By R.

DURAISINGAM,
AEE/M, Conv, ETPS.
PUMPS: PUMPS:
Problems encountered & Problems encountered &
Remedy Remedy
Spares & case studies. Spares & case studies.
Pumps
Obiective:- to impart energy to the
Iluid.
Pressure/ potential energy.
Velocity/ kinetic energy.
Types:- two basic types
Rotodynamic.
Posiitive displacement.
Roto-dynamic pumps
Flow is continuous.
Creates a vacuum by
the action oI
centriIugal Iorce.
Kinetic energy is
imparted.
Roto-dynamic
pumps
CentriIugal
Axial
Single stage
Multi stage
Mixed
Radial
Single suction
Double suction
SelI priming /
non priming
Single stage /
double stage.
Positive displacement pumps
Flow is moved in
discrete quantities
deIined by the
machine geometry.
It gives low mass
Ilow and high
pressure rise.
Positive displacement pumps
Reciprocating
Diaphragm
Piston
plunger
Single acting
Double acting
Diaphragm pump
Positive displacement pumps
Rotary
Single rotor
Vane
Screw
Piston
Multiple rotor.
Gear
Lobe
Screw
Gear pump external, internal
Vane pump
Rotating vanes trap the Iluid, transports and
discharges.
Vane pump
Lobe pump
Screw pump
Three rotors design is
normally used.
Runs without pulsation.
Reliable, low noise &
longer liIe.
There is a rolling action
between the drive and
idler screws.
Submersible pumps
Other types oI pumps
Monobloc pumps.
Jet pumps.
Air compressor iet type.
Special pumps Ior acid /
chemical handling.
Pumps with agitator /
cutters.
Metering pumps.
Concrete volute pumps.
oncrete Volute Pump Pumps are expected to
run continuously Ior a
prolonged time.
ThereIore, operational
reliability is a crucial
Iactor. As the size oI the
pump increases, the
dimensions and weights
oI the heaviest parts
have a large inIluence on
the choice oI the
construction material
used. oncrete is.
therefore. the natural
choice for the pump
body.
oncrete Volute Pump
The pumps are called
Concrete Volute Pumps
because the casing and
suction draIt tube is cast
in concrete. The
rotating parts are
metallic. A very simple
mechanical design is the
maior advantage oI the
CVP.
SpeciIic speed Addison proposed that a pump
oI standardized size will
deliver energy at the rate oI
one horsepower when
generating a head oI one Ioot
when it is driven at a speed
called the speciIic speed.
Used Ior characterizing the
perIormance oI a pump without
including its dimesions.
Ns KN sqrt Q divided/ by
H to the power oI /.
K, a constant containing Iluid
density and a correction Iactor.
Positive displacement pumps
Total Flow
trapped volume / swept volume each stroke
X strokes per minute.
X displacement
X speed.
Pulsation / Iluctuation is minimised by
increasing the number oI cylinders,
number oI teeth, speed.
Accumulator is also provided.
Accumulator.
Increased number oI
cylinders reduces
Iluctuations.
Accumulator reduces
Iluctuations.
Acts as a temporary
storage.
Air is normally used to
keep the pressure
uniIorm.
Used in Fire hydrant
iockey pump.
EIIiciency
Hydraulic power, Ph
Q (Ilow in m3/sec)
X h
d
h
s
(delivery and suction head in
metres)
X p (density in kg/m3)
X g (acceleration due to gravity in m3/sec)
/ by 1000
Pump eIIiciency
Hydraulic power / Pump shaIt power
Motor eIIiciency
Pump shaIt power / Electrical input power.
EIIiciency
Overall eIIiciency
hydraulic eII x volumetric eII x mechanical
eII.
Actual power to Iluid / power to shaIt
Actual energy rise/ euler energy rise.
Delivered Ilow/ Ilow through rotor
Fluid power / input shaIt power.
