ANSI/HI 1,3-2000 ANSI y/ American National Standard for Centrifugal Pumps Sor Design and Application SHydrguiic 9 Sylvan Way Parsippany, New Jersey 07054-3802 www. pumps.org‘Sponsor Hydraulic institute ‘www.pumps.org Approved November 9, 1999 American National Standards Institute, Inc. ANSI/HI 1.3-2000 American National Standard for Centrifugal Pumps for Design and Application Recycled paperAmerican National Standard Publishes By Approval of an American National Standard requires verification by ANSI that the requirements for due process, consensus and other criteria for approval have been met by the standards developer. Consensus is established when, in the judgement of the ANSI Board of Standards Review, substantial agreement has been reached by directly and materially affected interests. Substantial agreement means much more than a simple majority, but not neo- essarily unanimity. Consensus requites that all views and objections be considered, and that @ concerted effort be made toward their resolution ‘The use of American National Standards is completely voluntary; their existence does Not in any respect preclude anyone, whether he has approved the standards or not, from manufacturing, marketing, purchasing, or using products, processes, or proce. dures not conforming to the standards, ‘The American National Standards Institute does not develop standards and will in no Circumstances give an interpretation of any American National Standard. Moreover, no Person shall have the right or authority to issue an interpretation of an American National Standard in the name of the American National Standards Institute, Requests {or interpretations should be addressed to the secretariat or sponsor whose name appears on the tile page of this standard. CAUTION NOTICE: This American National Standard may be revised or withdrawn at any time. The procedures of the American National Standards Institute require that action be taken periodically to reaffirm, revise, or withdraw this standard, Purchasers of ‘American National Standards may receive current information on all standards by call- ing or writing the American National Standards Institute. Hydraulic Institute 9 Sylvan Way, Parsippany, NJ 07054-3802 ‘www.pumps.org Copyright © 2000 Hydraulic Institute All rights reserved. ‘No part ofthis publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher. Printed in the United States of America ISBN 1-880952-28-9Contents Foreword 1.3 1.3.1 1.3.2 133 1.3.3.1 1.3.3.2 1.3.3.3 1334 1.3.35 1.8.36 1.8.8.7 1.3.38 1.3.39 1.3.3.10 13.3.1 1.3.8.12 1.33.13 1.8.3.14 1.34 13.44 13.42 1.3.43 1.3.44 1.8.45 13.4.6 1.3.47 13.48 1.3.49 1.3.4.10 1.3.4.11 135 1.3.6.1 1.8.5.2 1.3.53 135.4 1355 1.3.56 Design and application . Scope .. : Preferred units for pump applications ‘Typical applications. Booster service. . sees Process service (chemical, pttochemical Transfer pumping ....... Mine dewatering . Well pumping . Inrigation service .. : Pumps for steam power plants... Fire pumps . : Pumps used as hydraulic turbines . .. General purpose service... . : ‘Wastewater service (solids and non-clog) ........ : 4 Pulp and paper applications . .. bebe eeteee tee eeeeenee 15 Slurry service 7 Liquids with vapor or gas 19 Performance, selection criteria... . 21 ‘System requirements . Determination of operating duty . : Efficiency prediction method for contitugal pumps .. Operation away from the best efficiency point . Noise levels...... Suction conditions. . 87 Mechanical features 58 Impeller types 75 Casing type. 76 Drivers: type and size . : : 76 Pump quid temperature limits on end suction Pumps... 78 Horizontal pump baseplate design . Introduction... Functional requirements . Definitions... Tolerancing. Shims and fasteners Stress levels ..1.8.5.7 Rigiaty fovetteeeeee Sites BA 1.95.8 Miscellaneous ented... e eee Bb Appendix A Torsional Stitiness 86 Appendix B Recommended Equipment Mounting Driling Dimensions. ..... 87 Appendix References .......... feet eee sees 88 Appendix D Index ... Figures 1.47 — Diagram of a simple steam power cycle . wee 1.48 — Diagram of a typical condensing steam power plant... - 1.49 — Diagram of a closed feedwater cycle ........... 7 1.50 — Diagram of an open feedwater cycle with one deaerator and three closed heaters fit teeettteeeeeeeee 1.51 — Turbine characteristios ....... 1.52— Turbine performance... sees. 1.83 — Selt-priming pump — construction industry, 1.54 — Selt-priming pump — chemical industry tetteee lec 1S 1.55 — Nomograph of the relationship of concentration to specific gravity in aqueous slurties........ bette eeeneees : 18 1.56 — Typical performance characteristics —non-setling slurries......... 19 1.57 — Typical performance characteristics — settling slurries ............ 19 1.58 — Effect of gas on pump performance ..... settee 20 1.89— Inducer... cee : seteeesees 20 1.60 — Venting the eye of the impeller ..... 1.61 — Top suction impeller... .. sete 1.62 — Pump versus system sees : 1.63 — Torque curve... : pete teeeteeeesee nee 1.844 — Performance correction chart for viscous liquids (metric)... 1.848 — Performance correction chart for viscous liquids (US units)... 25 1.858 — Performance correction chart for viscous liquids (metric) = 26 1.858 — Performance correction chart for viscous liquids (US units) . 27 1.66A — Sample performance chart (Metric). + 30 1.668 — Sample performance chart (US Units) ......... fees BH {.S7A— Recommended typical operating speed limits for single suction pumps (metric). . : : : 33 1273 Recommended typical operating speed limits for single suction pumps (US units)... +34 1.88A— Recommended typical operating speed limits for double suction pumps (metric). ee1.68B — Recommended typical operating Speed ite for double suction pumps (US Units) ......eeeeeeceeeeseeseteceeeseees 36 1,694 — NPSHR reduction for pumps handling Pyeaton liquids and high-temperature water (metric). 40 1.69B — NPSHR reduction for pumps handling hydrocarbon liquids and high-temperature water (US units). we 1.70 — Pumps operating in series. 1.71 — Pumps operating in parallel 1.72A — Pump performance (Metric) 1.73A — Temperature rise (Metric) ....... 1.728 — Pump performance (US Units) .. 1.738 — Temperature rise (US Units). . 1.74 — Impeller with angled outside diameter : 1.75A — Optimum general attainable efciency chart (Metric) +. 50 1.758 — Specific speed-efficiency correction chart (Metric) . a) 1.756 — Optimum generally attainable efficiency chart (US Units) -s1 1.75D — Specific speed-etficiency correction chart (US Units)... 181 1.76A — Deviation from generally attainable efficiency (Metric) ............ 62 1.768 — Deviation from generally attainable efficiency (US Units). 52 1.77A — Estimated efficiency increase due to improved surface finish (Metric) vee . 54 1.778 — Estimated efficiency increase due to finish (US Units) wees . 54 1.78A — Estimated efficiency decrease due to increased wear ring clearance (Metric) a : 55 1.78B — Estimated efficiency decrease due to increased wear ring clearance (US Units) ..... ween : 1.79 — Inducer. 1.80 — Single volute casing. ...... : 1.81 — K versus rate of flow for single volute casing . 1.82 — Dual (double) volute casing. . : 1.83 — K versus rate of flow for dual (double) volute casing 59 4.84 — Circular casing : 1.85 — Pressure distribution on enclosed impeller shrouds . 60 1.86 — Enclosed impeller with plain back shroud . ... 6 — Impeller with back ring. 1.88 — Mechanical seal classifications . 1.89 — Stutfing-box without lantern ring 1.90 — Stutfing-box with lantern ring . 1.91 — Overhung impeller . 1.92 — Impeller between bearings 1.93 — Grouted baseplate1.94 — Free-standing baseplate . : settee tennessee 79 1.95 — Height of mounting surfaces 2... cece e eee Bt 1.96 — Equipment mounting surface flatness . -8t 1.97 — Motor mounting pads. . 81 1.98 — Mounting block dimensions. 85 ‘A.1 — Baseplate support and anchoring. . fierce 86 B.1 — Recommended equipment mounting driling dimensions . - 87 Tables 1.3.1 — Symbols 1.8.2 —Subsoripts cee 3 1.3.3 — Sample calculations (Metric) 30 1.3.38 — Sample calculations (US Units)... 32 1.3.4 — The influence of pump type on efficiency. 56 1.3.5 — Rolling element bearing types - 64 1.3.6 — Product lubricated sleeve bearing material selection guide (Commonly used in vertical turbine pumps) ... 1.3.7 — Guidelines for minimum and maximum pump liquid temperature for cast grey iron and ductile iron pumps (°C)..........066... 78 {1.3.8 — Guidelines for minimum and maximum pump liquid ‘temperature for cast grey iron and ductile iron pumps (°F)... eee... 78 1.3.9 ~ Metric manufacturing tolerances tet tttt eee eee 1.3.10 ~ US units manufacturing tolerances . cette eteeeeee ee 80Foreword (Not part of Standard) Purpose and aims of the Hydraulic Institute The purpose and aims of the Institute are to promote the continued growth and welkbeing of pump manufacturers and further the interests of the public in such ‘matters as are involved in manufacturing, engineering, distribution, safety, trans- Portation and other problems of the industry, and to this end, among other things: ) To develop and publish standards for pumps; b) To collect and disseminat public; information of value to its members ‘and to the ©) To appear for its members before governmental departments and agencies and other bodies in regard to matters affecting the industry; d) To increase the amount and to improve the quality of pump service to the public; ©) To support educational and research activities; 1) To promote the business interests of its members but not to engage in busi- ness of the kind ordinarily carried on for profit or to perform particular services for its members or individual persons as distinguished from activities to improve the business conditions and lawful interests of all of its members. Purpose of Standards 1) Hydraulic Institute Standards are adopted in the public interest and are designed to help eliminate misunderstandings between the manufacturer, the purchaser and/or the user and to assist the purchaser in selecting and ‘obtaining the proper product for a particular need. 2) Use of Hydraulic Institute Standards is completely voluntary. Existence of Hydraulic Institute Standards does not in any respect preclude a member from manufacturing or selling products not conforming to the Standards. Definition of a Standard of the Hydraulic Institute Quoting from Article XV, Standards, of the By-Laws of the Institute, Section B: “An Institute Standard defines the product, material, process or procedure with reference to one or more of the following: nomenclature, composition, construc- tion, dimensions, tolerances, safety, operating characteristics, performance, qual- ity, rating, testing and service for which designed.” Comments from users Comments from users of this Standard will be appreciated, to help the Hydraulic Institute prepare even more useful future editions. Questions arising from the con- tent of this Standard may be directed to the Hydraulic Institute. It will direct all ‘such questions to the appropriate technical committee for provision of a suitable answer. If a dispute arises regarding contents of an Institute publication or an answer pro- vided by the Institute to a question such as indicated above, the point in question shall be referred to the Executive Committee of the Hydraulic Institute, which then shall act as a Board of Appeals. vilRevisions The Standards of the Hydraulic Institute are subject to constant review, and revie sions are undertaken whenever it is found necessary because of new develop. ments and progress in the art. If no revisions are made for five years, the standards are reaffirmed using the ANSI canvass procedure. Units of Measurement Metric units of measurement are used; and corresponding US units appear in brackets. Charts, graphs and sample calculations are also shown in both metric and US units. Since values given in metric units are not exact equivalents to values given in US units, itis important that the selected units of measure to be applied be stated in Teference to this standard. Itno such statement is provided, metric units shall govern, Consensus for this standard was achieved by use of the Canvass Method The following organizations, recognized as having an interest in the standardiza- tion of centrifugal pumps were contacted prior to the approval of this revision of ‘the standard. Inclusion in this list does not necessarily imply that the organization ‘concurred with the submittal of the proposed standard to ANSI. AR. Wilfley & Sons KSB, Inc. ANSIMAG Inc. M.W, Kellogg Company Bechtel Corp. Malcolm Pirie, Inc. Black & Veatch Marine Machinery Association Brown & Caldwell Marley Pump Company ‘Camp Dresser & McKee, Inc. Marshall Engineered Products Carver Pump Company Company Cheng Fluid Systems, Inc. Montana State University Crane Company, Chempump Div. MWI, Moving Water Industries Cuma S.A. Oxy Chem Dean Pump Div., Metpro Corp. Pacer Pumps DeWante & Stowell Paco Pumps, Inc. Dow Chemical Pinellas Cty, Gen. Serv. Dept. EnviroTech Pumpsystems ‘The Process Group, LLC Essco Pump Division Raytheon Engineers & Constructors Exeter Energy Ltd. Partnership Reddy-Butfaloes Pump, Inc. Fairbanks Morse Pump Corp. Robert Bein, Wm. Frost & Assoc, Fluid Sealing Association Scott Process Equipment Corp. Franklin Electric Settler Supply Company GKO Engineering Skidmore Grundfos Pumps Corp. ‘South Florida Water Mgmt. Dist llinois Dept. of Transportation Sta-Rite Industries, Inc. IMC - Agrico Chemical Corp. Sterling Fluid Systems (USA), Inc. Ingersoll-Dresser Pump Company ‘Stone & Webster Engineering Corp. ITT Fluid Handling (B & G) Sulzer Bingham Pumps, Inc. ITT Fluid Technology ‘Summers Engineering, Inc. ITT Industrial Pump Group Systecon, Inc. Iwaki Walchem Corp. Val-Matic Valve & Mfg. Corp. J.P. Messina Pump & Hydr. Cons. ‘Yeomans Chicago Corp. John Crane, Inc. Zoeller Engineered Products Krebs Consulting Service vi) 1.3. Design and application ‘The purpose of this section is to provide a guide for the application of centrifugal pumps for various ser- vices. No attempt has been made to cover all phases of centrifugal pump application, but an endeavor has been made to point out some of the principal features of pumps and the precautions which should be taken in their use. 1.34 Scope This Standard is for centrifugal and regenerative turbine ‘pumps of all industriaV/commercial types except vertical single and multistage diffuser types. It includes design and application, 1.3.2 Preferred units for pump applications Preferred terms, units and symbols to be used in the technology of pump applications are shown in Tables 1.3.1 and 1.3.2, 1.3.3 Typical applications 1.3.3.1 Booster service Centrifugal pumps in this service handle liquids piped to them at various levels of pressure, normally above atmospheric, and discharge at a higher pressure into the system. Accurate specifications of the liquid char- acteristics and the range of suction pressures expected must be provided with rate of flow and total head for the pump manufacturer to make a proper selection. 1.3.3.2 Process service (chemical, petrochemical, injection) 1.3.3.2.1 Chemical pump Pumps used for handling corrosive liquids or slurries are commonly termed chemical pumps. The materials of construction for the parts in contact with the liquid, including stutfing-boxes or seals, must be selected to offer maximum resistance to corrosion and abrasion at the pumping temperature, with due consideration to the economy of such use. Each application must be carefully scrutinized to determine the severity of corrosion or abrasion, vis- Cosities at the extreme pumping temperatures, the hazard involved in the material to be pumped, changes in the composition of the liquid, true vapor pressure, HI Centrifugal Pump Design and Application — 2000 net positive suction head (NPSH), prolonged operation at or near shut-off, or any other pertinent characteris- tics of the liquid or the application, ‘The physical and chemical properties of materials, the available forms, and methods of fabrication must be considered in the design of satisfactory equipment. Dissimilar materials in contact with the liquid pumped should be avoided unless the combination is one which is known to be satisfactory for the particular service. ‘Special seals or deep stutfing-boxes, with provision for lubrication or sealing by clear cold water, are fre- quently necessary. Large unobstructed liquid pas- sages are desirable. The unit should be designed for easy and quick disassembly for inspection, cleaning or repair. Water jackets, steam jackets, or smothering type glands may be mandatory. The need for these features can be determined only after careful consid- ‘eration of application requirements. ANSVASME B73.1, B73.2 and B73.5 covering specifi- cations for horizontal end suction and vertical in-line Pumps for chemical process may be used for more information, The manufacturer's instructions with reference to installation should be strictly followed. In many cases, such instructions may be radically different from those. for clear water pumps. Regularly established schedules for periodic examina- tion and maintenance are essential, 1.33.22 Hot oil pump Pumps for handling oils within the range of 150°C to 450°C (300°F to 850°F) are commonly termed hot oil pumps. Itis important that sufficient NPSH be available, as the liquid is almost always near the boiling point. Provision should be made to allow self-venting of vapors from the impeller eye by venting the suction eye of the first stage except where the suction nozzle is ina vertical upward position. The stuffing-boxes and bearing housings should be provided with cooling jackets. The glands should be of the smothering type. If packing conditions require seal oil, lantern rings together with the necessary pipe con- nections should be provided. During operation, the"nuuio} uy pesn syun uo puadep iy senjen ‘pasn jou ave suEIUEWG “Syn ujeuu = stun yoybu3 x 10}084 UO|sIBALOD uinjep mojeq 30 HI Centrifugal Pump Design and Application — 2000 sv08'0 u 189) w Joyous enoge eourisip ofne8 uoperorg z t ‘uou uu ‘euou euou wouodxg x vse 05/u puoses/seuou) spa uoweiqHa U AiDo}eA, (ud) @ ep08'0 esi uoses05) sj uodesjiojou! eA * oz urzo sayout-eouno 0-6 sojounuod-wes8 ‘e0upjequn jenpisey n ose’ a 19}-punod uN J9]6u-uoWeN enbioy (ne) 2 6g (2e-de) de woyuaiye soesGop De snjsjeg seei6op emnperoduay 7 1 = ss9|uo|suowp - ‘Ayre16 oyoodg 8 ygHSdN/p,DU = zou - qbesn you = qpesn jou poeds ayioeds tuogong s 2091 aval — yoo} ojqnoyssew punod —guyB———_sayau'o}qno/weIBOp4 Aysueg (ow) 6 erry 3a (2010)) spunod N uoweN ysmayy [eIpey, la L = Sseluo|suswp - ssejuoysusiuip ‘one: jepow se6ury wa 1220 was ‘ejnujuysuoye6 Sr, eu snoyjeyow 91qn9 (Ayoedeo) moy so ory ° ve 101 9898/4 uodes;je94 o19n0 gut snoypiajeut 2}qn9 (Gyoeded) moy jo ore 6 sSrL0 ayy Jemodesioy mt weMoD, Jeod d s68'9 wed yout exenbs/spunod Po reosedoyp4 einssalg q t — ‘ss9juo|suoUp = ssojuoisueuyp alpve=id x“ o06'z6 288/4 —pucossyporenbs joj sj, —_oas/pexenbs sejewuu! ‘Aysoosin onewoUry (ou) « zone = ghesn jou — qpesn jou wicHlz4DU= SN peads oyjoads SN eroe'0 u 389) w Jejeu PouinBes peoy uopons omnjsodioN WHEN ‘y08'0 u 129) w sojou! siqeyene pesy uonons enusodieN — VHSdN L wc ‘e;nujuysuonnjonas wd fenuuyysuowinjonos peeds u roe" u 1894 w Jejour oni 1 1 - ‘ssojuoysuewip = Joy9e} snuuy eIpER x ev0e0 u 094 w Peoy (eIoL H sr0e'0 u 89 w PeeH 4 evar 1004 o/qno/spunod 1yBiem oypoadg (ewes) 4 aroc'o P95; —_pasenbs puosesjos, =, ss perenbs puoses eye uoqeieja00e feuoNe} AED 6 b % queoied % tusoied a (eo) b = ssajuojsueuip = ssejuojsueusp eousiayia, (euep) v vse se4ou wus s3}0weIg a L ssojuorsuot — ss9luo|siounp ‘oes e040 10 J8}9)4 (e109) 4 z'svo ‘se4youl exenbs uu Jojoumiua exenbs eon v ~OIe}—_uOREINeIGaY yun EWOIENg SA uOHeINeNagy un ouey way TequrS Uojsienuog) sjoquiAs — Le"L e1qe,HI Centrifugal Pump Design and Application — 2000 Table 1.3.2 — Subscripts Subscript Term ‘Subscript Term Subscript Term 1 Test condition or a Gauge 8 Suction model 2 Specific condition max Maximum t Theoretical or prototype a Absolute min Minimum v Velocity atm Atmospheric mot Motor vp Vapor pressure b Barometric ot Operating temperature w Water 4 Discharge OA Overall unit dvr Driver input Pp Pump seal oil pressure in the lantern ring should be held to a minimum of 175 kPa (25 psi) above stuffing-box Pressure. Mechanical seals must be chosen specifi- cally for the oil, temperature, pressure and speed. ‘The materials used for the construction of hot cil pumps should have a uniform coefficient of expansion and should be selected with particular reference to the Corrosive nature of the oil, as well as the actual pump- ing temperature, Due to the high pumping temperature, the support of the pump should be arranged in such a manner as to Permit expansion of the pump casing without adversely affecting the coupling alignment. API Standard 610 Centrifugal Pumps for General Refinery Service may be used for more information, {tis important that the suction and discharge piping be Supported to avoid pipe strains being imposed on pump nozzles. The unit must be aligned at the operat- ing temperature, 1.3.3.2.3 Volati liquid pump Pumps for handling volatile petroleum products, or other liquids having similar properties, are commonly termed volatile iquid pumps. The determination of the net positive suction head available (NPSHA) for pumps handling volatile, multi- component liquids such as gasoline should be based, whenever possible, on the true vapor pressure of the Particular liquid at the actual pumping temperature. The NPSH required by a pump at a given flow is a function of the individual pump proportions and of the liquid pumped. The NPSH available must exceed the PSH required by the pump and can be established correctly only when the true vapor pressure is known, For refinery process applications, the true vapor pres- sure is usually available. For the pumping of finished Petroleum products, the Reid vapor pressure is usually the only information available. This is the vapor pres- sure determined by the use of apparatus and proce- dure corresponding to the ASTM Standard D-323, Because of certain inadequacies of the test proce- dure, Reld vapor pressures are generally significantly lower than the true vapor pressures. Precautions must therefore be taken when the NPSH available must be determined on the basis of the Reid vapor pressure. if the commercial grade of the liquid handled is known, the use of one of the standard handbook correction charts for conversion of Reid vapor pressure to true vapor pressure is indicated. Also, see Section 1.3.4.1.16.4 and Figure 1.69, The suction piping should be arranged to avoid any ‘accumulation of vapor and provision should be made: {o allow self-venting of vapors by venting the first stage. ipeller suction eye, except where the suction nozzle 's in a vertical position and facing upwards. Since the suction pressure may vary over a wide range and the liquid pumped is frequently flammable or toxi, the stuffing-box may require the use of a mechanical ‘Seal, oF, if packed, the use of one or more of the follow ing elements: water jacketing, bleed-off connection, lantern ring for an oll or grease seal, or smothering. ‘ype gland.HI Centrifugal Pump Design and Application — 2000 The materials of construction should be selected with due regard to any corrosive action of the liquid pumped. 1.3.3.3 Transfer pumping This service is normally a part of a process where a fluid is transferred from one location or process to another in a given plant. The type of pumps used will vary with the duty involved as will construction details and materials of construction. 1.3.3.4 Mine dewatering Pumps used for handling acid or gritty mine water and! or abrasive mixtures, slush, etc., are commonly termed mine pumps. ‘The pump should be liberally designed, with a heavy casing wall having ample corrosion allowance, and with provisions to keep corrosive liquids from the pump shaft. The design should provide for easy renewal of parts subject to corrosion or wear. ‘The materials of construction for parts in contact with the liquid pumped must be selected for maximum, resistance to corrosion and erosion, 1.3.3.5 Well pumping Installation of centrifugal pumps with the suction sup- ply water in a well below the ground surface on which the pump is located is possible when the pumping water level is close enough to the pump for atmo- spheric pressure to provide the pump's NPSH required. The “draw down” of the well must be known atthe pump's maximum rate of flow. For a pump that is not self-priming, the suction pipe may be equipped with a foot valve, or an ejector may also be used to fill the suction pipe and pump casing. Automatic unat- tended operation is rarely successful with the installa- tions as described unless automatic priming systems ate installed. A self-priming pump's casing must be filed with water before it is started. itis important to ensure that air leaks in the suction pipe are virtually eliminated for satisfactory operation. 1.3.3.6 Irrigation service Centrifugal pumps in this service provide water either {© open ditches for gravity flow to the points of applica- tion or to sprinkler systems of various types. The suc- tion supply varies; it can be a well, a pond, a lake, a river or stream, or a distribution main under pressure (Sometimes from a vertical pump). The pump may be of the single suction or double suction type, with the impeller enclosed or semi-open. A suitable suction strainer is normally used to avoid clogging problems in either the pump or the sprinkler system. Single stage pumps normally supply the necessary head. Packing or mechanical seals may be used, Drivers are nor- mally either induction motors or internal combustion engines. 