal with are

AESSEAL plc 2002 www.aesseal.com

All pumps designed within the last 10 years are

International Standards such as ANSI B 73.1,

AESSEAL plc 2002 www.aesseal.com

A pump designed 20 or 30 years ago may or

Perhaps more importantly an older pump is

AESSEAL plc 2002 www.aesseal.com

Mixed Flow Radial Flow Axial Flow

Single Suction Double Suction Single Suction

Self Priming Multistage Single Stage Single Stage Multistage

Single Volute Double Volute

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Used on large pumps. The

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OPEN IMPELLER CLOSED

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Generally less efficient

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As the wear ring

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The use of balance

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Head POWER abs 15KW

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Can we handle the

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ACTUAL SYSTEM HEAD

4 INCREASE IN npsh Head

True. In fact head varies by the square of the change

Ans. (3600/3000)2 = (1.2)2 = 1.44. 10 x 1.44 = 14.4 M

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True. In fact power required varies by the cube of the

Ans. (3600/3000)3 = (1.2)3 = 1.728. 10 x 1.728 = 17.28kW

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Pressure and Head

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HEAD is totally independent of density (S.G.) of

PRESSURE is dependent on the density (S.G.) of the

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S.G.- 1.2 S.G.- 1.0 S.G.- 0.7

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S.G.- 1.2 S.G.- 1.0 S.G.- 0.7

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60 psi 50 psi 35 psi

S.G.- 1.2 S.G.- 1.0 S.G.- 0.7