Euler equation: gHu2 x Vu2 u1 x Vu1.
Peripheral velocity x peripheral component
oI absolute velocity, Flow is continuous.
gH ideal u2 Vu2.
AIIinity laws
Q N or/also D
H N

or/also D

P N

or/also D

Discharge is proportional to the speed / impeller

diameter.
Similarly Ior the Head and Power it is proportional
to the square and cube oI speed and diameter.
Trim Impeller only up to 75 to reduce head by 50
For wide ranges speed reduction has to be employed.
Pump perIormance curves
Head,
eIIiciency,
power,
NPSH-required
versus
Flow rate
Flow rate
Head
EIIiciency
Power
NPSH required
EI
H
P
NPSH r
Pump operating point
Intersection oI pump
characteristic (head-Ilow)
curve with the system
resistance curve. (Duty
point)
Total head static head
dynamic head.
Dynamic head is
proportional to the square
oI the Ilow.
Head Ilow curve
System curve
Flow
Head
Op. pt
Static head
Friction head Total s ystem head
SelI packing / Mechanical seals
Cost.
Reliability- possibility oI
correction.
Installation simple.
Maintenance regular.
Spares length Iorm /
preIormed sets.
ShaIt wear considerable
Irictional losses are high.
Costlier.
Sudden
complete Iailure.
Skilled.
Zero.
Spare seals.
Nil.
NPSHa net positive suction head
available
Pressure in absolute terms (atmospheric /-
gauge pr).
Less losses (in suction pipeline).
Add margin Ior Ilooded suction or subtract
in case oI suction liIt.
Less vapour pressure.
NPSHr net positive
suction head required
In order to sustain the Pump
operation.
And To avoid cavitation
NPSH available ~ NPSH
required.
Critical NPSH required is
deIined as the point at which
pump head Ialls by 3 .
Cavitation causes considerable
damage as bubbles oI gas corm
and then collapse.
EIIect oI viscosity on Pumps
II viscosity is increased
EIIiciency decreases
Discharge / Flow
decreases
Power required
increases
Portable
Iire
pumps
Atmospheric Suction
Water hammer (or, more
generally, fluid hammer)
Water hammer is a pressure surge or wave
resulting when a Iluid (usually a liquid but
sometimes also a gas) in motion is Iorced to
stop or change direction suddenly (momentum
change). Water hammer commonly occurs when
a valve is closed suddenly at an end oI
a pipeline system, and a pressure wave
propagates in the pipe.
It may also be known as hvdraulic shock.
EIIects oI Water Hammer
The eIIect oI water hammer cannot be
underestimated as its Iorces have been
documented to result in many oI the
Iollowing:
1. Collapse the elements in all designs oI
steam traps
2. Overstress pressure gauges
3. Bend internal system mechanisms
4. Crack steam trap bodies
5. Rupture pipe Iittings
EIIects oI Water Hammer
6. Cause valve Iailures
7. Cause heat exchanger equipment tube
Iailures
8. Break pipe welds and even rupture piping
systems
9. Failure oI pipe supports.
Conditions causing Water
hammer
1. Hydraulic shock
2. Thermal shock
3. Flow shock
4. DiIIerential shock
Hydraulic shock
Pumps are oIten installed with check valves.
As the pump starts and stops. hydraulic
shock can occur as the flow rapidly stops
and the check valves restrict the Ilow in one
direction. Slow closure of the valve, is the
solution to this problem. When a column oI
water is slowed beIore it is stopped, its
momentum is reduced gradually, and
thereIore, damaging water hammer will not
be produced.
Thermal Shock
One pound oI steam at 0 psi occupies 1,600
times the volume oI a pound oI water at
atmospheric conditions. This ratio drops
proportionately as the condensate line
pressure increases.
When the steam collapses. water is
accelerated into the resulting vacuum
from all directions with great speeds.