1.3.3.7 Pumps for steam power plants 1.33.7.1 Steam electric power plants Steam power plants convert nuclear energy or organic ‘energy, in the form of coal, oll or gas, into electrical energy through the generation and expansion of steam from a high pressure to a low pressure in a prime mover, typically a steam turbine. When the elec- ‘tical output of the generating plant is distributed for general sale, the plant is referred to as a central sta- tion. If the plant is operated by a manufacturing com- Pany that takes the output for its own use, itis referred fo as an industrial plant. Figure 1.47 diagrams a simple steam power cycle. A oncondensing plant discharges the steam from the turbine at an exhaust pressure equal to or greater than atmospheric pressure. A condensing plant (as shown in Figure 1.47) exhausts steam from the turbine into a condenser at a pressure less than atmospheric pres- sure. Central station plants are condensing plants because their sole output is electric energy. A reduc tion in the exhaust pressure at the turbine decreases tho amount of steam required to produce a given quantity of energy. Industrial plants are noncondensing Plants because large quantities of low pressure steam are required for manufacturing operations. The power required for operation of a manufacturing plant may be obtained as a by-product by generating steam at high Pressure. This steam is expanded in a prime mover to the back pressure at which the steam is needed for manufacturing processes, Figure 1.48 diagrams a coal-fired, condensing-type steam power plant, and identifies major plant compo- ents. The steam generating unit consists of a fur- nace, in which the fuel is burned, a boiler, superheater, ‘and economizer, in which high-pressure steam is gen- erated, and an air heater in which the loss of energy due to combustion of the fuel is minimized. The boiler ‘consists of a drum and a bank of inclined tubes con- nected to the drum. A water level is maintained at about the midpoint of the drum to permit separation of the steam from the water. Water circulates from the drum through the tubes and back to the drum, Part ofHI Centrifugal Pump Design and Application — 2000, Turbine Steam a Condenser == soter raatng um Conlrsate nine solar Feed mre Figure 1.47 — Diagram ofa simple stoam power cycle Five gas to chimney. oust cr as L Forced tan —+(©)-> rain Air Airheater = | aie sat Salers, eT z Be esse [tem | NG ce y ‘ oneal ce Tost Kcporteater | fron hosts : Sx a Furdeo Fooder 2] Fuel = Condenser Bet ‘Burner feed [Condensate Condenser vn oe eae river | [tng Puverzer River water Softenea _} vel ump anid a her Figure 1.48 — Diagram of a typical condensing steam power plantHI Centrifugal Pump Design and Application — 2000 the water in the tubes is evaporated by the flow of fur- ace hot products of combustion across the tubes. ‘The furnace walls are lined with tubes that are also connected to the boiler drum to form very effective steam generating surfaces. The steam separated from the water in the boiler drum flows through a super- heater (essentially a coil of tubing surrounded by the hot products of combustion). The temperature of the steam increases in the superheater to as much as 425 to 600°C (800 to 1100°F) before it is piped to the turbine, ‘An economizer may be used to recover part of the energy in the gaseous products of combustion that leave the boiler tube bank at a relatively high tempera- ‘ure and discharge to the chimney. The economizer consists of a bank of tubes through which the boiler feedwater is pumped on its way to the boiler drum. This feedwater will be at a temperature considerably below that of the water in the boiler tubes. The temper- ature of the products of combustion may be reduced in the economizer to less than the boller exit-gas temper- ature. A further reduction in flue gas temperature can be achieved by passing the products of combustion through an air heater (heat exchanger) cooled by the air required for combustion, This air is supplied to the air heater at normal room temperature and may leave the air heater at 200 to 315°C (400 to 600°F), thus returning energy to the furnace which would otherwise be wasted. The products of combustion are usually Cooled in an air heater to an exit temperature of 135 to 200°C (275 to 400°F), after which they may be passed through a dust collector (to remove objectionable dust) and an induced-draft fan to the chimney. The function of the induced-draft fan is to pull the gases through the heat transfer surfaces of the boiler, supetheater, econ- comizer and air heater and to maintain a pressure in the furnace that is slightly less than atmospheric pressure (to eliminate leakage into the boiler room). A forced- draft fan forces the combustion air to flow through the air heater, duct work and burner into the furnace. If both a forced-draft fan and an induced-draft fan are used in combination, the system is called balanced draft The diagram of a condensing steam power plant (Fig ture 1.48) shows the coal being fed into the system by use of an overhead raw-coal bunker, where it flows by gravity through a feeder. in the pulverizer, the coal is ground to a fine dust. Some of the hot air from the air heater is forced through the pulverizer (mill) to dry the Coal and pick up the finely pulverized particles and carry them in suspension to the burner. They are then mixed with the air required for their combustion and discharged into the furnace at high velocity to promote 900d combustion. The high-pressure, high-temperature steam from the boiler is expanded in a steam turbine which is connected to an electric generator. Three to 5 percent of the output of the generator is needed to light the plant and to operate the motors required for Pumps, fans, etc. in the plant. In a central station plant, the exhaust steam from the turbine is delivered to a condenser to turn it into water at the lowest possible pressure. The condenser is a large, gas-tight chamber filled with tubes through which cold water is pumped. For normal operation, 728,000 kg (800 tons) of cooling water are required in the condenser for each 900 kg (1 ton) of coal burned in the furnace. This means that large power plants must bbe located on lakes, rivers or on the seacoast. Turbine ‘exhaust steam is condensed because: * _ itwas distilled in the boiler and is, therefore, free of scale-forming material and should be retained in a closed system, + the efficiency of the plant is increased substantially by reducing the exhaust pressure at the turbine to as low a pressure as possible. in the exhaust pressure reduce the coal consump- tion of the average plant by as much as 4 to 5 percent. Condensed steam, which is at a temperature of 22 to 38°C (70 to 10°F), is pumped from the condenser by @ condenser hotwell pump and discharged through several feedwater heaters to a boller feed pump which delivers water through an economizer to the boiler Figure 1.48 shows a high-pressure heater, an interme= diate-pressure heater and a low-pressure heater, all supplied with steam that extracted from the turbine at appropriate pressures after having done some work by ‘expansion to the extraction pressure in the turbine. Theso are closed heaters. Figure 1.49 diagrams a closed feedwater cycle whore the boiler feed water flows through tubes in the heaters and never directly contacts the steam extracted from the turbine. The Condensed steam in a closed heater is collected and returned to the boiler water system (see Figure 1.49). Direct contact heaters would have thermodynamic advantages, but a separate pump would be required for each heater. The use of a group of closed heaters (as in Figure 1.49) permits a single boiler feed pump to discharge through all the heaters and into the boiler. Many power plants are based on a compromise sys- tem which uses one direct contact heater (which also provides for feedwater deaoration) and several closed- type heaters located both upstream and downstream ( (HI Centrifugal Pump Design and Application — 2000, of the direct contact heater and the boiler feed pump. _used, the closed cycle system uses either the con: Such a cycle is termed an open cycle ands diagrammed denser hotwell or a separate vessel for deaeration, All ) in Figure 1.50. Wen no dtect contact hoster mre the heaters are of the closed type. ==> stoam —> water Generator (Closed (Closed (Closed Closed Heater Pe] Heater bay Heater Heater Nod Nos No.2 Not 5 Boiler Feed Pump Figure 1.49 — Diagram of a closed feedwater cycle ==> steam Water Generator Lt treater Heater Goriact et eater No.4 No.3 No.2. Not LJ Bolte Feed Pump Figure 1.50 — Diagram of an open feedwater cycle with one deaerator and three closed heatersHI Centrifugal Pump Design and Application — 2000 1.3.3.7.2 Power plant pumps ‘There are dozens of pump applications in conventional (fossil fuel) steam power planis, Most of these applica tions fall into the “miscellaneous” category, which includes such services as chemical feed, fuel oil, lubri- cating oil, fre protection, heating/ventilating/ai-condi tioning, service water and support systems (such as ash sluicing, acid cleaning and hydrostatic pressure test pumps). The major categories include boiler feed, boller feed boosting, condensate, condenser circulat- ing, boiler circulating, and heater drain, 13.3.7.3 Boiler feed pumps ‘The type of boiler feed pump required by a generating plant is determined by the maximum boiler flow (capacity), the suction conditions (NPSHA), total pres- sure (head) required to be generated, and the operat- ing temperature, For low flow, low-pressure boiler feed systems, it may be possible to fulfil flow and head requirements with a single stage pump. In most cases, pressure (head) requirements are such that multistage pumps are nec- essary. In these cases, the pump can be one of sev- eral types and construction: + Low. to medium-pressure/temperature systems ‘may require a pump of ring-section construction, where the individual stages are made up of impel- lers and segmental rings (or casing sections, Which include collectors to lead the flow from one stage to another), held together with tie rods. End heads contain the pump suction and discharge nozzles (see Figure 1.21 in ANSVHI 1.1-1.2) * Medium-pressure/temperature systems may require axially split or ring-section pumps. Axially split Pumps, unlike the ring-section pumps described above, may be of either back-to-back or in-line impeller construction and use cast casings, the lower half of which contains the pump suction and discharge nozzles. These pumps can be of either diffuser or volute construction. A back-to-back impeller pump design with volute construction is shown in Figure 1.20 in ANSVHI 1,1-1.2. + Higher pressure/temperature systems require the use of pumps with confined, controlied-compression gasketed joints. This can be accomplished by selecting pumps of either barrel or ring-section design to ensure containment of the high-pressure/ high-temperature boiler water, and to resist the considerable nozzle loads that can be imposed on the pump as a result of temperature changes. Barrel-type pumps (see Figure 1.22 in ANSI/HI 1.1-1.2) are often chosen for ease of maintenance and the double case construction feature. The user must determine the pump type that is appro- priate for the system. Such decisions as pump con- struction (axially spit, radially split casing, ring-section or barrel casing), rotor construction (back-to-back rotor arrangement or in-line rotor arrangement, with balance drum or balance disk), bearing type and pump support system requirements are usually made in conjunction with the pump manufacturer and take into account the manufacturer's specific installation and service experience. ‘A key factor in pump selection for demanding boller feed service is rotor hydraulic axial balance. Two types of rotor construction need to be considered: in-line impellers and opposed impellers. With in-line impek lers, the hydraulic axial thrust of the impellers is usu- ally countered by a balancing device: either a balance disk or a balance drum, or sometimes a combination of both, ‘The advantages of a balance disk design may include reduced leakage (better volumettic efficiency) and the ability of the disk to compensate for wear and the amount of thrust that requires balancing. The disk is referred to as a “self-compensating” balancing device, and may be utilized to exclude an axial thrust bearing in certain designs, thus reducing inital cost and simpli- fying rotor construction and assembly. The balance drum does not compensate for changes in thrust imposed on it, and it typically exhibits more leakage loss than a balance disk. The advantage of the balance drum over the balance disk is in the open- ness of its running clearance. For pumps in systems whore severe upsets may occur, or where foreign material is continuously present, balance drums (with their larger running clearances) may prove less sensi- tive (less susceptible to damage) than balance disks Bearing types vary from simple rolling element bear- ings (either ball or roller) to more sophisticated hydro dynamic versions which require support lubrication systems. Ball and roller bearings are usually selected for pumps with power requirements less than 1500 horsepower up to 3600 rpm. Pumps operating at higher speeds or higher horsepower are usually equipped with hydrodynamic radial and thrust bear- ings with force-feed lubrication support systems. (1.3.3.7.4 Boiler feed booster pumps Boiler feed booster pumps are used to provide pres- sure to the feed pumps to meet their NPSH require- ments and avoid cavitation. As the sizo and speed of boiler feed pumps has increased, the NPSH require- ments have increased as wall. It is not practical to install the direct-contact heaters from which feed Pumps take their suction at sufficient elevation to pro- vide adequate NPSHA without “boosting” the suction Pressure to the feed pumps. The suction pressure is, increased by utilizing low speed booster pumps ahead of the feed pumps. Boiler feed booster pumps are generally of the single stage, double suction design (refer to ANSVHI 1.1-1.2 Figures 1.18 for axially split case and 1.19 for radially split case versions of this design configuration) and operate at lower speeds than the feed pumps, typically at four-pole motor speeds. The NPSH required by the booster pumps is much lower than that required by the food pump it supplies. It is not unusual for the NPSH requirements of large, high speed boiler feed pumps to be in excess of 60 m (200 ft). Such requirement is much more than could be economically provided by elevation differences from feedwater heater placement to the feedwater pump. 1.33.7.5 Condensate pumps Condensate pumps take suction from a condenser hotwell and discharge either to a deaerating heater in an open feedivater system (see Figure 1.50) or directly {o the suction of a boiler feed pump in a closed system (see Figure 1.49). Condensate pumps operate at very low absolute suction pressures. Because it is desirable to locate the condenser hotwell as low as possible to inimize the elevation of the power plant, the NPSH available is usually extremely low. This may require the use of a deep pit for the condensate pump. The NPSHA, with absolute pressures in the condenser near zero, is only the submergence (or elevation) between the water level in the condenser hotwell and the centerline of the pump impeller (frst stage impeller {for multistage pumps). This value could be as low as 0.6 to 1.2 m (2 to 4 ft), which means that friction losses between the condenser hotwell'and the pump suction must be kept to an absolute minimum to avoid reduc- ing NPSHA. further. To minimize friction losses, calcu- lated velocities in the suction piping and within the suction can of vertical pumps should be no more than 1.2 mis (4 tus). Condensate pumps can be either horizontal or verti- cal, single or multistage, depending on the system HI Centrifugal Pump Design and Application — 2000 head requirements. Because of the low NPSHA, hori- zontal pumps operate at relatively low speeds, from 1800 rpm for low flow requirements to 900 rpm or even less for higher flow requirements. Vertical can-type Pumps (see Figure 2.6, ANSVHI 2.1-2.2), which can ‘be installed below ground and attain higher values of submergence of the impeller (higher NPSHA), can ‘operate at higher speeds. Vertical can-type pumps are available with single and double suction first stage impellers and typically operate to 3600 rpm for low flow applications and 1200 rpm for higher flow require- ments. Condensate pumps are designed or arranged ‘such that they have discharge pressure (or at least a Positive pressure above atmosphere) on the seal ‘chamber (or stuffing box) to prevent air from entering the pump. If desired, pressure can be reduced through a throttle bushing at the bottom of the stuffing box and through an orifice back to suction. To prevent air leak- age into an idle pump, the seal cages of multipe pumps can be piped together and connected to a com- ‘mon pump discharge header. It is standard practice to vent the suction chamber back to the condenser above the water level to minimize vapor entrainment. 1.3.7.6 Condenser circulating pumps Condenser circulating pumps take cool water from a ‘iver, lake, stream or a cooling tower basin and circu- late it through the condenser to condense exhaust steam from the main turbines. The pumps work against low to moderate heads (typically from 25 to 45 m [80 to 150 ft) and are installed to operate in par- allel. These pumps can be added to of removed from service as heat load and demand for cooling water varies (a function of ambient temperature and plant load). Circulating pumps may be of either horizontal or verti cal construction. The horizontal circulating pumps are low speed, axially split, single stage, double suction volute designs (see ANSV/HI 1.1-1.2 Figure 1.18). They are located in a dry pit which allows full access for servicing, dismantting and inspection. The vertical circulating pumps are of wet pit design (see ANSI/HI 2.1-2.2 Figures 2.8 and 2.9), which means they are fully submerged in the water pumped. They employ a Jong pipe column: which supports the submerged Pumping element and the vertical driver is mounted on the top. Some vertical wet-pit designs allow removal of the pumping element without dismantling the pump casing or piping; these are referred to as “pull-out” designs. An alternative to the wet pit design is a dry pit, where the vertical pump operates surrounded by air. Single stage double suction pumps (as shown in ANSVHI 1.1-1.2 Figure 1.18) are sometimes mountedHI Centrifugal Pump Design and Application — 2000 vertically in a dry pit as well. Actual pump type selec- tion is determined by plant layout and the experience of the plant designers and operators. 1.3.3.7.7 Boller circulating pumps Boiler circulating pumps circulate water within the boiler to enhance boiler operation. They take suction from a header connected to several downcomers from the bottom of the boiler drum and discharge through additional tube circuits. This means the water pumped is at boller temperature and pressure. The pumps must devolop only enough head to overcome the ftic- tion of the tube circuits. Boiler circulating pumps are designed for high temperature (usually between 150 and 315°C (00 and 600°F], depending on boiler size and rating), and high pressure (corresponding to boiler temperature and water vapor pressure). This combina- tion of high temperature and pressure results in seal ing conditions that require special sealing devices. For small boilers, with relatively low temperatures and pressures, conventional overhung pump designs (see Figure 1.14) may be suitable for boiler circulating ser- vice. Because of the relatively low head requirements, the pumps are single stage with single suction impel lors and a single seal chamber. This creates a problem of unbalanced axial thrust which may require special Pump bearing systems or balancing arrangements. A Solution is to utilize pumps of wet motor construction, Where the pump and the motor are inside the pressure vessel, eliminating sealing and unbalanced axial thrust issues. These special pumps are welded into the boller piping. For higher temperatures to 365¢C (685°F) and pressures from 12,400 to 19,200 kPa (1800 to 2800 psi), special pump designs are required. 13.3.7.8 Heater drain pumps Condensate from closed heaters (see Figure 1.49) is cascaded from the heater drain to the steam space of 8 lower pressure heater where it is flashed to steam. Atter the lowest pressure heater, the condensate in the heater drain is pumped back into the feedwater cycle. Because the pump takes suction from the heater hotwell where the pressure is low, this service is referred to as “lovepressure” heater drain service. In an open feedwater cycle, the drains from heaters located beyond the deaerator are cascaded back to the deaerator. The deaerator is located above the closed heaters and *high-pressure” heater drain pumps are used to transfer these drains to the deaerator and overcome static head and system frictional losses. 10 High-pressure heater drain pumps are subjected to more severe operating conditions than even the boiler feed pumps. Their suction pressure and temperature are generally higher, and the available NPSH is gener- ally limited. They experience more severe transients than the feedwater pumps, primarily because of the extremely limited NPSHA. Heater drain pumps are low speed, heavy duty designs. They may be either single or multistage, depending on pressure and flow require ments of the particular system. Single stage end suction pumps of the heavy duty process type (see ANSU/HI 1.1-1.2 Figure 1.14) are popular for both low and high Pressure services. Where NPSHA is very low, or head requirements exceed that of a single stage pump, ver- tical can pumps (see Figure 2.6, ANSVHI 2.1-2.2) are. ‘sometimes utilized. Heater drain pumps are vented to fan appropriate heater steam space to release any entrained vapors. NOTE: Pump types other than those discussed may be suitable for the various applications highlighted. 1.3.3.8 Fire pumps Pumps currently used today for fire protection in build- ings are of the centrifugal variety and provide water to ‘a sprinkler and/or standpipe system. NFPA (National Fire Protection Association) issues a document titled “Standard for the Installation of Centrifugal Fire Pumps,” which provides a national guideline for the selection and installation of centrifugal pumps for fire protection. A “Technical Committee on Fire Pumps,” consisting of a broad range of interested parties involved with fire protection, reviews and updates this document (referred to as pamplet NFPA-20) on a three-year cycle, NFPA published its first standard for automatic sprin- Kfers in 1896, and through the workings of the "Techni- cal Committee on Fire Pumps,” each edition of NFPA-20 has incorporated appropriate provisions to cover new developments and has omitted obsolete Provisions. NFPA-20 1996 has been approved by ANSI and is used not only as a national standard but is accepted internationally as well. Information provided within the NFPA-20 standard regarding the installation requirements for centrifugal fire pumps is based upon sound engineering princi- ples, test data, and field experience. The standard includes single stage and multistage pumps of hori- zontal or vertical shaft design with guidelines being established for the design and installation of these Pumps, pump drivers and associated equipment. (’ Fire pumps have rated flow rates ranging in discreet flow ingrements from 6 mh (25 gpm) through 1135 mn (5000 gpm), with net pressures starting from 275kPa (40 psi) and curently progressing through 4410 kPa (640 psi). In order for a centrifugal ump to be used as a fire pump it must meet stringent mechanical and hydraulic requirements witnessed and certified by Underwriters Laboratory (UL) and Factory Mutual (FM), two independent testing agencies, These testing agencies have established (with input from industry experts) certain engineering requirements that a pump must be capable of meeting before it can be listed or approved as satisfactory for fire service, The “Authority Having Jurisdiction” (AH) is the organi- zation, office, or individual responsible for approving equipment such as a fire pump when used for the pro- tection of life and property. Double suction axial split case pumps, close-coupled vertical in-line pumps, and horizontal end suction Pumps can be used for alll fire pump ratings 57 m°/h (250 gpm) and higher. If an installation has a static suction lif, then a vertical turbine type pump must be utlized. The primary drivers for fire pumps are electric motors or diesel engines and almost all are started automatically, 1.3.3.9 Pumps used as hydraulic turbines Centrifugal pumps of all sizes, types and specific speeds may be operated in reverse rotation as hydrau- lic turbines. While running in the turbine mode, the performance characteristies of a PAT (pump as turbine) differ signif cantly from pump operation. See Figure 1.51. The applied head is usually constant, so the other parame- ters are shown as they vary with speed. The discharge nozzle of the pump becomes the inlet of the turbine, the suction nozzle of the pump becomes the outlet of the turbine, and the impeller of the pump, rotating reverse direction, becomes the runner of the turbine. Tho impeller orientation to the casing is the same for both pump and turbine. Reverse running pumps are an excellent alternative to Conventional turbine designs. A common application is hydraulic power recovery turbines (HPRT). The poten- tial for power recovery from high-pressure liquid streams exists any time a liquid flows from a higher Pressure to a lower pressure in such a manner that throtting occurs. Reverse running pumps are used instead of throtting valves to recover the power in the high-pressure liquid, HI Centrifugal Pump Design and Application — 2000 ‘The installation costs for PATs are about the same as for an equivalent pump, and reliability and maintain- ability are also comparable. Because the efficiency of a pump operating as a turbine is comparable to the pump efficiency, the use of reverse running pumps as primary or secondary drivers becomes quite practical. Pumps operating as turbines are classified by their tur- bine specific speed (NST), which is a quantity that governs the selection of the type of runner best suited {for a given operating condition, pos a NST = mx Ts Where: NST = Turbine specific speed fa = Revolutions per minute P, = Developed power in kW (hp) at best offi- ciency point (BEP) H, = Net head in meters (feet) per stage across the turbine The values of NST will be slightly different between a Pump operating as a pump and the same pump oper- ating as a turbine. The rate of flow and total head at BEP will be greater for the turbine operation than for a ump operation. The amount of shift from pump por- formance depends on the specific speed and other design factors. ‘TOTAL HEAD CONSTANT 8 Rate of Flow Efcieney & 8 8 Powor—% MAX ° 100% ‘Speod ~ % Full Spoed RPM Figure 1.51 — Turbine characteristics "HI Centrifugal Pump Design and Application — 2000 For preliminary selection, a rough approximation pro- cedure can be used to estimate the turbine perfor- ‘mance from known pump performance. 2 a H, a, = fe a Where: Q = Rate of flow as turbine Q, = Rate of flow as pump Hp = Total head as pump Hy = Total head as turbine 1 = Efficiency Most centrifugal pumps are suitable and capable of operating as turbines. Because of the reverse rotation, bbe sure that the bearing lubrication system will operate in reverse, and threaded shaft components, such as impeller locking devices, cannot loosen. The power output is the rotational energy developed by the reverse running pump. Its value is calculated in a similar manner as for a pump except for the place- ment of the efficiency term, Qx Hxsxn; Metric Pp, = ts QxHxsxn, IS = t Usunits P, RE Where: P, = Power output from turbine - kW (hp) Q = Rate of flow.