Flow Shock
Flow shock is most commonly caused by lack
of proper drainage ahead of a steam line
isolation valve or steam control valve. For
example, consider a steam line isolation valve
(typically used with pipe oI 3in. or larger)
opened without the use oI a warm up.
Flow Shock
When the large valve is opened, steam rushes
down a cold pipe producing a large quantity
of condensate at high velocity. This
condensate will continue to build in mass as
it travels along the pipe and a large wave of
condensate is created.
Flow Shock
The wave will travel at a high velocity until
there is a sudden change in direction,
possibly an elbow or valve in the line.
When the condensate changes direction.
the sudden stop will generate water
hammer.
DiIIerential shock
DiIIerential shock, like Ilow shock, occurs
in bi-phase systems. It occurs whenever
steam and condensate flow in the same
line. but at different velocities.
DiIIerential shock
This is commonly seen in condensate return
lines. In bi-phase systems, velocity oI the
steam is oIten 10 times the velocity oI the
liquid. II condensate waves rise and Iill a
pipe, a seal is Iormed temporarily between
the upstream and downstream side oI the
condensate wave. Since the steam cannot
Ilow through the condensate seal, pressure
drops on the downstream side.
DiIIerential shock
The pressure diIIerential now drives the
condensate seal at a high velocity
downstream accelerating it like a piston. As
it is driven downstream it picks up more
liquid, which adds to the existing mass oI
the slug, and the velocity increases.
WATER HAMMER - REMEDY
II the system is properly designed and
correctly operated, water hammer in any
Iorm will not occur. It is possible to have
high pressure steam systems operating
without water hammer and a long
operational liIe Irom the steam components.
Preventing or Resolving Water
Hammer
There are a variety oI design or system changes
that can be implemented to prevent or eliminate
water hammer:
1. Proper training Ior plant personnel.
2. Ensure correct steam and condensate design
3. Have documented SOP`s (standard operation
procedures) Ior steam system startups and shut
downs.
4. Have installation standards Ior steam
components.
Remedy
5. Properly speciIy and place steam line
drip steam traps on the steam system.
6. Correct condensate connections oI branch
lines to the main condensate line and enter
only on the top.
7. Use steam traps that are properly sized
and appropriate Ior the application.
8. Use warm up valves on steam line
isolation valves larger than 2 inch. Do not
'crack open large steam isolation valves
Remedy
9. Check or repair the pipe insulation. It
saves energy and reduces accumulation oI
condensate in the piping system.
10. Condensate line sizing is crucial to
insure proper operation oI the steam system.
Under-sizing the condensate lines is one oI
the largest contributors to water hammer.
11. System that has a modulating control
valve should have a drip leg trap upstream
oI the valve to remove condensate during a
closed condition Ior the valve.
12. Always gravity drain away Irom the
Remedy
9. Check or repair the pipe insulation. It
saves energy and reduces accumulation oI
condensate in the piping system.
10. Condensate line sizing is crucial to
insure proper operation oI the steam system.
Under-sizing the condensate lines is one oI
the largest contributors to water hammer.
11. System that has a modulating control
valve should have a drip leg trap upstream
oI the valve to remove condensate during a
closed condition Ior the valve.
Remedy
12. Always gravity drain away Irom the
process applications with a modulating
control valve.
13. Condensate can be drained into a
pressurized condensate return line only iI
proper differential is maintained.
14. Properly label the steam and condensate
lines.
15. Remove Abandoned steam and
condensate lines, remove Irom the system.
CAVITATION
avitation is the Iormation oI vapor
bubbles oI a Ilowing liquid in a region
where the pressure oI the liquid Ialls below
its vapor pressure. Cavitation is usually
divided into two classes oI behavior: inertial
(or transient) cavitation, and noninertial
cavitation.
CAVITATION
Inertial cavitation is the process where a
void or bubble in a liquid rapidly collapses,
producing a shock wave. Such cavitation
oIten occurs in control valves, pumps,
propellers, impellers, and in the vascular
tissues oI plants.
Bubble Iormation, rupture & collapse oI
bubbles and cavity Iormation.
CAVITATION
Noninertial cavitation is the process in
which a bubble in a Iluid is Iorced to
oscillate in size or shape due to some Iorm
oI energy input, such as an acoustic Iield.
Such cavitation is oIten employed
in ultrasonic cleaning baths and can also be
observed in pumps, propellers, etc.
CAVITATION
Since the shock waves Iormed by cavitation
are strong enough to significantly
damage moving parts. cavitation is
usually an undesirable phenomenon. It is
speciIically avoided in the design oI
machines such as turbines or propellers, and
eliminating cavitation is a maior Iield in the
study oI Iluid dynamics.
Hydrodynamic cavitation
Hydrodynamic cavitation describes the process
of vaporisation. bubble generation and
bubble implosion which occurs in a Ilowing
liquid as a result oI a decrease and subsequent
increase in pressure. Cavitation will only occur
iI the pressure declines to some point below the
saturated vapor pressure oI the liquid. In pipe
systems, cavitation typically occurs either as the
result oI an increase in the kinetic energy
(through an area constriction) or an increase in
the pipe elevation.
Do`s & Don`ts
Do make sure the suction hose is well connected
and air tight when priming
Do Ilush any pump used on sea water or corrosive
liquids with Iresh water
Do watch to make sure the cooling water is
Ilowing Ireely on a water-cooled pump engine by
watching the temperature gauge or warning light
Do start and run on water every Iew weeks to
ensure they are working correctly, the pump seal
is in good condition and the starter battery is
charged.
Do`s & Don`ts
Don`t run the pump dry Ior long periods
Don`t run the pump against a closed outlet
valve Ior long periods
Don`t Iill the Iuel tank with the engine
running unless the tank is speciIically
designed Ior this purpose
Most importantly
1. Use only brass or plastic tools to pry.
. If you must hammer on the pump. use
a clean plastic hammer (no imbedded metal
chips, etc.) and tap lightly; Use force. not
impact. to move stubborn parts. Treat the
pump as a precision gauging instrument.
. Do not perform maintenance on the
silicon carbide sleeve bearings.
Most importantly
4. Always flush the piping system before
connecting the pump.
5. Filters should be installed upstream of
the pump. Eg (5) microns.
6. pumps must never be run without a
fluid.
7. Turn pumps by hand beIore start-up to
ensure Iree rotation beIore starting the
drive.
Most importantly
8. For applications above ambient
temperatures. iI using heaters, heat the
pump slowly and evenly (including the seal
arrangement) prior to introducing hot Iluid
into the pump. This prevents thermal shock
and material distortion.
9. Make sure that process fluid is in the
pump beIore starting. Apply positive
pressure to the pump inlet when metering
high-viscosity Iluids to prevent cavitation.
Most importantly
10. Install a pressure regulating valve
downstream oI the pump, iI necessary, to
ensure there is at least 20 psig diIIerential
pressure at all times.
Flow and pressure relationship
of a pump
When the Ilow increases, the discharge
pressure oI the pump decreases, and when
the Ilow decreases the discharge pressure
increases.
Flow and pressure relationship
of a pump
. Do not let a pump run at zero flow
. Use pressure gauges
Make sure your pump has a pressure gauge
on the discharge side close to the outlet oI
the pump this will help you diagnose pump
system problems.
4. Do not let a pump run dry. use a check
valve
PIPING SYSTEM
The right pipe size
The right pipe size is a compromise between cost
(bigger pipes are more expensive) and excessive
Iriction loss (small pipes cause high Iriction loss
and will aIIect the pump perIormance). Generally
speaking, the discharge pipe size can be the same
size as the pump discharge connection, you can
see iI this is reasonable by calculating the Iriction
loss oI the whole system. For the suction side,
you can also use the same size pipe as the pump
suction connection, oIten one size bigger is used.