~ m/hr (gpm) H = Total head in meters (feet) Specific gravity Tr = Efficiency of the turbine 12 Special care should be taken in PAT applications to ‘ensure that the mechanical design of the unit will allow Sato operation. Fequenty these applcatons subject the PAT to increased mechanical stresses, torque, and. speed levels beyond original pump design values. Additionally, the turbine characteristics are such that both hydraulic forces and torsional stresses increase with increasing rate of flow. All pumps applied as tur- bines should be subject to a careful calculation of combined stresses in shafts. Pumps operated in reverse as turbines tend to have relatively narrow operating bands compared to vari- able nozzle turbines. At constant speed, the power developed and efficiency drop to zero at approximately 40 percent of the hydraulic turbine best efficiency rate of flow. See Figure 1.52. Energy must be added to the hydraulic turbine in order for it to rotate at the constant speed below this rate of flow. Changing the impeller diameter has little effect on adjusting the performance of a hydraulic recovery turbine. These facts, coupled with the difficulty in predicting hydraulic turbine perfor- mance from pump performance, results in some uncertainty when applying a pump to a power recov- ery turbine application unless actual test data is avail- able on the specific pump running in reverse as a turbine, Prat about ao be akan to ensue tat te PAT will operate without cavitation. The turbine indus- tty typically uses the terminology TREH (total required exhaust head) and TAEH (total available exhaust head) in place of NPSH. Total exhaust head is defined ‘SPEED CONSTANT | 8 z Head, Power, Ecionoy Se ° 30 700% Rate of Flow ( Figure 1.52 — Turbine performanceas the total fluid energy at the impeller eye less the ‘vapor pressure of the fluid, ‘Some of the other factors which affect the use of Pumps as turbines are: + Runaway speed ‘+ Rate of flow at runaway speed + Required solids passage + Fluid-bome abrasives * Torque reversals during start-up or shut-down + Overspeed trip and control 1.3.3.10 General purpose service 1.3.3.10.1 Self-priming pump ap; Self-priming pumps are designed to have the following abilities: to prime themselves automatically after being initially filed, when operating under a suction lift; to free themselves of entrained gas without losing thei rime and to continue normal pumping without atten- tion. Pumps in this class usually have single inlet impellers. Self-priming centrifugal pumps have these additional features when compared to a centrifugal pump: * A reservoir, either integral with or external to the volute and impeller, to retain priming liquid. This reservoir is filed during the initial prime of the Pump. The suction line itself is not filled, When the Pump completes a pumping cycle and shuts down, the reservoir retains liquid for the next priming cycle. * A means of recirculating liquid. The majority of modern self-priming pumps have integral reser- voirs with internal recirculation, the most common being the recirculation from the pressure side of the volute back to the periphery of the rotating Impeller. A less common method of recirculation directs the priming liquid back into the suction side of the pump. ‘+ An integral suction check valve to prevent the loss Of liquid in the suction leg is common in many designs. Some designs allow for check valve fail- lure due to debris-laden water and will reprime with residual amounts of priming liquid, HI Centrifugal Pump Design and Application — 2000 Sel-priming can also be accomplished in diffuser design centrigugal pumps used primarily for clear liq- uids. Closed impellers with suction side wearing rings can also be used. Self-priming centrifugal pumps are commonly placed up to about 8 meters (25 feet) above the liquid level of the source. All suction connections must be air-tight. During initial start-up, the impeller rotation causes the liquid in the impeller and suction side of the pump res- ervoir to be forced to the discharge cavity via centritu- gal force. Differential pressures cause the priming recirculation to start. The priming action reduces pres- ‘ure in the impeller eye and allows atmospheric pres- ‘sure on the liquid source to fil the suction line, During priming, air in the discharge chamber sepa- rates up and out from the mixture while the heavier water continues to recirculate. It is important that the air in the discharge chamber have a means to escape either through the discharge pipe or an air release valve. This process continues to draw air from the sub- ‘merged suction line until itis full of liquid and the pump goes to normal pumping. ‘The different designs of self priming pumps have lim- lted and varied capabilities of priming against charge heads. When a discharge check valve is used, or the discharge design can form a pressure trap, air release lines or valves may be necessary to get rid of air from the suction side. Selt-priming centrifugal pumps are frequently used for unattended service in industrial, construction dewater- ing, waste water and agricultural applications where manual priming is not practical during operation. Most pumps are designed to accept the major modern drive sources through direct drive, flexible coupling or bolt drives. The materials of construction are usually cast Iron, steel, stainless steel or bronze, depending ‘on the application, Many manufacturers of selt-priming pumps build units to conform to the specifications established by the Contractors Pump Bureau, an arm of the Construction Industry Manufactures Association (CIMA). See Fig- ure 1.53. In these cases, the pumps may carry a CPB rating decal and are built to conform to CPB specifica- tions. Other manufacturers build pumps that are closer in concept to the Chemical Industry requirements and appear as shown in Figure 1.54. 13HI Centrifugal Pump Design and Application — 2000, 13.3.10.2 Hydraulic pressure pump ‘These pumps are used for supplying water under pressure for scale removal from steel products and for operation of presses, leveling tables, hydraulic press service, elevators, etc. ‘The suction supply should be adequate to prevent Parting of the liquid column during sudden demands for high rate of flow: If this situation occurs, an accu- mulator may be required. ‘The demand is frequently intermittent and the control valves are usually rapid in action. The sudden demand or cessation of demand causes accelerations and decelerations of water in the piping, resulting in pres- sure waves of great intensity, These waves are famil- jarly called *shock" or “water hammer.” The waves originate at the point of valving and travel back through the line toward the pump. To protect the pump against damage from shook, an air-ballasted alleviator is recommended. The alleviator should have a free liquid surface against which the shock waves cannot by-pass the alleviator. Alleviators mounted on side outlets of tees are of little value. 1.3.3.10.3 Sanitary pump Pumps designed to handle foodstuffs and beverages are commonly called sanitary pumps. The materials of construction for parts in contact with the liquid Pumped, including the stuffing box or shaft seal, are ‘selected to prevent bacterial, chemical, color, or taste contamination. Materials such as stainless steel, monel, porcelain, glass, ete., are frequently used. San- itary pumps are constructed to permit ready access for cleaning, flushing, and draining. If the liquid to be Pumped contains solids, the maximum size solid must be specified, ‘The user is cautioned that many states prescribe regu- lations regarding sanitary pumps. Adherence to such regulations is mandatory. The responsibility for deter- mining these requirements rests with the user. 1.33.11 Wastewater rvice (solids and non-clog) Pumps designed to assure maximum freedom from. clogging when handling liquids containing solids or stringy materials are commonly called non-clog ‘pumps. They are also designated as sewage or trash pumps. r+ —_— Figure 1.53 — Self-priming pump — construction industry 14Non-clog pumps are recommended for handling raw or unsettled sewage, activated sludge, industrial waste waters containing solids, and similar liquids where excessive clogging would otherwise be encountered, The largest solid sizes that the pump will be required to handle in normal operation must be specified. The term “sphere size” denotes the largest diameter ball \which can be passed through the pump. Comminution and/or adequate bar screens must be provided to pre- vent large solids from entering the pump. When used, bar screen openings should be sized to prevent clog- ging from irregular-shaped solids. ‘Storm water and/or domestic sewage may be handled successfully by mixed flow and axial flow pumps, using the preceding guidelines. For domestic sewage service, pumps built to the indi- vidual manufacturer's material specifications are ordi- narily used. Corrosion-resistant and wear-resistant shaft sleeves and wearing rings are desirable for maxi- Ta HI Centrifugal Pump Design and Ap; tion — 2000 mum life. Inspection openings in the casing or adja- cent piping, for access to the impeller, are recommended. Stuffing-boxes may be furnished with mechanical seals or packing, either water or grease lubricated. When water is used for the stuffing-box or wearing ring lubricant or flush, the supply line must be isolated from any potable water system, If the pumpage is corrosive and/or abrasive, the mate- rials of construction for parts in contact with the liquid should be selected for resistance to the effects of the pumpage. 1.3.3.12 Pulp and paper applications 1.3.3.12.1 Paper Stock Consisting of a mixture of water and wood fibers in suspension, paper stock is created by a number of dif- ferent methods, and from a number of different wood varieties. The pumpability of paper stock depends Ws Figure 1.54 — Self-priming pump — chemical industry 15HI Centrifugal Pump Design and Application — 2000 mainly on the characteristics of the raw material and the consistency of the stock. Paper stocks are generally separated into three dis- tinct consistency categories, namely low, medium and high. Low-consistency stock usually refers to a class of products with 1~7% fiber content by weight. These paper stocks are normally handled by end-suction centrifugal pumps equipped with semi-open impellers and contoured wearplates. Medium-consistency stocks are made of 8-15% paper ‘iber. The rheological properties of fiber-water suspen- sions in this range are dependent on the properties of the individual fibers and the viscoelastic network that they form. Special designs of centrifugal pumps are required to handle this type of paper stock. For exam- ple, some form of “shear generator” is needed at the Inlet to create turbulence, and reduce the effective fluid Viscosity. Special impeller design and air-extraction devices are also required to prevent airbinding. ‘An end-suction centrifugal pumping unit must be spe- cifically designed to handle medium-consisteney stock mixtures without clogging the device, or dewatering the stock. A large suction-eye and unobstructed water- ways can be provided by an overhung, semi-open impeller design. This keeps the suction velocity low to Promote smooth flow, avoid air binding and prevent separation of stock fibers from water. The contoured front surfaces of the impeller vanes interface with the replaceable wear plate. This arrangement provides a self-cleaning effect whereby the impeller resists clog- ging to improve its reliability. High-consistency paper stocks contain more than 15%. Paper fiber, and are found in the bleaching operation, Centrifugal pumps cannot handle such high consisten- cies, and therefore, positive-displacement rotary units are used. Proper suction-piping design has to be included to help this high solids mixture to enter the suction cavities of the rotary pump. Normally two-screw or clove-rotor types of rotary Pumps are used for handling high-consistency paper stock. Once the stock has been introduced into the suction area, the positive displacement principle is ‘employed to force the product through the pump, and ut the discharge opening. ‘Special rotor designs and clearances are often used to obtain the mostetfcient pumping action. When extrane- ous material and air are entrained in high-consistenoy 16 Paper stocks, there can be serious difficulty in han- dling these liquids. A thick-wall casing design is used to allow for ample corrosion, and withstand reasonable piping loads com- ‘monly encountered in handling hot stocks. Large shaft diameters and heavy-duty bearings, mounted in a rigid, one-piece bearing frame, improve the unit's reli- ability in difficult services. The impeller-shaft assembly can be moved via an adjustment feature located on the thrust-bearing housing to maintain close clear- ances between the impeller and the wear plate, thus ensuring maximum operating efficiency. Some designs provide adjustability in tho wear plate for the same. purpose. To resist corrosion from the process chemicals, differ ent areas of the paper-making process require differ- ‘ent materials of construction for the equipment. Cast iron, Types 316, 317 and 317L stainless steels, and Alloy 20 are commonly used in units handling paper stocks. These materials can also be used in various combinations to provide the corrosion resistance as well as mechanical strength, 1.3.3.12.2 Hydraulic performance correction ‘The many different paper stocks available and their varied characteristics make it difficult to predict the effect of a given type of paper stock on pump perfor mance. Stil, many tests have been conducted on dlf- ferent pumps and paper stocks to establish Performance correction criteria, to relate water perfor- mance of a pump to predicted performance on various types and consistencies of paper stock. However, for accurate prediction this data is limited to the type of paper stock and type of pump from which the data was. obtained. Testing continues to this day to derive more-accurate correction data. For many applications of mid-sized to large-sized pumps, no performance correction is required for up to 6% stock consistency, Modern data indicates that in some cases, pumps smaller than those previously chosen can be used for paper stocks. Clearly, this data also suggests an improvement in effi- ciency of modern units. Refer to the pump manufac- turer when precise performance correction data is required. ‘While corrections for consistency for up to 6% are not critical, the user must still make sure that air entrain- ‘ment is taken into consideration. Also, optimum suc- tion-conditions and adequate net positive suction head (NPSH) must be available to ensure that the desired ( (Performance will be achieved on the given paper stock. The essential requirement is to get the stock to the impeller. To do so, every effort should be made to keep the suction piping as large and straight as possible, 1.3.3.13 Slurry service Centrifugal slurry pumps may be used for inplant, pro- cess and pipeline applications where heads are not high enough to warrant the use of reciprocating or rotary units. The other factors which affect the selection of centrifu- gal slurry pumps are: — Rate of flow; — Pressure; — Abrasiveness (e., particle size, density, concen- tration, shape, hardness); — Pump Performance (.e., particle size, density, concentration, carrier, viscosity). Pumps are commonly applied for rates of flow from 2 to 4500 msn (10 to 20,000 gpm) with heads up to 90 meters (300 feet) per stage. Pumps may be installed in series for higher head and severely abra~ sive applications. ‘There are many different slurry pump designs avall- able to accommodate various industrial applications. ‘Those applications include the pumping of solids encountered in mineral ore treatment, dredging, sew- ‘age handling, land reclamation, paper manufacture, solids transportation and chemical processing. 1.3.3.13.1_ Performance changes pumping slurry ‘The characteristic performance curve of a centrifugal pump differs from its clear water performance when Solids are included and the flow becomes two phase, , the head and efficiency will decrease. The magni- tude of the reduction and the shape of the characteris- tic curve will depend mainly on solids size, volumetric concentration and density. The pump horsepower will increase directly with the slurry specific gravity, A Nomograph relationship between concentration and Specific gravity for aqueous slurries is shown on Figure 1.55. HI Centrifugal Pump Design and Application — 2000 ‘The pump manufacturer will make allowances in the Pump selection for head and efficiency reduction, pro- vided the slurry characteristics are defined. 1.34 13.2. Non-settling slurries Slurries with a narrow band distribution of small parti- cles where the average size is usually less than 100 microns will be “non-settiing” and behave as a Newto- nian liquid. Standard viscosity correction procedures can be used, provided the apparent viscosity of the slurry is known. See Figure 1.56 for typical perfor mance characteristics. Cv = % solids by volume. Non-setting slurries which have higher apparent vis- cosities such as pastes, filter cakes, etc., should be pumped at lower velocities to minimize friction losses in the system, 1.3.3.13.3 Settling slurries Slurries with a distribution of larger particles exhibit “setting” and the particles and the liquid exhibit their own characteristics, since energy is dissipated due to liquid drag. See Figure 1.57 for typical performance characteristics. The critical factor governing a system handling a watery slurry in which the solids have a much higher specific gravity than the carrier liquid is the settling rate and characteristic. Coarse solids with a high settling rate are carried in a centrifugal pump with many. pre- cautions to prevent plugging, draining and squeeze out. In applying centrifugal slurry pumps to handle setting slurries, one must be certain that the head require- ‘ments of the system above the critical carrying velocity would be met by the pump. If the head produced is insufficient, the rate of flow is reduced and the solids will settle in the fine. Since the head versus rate-of- flow curve of most slurry pumps has little slope, such an increase can make a large reduction in the volume pumped, further reducing the flow velocity and leading to plugging in the system pipe. This situation can usu- ally be avoided by using conservative values for the slurry critical carrying velocity. 1.3.3.13.4 Materials of construction for slurry pumps Pumps designed to resist abrasion are normally made of hard metals (abrasion-resistant cast irons and steels), elastomers or ceramics. As a general guideline, hard metals are often used in applications characterized by 7HI Centrifugal Pump Design and Application — 2000 large, sharp-edged solids, and elastomers for smaller round-edged solids. Either high-chrome irons or elas- tomers are used for their corrosion resistance. In spé cial applications with low head requirements, solid ceramic-lined pumps are used for pumpages contain- ing fine material, ‘Some pump design techniques to minimize wear are: ) Utilize pumping elements which are harder than the hardest sturry particles; 0 sous by Volume ow SSatse by Weight ») °) a) Utilize pumping elernents which combine soft and hard materials in such a fashion as to reduce abrasion and provide resiliency; Increase material thicknesses in areas of high wear; Utilize hydraulic designs with specific speeds of 1400 or less. sm Story ‘Spectic rast Figure 1.55 — Nomograph of the relationship of concentration to specific gravity in aqueous slurries 18 (y 1.3.3.13.5 Rotational speed of slurry pumps ‘Speed is one of several contributors to wear rate. With abrasive solids, wear rate is generally proportional to relative velocity between the slurry and the pump ele- ments to the power of two or three. 8 i 3 £ 2 * ovat iog~ = i oo i Rate of flow igure 1.56 — Typical performance characteristics —non-settling slurries at 4 Head g a 3 i = Water 2 Cy = 15% ‘ent ‘ 3] Water 5] 7 i oe oon : ioe es z Fate of ow Figure 1.57 — Typical performance characteristics — settling slurries HI Centrifugal Pump Design and Application — 2000 Impeller tip speed as distinct from rotational speed is often used as a guide for wear in the selection of slurry Pumps: — for dirty water-type applications, limited to 40 m/s (130 flisec); — for medium slurries up to 25% solids concentration by weight and mean solids size of 200 microns, limited to 35 m/s (118 f’se0); — for slurries with higher concentrations of solids and much larger solids size, restricted to 30 m/s (100 tsec); — pumps fitted with elastomeric impellers are com- monly limited to 26 mis (85 ft/seo). 1.33.14 Liquids with vapor or gas ‘Two phase flow pumping applications include situa- tions where undissolved vapors or gases are being cared by the pumpage. One example is biological- fluid processing, such as the fermentation process Used in yeast production. In this application, the pro- cess liquid is circulated from the bottom to the top of an aerator that injects large amounts of air into the process liquid. The fluid entering the pump may con- tain as much as 50% air by volume. il production from wells often requires the pumping of crude oil that contains large amounts of natural gas mixed with the oil. In many cases, the inlet pressures. for the pump range from 10,000 to 20,000 kPa (1500 to 3000 psi). Other applications are those where the inlet pressure is below atmospheric pressure, As a consequence, air can leak into the system, resulting in gas-liquid mix- tures that must be handled by the pump. Even small amounts of air can cause problems because the air expands substantially under low pressure to increase its volume, particulary at the inlet of the pump impeller. 1.3.3.141 Effect of gas on performance Tho most dramatic effect of gas or vapor on centrifugal Pump performance is the complete blocking of the impeller inlet as the pump becomes “airbound.” When this happens, the impeller acts as a centrifuge, and tends to separate the heavier liquid from the gas that builds up at the impeller inlet. At low rates of flow, the liquid flow cannot even carry the air through the impel- Jer, and the gas bubble grows until it completely fils 19HI Centrifugal Pump Design and Application — 2000 the impelier eye (suction side), The result is complete cessation of liquid flow. Even when small amounts of gas are carried through the impeller, the liquid rate of flow and pump discharge Pressure are reduced (Figure 1.8). This reduction is, the result of the blockage of the flow by the gas, and a reduction in developed pressure due to the reduced specific gravity of the pumped mixture, When the spe- cific gravity of liquid alone is used to convert pressure to head, a lower head measurement is indicated, It can be seen from Figure 1.58 that even with small percentages of air, the unit stops pumping liquid due to ‘accumulated air in the impeller when operating near the shut-off condition of the pump. High velocities at higher rates of flow can carry with it higher percentages of gas. Therefore, when gas entrainment is a potential problem, Pumps should be operatad at or beyond the BEP rate of flow specified by the manufacturer. Inducers or inlet boosters (Figure 1.59) are devices designed to benefit the functioning of the impeller in that they increase the fluid pressure before the mixture enters the pump. This increase in pressure reduces the volume of the ait, thereby reducing its negative effect on the impeller performance. Since inducers generate low levels of pressure, they will have litte benefit on high suction pressure applications. Laboratory tests have shown that pumps with higher specific speed (above 3500 [3,000)) are affected less by the presence of gas than those with low specific speed (below 1150 [1,000]). In some cases, it may be helpful to use a high specific speed booster pump in series with a low specific speed pumping unit in order to minimize the effect of the gas. Total Head 2 34° Percent gas by volume Total Head ‘oO Liquid Rate of Flow Figure 1.58 — Effect of gas on pump performance 20 Open impeliers may handle gas better than closed impellers, particularly with large clearances between the impeller and the casing. The large clearance gen- erates turbulence which helps prevent the accumula- tion of large gas pockets. Another helpful action is to provide a gas vent at the Pump inlet. The suction pipe should be sized about twice as large as the flange at the pump inlet in order to keep inlet velocities low. A vent connection should be located at the top of the pipe, close to the pump so that gas can escape back to the source. It the pump takes suction from a closed tank, it may be Possible to pressurize the inlet, thereby reducing the volume of entrained gas, or turn some vapors back to liquid. Where vapor is the primary problem, subcooling of the inlet pipe may be helpful. This will also tend to turn vapor back to liquid, and thus reduce the volume of free vapor that must be handled by the pump. 1.3.3.14.2 Special designs for vapor or gas Venting the eye of the impeller through the back shroud and eventually back to the atmosphere of liquid source, reduces the tendency of the impeller to be clogged by gas (Figure 1.60). This allows the impeller to accept liquid with a higher percentage of gas. How- ever, this higher gas volume does not actually go ‘through the impeller blades. A top suction impeller (Figure 1.61) is also ettective in venting excess gas. Figure 1.59 — Inducer (Self-priming pumps (Figure 1.53) can handle higher amounts of gas without becoming completely clogged (airbound), especially at low rate of flow. These units will not become airbound because they will revert to the priming mode if necessary and evacuate the air on the suction side. However, they will suffer reductions in rate of flow and head similar to conventional centrifu- gal pumps when operating at higher rates of flow with entrained gas. Rotary pumps, especially the screw-type units, can also handle large amounts of gas because they use Positive displacement and are not subject to the prob- lems caused by the complex fluid dynamics associ- ‘ated with the centrifugal pumping action, The single ‘screw pump is particularly suitable in that it can handle ow viscosity liquids. Many other rotary units, such as gear and vane pumps, depend on the viscosity of the liquid being pumped to lubricate the moving parts. Vent to tonk Figure 1.61 — Top suction impeller HI Centrifugal Pump Design and Application — 2000 1.34 Performance, selection criteria 1.3.4.1. System requirements ‘A pumping system comprises the piping, the valves, the vessels, the flow measuring equipment, and any other conduits through which the liquid is flowing. For a successful pump application, the pump, the sys- tem components and the system must be. properly matched to each other. ‘The requirements for and the characteristics of the system must be determined before the pump can be selected. Modifications to the system may be Needed for compatibility of all components, Some important features of the system are given in the fol- lowing paragraphs. 1.3.4.1.1 Pumps versus system curve A typical simple system and pump curve is shown in Figure 1.62. it will be noted the pump always operates at the intersection point of its head versus rate of flow ccurve with the system curve. With more complex systems, the static head varies as the suction and discharge liquid levels, or pressure, change. Friction head is affected by changes in the piping, valve opening or pipe condition. Similarly, the pump characteristics change if the Pumps are operated at variable speed, or several Pumps are operated simultaneously (see Section 1.3.42.1). All these changes generate new intersection points of the pump and system curves. A complete plot of these Curves Is a very useful tool for the system designer to determine the complete pump operating range. < Syste Fiction head Pump head Total Head ‘Sytem Static head Fate of flow Figure 1.62 — Pump versus system atHI Centrifugal Pump Design and Application — 2000 1.3.4.1.2 System pressure limitation ‘The system must be capable of withstanding the pres- sures at the operating conditions, as well as at any other conditions, which may be reasonably expected. If the system is equipped with a discharge shut-off valve, the piping should be designed for pump shut-off Pressure or protected with a pressure relief valve of adequate capacity. ‘The possibility of pressure surges in the system must also be considered, as it is discussed in more detail in Section 1.3.4.1.4 below. 1.3.4.1.3 Reverse runaway speed Refer to Section 1.4.4.4.4 in Hl 1.4-2000. 1.3.4.1.4 Water (hydraulic) hammer Water hammer is an increase in pressure due to rapid changes in the velocity of a liquid flowing through a pipe line. This dynamic pressure change is the result of the transformation of the kinetic energy of the mov- ing mass of liquid into pressure energy. When the velocity is changed by closing a valve or by some other ‘means, the magnitude of the pressure produced is fre- quently much greater than the static pressure on the line, and may cause rupture or damage to the pump, Piping or fitings. This applies both to horizontal and vertical pump installations. Starting at the closed valve, a wave’of increased pres- sure is transmitted back through the pipe with constant velocity and intensity. When the pressure wave has travelled upstream to the end of the pipe where there 's a reservoir or large main, the elasticity of the com- Pressed liquid and of normal pressure travels down- stream, the flow being progressively reversed as the liquid expands. Ifthe liquid were incompressible and the pipe inelastic, the instantaneous closure of the valve would create infinite pressure. Since itis impossible to close a valve instantaneously, itis apparent that a series of pressure waves is created, thus causing an increased pressure at the valve. If the valve is completely closed before the fist pressure wave has time to return to the valve a8 a wave of low pressure, the pressure increases Continuously up to the time of complete closure, and the resulting pressure is the same as if the valve had been closed instantaneously. The velocity of the pres- sure wave depends upon the ratio ofthe wall thickness to the inside pipe diameter, on the modulus of elasticity 22 of the pipe material, and on the modulus of elasticity of the liquid, ‘The head due to water hammer in excess of normal static head is a function of the destroyed velocity, the time of closure and the velocity of pressure wave along the pipe. The value of water hammer can be calcu- lated with a fair degree of accuracy by an engineer thoroughly experienced in this work, providing all of the factors influencing water hammer are known. Water hammer may be controlled by regulating valve closure time, relief valves, surge chambers and other ‘means. It Is recommended that specialized engineering ser- vices be engaged for such calculations, since few Pump users or pump manufacturers have the knowl ‘edge and experience necessary for this work. 1.34.1.5 Start-up and shut-down During start-up, the pump torque and the driver torque vary as the pump is accelerating. The driver must be capable of supplying more torque at each speed than required by the pump. Following certain procedures reduces pump torque requirements and assists the driver during the starting process. 