PIPING SYSTEM
A typical velocity range used Ior sizing pipes on
the discharge side oI the pump is 9-12 It/s and Ior
the suction side 3-6 It/s.
PIPING SYSTEM
14. Pressure at high point of system
Calculate the level oI pressure oI the high point in
your system. The pressure may be low enough Ior
the Iluid to vaporize and create a vapor pocket
which will be detrimental to the perIormance oI
the system. The pressure at this point can be
increased by installing a valve at some point past
the high point and by closing this valve you can
adiust the pressure at the high point. OI course,
you will need to take that into account in the total
head calculations oI the pump.
Pressure at high point
PIPING SYSTEM
15. Pump pressure rating and series
operation
For series pump installations make sure that the
pressure rating oI the pumps is adequate.
Inadequate pump suction
submersion
There is a minimum height to be respected
between the Iree surIace oI the pump
suction tank and the pump suction. II this
height is not maintained a vortex will Iorm
at the surIace and cause air to be entrained
in the pump reducing the pump capacity.
anger of increased pressure due to
a plug in a series pump svstem.
Pump selection
Select your pump based on total head (not
discharge pressure) and Ilow rate. The Ilow rate
will depend on your maximum requirement.
Total head is the amount oI energy that the
pump needs to deliver to account Ior the
elevation diIIerence and Iriction loss in your
system.
Impeller selection
Effect of viscosity on pump
performance
Viscosity is the main criteria which
determines whether the application requires
a centriIugal pump or a positive
displacement pump. CentriIugal pumps can
pump viscous Iluids however the
perIormance is adversely aIIected. II your
Iluid is over 400 cSt (centiStokes) in
viscosity consider using a positive
displacement pump.
Avoid running pump in reverse
direction
Avoid running a pump in reverse direction,
pump shaIts have been broken this way
especially iI the pump is started while
running backwards. The simplest solution is
to install a check valve on the discharge
line.
Minimum flow rate
Most centriIugal pumps should not be used
at a flow rate less than 50 of the B.E.P.
(best eIIiciency point) Ilow rate without a
recirculation line. (What is the B.E.P.?) II
your system requires a Ilow rate oI 50 or
less then use a recirculation line to increase
the Ilow through the pump keeping the Ilow
low in the system, or install a variable speed
drive.
Portable
Iire pump
-
constructi
on
HFO pump - speciIication
Pour point/ sp. gravity(15
0
C - 75
0
C/ 0.98.
Pumping temp -80
0
C
Viscosity - 75 to 300 cst.
Capacity - 1220 to 1250 LPM.
Delivery Pr. - 32 kscg
NPSH reqd. - 5.3 m.
BHP - 100 to 105 hp.
LDO pump - speciIication
Pour point/ sp. gravity(15
0
C 12-18
0
C/ 0.83.
Pumping temp - 25 to 50
0
C
Viscosity - 2 to 20 cst.
Capacity - 96 LPM.
Delivery Pr. - 20 kscg
NPSH reqd. - 5.0 m.
BHP - 7.6 hp.
Typical
speciIication -
BFP
Model FK 6D 30.
Barrel casing type.
Feed water temp/ des - 160.5
Feed water sp.gr. - 0.9069
Capacity/ rated 102 kg/s.
Total head 2108 m.
Shut oII head/ rated sp 2490 m.
Speed 5136 rpm.
NPSH required 21.75 m.
No. oI stages 6.
Suction / delivery pressure 16.6/
207.8 bar.
Power input 2603 KW.
EIIiciency 81
EIIiciency hyd 97.8
CW pumps - speciIication
Capacity/ design 14600 m3/hr.
Total head 17 m.
Shut oII head 38 m.
Speed 490 rpm.
Power output/ water hp 684 KW.
EIIiciency 87
CE pumps - speciIication
Capacity/ design 185 kg/sec.