1.3.4.1.6 Sta \g with closed discharge valve A high or medium head centrifugal pump, when primed and operated at full speed with the discharge valve closed, requires much less power input than when itis operated at its rated flow rate and head with the discharge valve open. For this reason, it is advan- tageous to have the discharge valve closed when the pump is being started. After starting the pump, do not operate with a closed discharge valve, 1.34.1.7 Starting with open diseharge valve (mixed flow and axial flow type pumps) Pumps of the mixed flow type frequently require greater input power with the discharge valve closed ‘than with it open. Axial fiow type pumps nearly always require a great deal more power at shut-off than at rated conditions and must be started with the dis- charge valve open. The manufacturer's instructions should be consulted for the characteristic curve of ‘such pumps.1.3.41.8 Shut down Avoidance of water hammer is the primary concern during the shut down of a pump, especially in installa- tions with long discharge piping. Gradual closing of the discharge valve is one way to eliminate or reduce the water hammer. For water hammer, see Section 1.3.4.1.4 for further information. Running at shut-off conditions (with the discharge valve closed) for extended periods is not recommended. It induces increased radial thrust in many pumps and overheats the liquid in the pump. Recirculation provisions will help, as recommended by the pump manufacturer. 1.3.4.1.9 Pump and motor speed torque curves A plot of torque versus speed requirements during the starting phase of a centrifugal pump is sometimes checked against the torque versus speed curve of the driving motor. The driver must be capable of supplying ‘more torque at each speed than required by the pump in order to bring the pump up to rated speed. This con- dition is generaly attainable with standard induction or synchronous motors but under certain conditions, such as high specific speed pumps or reduced voltage starting, a motor with high pullin torque may be required. Where centrifugal pumps, in the low to medium spe- cific speed range (under 4000 [3500)), are started with the discharge valve closed, the procedure used to ca- culate the minimum torque requirements at various speeds under this condition is as follows: — Determine the maximum pump power input required at rated speed under shut-off conditions, Convert this power to torque. — Torque of the pump varies as the square of its speed; see curve, Figure 1.63. ‘At zero speed, the torque would theoretically be zero, but the driver must overcome stuffing-box friction, rotating element inertia and bearing friction in order to start the shaft tuming. This requires a torque at zero ‘speed of from 2 percent to 15 percent of the maximum. ‘Speed torque requirements for starting conditions ‘ther than closed discharge will vary depending on the percentage of static head to total head; the cubic con- tent of the discharge line; the condition of the dis- charge line, whether full, partly full, or empty; and conditions which may change during the starting Period, such as the opening or closing of bypass valves. Each of these conditions determines a different HI Centrifugal Pump Design and Application — 2000 torque requirement at any specified speed which should be obtained from the pump manufacturer when necessary. 1.3.4.1.10 Effects of handling viscous liquids The performance of centrifugal pumps is affected when handling viscous liquids. A marked increase in brake horsepower, a reduction in head, and some reduction in rate of flow occur with moderate and high viscosities. Figures 1.64A and B and 1.658 and B provide a means of determining the performance of a conven- tional centrifugal pump handling a viscous liquid when its performance on water is known. Figures 1.644 and B and 1.65A and B can also be used as an aid in selecting a pump for a given application. The values shown in Figures 1.654 and 8 are averaged from tests of conventional single stage pumps of 50 to 200 mm (2 to @ inches), handling petroleum oils. The values shown in Figures 1.64A and B were prepared from other tests on several smaller pumps (25 mm [1 inch] and below). The correction curves are, therefore, not exact for any particular pump. When accurate information is essential, performance tests should be conducted with the particular viscous liquid to be handled. 1.3.4.1.11 Viscous liquid performance correction chart limitations Reference is made to Figures 1.64A and B and Figures, 1.65A and B. Since these charts are based on empirical rather than theoretical considerations, extrapolation, beyond the limits shown would go outside the expe- rience range which these charts cover and is not recommended. +100 75 4 50 2 1% of rated (tl) speed ° | 0 02 Of 6080 Full speed torque mutiplier Figure 1.63 — Torque curve 23HI Centrifugal Pump Design and Application — 2000 Use only for pumps of conventional hydraulic design, Use only where adequate NPSH is available in order in the normal operating range, with open or closed _to avoid cavitation. impoliers. Do not use for mixed flow or axial flow pumps or for pumps of special hydraulic design for Use only on Newtonian (uniform) liquids. Gels, slur- either viscous or non-uniform liquids. ties, paper stock and other non-uniform liquids may produce widely varying results, depending on the par- ticular characteristics of the liquids. =I S = “ r iS g 5= | a 0 1 30 x 20) 4 4 249/e5 as 833 4h 3B RSS beet ley 9) Ly ‘Total Head - meters (per stage) 2 i 3 4 6 es 10 1520 ato of Flow m®m (at BEP) Figure 1.64A — Performance correction chart for viscous liquids (metric) 24Hoad infest (por stage) Correction Factors HI Centrifugal Pump Design and Application — 2000, =p Ci = Ta & i | i as foks|eay 84 36 GES 8 sf S xe % r 8 * % $ | ° ES c i 8 SS 3 e . I 3 a : 3 e \ eI NA \, 3 AAAS, 9 arson 8 3 Se 8 Sa) ee EF ar 1s 2 25 80 40 80 60 70 @0 20100 Rate of Flow-galons per minuto (at BEP) Figure 1.648 — Performance correction chart for viscous liquids (US units)HI Centrifugal Pump Design and Application — 2000 100 Heed 8 Ccontecton Factors 8 toot Flow ad Eteleney 8 20 Tet Head- Meters portage) gage 8 20 60 mie ase og Rate of Flow - mm (at BEP) Figure 1.65 — Performance correction chart for viscous liquids (metric) 268\ conection Factors HI Centrifugal Pump Design and Application — 2000 100 g Hosa Be Rate of Flow and Eticency CENTISTOK) 3 4) oad in Fet fer sag) co) 8 19 1520 40-60 80 i00 Fate of Flow in 100 GPM at BEP_ T 2 a6 Figure 1.658 — Performance correction chart for viscous liquids (US units) 27HI Centrifugal Pump Design and Application — 2000 1.8.4.1.12 Viscous liquid symbols and definitions ‘These symbols and definitions are: Qyig = Viscous rate of flow in m*sh (gpm): the rate of flow when pumping a viscous liquid; He = Viscous head in meters (feet): the head when pumping a viscous liquid: wis = Viscous efficiency in percent: the efficiency when pumping a viscous liquid; Puis = Viscous power: the power required by the pump for the viscous conditions in kW (hp); Qy = Water rate of flow in m°/h (gpm): the rate of flow when pumping water; Hy = Water head in meters (fect): the head when pumping water; Tw = Water efficiency in percent: the efficiency when pumping water; 8 = Specific gravity, Cg = Rate of flow correction factor; Cy = Head correction factor; Ch = Efficiency correction factor; Qhy = Water rate of flow at which maximum effi- ciency is obtained The following equations are used for determining the viscous performance when the water performance of the pump is known: vig = Cox Qw Hyig = Cyx Hy Mis = Oy * hy ie QrisX HyigX $ tri Avis Tis S (etic) Pie = Sera Qvig% Hyig® S (US Units) Py, = vis * “3960 X Ayig 28 Cg, Cy and Cr are determined from Figures 1.644. and B and Figures 1.65 and B, which are based on water performance. Figures 1.64A and B are to be used for small pumps having rate of flow at best effi- ciency point of less than 25 m°/h (100 gpm) (water performance). The following equations are used for approximating the water performance when the desired viscous rate of flow and head are given and the values of Cg and Cy must be estimated from Figures 1.64A and B or 1.65A and B using Qyis and Hyg as: ay(apprex) = See lapprox.) = 2H8 Pr Ze Hel ) = hus {ylapprox.) = v8 Cy 1.3.4.1.13 Instructions for preliminary selection of a pump for a given head, rate of flow, viscosity condition Given the desired rate of flow and head of the viscous liquid to be pumped, and the viscosity and specific gravity at the pumping temperature, Figures 1.64A and B or 1.65A and B can be used to find approximate ‘equivalent rate of flow and head when pumping water. Enter the desired viscous capacity at the bottom of the appropriate chart, (Qyie) and proceed upward to the desired viscous head (Hye). For multistage pumps, use head per stage. Proceed horizontally (either left or right) to the fluid viscosity, and then go upward to the correction curves. Divide the viscous rate of flow (Qyis) by the capacity correction factor (Cq) to get the approximate equivalent water capacity (Qw approxi- mately). Divide the viscous head (Hyjs) by the head correction factor (Cy) from the curve marked “1.0 x Quy’ to get the approximate equivalent water head (Hw approximately). Using this new equivalent water hoad-rate of flow point, select a pump in the usual manner, The viscous efficiency and the viscous brake horsepower may then be calculated. This procedure is approximate, as the scales for rate of flow and head on the lower half of Figures 1.648 and B or Figures 1.654 and B are based on water per- formance. However, the procedure has sufficient accu- racy for most pump selection purposes. Where the corrections are appreciable, itis desirable to check the selection by the method described below. (Example in Metric Units: Select a pump to deliver 170 m®/h at 30 meters total head of a liquid having a vis- cosity of 20 mm?/s and a specific gravity of 0.90 at the pumping temperature. Enter the chart (Figure 1.65A) with 170 mh, go up to 30 m head, over to 220 mm#/s, and then up to the cor- rection factors: Cg = 0.95 CH = 0.92 (for 1.0 Quy) Cn = 0.635 170 3) Ow = ggg = 179m% 30 Hw = agp = 926m Select a pump for a water capacity of 179 m%h at 32.6 meters head. The selection should be at or close to the maximum efficiency point for water performance. If the pump selected has an efficiency on water of 81 percent at 179 m°/h, then the efficiency for the viscous liquid will be as follows: Tivis = 0.635 x 81% = 51.4 percent ‘The input power for pumping the viscous liquid will be: 170 x 30x .9 Pus = 3erx05td Sf = 24.3 kW For the performance curves of the pump selected, cor- rect the water performance as discussed below. Example in US Units: Select a pump to deliver 750 ‘9pm at 100 feet total head of a liquid having a viscosity of 100 SSU and a specific gravity of 0.90 at the pumping, temperature. Enter the chart (Figure 1.658) with 750 gpm, go up to 100 feet head, over to 1000 SSU, and then up to the correction factors: Cq = 095 Cu = 0.92 (for 1.0 Quy) Cn = 0.635 = 750 _ Qw = ER = 790.9pm HI Centrifugal Pump Design and Application — 2000 100 Hw = J&B = 109'te0t Select a pump for a water capacity of 790 gpm at 109 feet head. The selection should be at or close to the maximum efficiency point for water performance. Ifthe pump selected has an efficiency on water of 81 por- cent at 790 gpm, then the efficiency for the viscous lig- uid will be as follows: Tvig = 0-635 x 81% = 51.4 percent ‘The input power for pumping the viscous liquid will be: = 750x100 x 0.90 Pus = “3960x0514 33.2 hp For the performance curves of the pump selected, cor- rect the water performance as discussed below. 1.3.4.1.14 Instructions for determining pump performance on a viscous liquid when Performance on water is known Given the complete performance characteristics of a Pump handling water, determine the performance when pumping a liquid for a specified viscosity. From the efficiency curve, locate the water capacity (1.0 x Quy) at which maximum efficiency is obtained. From this capacity, determine the rates of flow (0.6 x Oro), (0.8 x Qn) and (1.2 x Qqay). Enter the chart at the bottom with the capacity at best efficiency (1.0 x Qyyy), go upward to the head devel oped (in one stage) (Hw) at this rate of flow, then hori- zontally (either left or right) to the desired viscosity, ‘and then proceed upward to the various correction curves. Read the values of (Cn) and (Gq) and of (Cy) forall four rates of flow. Muttiply each head by its corresponding head correc- tion factor to obtain the corrected heads. Multiply each efficiency value by (Cn) to obtain the corrected eff ciency values which apply at the corresponding cor- rected rates of flow. Plot corrected head and corrected efficiency against corrected rate of flow. Draw smooth curves through these points. The head at shut-off can be taken as approximately the same as that for water.HI Centrifugal Pump Design and Application — 2000 Calculate the viscous input power (Pys) from the for- mula given in Section 1,3,4.1.12, Plot these points and draw a smooth curve through them, which should be similar to and approximately Parallel to the input power curve for water. Example in Metric Units: Given the performance of a Pump (Figure 1.66A) obtained by test on water, plot the performance of this pump when handling oil with @ specific gravity of 0.90 and a viscosity of 220 mm?/s at pumping temperature. On the performance curve (Figure 1.66A), locate the best efficiency point which determines Quy. In this example, itis 170 mh. Tabulate rate of flow, head and efficiency for (0.6 x 170), (0.8 x 170), (1.0 x 170) and (1.2 x 170). (See Table 1.3.3, Sample calculations [Metric]). 50 4 ker oa 45 | TOT a 2 = 40 4 18 i 35 0 § Is (read sf gs ° : 20 80 row oo # | oe 5 - - » § °o 20 40 60 680 100 120 140 160 180 200 220 240 ° Rate of Flow - mn Figure 1.66 — Sample performance chart (Metric) Table 1.3.3A — Sample calculations (Metric) 08x Ow | 08xQny | 10xGqy | i2@sGm Water rate of flow (Qyy) - m@ih 102 136 170 204 Water head (Hy) - meters 342 92.4 300 258 Water efficiency (ny) % 725 80 a2 795 Viscosity of liquid - mm/s 220 220 220 220 Ca trom chart 0.95 0.98 os 0.98 Cy from chart 0.98 094 ose 0.89 Cn from chart 0.695 635 0.635 0.695 Viscous rate of flow: Qw x Cg - mh 97 129 162 194 Viscous head: Hyy x Cy- metors 328 305 276 230 Viscous efficiency: ny x Cn = % 460 508 52.1 505 Specific gravity of quid 0.90 0.90 0.90 0.90 Viscous power- kW 170 19.0 210 ai7 30Using 170 m®/h, 30 meters head and 220 mm*%s, enter the chart and determine the correction factors. These are tabulated in Table 1.3.3, Sample calcula- tions. Multiply each value of head, capacity and eff- ciency by its correction factor to get the corrected values. Using the corrected values and the specific gravity, calculate input power. These calculations are shown in Section 1.3.4.1.12. Calculated points are plotted in Figure 1.66, and corrected performance represented by dashed curves. Example in US Units: Given the performance of a pump (Figure 1.66B) obtained by test on water, plot the performance of this pump when handling oil with specific gravity of 0.90 and a viscosity of 1000 ‘SSU at pumping temperature. On the performance curve (Figure 1.668), locate the best efficiency point which determines Quy In this example, itis 750 gpm. Tabulate rate of flow, head and efficiency for (0.6 x 750), (0.8 x 750), (1.0 x 750) and (1.2 x 750). (See Table 1.3.98, Sample calculations [Us Units). HI Centrifugal Pump Design and Application — 2000 Using 750 gpm, 100 feet head and 1000 SSU, enter the chart and determine the correction factors. These are tabulated in Table 1.8.38, Sample calculations Multiply each value of head, capacity and etficiency by its correction factor to get the corrected values. Using the corrected values and the specific gravity, calculate input power. These calculations are shown in Section 1.3.4.1.12. Calculated points are plotted in Figure 1.668, and corrected performance is represented by dashed curves. Figures 1.64A and B are used in the same’manner as Figures 1.65A and B except that only the best eff- ciency point corrected performance is obtained, Through the corrected head versus rate of flow point, draw a curve similar in shape to the curve for water Performance and having the same head at shutoft. ‘The corrected efficiency point represents the peak of the corrected efficiency curve, which is similar in shape to that for water. The corrected input power ‘curves are generally parallel to that for water. 86 Input Power- hp Total Head in feet Efficioncy-9% ° 200 400 600 00 1,000 Rate of Flow - GPM Figure 1.668 — Sample performance chart (US Units) atHI Centrifugal Pump Design and Application — 2000 ‘Table 1.3.38 — Sample calculations (US Units) 1.3.4.1.15 Speed limitations (suction specific speed) Increased pump speeds without proper suction condi- tions can result in abnormal wear and possible failure from excessive vibration, noise and cavitation damage. Suction specific speed has been found to be a valu- able criterion in determining the maximum permissible speed for a pump. The curves presented in this stan- dard are based on a suction specific speed value of 10,000 (8500). This represents a practical value; actual pump values may be lower or higher. ‘Suction specific speed is an index number for a centtit- lugal pump similar to discharge specific speed and is Uuséd to define its suction characteristic. itis defined as follows: nas NPSHR® Where: S = suction specific speed; a rotative speed in revolutions per minute; @ = flow in mh (gpm) per minute (use half of ‘the total flow for double suction pumps); NPSHA = net positive suction head required in meters (feet). 06x Qnw | 0.8xQxw | 1.0xQnw | 12x Quw Water rate of flow (Qw) - gpm 450 600 750 200 Water head in feet (Hy) - fest 114 108 100 86 Water efficiency (ny) - % 725 80 82 795 Viscosity of liquid - SSU 1000 1000 1000 1000 Cq from chart 0.95 0.95 0.95 0.95 Cy from chart 0.96 0.94 0.92 0.89 Cn from chart 0.635 0.635 0.635 0.635 Viscous rate of flow: Qw x Gg - gpm 427 570 72 855 Viscous head: Hyy x Cy - feet 109.5 101.5 92 765 Viscous efficiency: ny x Cn - % 46.0 50.8 52.1 505 Specific gravity of quid 0.80 0.90 0.90 0.90 Viscous power - hp 28.1 25.9 28.6 29.4 — ‘The formula for “S* may be rearranged to solve for “n” with 10,000 (8500) being used as a typical pump suc- tion specific speed and the available NPSH (NPSHA) and capacity Q. (etic) n = too00tNeSHA 7s (US Units) n= sso0WPSHA)7® ‘The curves in Figures 1.67 and 1.68 are graphical rep- resentations of this formula. The curves show speeds for normal operating conditions and are based on the premise that the pump is operating at, or near, its point of best efficiency. ‘The curve in Figure 1.67 A and B covers single suction centrifugal pumps. ‘The curve in Figure 1.68 A and B covers double suc- tion pumps. Normally, the highest value of “S* is at, or near, the rate of flow corresponding to the best efficiency. How- ever, special designs may cause the highest value of “S" to shift away from the point of best efficiency. Higher numerical values of “S" are associated with better suction capabilities. The numerical value of “S” is mainly a function of the impeller inlet and suction inlet design. For pumps of normal design, values of *S”HI Centrifugal Pump Design and Application — 2000 5 8 =u ex WHSEN) 0001 -sduind uorons e[6uys ym os s04 000'0! = $ qUBIsUCO ye UMOYS ‘speeds 40) Moy JO 8721 SA YHSUN soba F 2 we sy z U fell - Mold Jo e1ey ole 9 ¥ z ole 9 ¥ NPSHA - Meters 1gle suction pumps (metric) Figure 1.67A — Recommended typical operating speed limits for 33HI Centrifugal Pump Design and Application — 2000, ° [s ° 1385 beet sats Eee Se, 283°, % ss fs | f Lt 24) 4-7 [4-7 be se |p A pt——17 100 Lat 6 a «| —e4 Ls y 7 Zz f Z| 20 7 / ¥ f 4 10 t L a “100 2 40680100 200 Temperature °C Figure 1.69A — NPSHR reduction for pumps handling hydrocarbon liquids and high-temperature water (metric) 08 0.45, 03 ots, NPSHR reductionVapor pressure - Psia HI Centrifugal Pump Design and Application — 2000 NPSHR reduction 0 50 100 150-200 300 400 ‘Temperature °F Figure 1.698 — NPSHR reduction for pumps handling hydrocarbon liquids and high-temperature water (US units) 41HI Centrifugal Pump Design and Application — 2000 — Example (US Units): A pump that has been selected for a given rato of flow and head requires a minimum of 16 feet NPSH to pump that rate of flow when handling cold water. In this case, the Pump is to handle propane at 55°F, which has a vapor pressure of 100 psia. Following the proce- dure indicated above, the chart yields an NPSH reduction of 9.5 feet, which is greater than one half of the cold water NPSH required. The corrected value of NPSH required is therefore one half the cold water NPSH required, or 8 feet. — Example (US Units): The pump in the example above has also been selected for another applica- tion: to handle propane at 14°F, where it has a vapor pressure of 50 psia, In this case, the chart shows an NPSH reduction of 6 feet, which is less than one half the cold water NPSH. The corrected value of NPSH is therefore 16 feet less 6 feet, or 10 feet. 1.3.4.1.16.6 Use of chart for net positive suction head reduction (Figures 1.69A and B) for liquids other than hydrocarbons or water The consistency of results which have been obtained on tests which have been conducted with both water and hydrocarbon fluids suggests that NPSH required by a centrifugal pump may be reduced when handling any liquid having relatively high true vapor pressure at Pumping temperature. However, since available data are limited to the liquids for which temperature and vapor pressure relationships are shown on Figures 1.694 and B, application of this chart to liquids other than hydrocarbons and water is not recommended except where it is understood that such usage can be accepted on an experimental basis. 13.4.2 Determination of operating duty 1.3.4.2.1 Series and parallel operation Pumps operating in series produce head which is additive at the rate of flow at which they would run ind ‘vidually. Two pumps, each capable of 1000 mh at 50 meters of head, when connected in series, could deliver 1000 m®sh at 100 meters of head. Series oper- ation is therefore used where higher pressures are ‘equired than the pressures which an individual pump can supply. See Figure 1.70. Pumps operating in parallel produce a rate of flow Which is additive at the head at which they would run individually. Two pumps, each capable of 600 m°fh at 42. 35 meters, when connected in parallel could deliver 1200 mth at 85 meters of head (see Figure 1.71) ( 1.3.4.2.2 Continuous, intermittent and cy: service Continuous service is often defined as operation for at least an eight-hour shift without stopping. In many ceases, the pump operates 24 hours per day for pro- longed periods. Intermittent or cyctic service Is often controlled by automatic controls; liquid level or pressure switches are the most common. The pump is started by some controller and, when a liquid level or pressure condi- tion is satisfied, the pump is stopped. Precautions may be needed to avoid too many starts of an electric motor and prevent its overheating. Two pumps: — inseries Total head 8 8 system head 1000) Rate of Flow Figure 1.70 — Pumps operating in series ‘Two pumps: =— inparalel ‘Operating Total head ~ 600 ~~S~S~*« RO Rate of Fow ¢ Figure 1.71 — Pumps operating in parallelPump construction is relatively insensitive to any of the services described above. As the pump increases in size for horsepower required, so does the need for full disclosure of operating conditions to the pump manufacturer. See ANSV/HI 1.4-2000 for operating recommendations. 1.3.4.2.3. Minimum flow All centrifugal pumps have limitations on the minimum ‘and maximum fiow at which they should be operated continuously or for an extended period of time. After starting a pump, do not operate with a closed discharge valve. Operation of pumps at reduced rates of flow may lead to the following problems: — Temperature buildup: Absorption of the input Power into the pumped liquid raises the liquid tem- erature. Generally, temperature rise across the Pump should be limited to manufacturer's recom- mendations (see Section 1.3.4.2.4); — Excessive radial thrust: Single volute pumps may have limitations in this regard. See Section 1.8.4.7.2. Twin volute and diffuser pumps are gen- erally not limited because of radial thrust; — Suction recirculation: Circulatory flow in the impelier eye can cause localized pitting and mechanical damage. Such flow depends on the impeller inlet design. Continuous operation with suction recirculation should be avoided in high- energy pumps (see Section 1.2.6.6 in ANSVHI 1.1-1.2-2000); — Discharge recirculation: Circulatory flow in the discharge area of impellers can cause large forces ‘on impeller shrouds, resulting in random axial unbalance of forces and high thrust. Mechanical vibration and bearing failures can occur. The prob- lem is most severe in high-energy pumps (see Section 1.2.6.6 in ANSVHI 1.1~1.2-2000); — Insufficient net positive suction head: In some designs, the NPSH required by the impeller can increase at low flows and noise, impeller pitting and other symptoms can occur. The pump manu- facturer’s performance curve should be checked for NPSH or minimum flow recommendations. ‘The pump energy level is an important consideration for the minimum flow limitation, since the destructive forces are greater at higher energy levels. Generally HI Centrifugal Pump Design and Application — 2000 Pumps with heads greater than 200 meters (650 feet) Per stage and/or more than 225 kW (800 hp) per stage are considered high energy. See Section 1.2.6.6 in ANSVHI 1.1~1.2-2000 for a definition of high energy. For low-head, low-specific speed impellers, the Tequired minimum flow may be only 20% of the best efficiency point (BEP) flow. Limitations as high as 70% of the BEP may be required for the high-energy types. Consult the pump manufacturer for specific minimum. flow recommendations, 1.8.4.2.4 Liq pump ‘temperature rise in a centrifugal 1.3.4.2.4.1 Temperature rise calculation Pump efficiency is the ratio of the energy imparted to the liquid by the pump (Py) and the energy delivered to the pump shaft (P,) expressed in percent.The diffor- ence between the Py and the P, represents the power losses within the pump itself, due to internal recircula- tion, friction, bearings, mechanical seal, etc. Except for ‘small losses in the bearings, the power losses are con- verted into thermal energy (heat) and transferred to the liquid passing through the pump. A convenient equation relates temperature rise to the total head and pump efficiency: a eee) AT = sathae( 1) maxed”) (US Units) aT Where: ar temperature rise through the pump, °C (°F); H = total developed head at flow being consid- ered, m (ft); 778 = constant; 10.4 = constant; Cp = specific heat of the liquid at pumpage tem- perature, kNmikg °C (BTU/Ib ~°F); 1. = efficiency of the pump at flow being consid- ered, expressed as a decimal. 43HI Centrifugal Pump Design and Application — 2000 Example (Metric): A pump has performance as shown in Figure 1.72A. Create a curve depicting temperature rise as a function of rate of flow if the liquid to be pumped is water at 15°C. Pover-h, ten -peeant Bg Figure 1.72A — Pump performance (Metric) Solution: H and 1 are obtained from the perfor- ‘mance curve for various rates of flow. Water at 15°C. has Cp equal to 41.5. AT may then be caloulated using the above equation, and tabulated as shown in the table below. Ratectfiow | Head | at mn meters % °c 25 se | 340 | 087 20 145 | 340 | 065 15 160 | 205 | 028 10 170 | 225 | 1.04 5 too | 125 | 290 2 tes | 60 | 670 1 te7 | 30 | 13.90 44 The calculated temperature tise is plotted in Figure 178A, S20 e Bos iit i | Boo Rate of flow — mn Figure 1.73A — Temperature rise (Metric) Example (US Units): A pump has performance as shown in Figure 1.72B. Create a curve depicting temperature rise as a function of rate of flow if the liquid to be pumped is water at 60°F, Input power horsepower Pump efcency- percent 8 Tt ead Fate of fow gem Figure 1.728 — Pump performance (US Units) () Solution: H and 7 are obtained from the perfor- mance curve for various rates of flow. Water at 60°F has Cp equal to 1.0. AT may then be calculated using the above equation, and tabulated as shown in the table below. Rateoffion | Head | 7 at gpm feet | % °F 120 360 | a2 0.98 80 500 | 33 1.30 60 sao | 28 178 40 ss | at 278 20 600 | 115 | 593 10 605 6 | tate 5 610 3 | 25.35 The calculated temperature rise is plotted in Figure 1.738, Temperature rise through pump ~ °F 8 ° = «0 0 4 10 129 Fate of fou - gpm Figure 1.738 — Temperature rise (US Units) ‘As evidenced by the previous example, temperature tise through a pump increases as flow is decreased, When a pump is run at or near shutoff, the majority of the power input is converted to thermal energy, caus- ing a rapid temperature rise. if the temperature rise continues, the parts will ‘expand. Vaporization doesn't allow thermal expansion of the parts. Temperature rise does. This could result seizure of the rotating parts, complete pump failure oF destruction of the pump and associated equipment. HI Centrifugal Pump Design and Application — 2000 Vaporization can cause a rapid and excessive pres- sure increase in the pump, possibly resuiting in ‘an explosion of the casing, An equation expressing the rate of temperature rise at shutoff is: ie) Te, = 20% Paso (Mette) Tro = Tope Us Units) 7,,, = 522*Pose (US Units) Trso = Top ES Where: Tiso = tate of temperature rise evaluated at shut- off, °C/min (°F/min); 60 = constant for unit conversion 5.09 constant for unit conversion; Input power at shutoff for the Pumped, in kW (hp); Poso = liquia V = casing internal volume - m3, (gal.); Cp = specific heat kikkg °C, (BTUMb-"F), Cp var- jes with temperature. For these calcula- tions, a constant value is used; P= density kg/m? S = specific gravity. This equation neglects, as does the first equation, the small effects of pump bearings, heat dissipation and compressibility of the liquid but is applicable to situa- tions normally encountered, Examplé (Metric): The pump used in the previous example has a casing (volute and discharge nozzle) capacity of 0.0255 m® and is again pumping water at 18°C, Determine: a) The rate of temperature rise; b) The time required to boil the water in the casing. 45HI Centrifugal Pump Design and Application — 2000 Solution: From the performance curve, power input at shut-off is 19.0 kW. Cp for water at 15°C is 4.19 and p is 1000. = 60x 19.0 0 = [0255 x4.19 x 1000 b) Time required to boll the water = (100 — 15y/10.7 = 7.95 min a) Ts = 10.7 *Cimin Example (US Units): The pump used in the previous example has a casing (volute and discharge nozzle) capacity of 6.75 gallons and is again pumping water at 6orr, Determine: ) The rate of temperature rise; b) The time required to boil the water in the casing. Solution: From the performance curve, power input at shut-off is 26 hp. Cp and s for water at 60°F are both 1.0. 509x268 B7EXxT.OxT0 ~ b) Time required to boil the water = (212 ~ 6019.6 =7 min, 45 seo 8) Treo = 19.6°F min NOTE: The liquid will first boil at the eye of the impeller where the pressure is approximately atmospheric. 1.3.4.2.4.2 Minimum flow in a pump due to temperature rise This discussion focuses on minimum flow required through a pump to prevent excess temperature rise. ‘A.commonly accepted practice limits temperature rise through a pump to 8°C (15°F). For most installations, this is adequate and minimum flow may be calculated with equations. For 8°C (15°F) temperature rise through a pump, (US Units) @ Where: @ = minimum flow rate, m°/h (gpm); 46 Pp = input power atthe minimum flow, KW (hp); 2.95 = constant; 439 = constant Cp = specific heat kl/kg °C, (BTUMb-*F p= donsty - kgm? 8 = specific gravity At the minimum flows calculated using the above equation, the power input is approximately the same as at shutoff, Example (Metric): Determine the minimum flow required to prevent the temperature of the pump used in the previous examples from rising more than 8°C. when pumping 15°C water, Solution: Shut-off power is 19 KW. Cp is 4.19 and p is 1000. 493% 19 3 = zyaxt005 = 196 m'/h Example (US Units): Determine the minimum flow required to prevent the temperature of the pump used in the previous examples from rising more than 15°F when pumping 60°F water. Solution: Shut-off power is 26 hp. Cp and s are both 1.0, ‘Temperature rise in excess of 8°C (15°F) may be per- missible in certain circumstances. The pump manufao- turer should be contacted if a temperature rise in excess of 8°C (15°F) is desired. As previously discussed, catastrophic failure of the pump and associated equipment may result if the liq- uid within the pump casing is allowed to vaporize. To prevent flashing, a flow must be maintained through ‘the pump which will keep the liquid below its saturation temperature. Special situations occur when a relatively small margin ‘exists between NPSH available and NPSH required by the pump, as in boiler feed services. A boiler feed ump normally takes suction from a deacrator or deaerating heater. A deaerator is a closed vessel in~ which the feed water is heated by direct contact with steam to remove air which could cause corrosion in the boiler. In a properly operated deaerator, the water is heated to boiling (i.., vapor pressure is equal to the deaerator pressure). ‘To establish the maximum allowable temperature rise, first determine the: a) absolute pressure in the deaerator or other suction source; b) additional absolute pressure available at the pump suction nozzle above that required by the pump, using (NPSHA-NPSHA) xp xg (Moti) = Wes (us Unis) p = (NPSHA-NPSHA) 3 Bat ) sum of the values determined in a) and b). The maximum allowable temperature rise is the differ- cence between the saturation temperature correspond- ing to the pressure determined in c) and the temperature of the suction source. Example (Metric): A pump is to handle 110°C water. The suction source is a heater under pressure, corre- sponding to this temperature, with 7.6 meters of NPSHA. Pump NPSHR is 3.4 meters. Determine the maximum temperature rise permitted. Solution: from thermodynamic tables, for water at 110°C, s = .952, and p = 952 kg/m? a) The absolute pressure in the heater is 143 kPa; b) The additional absolute pressure available at the suction nozzle is: (7.6~3.4) x 0.952 «9.81 et = 392 kPa ©) The sum of the values determined in a) and b) is 143 +39 = 182 kPa, Saturation temperature corresponding to this pressure is 117.4°0, HI Centrifugal Pump Design and Application — 2000 Maximum temperature rise is then 117.4 - 110 7.4°C, which is less than the normally accepted maxi- mum of 8°C. Example (US Units): A pump is to handle 230°F water. ‘The suction source is a heater under pressure, corre- ‘sponding to this temperature, with 25 feet of NPSHA. Pump NPSHR js 11 feet. Determine the maximum temperature rise permitted, Solution: from thermodynamic tables, for water at 230°F, s = 0.952, and: a) The absolute pressure in the heater is 20.78 psia; b) The additional absolute pressure available at the suction nozzle is: (25-11) x 0.952 i CaO = 5.77 psia ©) The sum of the values determined in a) and b) is 20.78 +5.77 = 26.55 psia. Saturation temperature correspon. is 243.3°R. to this pressure Maximum temperature rise is then 243.3 - 230 = 19.3°F, which is less than the normally accepted maxi- mum of 15°F, If the maximum allowable temperature rise is known, the second equation may be rearranged to calculate minimum flow: 3600 x P, ATxtpxp (Metric) Q = * ATK Opxe Where: © = minimum flow rate, gpm; 3600 = constant; 5.09 = constant; Pp = power input at the minimum flow, KW (hp); AT = maximum allowable temperature iso through the pump, °C (* a7HI Centrifugal Pump Design and Application — 2000 cp specific heat, kivkg °C (BTU/I P= density in kg/m? S = specific gravity. Example (Metric): Determine the minimum flow Fequired through the pump in the previous example if the shut-off power input is 75 KW. Solution: using the above equation: 3600 x 75 3, TAxATO x Geo = IMD Example (US Units): Determine the minimum flow equired through the pump in the previous example if the shut-off power input is 100 hp. Solution: using the above equation: 09 x 100 TSSx1.0x0952 = 40.2 gpm |n multistage pumps, the allowable temperature rise corresponding to the difference between the NPSHA and NPSHR should be considered to occur in the first stage. Temperature rise through the entire pump gen- erally should stil be limited to 8°C (15°F). Minimum flow is guaranteed by installing a bypass from the discharge line to some low-pressure point in the system. The bypass should not lead directly back to the pump suction, An orifice installed in the bypass line breaks down the differential pressure between the pump discharge and ‘the low-pressure point in the system. The bypass may be manually or automatically oper- ‘ated but must be open during periods of light load or when starting or stopping the pump. 3.4.2.5 Predicting pump performance after ipeller diameter change ‘A characteristic of both horizontal and vertical centrifu- gal pumps is that it is possible to determine the change in rate of flow, head and power at any point on the characteristic curves by calculation when there is a change in impeller diameter. The performance will vary based on the following equations known as the affinity laws: % 9 QD, Hy Dye lal Py . [ay Py Dy. Where; Q; = original impeller rate of flow ‘Me = nl importa head = ctiialimptor poor Dy = gal per dlameter Q2 = reduced impeller rate of flow ty = reed pote tl heed 2 = reduced impeller power reduced impeller diameter Normally the “D” diameter is the largest outside diam- eter (front shroud) of the impeller vanes, but if the impeller exits machined at an angle then the °D” shall be the average value between the diameters, or (DF + DBY?2. See Figure 1.74. If the thickness of the impelier vanes at the outside diameter has been reduced by filing or grinding, the reduced diameter impeller shall be similarly treated. Example (Metric) Dy = 300mm — Dp = 290mm 500mYh Hy = 100m =P, = 45 KW. Hea? Ay 3007? > 77 [bs0] = [aool 100 He 7.069 7.106 Q, = 484m%h Hy = 935m Py = 40.7 KW 2 b 2Example (US Units) Dy = 12in, = Dp = 11-4 Q, = 2000 gmp Hy = 103 —P, = 63 hp When changing impeller diameters more than 5%, the above equations are not recommended without con- sulting the pump manufacturer. NOTE: The system requirements may limit pump performance so that the rate of flow change in the system will not follow the above calculation. 1.3.43 Efficiency prediction method for centrifugal pumps ‘The major influences on centrifugal pump efficiency fare specific speed (NS), pump size, NPSHA or (NPSHR) and the type of pump selected to meet the service conditions. Average Figure 1.74 — Impeller with angled outside diameter HI Centrifugal Pump Design and Application — 2000 The efficiency prediction charts (see Figures 1.75A through D and 1.76A and B) relate to industrial class Pumps designed, manufactured and tested in accor- dance with recognized industry standards. Shown on Figures 1.76A and B are the deviation limits on effi- ny as influenced by the following: — desired curve shape (rise to shutoff, etc.); — dimensional conformance and quality (ie., shaft runout); — surface roughness; — internal clearances; — design compromise for manufacturability; — mechanical losses; — solids handling capability; — test tolerances, Not included in the efficiency prediction process are the detrimental effects when handling viscous mix- tures, entrained air and slurries. ‘A method is presented for predicting generally attain- able efficiency levels at the best efficiency point of selected types of centrifugal pumps when the rate of flow (Q), total head per stage (H), net positive suction head available (NPSHA) and the service conditions are known. The optimum efficiency occurs when the specific speed (NS) is in the vicinity of 2900 (2,500) and a suc- tion specific speed (S) is in the vicinity of 10,000 (8,500) (see Figures 1.75A and C). Pumps selected {or services with NS values that are not in the vicinity ‘of 2900 (2,500) will have lower efficiencies. The rela- tionship between the arithmetic efficiency correction and NS is shown on Figures 1.758 and D. ‘The recommended maximum operating speeds for single and double suction pumps are shown on Fig- ures 1.67A and B and Figures 1.68A and B. These charts provide a guide for the selection of the pump. speed when the value of S is 10,000 (8500). Note for double suction pumps S relates to halt the rate of flow. Using the above figures, the generally attainable effi- ciency of various types of centrifugal pumps at best efficiency point with maximum diameter impeller when Pumping clear water at 30°C (85°F) can be predicted.HI Centrifugal Pump Design and Application — 2000 0 92 © 0 ry soo 0 1 Values of NS for double suction pump are based upon Sscharge Bow aes. 2 Valves ofNS for mulsage pups ae cleats on bas cofhead per stage ‘NS mets based on ae of low in cubio metre por hour andhead in meters 1 90 Figure 1.758 — Specific speed-efficiency correction chart (Metric) 80 70 60 PUMP EFFICIENCY AT OPTIMUM SPECIFIC SPEED PUMP EFFICIENCY AT OPTIMUM SPECIFIC SPEED 50 20 10 100 +1000 RATE OF FLOW - CUBIC METERS PER HOUR, NoTEs: 1 The above charts depict the generally attainable efficiency levels of centritugal pumps at best efficiency point with maximum diameter impeller when pumping clear water at 30°C (85°F). 2 The above charts relate to industrial class pumps designed, manufactured and tested in accordance with recognized industry standards. Figure 1.75A — Optimum generally attainable efficiency chart (Metric)HI Centrifugal Pump Design and Application — 2000 ry 8 » & i : i +6 8 wo = “0 ea 10050 1 Values ot Ns for double sucton pumps ar based upon charge tw rates. 2 Values of NS for multstagepunps recalculated on base ofheaa per stage Figure 1.75D — Specific speed-offi (US Units) ney correction chart 60 PUMP EFFICIENCY AT OPTIMUM SPECIFIC SPEED & 10 1000 CAPACITY - US GALLONS PER MINUTE NoTEs: 1 The above charts depict the generally attainable eficiency levels of centritugal pumps at best efficiency Point with maximum diameter impeller when pumping clear water at 20°C (85°F). 2 The above charts relate to industrial class pumps designed, manufactured and tested in accordance with recognized industry standards. a Figure 1.75C — Optimum generally attainable efficiency chart (US Units) PUMP EFFICIENCY AT OPTIMUM SPECIFIC SPEED 51HI Centrifugal Pump Design and Application — 2000, MAXIMUM Smo ‘GENERALLY ATTAINABLE EFFICIENCY 17 Deviation as a percent of generally attainable efficiency 10 100 1000 10,000 Rate of flow - cubic meters per hour Figure 1.76A — Deviation from generally attainable efficiency (Metric) 4 2 10 Deviation as a percent of generally attainable efficiency 10 100 1,000 10,000 Rate of flow - US gallons per minute Figure 1.76B — Deviation from generally attainable e 52Example (Metric): Determine the generally attainable efficiency of an APltype single stage end suction pro- cess pump driven by a 50 hertz motor when pumping clear water at 30°C given Q = 700 mh, H = 130 m, NPSHA = 7.5 m Enter the chart (Figure 1.67) with 700 m°h and NPSHA with 7.5 m and select pump speed. In this case, the nearest synchronous speed would be 1500 rpm. Calculate NS: nas Ns = 5 Ng = 1800x2005 _ 144 130: Enter the chart (Figure 1.78A) with 700 m®/h and read off efficiency corresponding to the optimum specific speed for API end suction process type pumps = 85.5%, Enter the chart (Figure 1.758) with the calculated NS 1032 and read off efficiency correction = § points. Predicted efficiency = optimum efficiency — efficiency correction. Predicted efficiency = 85.5 - 5 = 80.5% From chart (Figure 1.76A) at 700 mh, the normal deviation is 3%; therefore, the predicted efficiency lies between 78% and 82.9%. Example (US Units): Determine the generally attain- able efficiency of an API-type single stage end suction Process pump driven by a 60 hertz motor when pump- ing clear water at 85°F given Q = 3000 gpm, H = 420 ft, NPSHA = 24 ft Enter the chart (Figure 1.678) with 3,000 gpm and NPSHA with 24 ft and select pump speed. In this case, the nearest synchronous speed would be 1780 rpm. Calculate NS: ngs NS = 5 1780 x 30005 Se = 1051 HI Centrifugal Pump Design and Application — 2000 Enter the chart (Figure 1.75C) with 000 gpm and read off efficiency corresponding to the optimum spe- cific speed for API end suction process type pump: 85%, Enter the chart (Figure 1.75D) with the calculated NS 1051 and read off efficiency correction = 3.5 points. Predicted efficiency = optimum efficiency ~ efficiency correction. Predicted efficiency = 85 ~ 3.5 = 81.5% From chart (Figure 1.76B) at 3000 gpm, the normal deviation is + 3%; therefore, the prodicted efficiency lies between 79% and 83.9%. Factors which can affect efficiency are: — Surface roughness: Efficiency increases due to improvements in waterway surface finish are very dependent on pump specific speed and size. Gen- rally, surface finish improvements are economi cally justifiable for small and low specific speed Pumps. Shown in Figures 1.77A and B is the effi ciency improvement that can be expected when the water passages are smooth; this would be added to the general predicted efficiency. — Internal clearances: Pump wear ring clearances can have a major influence on efficiency, particu- larly for low specific speed pumps (less than Ns = 1750 [1500)). See Figures 1,78A and B. — Mechanical losses: Bearings, lip seals, mechani- cal seals, packing, etc., all consume power and reduce the pump efficiency. Small pumps (less than 11 kW [15 HP)) are particularly sensitive, — High suction specific speed: Special impeller designs with S values above 13,000 (11,000) could reduce the attainable efficiency by upwards of 3 points. Very low NS pumps are less affected. — Impeller diameter trim: Reduction in efficiency due to impeller diameter trim must be expected. Efficiency reductions can range from 1 to 6 points for impeller diameter trim to 80% of the maximum. diameter. High specific speed pumps generally have greater reductions in efficiency due to trim than low specific speed pumps. — Viscosity: Viscous liquids have a detrimental effect on efficiency. Refer to viscosity correction ‘curves in Section 1.3.4.1.11. 532000 HI Centrifugal Pump Design and Application \stuy 208pns 0} on eseaiouAovsioye Jo sie 72000 ‘40006000 1000 Specie speed Metro. Figure 1.77A — Estimated efficiency increase due to improved surface finish (Metric) Specific speed - US units Figure 1.778 — Estimated efficiency increase due to improved surface finish (US Units) 54HI Centrifugal Pump Design and Application — 2000 ‘Specie sped Mote ‘gure 1.76A — Estimated efficiency decrease due to increased wear ring clearance (Metric) Fi ‘seats Buy Jean ere peree:U 0 ep eB88!20p KousDS Jo BNE ‘Specie speed- US units — Estimated efficioncy decrease due to increased wear ring clearance (US Units) Figure 1.788 55HI Centrifugal Pump Design and Application — 2000 —: Slurries: Larger volumetric concentrations of sol- ids in liquids cause reductions in pump efficiency. ‘The pump supplier should be consulted when making efficiency corrections for slurries, — Solids size: Low concentrations (below 10% by weight) of random-sized solids and tramp material in the liquid will not have a detrimental effect on efficiency; however, the pump configuration has to be compromised so that the impeller and casing passageways will be large enough to prevent clog- ging; e.g., sewage pumps which handle solids and rags often have only two or three vanes of unique shape, causing the efficiency to be lower. — Types of pumps: There are many different types of centrifugal pumps with unique configurations ‘and features to meet specific service conditions, ie, stock, sewage, slurries, etc, all of which by Virtue of their pectic speed and design have less Table 1.3.4 — The influence of pump type on ef than optimum attainable efficiency. Table 1. provides'some details on how pump features influ- ence efficiency. 1.3.4.4. Operation away from the best efficiency poi A centrifugal pump is designed for optimum perfor- mance at one specific head and rate of flow for given speed. This operating point is normally called the best efficiency point (BEP). It is most cost- and energy-efficient to operate the pump at the BEP. Pumps often do not run continuously at their BEP due to changing system requirements and the difficulty of matching the selected operating conditions with the BEP of the pump. Operation at flow rates below the BEP imposes additional strain on some parts and can be damaging to the pump (see Section 1.3.4.2.3). jency Pump type NS range | Figure® Factors which influence efficiency Severe duty, end suction, metal | 500-1600 - | Manufacturing considerations slurry pumps (400 - 1400) Medium duty, end suction, metal | 900-2300 | 1.13 | Manufacturing considerations and rubber siurry pumps (800 - 2000) End suction, 2 vaned sewage 800-3500 | 1.23 | The efficiency is compromised in order to pumps (700 - 3000) ass large solids End suction, 3 or 4 vaned sewage | 1250-6400 | 1.23 | The efficiency is compromised in order to pumps (1500 - 5500) pass large solids End suction stock pumps 800-4600 | 1.23 | Open impeller designed for pumping fibrous (700 - 4000) air-entrained mixtures compromise efficiency Horizontal multistage pumps: 800-2300 | 1.20 | Clearances, interstage bushings, shaft axially split, segmented ring (700-2000) | 1.21 | stiffness and surface finish diffuser barrel 1.22 End suction ANSI and API pumps | 350-3500 | 1.15 | Low horsepower pumps with special (300-3000) | 1.14 | mechanical seals which cause high mechanical losses will have efficiencies lower than stated in the figures ‘API double suction 800-2300 | 1.19 | Large shaft diameter through impeller eye, between bearings pumps (700 ~ 2000) large impeller ring clearance and suction inlets reduce efficiency Double suction pumps 500-5200 | 1.18 | Large diameter shatting (450 — 4500) * Figures appear in ANSUHI 1.1 — 1.2-2000. 56 (Operation of the pump at flow rates greater than the BEP may lead to problems as follows: a) Combined torsional and bending stresses or shaft deflection in single volute pumps may be in excess. of permissible limits (see Section 1.3.4.7.2); b) NPSH required may be in excess of the NPSH available; ©) Erosion damage, notse and vibration may occur due to high liquid velocities, ‘The anticipated range of flow rates over which the Pump is expected to operate should always be dis- cussed with the manufacturer. See ANSI/HI 9.6.3- 1997, Centrifugal and Vertical Pumps — Allowable Operation Region for more information. 1.3.4.5 Noise levels Most centrifugal pumps can be classified as quiet machines. Typically the electric motor-driven pump will have a greater contribution from the motor to the over- all noise level than that contributed by the pump. For those applications where minimum noise levels are Tequired, the primary application rule is to select the Pump at both a conservative rpm and liquid velocity level. This will offen rule out the use of the smallest, ‘most economical pump that will operate at the highest possible speed and with high liquid velocities. A quiet installation also demands complete freedom from pos- sible cavitation, and this means a conservative NPSH_ margin. Hydraulic noise can be the result of pump operation at flow rates well below or well above the design flow rate for the pump. Higher specific speed Pumps are more sensitive than lower specific speed Pumps in this regard. Refer to the ANSVHI 1.4-2000 for more details. 1 6 Suction conditions 1.3.4.6.1 Intake design ‘See ANSI/HI 9.8-1998, Pump Intake Design for an in- depth discussion of this subject. 1.3462 Special impeller or inducer Inducers are single stage axial flow helixes installed in the suction eye of centrifugal pump impellers to lower the NPSHR of the pump (see Figure 1.79). This allows use of increased rotating speed for a given NPSHA or a lower NPSHR for a given speed, Shallow blade inlet angles are used to draw liquid into the inducer channels, HI Centrifugal Pump Design and Application — 2000 Which are shaped to impart enough energy to provide sufficient NPSH for the main impellers to avoid detri- mental cavitation, Whereas centrifugal pump impellers often have a suc- tion specific speed, S, of about 9000 to 14,000 (8000 to 12,000), use of inducers can increase S to a range of 17,000 to 40,000 (15,000 to 35,000). This typically allows lower flow pumps to operate at 11,000 rpm with the same NPSH, which would be required at 3600 rpm without inducer, or reduce NPSHR of all pumps to less than half at the same speed, Cavitation damage of inducer blades may occur above certain experience-established inducer tip speeds. At lower tip speeds, cavitation will not produce damage regardless of S value. Allowable tip speed is also a function of inducer materials; e.g., titanium alloy is 20% higher than for stainless steel. Tip speeds may also be increased for lower specific gravity liquids. Inducer flow range must be designed and selected to provide sufficient S over the intended operating range to avoid cavitation in the main impeller. Suction spe- cific speed typically is reduced at low and high ends of inducer performance range. Figure 1.79 — Inducer 87HI Centrifugal Pump Design and Application — 2000 1.3.4.7 Mechanical features 1.3.4.7.1 Types of bearing arrangements ‘The pump bearing arrangement is normally one of two types: a) impeller overhung from bearings; b)_ impeller mounted between bearings. Close coupled and frame mounted single suction Pumps are commen examples of an overhung bearing load, Single stage double suction and muhistage hor zontal shaft pumps are common examples of the “between bearing impeller” load, Both arrangements can provide equivalent bearing life, 1.3.4.7.2. Calculation of radial thrust for volute pumps Single and dual volute pumps should be designed for uniform velocity around the volute of the casing at the design rate of flow (BEP). For pumps in operation near or at BER, the radial thrust may approach zero. For operation at flow rates higher or lower than BEP, the pressure distribution is not uniform, resulting in a radial thrust on the impeller. The magnitude and direction of the radial thrust changes with change in flow rate. The following expression is used to calculate radial thrust: (Metric) AT = Kx Hxpx gx Dox by Hxs (US Units) AT = Kx BE8x Dp x by Where: AT = radial thrust in Newtons (pounds); K = thrust factor, which varies with rate of flow and specific speed. See Figures 1.81 and 1.88 for values; HH = eveloped head per stage in meters (feet); P= density of the pumped liquid in kg/m®; specific gravity of the pumped liquid; impeller diameter in meters (inches); impeller width at discharge shroud(s) in meters (inches). including 58 For single volute pumps, the highest value of radial thrust is at zero flow in a direction from the shat centerline toward the cutwater. As the flow increases, the direction of the load swings around the volute toward the diminishing area and loses magnitude until itis nearly zero at BEP. The magnitude of the force then increases at rates of flow over BEP and the direc- tion also continues to change. See Figure 1.80. Sample calculation (Metric): What is the highest value of radial thrust for the pump with the following conditions? Given: Speed — 3000 rpm; Rate of flow ~ 125 m3/h; Head - 100 meters; 1000 kg/m’, D028 m; bp 0.022 m. 1g = 300% 125° 10075 1063 Ifthe casing is a single volute, flow (Figure 1.81): RT = .170x 100 x 1000 x 9.81 x 0.25 x 0.022 = 917 N If the casing is a dual volute, K = .020 (Figure 1.83): RT = .02 x 100 x 1000 x 9.81 x 0.25 x 0.022 = 108 N Dual (double) volute is when two volutes enclose the impeller. Dual volute casing reduces the radial load to Cutwator 0% 1 Percent flow rato < 125% 25% 100% 50% 78% Figure 1.80 — Single volute casing (1 to 27 times the load of a single volute (see Figures \ 1.82 and 1.83), ‘Specific speed - Metric (US Units) 0 2 40 6 e100 120140180 Porcont rato of flow Figure 1.81 — K versus rate of flow for single volute casing iyi | | ~) wy Figure 1.82 — Dual (double) volute casing [Sree speed - Mai (0S Una) ] rr ry Percent rate of ow 100 zo ¥ Figure 1.83 — K versus rate of flow for dual (double) volute casing HI Centrifugal Pump Design and Application — 2000 Sample calculation (US Units): What is the highest value of radial thrust for the pump with the following conditions? Given: ‘Speed ~ 9550 rpm; Rate of flow — 500 gpm; Head ~ 392 feet; Specific gravity ~ 1.0; Dz- 9.44 inches; bp — 0.85 inches. 