Design temp/ sp.gr 49
0
C/ 0.9884
Suction pressure 5 m.
Discharge pressure 190 m.
Shut oII head 244 m.
NPSH reqd 2.8 m.
Speed 1480 rpm.
Power input 415 KW.
Typical
speciIication -
BFP
Model 20 KHI (horizontal).
Discharge 7930 lpm
Total head 1830 m.
Speed 4320 rpm.
No. oI stages 6.
Suction pressure 12.3 ata.
Operating point 164.7 deg C.
EIIiciency 70-72
Oil servo torque 10 (205lts x
5.5 barrels).
Motor: 4000 KW; 6.6 KV; 3 ph-
50 Hz; class F; 408 A;
eIIiciency 96.4
Energy conservation
Ensure adequate NPSH.
Operate at / near best eIIiciency point.
ModiIy pumping system to minimise throttling losses.
Use VSD Ior wide load variation.
Use booster pumps Ior low Q and high H (pr).
Repair seals and packing to minimise water losses.
Use siphon or Iree-Iall/gravity return iI possible.
Optimise number oI stages.
Reduce system resistance by optimising the pipe size.
Downsize oversized pumps.
Installation oI
pumps
A solid Ioundation
is required.
A Iine sieve Iilter
is to be provided.
Installation
oI pumps
Ensure correct
alignment and
coupling gap.
Installation oI
pumps
Pumps shall be
primed beIore
starting.
Check the
direction oI
rotation beIore
coupling.
Installation oI
pumps
Flush the
pipelines beIore
starting oI the
pump.
1A
1V
1H
2H
2V
2A
3A
3V
4V
4A
3H 4H
OVERHUNG PUMP OVERHUNG PUMP
1A
1V
1H
2H
2V
2A
3A
3V
4V
4A
3H
4H
ENTER SUPPORTED PUMP ENTER SUPPORTED PUMP
VIBRATION
ANALYSIS
VIBRATION
ALIGNMENT
ROTATING ELEMENTS
BALANCING
CLEARANCE
DIRECTION OF ROTATION
LEAKAGES
MAINTENANE
SYSTEMATIC AND SCIENTIFIC
UPKEEP OF EQUIPMENTS.
OB1ETIVES
PROLONGING THE USEFUL
SERVICE LIFE OF THE
EQUIPMENTS.
ENSURING ITS OPTIMUM
AVAILABILITYAT ALL
TIMES.
INSTANT OPERATIONAL
READINESS. RELIABILITY.
SAFETY OF THE PERSONNEL.
ROTARY EQUIPMENTS
ROTATING
MACHINERY
TRANSMISSION OF
POWER
MOVING
COMPONENTS
FRICTION AND
WEAR OF
COMPONENTS.
ROTARY EQUIPMENTS
MAINTENANCE
LUBRIATION
- MINIMISING FRICTION AND WEAR
SURFAE ROUGHNESS - PROPERTIES
OF LUBRIANTS.
VISOSITY - INTERNAL FRICTION OR
RESISTANCE TO FLOW - THICKNESS OF
OIL AT A GIVEN TEMPERATURE.
VISOSITY INDEX - VARIATION IN
VISCOSITY RELATIVE TO
TEMPERATURE.
ROTARY EQUIPMENTS
MAINTENANCE
POUR POINT - Rough measurement oI a limiting
viscosity - Temperature at which oil ceases to Ilow iI held
horizontally Ior 5 seconds 2.5.
FLASH POINT - Temperature at which it gives suIIicient
vapour to Iorm a Ilammable mixture with air - indicative oI
contamination.
METAL BASED SOAP GREASES.
FILTRATION - TO REMOVE CONTAMINATION
WHICH IS THE MAJOR CAUSE FOR FAILURE.
ENTRIFUGING.
THANK You. & THANK You. &
WisH You ALL THc acsT. WisH You ALL THc acsT.