3,550,/506 NS = 3950-1809 _ 4994 332-75 I the casing is a single volute, K = (Figure 1.81): .175 at zero gpm AT = 175X382 1.09.44 x.85 aS = 202 ib It the casing is a dual volute, K = .020 (Figure 1.83): 102X382 x 1.0.x 9.44.85 ar Bai = 23 Ib Dual (double) volute is when two volutes enclose the impeller. Dual volute casing reduces the radial load to +1 to .27 times the load of a single volute (see Figures 1.82 and 1.83). Radial thrust changes with impeller diameter ratio to the third power because head changes as the diame- ter squared and the diameter is being reduced. This is approximate because be and N, change as impeller diameter is reduced: At, = arf Radial thrust changes with change of speed of the Pump to the second power of the speed ratio because. head changes as the square of the speed: APM? Ary = (pe) API, 59HI Centrifugal Pump Design and Application — 2000 ‘As a general guide, circular casings have a K of .05 at BEP up to NS equal to 875 (750) (see Figure 1.84). The radial force is dependent on the geometry of the casing cross section, K is similar to values for volute casings based on Ago- stinelli et al, An Experimental Investigation of Radial Thrust in Centrifugal Pumps, ASME Journal of Engi- neering, April 1960. 1.34.7.3 Calculation of axial thrust for enclosed impellers for volute pump Following is @ standard method for the calculation of axial thrust load developed within a single stage cas- ing acting on the impeller in a direction parallel to the shaft. This specification is for single stage pumps only (spe- cific speed range of 600 to 4000 [500 to 3500]) with ‘enclosed impellers having no back vanes with a plain horizontal ring(s) and with a diametral clearance of 25 to .5 mm (.010 to .020 inches). The complexity of the interaction of interstage pressures, casting tolerances and machining tolerances does not make it practical to have an overall method of axial thrust calculation for multistage pumps. For pumps in a vertical position, the weight of impeller and shaft should be added to the axial thrust. Also, depending on the construction, the coupling weight, the driver motor, or balancing device weight may also be added to the total axial thrust. ‘The values of axial thrust are for 0 to 25% of BEP rate of flow. Within this range, maximum axial thrust will be developed and can be determined by the following ‘equation: P= 80% (6, A9)-(t)| PA _ Figure 1.84 — Circular casing 60 Where: Fr = Net axial thrust in Newtons (pounds); Ap = Developed pressure of the impeller ~ kPa (psi , Hxp (Metric) Ap TOE #H (US Units) ap = 5a xs Ka = Percent of developed head at some loca- tion on the impeller shroud (Figure 1.85); = Average percent of developed head on the back shroud; Average percent of developed head on the front shroud; Area exposed to pressure on the back shroud - m? (sq. in.); Ap = Area exposed to pressure on the front shroud - m? (sq. in.); Ps = Suction pressure - kPa (psi); ‘An = Area of shaft, shaft sleeve or mid-point of mechanical seal rotating face exposed to atmosphere - m? (sq. in.) ‘The basic chart is based on a free vortex between the casing wall and impeller shroud. The liquid velocity is {0 be one-half the peripheral velocity of the impeller. The values have been adjusted using empirical data. The typical ratio ofthe distance from the casing wall to " T | 4000 (3500) [Sate spowe- ess OS Uo | ‘nis |_| i dans (8609) LT Le 750 3500 [= Hasors00. (400200) Reference ameter D Fulimpoiecdaneset ( 0) Figure 1.85 — Pressure distribution on enclosed impeller shroudsthe impeller shroud to maximum impellers diameter is the following for various specific speeds. Casing wall to shroud NS maximum impeller diameter '450— 1400 02 to 04 (400 1200) 1750 08 t0 05 (1800) 2300 ~4000 04 t0 06 (2000 - 3500) The values of Ka will increase or decrease as these ratios change. Kj is based on .25 to .50 mm (.010 to .020 inches) dia- ‘metrical ring clearance and is highly influenced by ring clearance. For further discussion of the subject, refer to Centrifugal and Axial Pumps by A.J. Stepanoff, Sample calculation (Metric): Enclosed impeller with plain back shroud (see Figure 1.86). Where: Q = 145m%h Hpop = 100m; Hey = 114m; P, = OkPa; n= 3550 rpm; 0.240 mi; Figure 1.86 — Enclosed impeller with plain back shroud HI Centrifugal Pump Design and Application — 2000, Dar = 0.121 m: Dy = 0.038 m; p= 1000 kgim 6 3550(145)5 _ 355 From Figure 1.85, Ka, = .75 Dre _ 0.121 Dy * Gna 75 From Figure 1.85, K,, = .65 Pe te Mane 75 Ky, = z 2e = 2038 «16 From Fguré 1.85, Ky, = 61 D, ~ 024 Kay Kat Ka, Kay, z Ag = 785 (0.242 0.038%) = 0.044 (m?) Ap = .785 (0.247 0.1212) = 0.034 (m2) An = -785 x 0.038? = 0.001 (m2) ap = 114%1000%9.81 _ jy47ypq 1000 = ts)-(6 Al] -Ate Fy = 6.84 kN ‘Sample calculation - impeller with back ring (see Fig- ture 1.87): Where: 1 Q = 145m; Hyep = 100m; Hey = 114m; Ps = 345kPa; n= 3550 1pm; 6HI Centrifugal Pump Design and Application — 2000 Dy = 0.240m; AP Hax600x9.61 671 kPa Dap = 0.121 m; Drag = 0.095 m; Fre aPA(Kny,Aa)~(Ka,,Ar)] Dy = 0.038 m; + Ag, x108-A,P, p = 600 kg/m3, Fz, = 671[(0.69 x0.038) - (0.7 x0.084)] + 0.006 x70" 0.001 x 345 = 1699 N towards suction From Figure 1.85,K,, = .75 Th rag behind the back ring is 70 kPa D, 1e average pressure bet ack ring is ARE. 0.121 ‘greater than suction pressure, when the area of the Dy 0.240 balance holes equals three times the area of the clearance of the back ring, From Figure 1.85, K,, ‘Sample calculation (US Units): Enclosed impeller with plain back shroud (see Figure 1.86).. Kat Ky ky =z FESS _ 79 Where: Pre _ 0.095 2 = 640 gpm ee 40 From Figure 1.85, K, Dz” 0240 ones Arg Hoop = 825 tt; Kat Ka Hep = S75 ft; kay 3 Ps = Ops Ag = .785 (0.247 0,095%) = 0.038 m' = 3850 rpm; Dp = 9.44 in; Ag, = .785 (0.95? ~ 0.038%) = 0.006 m’ Ope = 4.75in; Ag = .785 (0.2427 -0.1212%) = 0.034 m Dy = Ay = .785 x 0.038% = 0.001 m2. s = 10. Discharge fenge 8 I, = 3580(640)5 _ 4475 30575 Casing Volute Fron Back shroud “ - Fe 8) From Figure 1.85, Kay = 75 Front ng D 7 SAF. 475 | i + Be ~ Sag = 5 From Figure 1.85, K,, = .65 Orr tg Figure 1.87 — impeller with back ring 62= -16 From Figure 1.85, Ky, = .61 a Kay 754.61 _ 2 2 68 As = .785 (9.44?— 1.5%) = 68.2 (sq. in.) Ar = .785 (9.44? 4.75%) = 52.2 (sq, in.) An = 785 x 1.5% = 1.8 (sq. in.) Ap = SSX 1.9 «62 pg Bat =o) (6, Aa] AP = 162[(.68 x 68.2) -(.70x 52.2)]-1.8%0 Fr, = 1804 Ib towards suction ‘Sample calculation - impeller with back ring (see Fig- y ure 1.87): Where: Q = 640 gpm; Hoop = 925 ft; Heo = 375 tt; Ps = S0psi; n= 3550 rpm; Dp = 9.44 in; Opp = 478i; Drs = 875i; Dy = 1.8ins s= 6 Ng = 3850(640)5 32575 = 1173 HI Centrifugal Pump Design and Application — 2000 From Figure 1.85, Ky, = 75 From Figure 1.85, K, K4,+K, Ane 78+.65 2 D, AB _ 3.75 , “Dy * gag = 40 From Figure 1.65, K,, = 2 Kat _ at Kan 754.60 69 'e z 2 Ag = .785 (9.44?— 3.75%) = 59 (sq, in.); Ag, = 785 (3.782~ 1.52) .3 (sq. in.); Ag = .785 (9.44 — 4.752) 52.2 (sq. in.); Ay = .785 x 1.5? = 1.8 (9q. in). + Ag, x108—A,P, 971(.69 x59) - (.70 x 52,2)) +9.3x 1091.80 x50 Fy, = 410 lb towards suction *!The average pressure behind the back ring is 10 pst greater than suction pressure, when the area of the, balance holes equals three times the area of the Clearance of the back ring,HI Centrifugal Pump Design and Application — 2000 1.3.4.7.4 Guidelines for bearings and lubrication methods 13.47.41 Introduction ‘The type of bearings and lubrication system selected for a given pump application depend on the magnitude and direction of radial and axial loads imposed by the impeller and the rotational speed. Factors affecting loading are pump volute design, tolerance, misalign- ‘ment, rotor unbalance, service conditions, pump oper- ating point, and the type of pump supplied. Rolling element bearings will typically have associated With them an L-10 lifetime based on speed, operating loads and manufacturers rated capacity. Nominally, this means that 90 percent of all pump bearings should still be serviceable after this lifetime has elapsed. The lifetime (fatigue failure point) is rarcly realized because premature failure occurs as a result Of static overload, corrosion, lubricant failure, contami- nation or overheating. Selection and maintenance of the lubrication system is a critical factor in improving actual bearing life. Selection of bearing type and lubrication method is usually @ part of the pump design process. The bear- ing type and lube system design become an integral Part ofthe overall pump design. The end user may not have a choice, or options may be limited, as to alterna- tive bearing types and lubrication methods, 1.3.4.7.42 Bearing types 1.3.4.7.4.2.1 Rolling element bearings Various rolling element bearing designs are shown in Table 1.3.5. This table is not meant to be all-inclusive, but to represent the most common designs used in pumps. Generally, the ball bearing misalignment better than the cylindrical or tapered roller bearing designs. The ball bearing designs tend to run cooler than roller bearings due to lower friction but demonstrate lower load capacities. These designs are found on many chemical, petroleum, food and other process applications. Cylindrical roller bearings are typically used for siower speed, high radial load applications such as slurry transfer service. The use of spherical roller bearings provides higher load capacity than with the oylindrical roller bearing while also allow- Ing greater misalignment tolerances and some thrust loading. The tapered roller bearing exhibits the highest thrust and radial load ratings but is more sensitive to misalignment and poor lubrication. 1.347.422 Sleeve bearings Sleeve bearings operate on a sliding principle, the Proper operation of which depends on the mainte- ance of a lubricating film between wear surfaces. This lm is dependent upon lubricant viscosity, shaft speed, bearing running clearance and length and radial pressure on the bearing. Heat build-up and wear can be appreciable if there is insutficient lubrication. ‘Subsynchronous shatt whirling (orbiting) in the bearing Table 1.3.5 — Rolling element bearing types Bearing Type 1) Single row deep groove ball bearing 2) Double row angular contact ball bearing (Conrad styie) 3) Duplex (2) angular contact ball bearings 4) Tiplex (3) angular contact ball bearings 8) Cylindrical roller bearings 6) Spherical roller bearings 7) Duplex (2) tapered roller bearings Description ‘Accept low thrust in either direction and radial loads. ‘Accept high thrust in either direction and radial loads. Designed for improved higher thrust capacity than double row with good radial loads. Greater thrust rating, but cooling and lubrication more critical due to higher bearing friction, Designed specifically for very high radial loads. Alignment tolerances critical. Excellent for high radial loads, some thrust capacity Spherical outer race design increases alignment toler- ances. Excellent thrust and radial load capacity. Alignment, cooling and lubrication very eriticalresults when the lubrication film viscosity and thick ess are not adequate to dampen the dynamic action of the shaft. It is for this reason that shaft and bearing Materials are carefully chosen to minimize the coetti- lent of friction and optimize wear properties. Sleeve bearings can be cylindrical, grooved, elliptical, lobed or tilting pad designs. Cylindrical offers the advantage of simple design. The groove design facil- tates the expulsion of solids and contaminants from the bearing. Elliptical, lobed and titing pad designs have lower load capacities but demonstrate greater shaft stability especially for vertical journal bearings. ‘They are particularly useful for high speed, low load applications. An exception to this is the Kingsbury-type titing pad bearing, which exhibits very high thrust load capacity. Vertical turbine pumps and sump pumps use product lubricated sleeve bearings of the cylindrical and grooved design. Typical materials are metal alloys, rubber, and other nonmetallics. Table 1.3.6 lists some vertical turbine pump bearing materials for various applications, Sealless magnetic drive and canned motor type Pumps also use cylindrical or grooved type product lubricated bearings. Common materials for these applications are silicon carbide and graphite. 1.3.4.7.4.3 Bearing lubrication 13.47.43.1 Grease Grease lubrication is often used with rolling element bearings because this design facilitates the thorough dissemination of lubricant over the wear surfaces. Internal grease is heated to semi-liquid while cooler grease at the bearing-housing interface remains solid and acts as a barrier to extemal contaminants as well {85 providing a reservoir of lubricant between re-grease. intervals. Overheating due to inadequate circulation can occur if too much grease is injected into the bear- ing. A rule of thumb is to fil the bearing two-thirds full of grease. This allows room for circulation and expan- sion of grease. Grease is used on tapered roller bearings except at low speeds. It has proven to be an effective lubricant on vertical sieeve bearings where a grease line runs from the mounting plate to each bearing in series. Most designs result in some grease entering the pumped liquid. HI Centrifugal Pump Design and Application — 2000 Shielded/sealed rolling element bearings provide eco- omical maintenance-free service on some limited applications. The bearing is pre-greased and perma- rently shielded or sealed. Shielding is accomplished by using rigid covers attached to the stationary race with a close clearance to the rotating race. Sealing is accomplished by a flexible element attached to the stationary race and rubbing against the rotating race. Care must be taken in applying shielded/sealed bear. ings because there may be no provision to renew the lubricant. However, provisions can be made on shielded bearings to regrease through tie running clearance between the shield and inner bearing race. 1.3.4.7.432 Oil lubrication Various forms of oil lubrication exist. Flood oil uses an oll reservoir for which the level extends to the middle of the lower-most bearing ball. In some cases the oil level may be set higher, although care must be taken to ensure that excessive heat and foaming of the oil will ot be created. Bearing rotation disperses the oil throughout the bearing. Typically, a device is installed for visual inspection of the oil level. Constant level oil- ers may also be used to maintain the required level, Oil rings or fingers are used either to augment flood oll circulation or as a separate lubrication design entirely. For the latter case, the oil level remains below the lower-most bearing ball and the rings are the solo. ‘source of lubricant dispersion. Heat build-up due to the oil being chumed by the bearing balls is eliminated while the ring action substantially improves circulation cooling. Oil rings also deliver a finite supply of oil to the bearings. Oil rings and flingers are superior to flood lubrication particularly at high speeds; Dyn > 300,000 where Dm = 0.5 (I.D. + O.D,) in mm, and n = operating speed, rpm; and at loads where oll churning can sig- nificantly increase heat build-up. However, speed limits exist with oll rings to ensure proper ring rotation on the shaft without slippage. An evaluation must be made for high temperature services as oil cooling may be required to keep bearing temperature to an acceptable level. il mist lubrication is a centralized system providing a continuous pressurized feed of atomized oil through- ut the bearing housing. Purge oll mist uses a conven- tional oil sump, with the mist being used to purge the housing and replenish nominal oll loss. This action facilitates dissemination of oil over the bearings, improves cooling and prevents the intrusion of ambient ait and moisture. Oil in the mist will condense in the bearing housing and increase the level in the sump. Provision must be made to drain off this excess oil, 65HI Centrifugal Pump Design and Application — 2000 Purge oil mist does not eliminate the potential for bear- ing oxidation and wear from oil additive breakdown and wear particle contamination. The oil in the sump _ fresh oi must still be changed periodically. With pure oil ‘The bearing is lubricated by a continuous supply of ist, no lubricating oil sump is necessary. Turbulence generated by bearing rotation causes oil particles suspended in the oil mist stream to condense on the rolling elements. ‘Table 1.3.6 — Product lubricated sleeve bearing material selection guide (commonly used in vertical turbine pumps) “Temperature & with Babbitt Material Description S.G. Limits Remarks 1) Bronze SAE 660 (Standard) — 4510 120°C | General purpose material for nonabra- ASTM-B584-C93200 {-5010250°F) | sive, neutral pH service. Min, 8.6. of 0.6 _ | 7% Tin, 7% Lead, 3% Zinc, 83% Cu. 2) Bronze SAE 64 (Zincless) = 45 to 80°C Similar to standard bronze. Used for salt= ASTM-B584-C93700 (- 5010 180°F) | water service. Min. $.G. of 0.6 | 10% Tin, 10% Lead, 80% Cu, 3) Carbon-Graphite impregnated = 2700 150°C _—_| Corrosion resistant material not suitable (- 450 to 300°F) AIS.G, for abrasive services. Special materials available for severe acid services and for temperatures as high as 340°C (650°F), Good for low specific gravity fluids because the carbon is self-lubricating, (Nitrile Butadiene or Neoprene) 4) Metal impregnated Carbon = 2700 150°C | Corrosion resistant material not sultable Bearings (other than Babbitt) (- 450 t0.300°F) | for abrasive services. Special materials AIS. available for severe acid services and for temperatures as high as 340°C (650°F). Good for low specific gravity fluids, 8) PTFE with 25% Graphite = 450 120°C | Corrosion resistant except for highly ox (8010 250°F) | dizing solutions. Not suitable for abrasive AIS. services. Giass-filed PTFE also available, 6) Cast iron 010 80°C Used on nonabrasive caustic services and ASTM-A-48 CL30 Flash (820 180°F)_—_| some oil products. Avoid water services Chrome Coated Min. SG. of 0.6 | because bearings can rust to shaft when idle. 7) Lead Babbitt 010 150°6 Excellent corrosion resistance to a pH of (3210 300°F) | 2. Good in mildly abrasive services. 80% Lead, 3% Tin, 17% Antimony. 8) Rubber with Phenolic Backing 010 65°O Use in abrasive water services, Bearings (82 to 150°F) must be wet prior to start-up for total pump length of 15 m (50 feet) or more. Do not use for oily services, for stuffing-box bush- ings or with hydraulically balanced impel- lers. For services that are corrosive, backing material other than Phenolic must be specified. 9) Hardened Metals, Sprayed on Stainless Steel Shell (such as. ‘Tungsten Carbide) ‘All Temperatures AIS.G. Alternate for abrasive services. Hardfaced surfaces typically in the range of Re72. Other coatings are chromium oxide, tung- sten carbide, colmonoy, etc. 66Pure oil mist prevents oil sump contamination from wear particles and the breakdown of oxidation preven- O Sve adios. as a result ger pemisee bearing temperatures are possible. Additionally, wear particles are continuously washed away. No. petiodic oil changes are necessary, although proper handling of the condensate/draining must be considered. Oil mist systems will be greater in capital cost but lower in maintenance costs. A fail-safe system is desir- able to shut the pump down in the event of lubrication system failure, Force feed lubrication is used to augment circulation of oil throughout the bearing. Horizontal sleeve and iting pad (Kingsbury-type) bearings may require this feature to ensure that ol is property dispersed over the bear- ing pad or load area. Oil may be pressurized by a shatt-driven pump or independently driven pump. VarF- ous fiters, pressure and temperature gages and heat exchangers can be installed to monitor the ol. The determining parameters for using a force feed system with sleeve bearings are loading, oil temperature and bearing wear surface speed. It is critical that a fail-safe system be employed to shut the pump down upon a feed system failure. ) 1.3.4.7.43,3 Product lubrication Product lubricated bearings are usually of the sleeve. design. They are typically found in vertical turbine type, sealless magnetic drive and canned motor Pumps. Spring loaded, grooved and conical carbon graphite versus hard alloys have also proven successful. Product lubrication is introduced to the bearing either as a result of product flow through the pump and thus directly through the bearing or through a bypass from the main flow. Vertical turbine pumps introduce flow directly, while vertical sump pumps, magnetic drive and canned motor type use a bypass. Various types of external coolers, strainers, orifices, booster pumps, etc., may be used to treat the product before injection into the bearings. The sleeve bearing design is very sensitive to solids content. Various options such as extemal flushing, grease lubrication, etc., may be employed in lieu of direct or treated product flush. Vertical turbine pumps often use a hardened shaft and grooved rubber bear- ing arrangement to alleviate this problem. When rub- ber bearings are used, they must be flushed with clean pcr vsterte proven abrasion, HI Centrifugal Pump Design and Application — 2000 Where abrasive solid cannot be avoided or for extremely abrasive services, two commonly used solu- tions are: 1) extremely hard materials, such as ceram- ics; and 2) an enclosed oil-filled line shaft that isolates the bearings from the pumpage, extending their life but at a greater initial cost. ‘Caution is necessary to ensure that product lubricated bearings are not allowed to run dry. Table 1.13 provides applications guidelines for a vari- ety of sleeve bearing materials. This table is based on Use of the materials in vertical turbine pumps under product lubrication. Some of the materials may be suit- able for other pump types. 1.34.75 Type of couplings 1.3.4.7.5.1 Offset (flexible or drive shaft) This type of coupling is more often called a drive shaft and has a universal joint at each end plus a slip joint at ‘one end to permit free axial movement. A large diame- ter tube connects the two universal joints. The assem- bly has flanged yokes at each end to connect to the flanged hubs mounted on the driving shaft and the driven shaft. These “couplings” are best used to advantage when the driver and driven units are installed on separate foundations. The maximum par- allel shaft offset amount depends upon the speed and is obtained from the coupling manufacturer. 1.3.4.7.5.2 Limited end float ‘The most common use of limited end float couplings is with drivers having no axial thrust bearing, such as sleeve bearing motors. Such motors will have rotor end play limits provided on both their outline drawing and on the motor shaft itself. The coupling must be selected to permit the free axial movement of the driver rotor during operation while restricting axial ‘movement within limits established by the driver manu- facturer. Coupling manufacturers can supply buttons or discs to restrict driver shaft end float within the nec- essary limits. This type coupling is normally applied with a centrifugal pump that has a rotor fixed in the axial position by a thrust bearing. Should both the Pump and the driver rotors be free to move axially, the type of coupling must be investigated thoroughly with both the pump and driver manufacturer. 134753 Gear ‘The gear coupling consists of two hubs with external gear teeth and a floating sleeve assembly with internalHI Centrifugal Pump Design and Application — 2000 tooth. The hubs are fitted to the ends of the driver and driven shafts and, as the driving shaft rotates, the driv- ing hub teeth engage the internal teeth so that the entire assembly rotates as a unit. Sliding motion occurs between the teeth, so a supply of lubricant is necessary. This type of coupling Is often chosen for long life, where minimum coupling size is important or ‘where elastomer materials are incompatible with ambi- tent conditions. This type coupling is also applicable for higher than usual operating speeds. It is often also applied when a pump has a balance disk and where the pump shaft must move axially without excessive restraint. 1347.54 Disk This is an all-metal coupling with replaceable flexing element. No lubrication is required, and inspection may be made without disassembly. The coupling nor mally tolerates a wide temperature range but limits angular misalignment. Some couplings of this type will provide limited end float without modification or float restricting devices. This type of coupling has many of the characteristics of a gear coupling without the requirement for lubrication. 13.47.55 Elastomer In this type of coupling, torque is transmitted by com- pression or shear of a flexible elastomer element between the driving and driven hubs. No lubrication is required. The ambient conditions and range of temper- atures are typically restricted by the characteristics of the elastomer. The physical size of couplings in this, category may be larger than for all-metal designs, ‘Speed limitations for this type of coupling are typically more stringent than those for metal couplings. 1.3.4.7.5.6 Speed limitations ‘The maximum speed for a given coupling varies with the type of coupling and the materials from which it is constructed. The limiting speed is always provided by the coupling manufacturer and will be checked by a Pump manufacturer who supplies the coupling, 1347.6 Shaft seals The fluid pumped and the bearing lubricant require shaft seals in most centrifugal pumps. The stuffing-box is equipped with either a mechanical seal or packing. Bearings are equipped with closures or labyrinths, 68 1.3.4.7. 1 Typical schematics The iustations inthe Types and Nomenclature soo tion show some of the mechanical seal types. A dia- grammatic description of the various types of mechanical seals available is shown in Figure 1.88, The pump manufacturer will supply mechanical seal details for the specified service conditions. 1.3.4.7.6.2 Application of mechanical seals Mechanical seals may be applied to virtually any ser- vice and can be used in many applications where Packed stuffing-boxes are not suitable. Some of their Primary characteristics follow: 1) Very low leakage; 2) No periodic adjustment as with packing; 3) Capable of sealing at higher pressures and shaft speeds than packing; 4) For all but the simplest low-pressure cool water pumps, the mechanical seal will be more costly and will require @ much more complete disclosure of the liquid handled, Always give the pump manufacturer complete ( information on the liquid being handled, including the liquid description, suction and discharge pressure, temperature and condi- tion of the liquids (such as the type of solids contained, if any); 5) The piping to seal chambers equipped with mechanical seals is arranged in many ways depending on the type of pump and the appli cation conditions. The application rules for the choice of the flush or circulation piping required are complex, and a user is urged to discuss this point thoroughly with both the Pump manufacturer and possibly the mechani- cal seal manufacturer, ‘The user/specifier must work closely with the pump manufacturer as new pump specifications are devel ‘oped. Some important points follow: ) The manufacturer can best advise if the mechani- cal seal specified is the best selection based on his broad knowledge of pump and mechanical seal application history; b) The manufacturer can best tell you ifthe epeciiod seal will ft his stuffing-box;HI Centrifugal Pump Design and Application — 2000 Mechanical seal classiication T By arrangement By design (© Single seat ©) Multiple seals @ Unbatanced @) Balanced Double tandem (©) Double seals @ Inside mounted Both inside (©) Outside mounted inside outside Tandem Special cariridge ayle Rotary head- rotary seat inside - outside Rotary head- rotary head Rotary seat - rotary seat = @ Rotating head Back back (© Rotating seat Series SS PyPusherivee —] —_[kap) Norepusher ype 0" ting @) Belews wa Wedae OVting @) Packing Lore J Spit seal @ Elastomer Totton ‘ep Metal (5) Single spring (ers) Mullipie spring Figure 1.88 — Mechanical seal classifications ©) The manufacturer can best advise you that the metallurgy of the seal specified will be compatible with the pump. With the many mechanical seal types available, it is, recommended that full disclosure of operating condi- tions be given to the pump manufacturer rather than writing specific seal construction specifications. 1.3.4.7.6.3 Packed stuffing-box ‘The two most common stuffing-boxes are those with- out lantern rings and with lantern rings. The two fig- tres below show these two constructions. ‘The construction in Figure 1.89 is used where suction Pressure is above atmospheric and where pumped fluid is clear and its leakage to atmosphere is acoept- able. This type of stuffing-box is often used on mul stage pumps at the inlet of the second (or higher) stage impeller. The type of stuffing-box in Figure 1.90 is used where suction pressure is below atmospheric or at a low pos- itive pressure with the possibility that pressure may be below atmospheric. Often a clear pumped liquid is piped from the first stage discharge volute to provide the liquid for sealing and lubrication. When the pumped liquid is dirty or over 93°C (200°F), an exter- nal clear, cool liquid is connected to the tapped open- ing over the lantern ring of sufficient pressure to provide slight flow into the pump. Figure 1.89 — Stuffing-box without lantern ring 69HI Centrifugal Pump Design and Application — 2000, Other special purpose stuffing-boxes provide for cool- ing, throat bushings, quench glands and other special features for unusual service. Packed stuffing-boxes normally are limited to moderate pressures and tem- Peratures and require a slight leakage for packing lubrication and cooling. Care in adjusting the packing gland is required to avoid shaft sleeve and packing damage. The number of packing rings in the stuffing- box, the size of packing, together with the type of packing vary by manufacturer. In most cases, itis rec- ‘ommended that specifications omit exact details about the number of rings or the size or type of packing and let the pump manufacturer make his recommendation based on historical experience. 13.4. 4 Other sealing means Alternatives to mechanical seals or packed stuffing- boxes are available. Limited-leakage labyrinths are used for some large high-speed boiler feed pumps. Dynamic seals use an auxiliary impeller in the stuffing- box area to prevent leakage in severe corrosive or abrasive sealing applications in the process industries. In most applications these dynamic seals eliminate the need for seal water and therefore eliminate dilution of the product being pumped, Dynamic seals should be considered whenever a seal water supply is unavail- able or normal stuffing-box leakage of the pumpage is unacceptable. Stuffing-box maintenance is also greatly reduced with this type of seal. 1.3.4.7.6.5 Bearing housing closures, labyrinths Closures are typically lip type oil seals near a pump bearing to retain oil or grease and to exclude moisture and foreign material from the bearing space. An accu- rate and smooth shaft surface and concentric bore for the closure are requirements for optimum sealing. Since an oil seal has a lip that rubs on the shaft, there may be speed limitations that necessitate consider- ation of a labyrinth, J Figure 1.90 — Stuffing-box with lantern ring | 70 ‘A magnetic oil seal is sometimes used in place of a type oil seal. The magnetic oil seal is similar to a lip type mechanical seal but has a magnetized stationary ring mated to the rotating ring, This type of seal is also very compact. A labyrinth is a device that relies on the close clear- ‘ance path for the lubricant as it tries to leak out of the bearing housing. A return passage drains lubricant back fo the housing. This device is insensitive to speed, since there is no contact with the shaft. Life is indefinite. 1.34.77 Shaft deflection 1347.74 Description Shaft deflection is @ design criterion that greatly influ- ences pump performance due to its effect on the mechanical seal, intemal clearances and bearings. For a mechanical seal to reach its design life, a num- ber of requirements have to be met. From a static or dimensional point of view, the relative locations of the primary, stationary and rotating faces must be held within close tolerances. These tolerances can be met by using sound manufacturing procedures and processes. Dynamic deflection of the pump shaft changes the rel- ative location of the mechanical seal faces and thus has a large impact on the overall seal life In addition to influencing seal performance, limiting the deflection of the shaft will also improve satisfactory packing life, Internal clearances are also a function of shaft deflec- tion and can be verified with the shaft deflection equa- tions at critical locations. Shaft deflection can also have an effect on pump bear- ing life. Shaft defiection directly affects the angular misalignment between the inner and outer rings of the bearing 1.34.7.7.2_ Overhung impeller pumps, ANSI/ ASME B 73.1M “Dynamic shaft deflection at the impeller centerline shall not exceed 0.125 mm (.005 inches) at Maximum Load for pumps up to 75 * 100-250 (3 x 4-10) or Design Load for pump sizes 100 x 150-250 (4 x 6-10) and larger.”Maximum Load: Maximum hydraulic load on the larg- ‘est impeller operating at any point on its maximum. speed curve with a liquid specific gravity of 1.0. Design Load: The Maximum hydraulic load on the largest impeller operating within the manufacturers allowable operating range on its maximum speed curve with a specific gravity of 1.0. 1.3.4.7.7.3 Overhung impeller pumps, API Standard 610 Maximum shaft deflection is 0.05 mm (.002 inches) at the face of the stuffing-box or seal chamber and less than one-half the minimum diametral clearance (as specified in API 610) at all bushings and wear rings at the most severe dynamic conditions over the complete head versus rate of flow curve, with a maximum diam- eter impeller operating at specified speed. HI Centrifugal Pump Design and Application — 2000 1.3.4.7.7.4 Overhung impeller pumps, ISO 5199 Maximum shaft deflection is 0.05 mm (.002 inches) at the face of the stuffing box within the allowable operat- ing range of the pump at operating speed, Pump shafts should be designed to meet or exceed the appropriate specification to ensure satisfactory performance of the pump and sealing mechanisms. {f hydraulic radial load test data is not available, hydraulic radial loads can be calculated in accordance with Section 1.3.4.7.2, Calculations of Radial Thrust for Volute Pumps. 13. 7.8 Shaft deflection calculation methods Overhung Impeller Method P (Neglecting Coupling Weight) } Da For: 0. Figure 1.91 — Overhung impeller aHI Centrifugal Pump Design and Application — 2000 Impeller Between Bearings Method (Neglecting Coupling Weight) P For: X 0;0 = Impeller Centerline ~ P| (C+B)9-0? (A+ B+0)8-(B+ 0 Bo = ger[ Oe AES Ga Be oF E+O") For: 0 aphpceg Roller Bearings) Stacking bearings together to improve load caning ( capaci and ife doesnot incease the eapacty pro. portional to the number of bearings stacked. Thereader is referred to ANSI/AFBMA Standard 9 or 11 for further details of calculating the load carrying capacity and life. 1.3.4.7.8.3.2 Adjusted rating life ‘The basic rating life is associated with a 90% reliability for commonly used bearing materials and manutac- turing quality, and under conventionally clean, well- lubricated operating conditions. Some manufacturers offer materials with a higher fatigue life that will result in a greater bearing life. Also, many applications involve lubricating conditions that may difer from stan- dard cleanliness. Under other than standard condi tions the basic rating life is adjusted by means of three factors: bra = A Ag@qlig The lite adjustment factor for reliability, a4, is used to calculate an adjusted life for a reliability greater than 90% according to the following table: Reliability % Ln a; 20 Lio 1 \ 95 o 0.66 96 ly 053 97 G 0.44 98 a 0.33 99 G 021 ‘The life adjustment factor for special bearing proper- ties, ap, accounts for special material and/or manufac- turing or design characteristics. Values of this factor should be obtained from bearing manufacturers. The life adjustment factor for operating conditions, as, accounts for adequacy of lubrication and cleanliness inthe bearing cavity. The basic rating life is based on a minimum lubricant viscosity of 13 cs (70 SSU) at the operating temperature. A value of ag less than 1 should be considered if the lubricant viscosity is less. Similarly, the basic rating life assumes no foreign part- les are present in the lubricant. For pumps installed in dusty environments, or ones in which large tempera- ture swings occur which could cause condensation in the bearing cavity, a value of as less than 1 should be considered. For extremely clean environments, such as may be obtained with an oil mist lubrication, it may {2 lustiable to select a value of ag greater than 1 HI Centrifugal Pump Design and Application — 2000 13. 8.3.3. Bearing temperature The operating temperature of a bearing housing will vary greatly with the design and application. in many cases, the greatest contributor to bearing heating is churning of the lubricant. Exceeding the dosign oil level, or overgreasing a bearing, can raise the bearing ‘operating temperature by 22°C (40°F) or more above normal. Achieving the design beating life is contingent on maintaining an adequate quality and viscdsity of the lubricant. The minimum lubricant viscosity at the actual lubricant temperature should be 13 os (70 ‘SSU). For greases this should be the viscosity of the base oil. Mineral olls degrade rapidly at elevated temperatures. ‘A tule of thumb is that the degradation rate of the oll characteristics doubles for every 10°C (18°F) tempera- ture rise above 60°C (140°F). For this reason, it is often recommended that a maximum lubricant temper- ature of 82°C (180°F) be observed when using mineral ois, Lubricant temperature should be directly measured in the sump as the oil drains off the bearings. If that is not Practical, the lubricant temperature can be estimated at 11°C (20°F) above the outside temperature of the bearing housing at the bearing. 1.3.4.8 Impeller types 1.3.4.8.1 Single suction Impellers of this type have a single inlet for liquid entry, from where it is discharged either radially or semi- axially. Various means to control axial imbalance are used, 1.3.4.8.2 Double suction Impellers of this type have dual, opposed inlets for liq- uid entry, from where it is discharged radially into a ‘common stream. The discharge specific speed is typ cally below 5200 (4500). This impeller type can be used where the available NPSH is restricted for the desired pump operating speed and is inherently bal anced in the axial direction. 1.3.4.8.3 General Impellers described in the three following paragraphs are generally used in a wide variety of services. For certain specialty services, one type may be preferred 75HI Centrifugal Pump Design and Application — 2000, over the others. In all cases, however, the users and manufacturers experience is the best guide for their selection. Other special impeller types (such as vor- tex) may be offered for special applications. 1.3.4.8.3.1 Enclosed This impelier type is used for all pump types and for most applications, both single and double suction. The impeller has vanes fully enclosed. Efficiency can nor- mally be restored to original levels by renewal of the original clearances at the impeller inlet or inlets to the adjacent casing or casing wear ring. 1.3.4.8.3.2 Semi-open This impeller type is applicable only to single suction Pumps and has the vanes enclosed by a full or partial shroud on one side only. The exposed vanes run in close proximity to a matching casing wall or liner. The rotating element should be axially adjustable in the pump. 1.3.4.8.3.3 Open This type of impeller has no front or back shroud with vanes running in close proximity to matching casing walls or liners, As with the semi-enclosed impeller, axial adjustment should be possible. This design pro- ‘duces fow axial thrust. 13.4.9 Casing type 134.9.1. Single volute ‘An impeller discharges into a single spiral passage with one cutwater (tongue), and liquid discharges from the pump or into the next stage of a multistage pump. Ragial thrust varies with pump rate of fiow, with this type volute being lowest near BEP, and higher at reduced or increased flow rates. Radial thrust also var- ies with impeller diameter, impeller width and total head. Shatt deflection, combined maximum stress and bearing loads must be kept within acceptable limits by various means for best operation 1.34.92 Double volute ‘An impeller discharges into two spiral passages with two cutwaters (tongues) and fluid discharges from the Pump or into the next stage of a multistage pump. With Properly designed passages, radial thrust is mini- mized. Double volute is typically used to reduce shaft deflections or bearing loads or to permit use of a 76 ‘smaller shaft and bearing sizes. The casing complexity is greater than that for the single volute type. 1.3.4.9.3 Multi-volute (diffuser) An impeller discharges into multiple divergent pas- sages (normally two or more) with the casing as a sim- ple collector chamber directing fluid into the pump discharge or the next pump stage. This design is most often supplied in multistage pumps and for any head amount. With the diffuser design, radial thrust imized. 1.34.9.4 Corrosion allowance for metallic centrifugal pumps ‘The internal walls of pressure-containing pump com- Ponents subjected to corrosive attack shall be pro- vided with additional metal thickness over and above that required to meet the design conditions of deflec- tion, pressure, stress, nozzle loading, casting toler- ance and temperature. The end user should be cognizant of the manufacturer's corrosion allowance in the selection of pumping equipment. Material added for this purpose need not be the same thickness throughout if different rates or types of corro- sion attack are expected. ‘Typical corrosion allowances often specified for cast ‘components in contact with the pumped liquid are: + Water Pumps ... 1.5mm (.08 inches) * Chemical Pumps... 3mm ——(.12 inches) ‘* Boiler Feed Pumps... 3mm ——_(.12 inches) ‘The above criteria relates to centrifugal pumps located ina dry pit environment. Pumps submerged in a sump whose external surfaces are also subjected to corro- sion may require additional corrosion allowance. 1.3.4.10 Drivers: type and size In addition to being able to start the pump, the driver shall be sized to meet the load requirements of the Griven equipment throughout the normal operating range of the pump. These load requirements must consider torque, thrust, and inertia and must also reflect any additional requirements of accessory ‘equipment such as gears and fluid couplings. The type of driver will be specified by the purchaser.1.3.4.10.1 Electric motors For sizing, electric motors are specified by rated power, and service factor. Usual practice is to select the motor, such that its rated power is at least equal to the expected maximum continuous power required. The service factor is intended to cover incidental overload; thus, its magnitude depends upon the expected extent of overload. Refer to standards of the National Electri- cal Manufacturers Association (NEMA), latest edition, for further information. For smaller pumps with over 700 kPa (gauge) (100 psig) suction pressure, the motor size may need to be chosen based on the start- Ing torque required for the stuffing-box(es) or sealing device(s). 1.3.4.10.2 Engines Engine ratings are qualified by the severity of service, the extent of accessories, combustion alr conditions and performance variations due to manufacturing tok erances. Engine sizing is dependent on’ many factors, including brake horsepower required at various pump operating conditions, the duration of such operation and ambient conditions (altitude and temperature). 1.3.4.10.3 Steam turbine Steam turbine ratings are specified for particular inlet and exhaust steam conditions. Sizing is usually based. ‘on maximum continuous power required. Overloads, if applicable, are accommodated by allowing the turbine to slow down or by opening additional steam admis- sion valves. The expected load range and the desired load response should be given to the turbine manufacturer. 1.3.4.10.4 Magnetic drives In centrifugal pump drive trains, magnetic drives are used to vary pump speed. Losses to be taken into account in determining drive rating are slip, windage, etc. Magnetic drive selection is based on the torque to bbe transmitted and slip loss dissipation capacity. 1.3.4.10.5 Deceleration devices |n some applications, it is desirable to provide addi- tional rotating inertia in a pump in order to slow its rate of deceleration when power from the driver is cut off This slower deceleration may be necessary in order to maintain some limited flow and pressure for a longer than normal interval. This allows more time for check valves and other flow-control devices to work. The HI Centrifugal Pump Design and Application — 2000 result is less likelihood of damaging backflow through the pump or water hammer effects on the system. ‘Additional rotating inertia is usually provided by adding a flywheel to the drive train. The flywheel may be mounted on its own bearings, it may be part of the ump, or it may be mounted on either end of the motor shaft ‘TYypically, the moment of inertia of the flywheel might be equal to the moment of inertia of the pump/motor combination. While larger flywheels would increase the coast-down time of the pump, they are also more costly and may exceed the starting capabilities of the driver. Flywheel applications should be carefully analyzed to match need and performance before they are installed. 1.3.4.10.6 Variable speed drives and gears Centrifugal pumps can be accurately matched to sys- fom requirements that vary with time either by throt- ting the pump discharge or by changing drive speed. Control of the direct connected pump and driver speed can be manual or automatic. Variable speed drivers may be AC or DC electric motors, steam or gas tur- bines, internal combustion engines, variable frequency drives, or other devices. Intermediate variable speed hydraulic and mechanical drives are also used between the pump and a constant speed driver. For the pump manufacturer to make a proper selection, the operating conditions over the full range of rates of flow and heads must be provided. Suction conditions over the full range are most important. Possible vibra- tion problems must be checked over the full speed range by the manufacturer for all components in the set. The user must consider mounting arrangements more carefully than for a constant speed unit. The Giver and its automatic control when used must also be matched carefully to each other and the system requirements. Contritugal pumps may be operated at speeds other than the driver speed by using intermediate gears. The maximum permissible pump speed must not be exceeded. The lubrication system for gears requires careful maintenance. Cooling is often required using air or water. Noise levels may be a consideration when gears are employed. A user choosing a gear must check pump operating speeds with the pump's manu- facturer to avoid operating at or near critical speeds,HI Centrifugal Pump Design and Application — 2000 1.34.11 Pump liquid temperature limits on end suction pumps. Limits are placed on pumped liquid temperatures because of heat that travels from the pump casing through the shaft, motor adaptor or bearing frame. ‘This heat raises the bearing lubricant temperature and can adversely affect internal bearing clearances due to differential expansion. For pumps using close coupled motors, the motor winding temperature will increase. Bearing lubricant temperatures above 80°C (180°F) ccan cause the lubricants to oxidize and lose their lubri- cating ability, The degradation of the lubricant will shorten bearing life. itis possible with special bearings and synthetic lubricants to operate above the 80°C (180°F) limit. Itis also possible to control pump lubricant and bear- ing temperatures by external cooling. This can be ‘accomplished with either a coo! liquid passed through a finned tube immersed in the bearing lubricant or through passageways designed into the bearing frame or stuffing-box cover. Fins on the bearing frame exte- rior with air blown over the bearing frame by a fan is also an effective cooling method, ‘Temperature limits are also imposed by the materials of construction of the pump. For example, cast gray iron is limited to 175°C (350°F) due to its mechanical strength, whereas ductile iron has a higher limit of 340°C (650°F). Many factors including pump liquid temperature, ambi- ent conditions, speed, bearing type, lubrication method, pump design and cooling methods influence the final bearing lubricant temperature, The guidelines in Table 1.3.7 and 1.3.8 are based on general experi- ence and are commonly adopted in the pump industry. For temperatures beyond these limits, consult the pump manufacturer. Deviations can be justified based ‘on special design, testing and field experience. 1.35 Horizontal pump baseplate design 1.3.5.1 Introduction This standard establishes the minimum technical design criteria to be used in designing horizontal cen- trifugal pump baseplates. The criteria herein are appli- cable for all baseplates, although additional or more stringent criteria may apply to certain classes of equip- ment, such as high-energy pumps, and should be specified accordingly. Included within this standard are. criteria for dimensioning, tolerancing, working stresses and stiffness. Design features such as style of base, drip collection features, continuous versus intermittent, weld, etc., are not covered. Table 1.3.7 — Guidelines for minimum and maximum pump liquid temperature for cast grey iron and ductile iron pumps (°C) Frame Mounted Pumps Close Coupled Pumps Minimum Temp. “Without Cooling With Cooling Without Cooling With Cooling Material °C °C. °c °C °C Cast Gray ron 30 175 175 120 175" Ductile Iron =30 175 340 120 175-340" * Temperature limit is dependent on cooling system design. Table 1.3.8 — Guidelines for minimum and maximum pump liquid temperature for cast grey iron and ductile iron pumps (°F) Frame Mounted Pumps Close Coupled Pumps Minimum Temp. Without Cooling With Cooling Without Cooling With Cooling Material oF °F °F °F °F Cast Gray Iron 20 350 350 250 3508 Ductile Iron 20 350 650 250 350-650" * Temperature limit is dependent on cooling system design. 738 (This standard is not intended to cover baseplates for Pump designs in which the driver and pump are inte- gral. Such machines do not have separate shafts which require alignment. Examples of pumps with into- gral drives are close coupled pumps and canned motor pumps. 1.3.5.2 Functional requirements The purpose of a baseplate is to provide a foundation under a pump and its driver that maintains shaft align- ment between the two. This baseplate must allow for initial mounting and alignment of equipment, survive handling during transportation to the installation site, be capable of being installed properly with minimum difficulty, allow final alignment of the mounted equip- ment, and allow removal and reinstallation of equip- ment, It must be recognized that it is not necessary that an absolutely rigid baseplate be designed to meet these requirements. At the same time, the baseplate must not be permanently deformed after the equip- ment is mounted at the manufacturing facility. Compli- lance with these design criteria, in conjunction with proper installation procedure, will contribute signifi cantly to meeting the functional requirements. 1.35.3 Definitions 1.3.5.3.1 Baseplate A structure to which a pump and driver are mounted. The structure usually consists of sub base to which the pump is mounted, and a Superstructure/s or riser block/s mounted on the sub base, upon which the driver or gearbox is mounted. 13.5.3.2 Grouted baseplate A baseplate design which relies upon a poured in-place grout for most of the baseplate’s installed rigidity. The baseplate is designed to allow grout to be placed underneath and fully support it. See Figure 1.93. 1.35.33 High-energy pump See ANSV/HI 1 12-2000, Centrifugal Pumps for Nomenclature and Definitions, Section 1.2.6.6, SUPERS RUCTURE /NOUNTEME ALK Figure 1.93 — Grouted baseplate HI Centrifugal Pump Design and Application — 2000 1.35.34 Mounting blocks A means of elevating a ump, driver, or gearbox so that the centertines of the mating shafts are collinear. Mounting blocks are not fastened permanently o the baseplate, but are usually held in place with bolting. Individual blocks may be used under each foot of the elevated component, or the block may be large enough to encompass all feet. When the elevating surface is integral with the base, i.e., welded or cas, itis referred to as a mounting pad. See Figure 1.93, 1.35.35 Mountingpads The contact surfaces upon which the pump and driver rest. Often the con- tact surface is the surface of the sub base or super- structure. In some cases a raised integral surface is used for mounting and is usually machined. See Fig- ure 1.93. 1.38.3.6 Shim A thin plate (usually metal) placed under a driver or gearbox foot to elevate it. Shims are Jess than 6 mm (.25 inches) thick. Thicker plates are referred to as mounting blocks. See Figure 1.93. 1.35.3.7 Free standing baseplate A baseplate design which is intended to be elevated off the floor and supported by stits or shims. This type of base~ plate must be designed to provide its own rigidity as there is no grout for support. See Figure 1.94. 1.35.3.8 Sub base The basic structural element in a baseplate. A sub base extends under both pump and driver. See Figure 1.93. 1.35.39 Superstructure A fabricated structure, fastened permanently to the sub base, which is used to elevate either pump or driver. See Figure 1.93. Optional tits Figure 1.94 — Free-standing baseplateHI Centrifugal Pump Design and Application — 2000 1.3.5.4 Tolerancing ‘Small pumps, less than 7.5 kW (10HP), are often mounted on unmachined, light duty baseplates, here- after termed Class C baseplates. Heavier duty small process pumps, less than 150 kW (200 HP), are often mounted on heavier duty Class B baseplates which provide greater rigidity and more consistent mounting surfaces. Because of more precise coupling require ments for larger pumps, baseplates for pumps requir- ing 150 kW (200 HP) or greater are often mounted on machined baseplates, hereafter termed Class A baseplates. Driver size does not necessarily determine the class of baseplate. Installation procedures along with equip- ment size are factors taken into consideration when specifying the class, Design criteria and manufacturing tolerances are defined below, and tolerances listed for each base- plate class in Tables 1.3.9 and 1.3.10. Table 1.3.9 ~ Metric manufacturing tolerances Criteria A B Bmax ct c2 D Class mm mmm mm mm mm mm = Nemirad A 32 017 025 O.47im = 0.47Im 025 1.4« 108 B 32 1.25 152 0.75 075 075 1.4% 108 Cc 3.2 2.50 3.00 0.75 0.75 0.75 6.8 x 104 NOTE: For bases longer than 2.6 meters the values may be doubled. ‘A~ Tolerance, mounting surface height from plane of baseplate bottom — Mounting surface flatness per unt of mounting surface length C1 ~ Driver mounting surtace co-planarity(f surfaces are separate) C2— Driven equipment mounting surface co-planariy (if surfaces are separate) D - Parallelism of equipment mounting surfaces (if surfaces are separate) Kron ~ Torsional stiiness Table 1.3.10 — US units manufacturing tolerances Criteria A B Borax ct c2 D Kor Class inches inft inches inches inches inches in Ib/rad A 125 002 010 o02ft 002i 010 1x 10% B 125 015 060 030 030 030 1 108 c 125 030 120 030 030 060 5x 104 NOTE: For bases longer than 96 inches, the values may be doubled. ‘A~ Tolerance, mounting surface height irom plane of baseplate bottom 8 — Mounting surface flatness per unit of mounting surface length C1 ~ Driver mounting surface co-planarity (if surfaces are separate) C2 Driven equipment mounting surface co-planarity (if surfaces are separate) D ~ Parallelism of equipment mounting surfaces (if surfaces are separate) Kop ~ Torsional stiffness 80 (All tolerances should be reviewed carefully in terms of necessity. Excessively tight tolerances increase manu- facturing cost, while excessively loose. tolerances increase assembly or rework costs. 4) Height of all equipment mounting surfaces, (Figure 1.95) measured at the corners, from the plane of the bottom of the base, shall be toleranced as, listed in the columns labeled A in Tables 1.3.9 and 1.3.10. ») Equipment mounting surface flatness (Figure 1.96) is dependent on the greatest length of the ‘mounting surface. The column labeled B in Tables 1.3.9 and 1.3.10 denote the flatness per unit of length. The maximum flatness is subject to a limit ‘as provided in columns labeled Bmax- ©) Motor mounting pads, when separate (Figure 1.97), shail be co-planar with each other within the values listed in columns C1 of Tables 1.3.9 and 1.3.10. The pump mounting pads, when separate, shall be co-planar with each other within the value listed in columns C2 in Tables 1.3.9 and 1.3.10. 1 pump and motor mounting surfaces are separate, the planes of the pump and motor mounting surfaces shall be parallel to each other within the values listed in column D. jure 1.95 — Height of mounting surfaces Bn 1 I] Bax Figure 1.96 — Equipment mounting surface om — Figure 1.97 — Motor mounting pads HI Centrifugal Pump Design and Application — 2000, If the equipment mounting surfaces are to be machined, the sub base shall not be distorted from its free-standing position by clamps during the pad machining operation. Shim whore necessary: under the base before clamping. Coupling alignment requires accurate driling of driver, gearbox, and pump mounting holes. Pump and driver ‘mounting hole tolerancing must be carefully reviewed to ensure that coupling alignment can be attained. The required tolerancing on mounting holes is a function of the clearance between the mounting fasteners and the holes in the equipment feet, the distances between the equipment mounting holes, and the distances from the end of the driven equipment shaft to the driven equip- ment mounting holes. These relationships vary with different types of equipment, but tolerances greater than 0.75 mm .030 inches) expressed in terms of true Position, would be unusual. It is recommended that all tolerancing be done from one mounting hole. An ‘example is shown in Appendix B where tolerancing is done from a motor mounting hole. 1.3.5.5 Shims and fasteners ‘A minimum of 3 mm (.125 inches) of shim pack thick- ness shall be provided under all drivers. Because of the pad height and parallelism tolerances, it is often necessary to design for a shim pack thickness of 9 mm. (875 inches) under the driver to ensure that the mink mum of 3 mm (.125 inches) will be achieved. Baseplates are not normally designed with shims Under the pumps, although drive trains involving three Pieces of equipment may require shims under the Pump for alignment. Good engineering practice limits the number of shims in a pack to five or less. Installa- tion instructions shall emphasize the importance of minimizing shims. Fasteners used in driver mounting holes should be 3 mm (.125 inches) diameter smaller than the nominal mounting hole diameter where possi- ble. The minimum fastener size for mounting equip- ment is 9 mm (.375 inches) except on 215 frame and smaller motors. When washers are used under fasten- ers, they shall be either hardened or extra thick. 1.3.5.6 Stress levels, The baseplate shall be designed so that the maximum. Static stress in the sub base shall not exceed 20% of the baseplate material yield strength (YS) when the baseplate is lifted at any corner with the equipment ‘mounted. Weight of the sub base and superstructure shall be included. Superstructure and equipment ‘weights shall be treated as point loads applied at their 81HI Centrifugal Pump Design and Application — 2000 respective centers of gravity. Credit shall not be taken for base strengthening due to the superstructure. If shear stresses in welds are kept below 20 MPa, (3000 psi), reinforcements welded to the underside of the base can be considered to form a composite section rather than individual sections. These recommendations are based on the following assumptions: a) The material used for the sub base has a yield strength of 200 MPa (30,000 psi). b) Normal handling in transit and on the job site will subject the baseplate to maximum shock loads of 39's vertically when the baseplate is supported on the comers. Thus a static stress of 20% of YS, 40 MPa (6000 psi), will increase to 60% of YS, 120 MPa (18,000 psi), working stress. ©) The structural complexity of a baseplate and the uncertainty of the welds require a factor of safety of 1.5 at yield. )_ If’ shock loads greater than 3 g's are expected dur- ing transportation, the baseplate shall be skidded ina manner to provide adequate support. ©) Normal liting processes will subject the unit to a maximum shock load of 8 g's vertically, or in the direction of lifting. Welds that are loaded during lifting operations shall be designed with a static stress of 13 MPa (2000 psi) or a working stress level of 40 MPa (6000 psi) It the above stress level criteria becomes impractical to meet, consideration should be given to shipping the driver separate from the base, and mounting it after the base is installed in the field. Example 1. (Metric units) A baseplate is designed as shown in the drawings below and is to be fabricated from 12-mm thick carbon steel. All welded joints are welded on both sides with a continuous filet weld whose throat dimension is 10 mm. It is desired to mount a 450-kg pump and a 550-kg motor on the base. The center of gravity of the motor is 450 mm in from the left end and the center of gravity of the pump 's 380 mm in from the right end. What is the maximum stress in the base? 82 swodg eel tg _ soem [Ory Fy ae “75 men | 00 nn +} scone, SOLUTION ‘The worst design case occurs when the baseplate is supported only at the ends. To calculate the shear dia- grams, the unit weight of the baseplate must be calcu- lated, For the 900-mm length of the superstructure—sub base section, the unit weight is 2 Nimm (21 kg/mm) and for the remainder of the sub base 1 Nimm (12 kg/ mm). Thus the free body diagram becomes: ry 1550 kg 450mm N/mm) [21 kg fmm a "450 kg 360 mm (1.N Jn) 12 kg /mm Ry Re Reactions Ry and Re are calculated as: Ry = 6.7 kN Ro = 6.0 KN The shear diagram then becomes: G7 kN SBN oak 122 5.62 KN ~6.0KN And the moment diagram 2813Nem 28580 2261 NemA maximum bending moment of 2853 Nem occurs 650 mm in from the left end. Since the superstructure is not to be considered as a strengthening member, then the maximum bending stress occurs at this point. If the Superstructure was designed to strengthen the base, then due to the increased baseplate moment of inertia in the superstructure section the stress would have to be checked at the end of the superstructure (900 mm from the left-hand end) where the moment of inertia is considerably less. In this analysis the strengthening effect of the super- structure is ignored. Thus the moment of inertia of the sub base is found to be: | = 7.3 x 10° mm* and the Neutral axis is 81 mm above the bottom of the sub base. The maximum bending stress in the sub base then ‘S = MC/I = 2853 Nm ,081m/7.3 x 10% m* S = 31.7 MPa (less than 15% of the yield strength) The stress where the axial reinforcing ribs are welded to the sub base must be checked to ensure that the weld is not over stressed. Since the throat of the two welds on either side of the rib is greater than the rib thickness, it is assumed that the stress in the weld will be no greater than in the parent material. Thus the shear stress at the weld joint is found from: S = VeQ/ ted Where: V = vertical shear = 5.8 kN @ = area mounted above the shear plane about the neutral axis = 117,000 mm? 1 = momento inertia of the base = 73x 108 mm* b = width ofthe base = 0.75 m Thus the horizontal shear stress is: S = 5.8KN 0117 x 10 m/7.3 x10 me.75m S = 124kPa ‘There is negligible shear on the weld and therefore the above analysis is valid. The design is acceptable from a stress analysis standpoint. HI Centrifugal Pump Design and Application — 2000 Example 1. (US customary units) A baseplate is designed as shown in the drawings below and is to be fabricated from Yinch thick 1020 carbon steel. All welded joints are welded on both sides with a continu- ous filet weld whose throat dimension is /g inch. It is desired to mount a 1000-pound pump and a 1200- Pound motor on the base. The center of gravity of the motor is 18 inches in from the left end and the center of gravity of the pump is 15 inches in from the right end. What is the maximum stress in the base? Je a = pes o et SECTION AA 7 SOLUTION: ‘The worst design case occurs when the baseplate Supported only at the ends. To calculate the shear dia- grams, the unit weight of the baseplate must be calcu- lated. For the 36-inch length of the superstructure—sub base section, the unit weight is 11.5 Ibvinch, and for the remainder of the sub base 6.5 Ib/inch. Thus the free body diagram becomes: 1200, . 1180Ins0098 vw | fo ts | erin Ry Re Reactions Ry and Rp are calculated as: Ry Re ‘The shear diagram then becomes: 1515 Ib 1380 Ib 151500, 108, 265% 1285, = 128018HI Centrifugal Pump Design and Application — 2000 ‘And the moment diagram is: 25914 ino 25407 ins 19088 ins A maximum bending moment of 25,914 in-b occurs 27.4 inches in from the left end. Since the superstruc- ture is not to be considered as a strengthening mem- ber, then the maximum bending stress occurs at this point. If the superstructure was designed to strengthen the base, then due to the increased baseplate moment of inertia in the superstructure section the stress would have to be checked at the end of the superstructure (36 inches from the left-hand end) where the moment of inertia is considerably less. In this analysis the strengthening effect of the super- structure is ignored. Thus the moment of inertia of the sub base is found to be: | = 19.3 in* and the neutral axis is 3.24 inches above the bottom of the sub base. ‘The maximum bending stress in the sub base then is: 25,914 3.24 S = Mo/| = BARS 2 ‘S = 4350 psi (less than 15% of the yield strength) ‘The stress where the axial reinforcing ribs are welded to the sub base must be checked to ensure that the weld is not over stressed. Since the throat of the two welds on either side of the rib is greater than the rib thickness, it is assumed that the stress in the weld will be no greater than in the parent material. Thus the shear stress at the weld joint is found from: S = VeQ/ lob Where: V = ‘Vertical shear = 1308 Ibs Q = area mounted above the shear plane about the neutral-axis = 8.55 in® 1 = moment of inertia of the base = 19.3 in* b = width of the base = 30in ‘Thus the horizontal shear stress is: S = 1808 «8.55/19.3 «30 S = 198 psi ‘There is negligible shear on the weld and therefore the above analysis is valid. The design is acceptable from a stress analysis standpoint. 135.7 Rigidity Basoplates may be designed to be installed free standing, or to be grouted. A free-standing baseplate must be rigid enough to maintain coupling alignment when subjected to loads from piping or motor torque. ‘The rigidity shall prevent no more than .010-nch (0.25-mm) parallel coupling misalignment and .005 inches/inches (.005 mm/mm) angular misalignment when subjected to maximum motor and piping loads simultaneously. ‘A grouted baseplate relies.on the grout for the majority of its stiffness but must be sufficiently rigid to permit handling and allow installation. It is recommended that this type of baseplate have torsional stiffness of 1.13 x 10% NeM/rad, (10° inelb/rad). See Appendix A for fur- ther discussion of torsional stiffness. 1.3.5.8 Miscellaneous crite 1) Fasteners used to hold equipment feet to the baseplate shall either be threaded into mate- rial whose thickness is at least equal to the thread diameter, or use nuts on the underside of the base. If material thickness equal to one thread diameter cannot be achieved, an analy- ‘sis of the joint must be made to determine if the necessary clamping force can be achieved with the thinner material, and to what torque the fastener shall be tightened. 2) Grout holes, at least 100 mm (4 inches) in diameter or 80 mm (3.5 inches) square must be provided and located to allow complete grouting of the base. The holes shall be spaced such that grout is not required to be forced more than 760 mm (30 inches). Vent holes, a minimum of 12 mm (.5 inches) diame- ter, shall be provided at the end of all grout runs. Provision shall be made for a minimum grout thickness of 25 mm (1 inch).3) Pumps shall be mounted directly on the sub base when possible. If it is necessary to raise the pump in order to clear flanges, casing volutes, hand hole covers, etc., a fabricated ‘superstructure or loose mounting blocks 6 mm (25 inches) or thicker may be used. Shims less than 6 mm (.25 inches) thick are not to be used under the pump feet. 4) Mounting blocks shall be made of cold-rolled steel plate (or other suitable of equal flatness), and only one layer of blocks may be used on an individual pump or driver. Refer to Tables 1.3.9 and 1.3.10, Column B, for required flat- ness. The blocks must be large enough to fully support the feet, but not as large as the entire foot. Figure 1.98 below indicates the minimum block dimensions. 5) Provision should be made for lifting the base assembly with pump and driver mounted. Lift- ing should be done from a minimum of four points. The four litfing points shall be as far apart from each other as possible to ensure stability, and in no event shall they be located axially inside the center of gravity of the pump or the driver. Preferred methods of lifting are: |) Holes through the side of the base allow- ing the insertion and looping through of slings. li) Holes in the side of the base for insertion of *S” hooks. lil) Holes in or at the end plates of the base for insertion of *S” hooks or shackles. Figure 1.98 — Mounting block dimensions HI Centrifugal Pump Design and Application — 2000 6) 7) If the iting point is designed around “S* hooks, care shall be taken to ensure that the attachment point is designed so that the load is applied to the throat of the hook, and not to the point. Welded on lifting devices shall not be used unless no alternative exists. Exterior edges designed to be surrounded by grout shall be radiused to reduce grout stress. Baseplates intended for grouting shall be clearly marked that grouting is required. 85HI Centrifugal Pump Design and Application — 2000 Appendix A Torsional Stiffness ‘This appendix is not part of this standard, but is presented to help the user in considering factors beyond the stan- dard pump design and application. ‘Torsional stifiness is the resistance a baseplate offers to twisting about its longitudinal axis. A slight amount of twist induced during the installation can produce a large amount of horizontal misalignment between the Pumps and driver shafts. This misalignment can easily be greater than can be compensated for by clearance between the fasteners and the holes in the pump or driver feet, A baseplate designed for a minimum level of torsional stifness will help prevent inadvertent twisting during installation. Calculation of torsional stiffness is very di ficult for most baseplate designs. Finite element meth- ods have been used with success for this calculation. A very direct and simple test can be conducted to measure torsional stiffness. For this test the baseplate ‘should be supported and anchored at three corners as. shown in Figure A.1. (Care should be taken to avoid supporting along the edges of the baseplate). A known weight is then placed on the unsupported comer and vertical deflection is measured. The torsional stiffness is calculated from: Kron = Fe Where: Kron = Tossona sins Nem/ad (fad) F = Weight placed over unsupported corner — N (Ib) W. = Wiath of baseplate—mm (inches) 8 = Deflection of unsupported comer ~ mm ( (inches) Figure A.1 — Baseplate support and anchoringHI Centrifugal Pump Design and Application — 2000 Appendix B Recommended Equipment Mounting Drilling Dimensions This appendix is not part of this standard, but is presented to help the user in considering factors beyond the stan- dard pump design and application. w cs Ba 2K 22019, UNe-28 Ey AEaces! (sis.39 Figure B.1 — Recommended equipment mounting drilling dimensions 87HI Centrifugal Pump Design and Application — 2000 Appendix C References This appendix is not part of this standard, but is presented to help the user in considering factors beyond the stan- dard pump design and application. ‘American Bearing Manufacturers Association 1200 19th Street N.W., Suite 300 Washington, DC 20036-2422 APL-American Petroleum Institute API Standard 610, Centrifugal Pumps for General Refinery Service ‘American Petroleum Institute 1220 L Street, Northwest Washington, D.C. 20005 An Experimental Investigation of Radial Thrust in Cen- rifugal Pumps by A. Agostineli, et al ASME Journal of, Engineering for Power, April 1960, ASME B73.1M-1991, Specifictions for Horizontal End ‘Suction Centrifugal Pumps for Chemical Process ASME B73.2M-1991, Specifications for Vertical-In- Line Centritugal Pumps for Chemical Process American Society of Mechanical Engineers United Engineering Center 345 East 47th Street New York, NY 10017 ASTM-American Society for Testing and Materials ASTM D-323, Test Methods for Vapor Pressure of Petroleum Products (Reid Method) ASTM 1916 Race Street Philadelphia, PA 19103-1187 CPB-Contractors Pumps Bureau Contractors Pump Manual Contractors Pump Bureau 18975 Connecticut Avenue Silver Spring, MD 20906 88 FW-Factory Mutual Research Corp. Factory Mutual Research Corp. 1151 Boston-Providence Turnpike Norwood, MA 02062 1S0-International Organization for Standards 180-1940-1978, Balance Quality of Rotating Rigid Bodies American National Standards Institute 11 West 42nd Street New York, NY 10036 NEMA-National Electrical Manufacturers Associations NEMA-MG1-1993, Motors and Generators National Electrical Manufacurers Association 2101 L Street, NW, Suite 300 Washington, D.C. 20037 NFPA-National Fire Protection Association NFPA 20, Installation of Centrifugal Fire Pumps National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269-9101 UL-Underwriters Laboratory Underwriters Laboratory 333 Pfingsten Road Northbrook, IL 60062 Stepanoff Centrifugal and Axial Pumps, Second Edition by AJ, Stepanoft John Wiley and Sons, Inc. 1 Wiley Drive Somerset, NJ 08875HI Centrifugal Pump Design and Application Index — 2000 This appendix is not part of this standard, but is presented to help the user in considering factors beyond this standard. Note: anf. indicates a figure, and a t. indicates a table. ‘Axial thrust (for enclosed impellers for volute pump), 60-63 Baseplates (horizontal centrifugal pumps), 78 defined, 79 exterior edges, 85 fasteners, 81, 84 free standing baseplate, 79, 79f. functional requirements, 79 grout holes, 84 grouted baseplate, 79, 79f,, 85 high-energy pump, 79 lifting base assembly, 85 motor mounting pads, 80t,, 81, 81f. ‘Mounting blocks, 79, 85, 85f. ‘mounting pads, 79, 81f mounting surface flatness, 80t,, 81, 81f. mounting surface height, 80t,, 81, 81f rigidity, 84 shims, 79f,, 79, 81 stress levels, 81-84 sub base, 79f, 79, 85 superstructure, 79f,, 79 Support and anchoring, 86, 86f, tolerancing, 80, 80t. torsional stiffness, 86, 86f. Bearings adjusted rating life, 74, 75 axial load, 74 basic dynamic radial load rating, 74 basic rating life, 74 dynamic equivalent radial load, 74 grease, 65 housing closures, 70 impeller mounted between, 58, 72f. impeller overhung from, 58, 70, 71f. labyrinths, 70, lite, 74 lubrication, 65-67 oil lubrication, 65 operating temperature, 75° Product lubrication, 66t., 67 radial load, 74 rating life, 74 reliability, 74 rolling element, 64, 64 sleeve, 64 types, 64 BEP See Best efficiency point Best efficiency point, 56 Boiler circulating pumps, 10 Boiler feed booster pumps, 9 Boiler feed pumps, 8 Booster service, 1 Casing types, 76 Chemical pump, 1 CIMA See Construction Industry Manufactures Association Circular casings, 60, 60f. Closed feedwater cycle, 6, 7f Condensate pumps, 9 Condenser circulating water pumps, 9 Construction Industry Manufactures Association, 13, Continuous service, 42 Contractors Pump Bureau, 13 Corrosion allowance for metallic centrifugal pumps, 78 in pulp and paper applications, 16 Couplings disk, 68 elastomer, 68 flexible, 67 gear, 67 limited end float, 67 offset, 67 speed limitations, 68 service, 42 Deceleration devices, 77 Diffusers, 76 Discharge recirculation, 43 Disk couplings, 68 Double suction pump specific speed, 32, 35f., 36f. Double volute casing See Dual volute casing Drive shaft, 67 89HI Centrifugal Pump Design and Application index — 2000 Drivers, 76 deceleration devices, 77 electric motors, 77 engines, 77 magnetic, 77 steam turbine, 77 variable speed, 77 Dual volute casing, 58, 59f,, 76 K versus rate of flow, 58, 59f. Efficiency, 43 best efficiency point (BEP), 56 and high suction specific speed, 53, and impeller diameter trim, 53 and mechanical losses, 53, optimum, 49 prediction charts, 49, 50f, 51f., 52f. prediction method for centrifugal pumps, 49-57 and pump type, 56, 561. and slurries, 56 and solids size, 58 and surface finish, 53, 54f. and viscosity, 53 and wear ring clearances, 53, 55f. Elastomer couplings, 68 Electric motors, 77 Engines, 77 Equipment mounting diling dimensions, 87, 87. Excessive radial thrust, 43 Fire pumps, 10 Flexible couplings, 67 Gas See Liquids with vapor or gas Gear couplings, 67 General purpose service, 13-15 Heater drain pumps, 10 Hot oil pump, 4 Hydraulic hammer, 22 Hydraulic pressure pump, 14 Hydraulic turbines, pumps used as See Pumps used as hydraulic turbines Impellers, 57, 75 See also Overhung impeller pumps axial thrust for volute pump, 60-63 with back ring, 62f. and bearing arrangements, 58 double suction, 75 enclosed, 76 enclosed with plain back shroud, 617 ‘mounted between bearings, 58, 72f. open, 76 overhung, 58, 70, 71 90 predicting pump performance after diameter change, 48, 49. pressure distribution on enclosed impeller shrouds, 60r. semi-open, 76 single suction, 75 top suction, 20, 21f types, 75 venting the eye of, 20, 24f Inducers, 20, 57, 571. Inlet boosters, 20 Intake designs, 57 Intermittent service, 42 Irrigation service, 4 Limited end float couplings, 67 Liquids with vapor or gas, 19-24 effect of gas on performance, 19, 20f. inducers (inlet boosters), 20 special designs for, 20, 21f, ‘top suction impeller, 20, 211. venting the eye of the impeller, 20, 21f Magnetic drives, 77 Mechanical seals, 68 applications, 68 classifications, 68, 69f. typical schematics, 68 Mine dewatering, 4 Minimum flow, 43 Mutt-volute casings, 76 Net positive suction head, 38-42 insufficient, 43 margin considerations, 39 NPSHA corrections for temperature and elevation, 38 reduction, 39, 40f, 41f reduction for liquids other than hydrocarbons or water, 40f,, 41f, 42 requirements for pumps handling hydrocarbon liquids and water at elevated temperatures, 39, 408, 41f, Noise levels, 57 Non-clog pumps, 14 NST See Turbine specific speed Offset couplings, 67 Open feedwater cycle, 7, 7f. Overhung impeller pumps, 70 Packed stuffing-box, 69, 69f, 7Of. Paper stock, 15 ‘See also Pulp and paper applications PATs See Pumps as turbinesPerformance and selection criteria, 21 Process service, 1 Pulp and paper apy corrosion, 16 hydraulic performance correction, 16 paper stock and consistency categories, 16 Pump versus system curve, 21, 217, Pumps operating in parallel, 42, 42f. Pumps operating in series, 42, 42f. Pumps used as hydraulic turbines, 11 total available exhaust head (TAEH), 12 total required exhaust head (TREH), 12 turbine performance characteristics, 11, 11f, 12f turbine specific speed, 11 tions, 15 Radial thrust calculation for volute pumps, 58 excessive, 43 Recirculation, 43, Reverse runaway speed, 22 Rolling element bearings, 64, 64t. Sanitary pump, 14 Self-priming pumps, 13, 14f, 15f Sewage pumps, 14 Shaft deflection, 70 ‘Shaft seals alternative, 70 mechanical seals, 68, 69. packed stuffing-box, 69, 69f, Shutdown, 22 Single suction pump specific speed, 32, 33f, 34f. Single volute casing, 58, 58f., 76 K versus rate of flow, 58, 59f, Sleeve bearings, 64 Slury service, 17-19 materials of construction for slurry pumps, 17 non-setting slurries, 17, 19F. relationship between concentration and specific gravity for aqueous slurries, 17, 18. rotational speed of siurry pumps, 19 setting slurries, 17, 19F. Start-up with closed discharge valve, 22 with open discharge valve, 22 Steam electric power plants, 4, Sf. boiler circulating pumps, 10 boiler feed booster pumps, 9 boilor feed pumps, 8 closed feedwater cycle, 6, 7f Condensate pumps, 9 ‘condenser circulating pumps, 9 heater drain pumps, 10 ‘open feedwater cycle, 7, 7f. pumps, 8 HI Centrifugal Pump Design and Application Index — 2000 steam power cycle, 4, 5f ‘Steam power cycle, 4, 5f Steam turbine drivers, 77 Subscripts, 3¢. Suction conditions, 57 Suction recirculation, 43 Suetion specific speed, 31, 337, 34f, 36f,, 36f Symbols, 1, 2 System pressure limitation, 22 ‘System requirements, 21 double suction pump specific speed, 32, 35, 36 effects of handling viscous liquids, 23, 24f, 26f, 26f, 2h. net positive suction head, 38-42 NPSH margin considerations, 39 NPSH reduction, 39, 40f,, 417. NPSH reduction for liquids other than hydrocarbons orwater, 40f, 41f, 42 NPSH requirements for pumps handling hydrocarbon liquids and water at elevated temperatures, 39, 40, 41f NPSHA corrections for temperature and elevation, 38 ump selection for a given head, rate of low, and viscosity, 28 pump versus system curve, 21, 21f reverse runaway speed, 22 shut-down, 22 single suction pump specific speed, 32, 33f, 34f. starting with closed discharge valve, 22 starting with open discharge valve, 22 start-up, 22 suction specific speed, 31, 33f,, S4f,, 36f, 36 system pressure limitation, 22 torque curves, 23, 23f, viscous liquid calculations, 308, 31, 32t viscous liquid performance correction chart limitations, 23 viscous liquid performance curves, 30f, 30, 31f viscous liquid performance when water performance is known, 29, 30f, 31f, viscous liquid symbols and definitions, 28 water hammer, 22 TAEH See Total available exhaust head Temperature bearing, 75 limits on end suction pumps, 78, 78t. Temperature buildup, 43 Temperature rise, 43 calculation, 43, 44f, 45 and minimum flow, 46 and pump performance, 44, 447 Terminology, 1, 2t ‘Top suction impellers, 20, 21f 1HI Centrifugal Pump Design and Application Index — 2000 ‘Torque curves, 23, 23f, Total available exhaust head, 12 ‘Total required exhaust head, 12 Transfer pumping, 4 Trash pumps, 14 TREH See Total required exhaust head Turbine specific speed, 11 Units of measure, 1, 2t \Vapor See Liquids with vapor or gas Variable speed drives, 77 Viscous input power, 29 Viscous liquids calculations, 30f,, 31, 32t. effects of handling, 23, 24f, 25f, 26F, 27f. performance curves, 30f, 30, 31f. performance when water performance is known, 29, 30, 34f, Pump selection for given head, rate of flow, and viscosity, 28 symbols and definitions, 28, 92 Volatile liquid pump, 3 Volute pumps calculation for radial thrust, 58 calculation of axial thrust for enclosed impellers, 60— 63 circular casings, 60, 60f. dual volute casing, 58, 59f, K versus rate of flow (double volute casing), 58, 59f. K versus rate of flow (single volute casing), 58, 59f. single volute casing, 58, 58f. Wastewater service pumps, 14 Water hammer, 22 Well pumping, 4