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FAQ’S OF PUMPS
Pump FAQsÂ® September 2001 Article #3 Q.
We have many centrifugal pumps, which take their inlet from an overhead tank. When the centrifugal pump draws down the liquid level in the tank, a vortex forms in the liquid and air is drawn into the pump. How can this problem be corrected? At low liquid levels, the formation of a vortex is dependent on the liquid velocity entering the pipe. Increasing the effective pipe area can reduce this liquid velocity. Installing a baffle plate above the pipe opening will simulate a larger intake area thereby reducing the vortex formation. See the figure below:
Pump FAQsÂ® September 2000 Article #1 Q.
Our plant is operating a system with several centrifugal pumps in parallel that exhibits water hammer problems when one of the pumps is shut down. The discharge pipe from the pump is 18 inches diameter, forty feet long up to the common header. The backflow after shutdown causes severe banging of the check valve. What can be done to relieve this problem? Much has been written on this subject, including a section in the â€œPump Handbook€ published by McGraw Hill which include fifteen pages on waterhammer plus twelve references. Some solutions that have been applied include:
• • • • •
Close to the pump isolation valve before shutting down the pump. Add a flywheel to the pump in order to slow its rate of coast down. Add a surge tank or air chamber which will absorb discharge pressure energy. Use a fast closing check valve which will close before reverse flow begins. Use a slow closing check valve which will allow the reverse flow to shut down more slowly and avoid the shock from the sudden stop of the backflow.
Pump FAQsÂ® September 1999 Article #3 Q.
Many manufacturers do not extend the NPSHR curve on their pump rating curve below about thirty percent of its best efficiency point. Can the NPSHR curve be extrapolated back to shut off in order to get this information? Extrapolation of the NPSHR curve back to shut off is dangerous, since different pumps act differently at very low flow rates. Some pumps exhibit a dramatic increase in NPSHR at very low flows. In addition, the condition known as suction recirculation becomes very pronounced at very low flows causing vortices in the impeller and localized pitting damage to the impeller blades
Pump FAQ’s by Hydraulic Institute (UK) The subject of low flow operation is discussed in ANSI/HI 9.6.3-1997 Centrifugal and Vertical Pumps - Allowable Operating Region.
Pump FAQsÂ® September 1999 Article #2 Q.
In our process, the primary circulating pump occasionally becomes air bound due to entrained air in the system and stops pumping. How much air can a centrifugal pump handle, and what can be done to prevent air binding? Centrifugal pumps can usually handle up to about five percent by volume of air. Above that, they will easily become air bound, especially at flow rates below the best efficiency point. Even when pumping five-percent air, the pressure developed will be reduced due to the reduced specific gravity of the fluid mixture. In order to avoid air binding, try the following:
• • •
Minimize air entrainment by any means possible. Add a bypass pipe to maintain a high rate of flow. Install a vent in the top of the suction pipe to vent air back to the source.
Pump FAQsÂ® September 1999 Article #1 Q.
We are operating a multistage centrifugal pump in our process that is producing too much head. We intend to reduce the pump head by reducing the impeller diameters. Can we reduce head by trimming only one or two impellers, and is it better to cut the impeller shrouds as well as the impeller vanes? It is not necessary to keep all of the impellers at the same diameter. However, it is better to limit the extent of impeller reduction to five percent or less due to loss in efficiency as the impeller is cut down. You should evaluate the possible loss in efficiency by cutting only one or two stages if the reduction is more than five percent. Regarding cutting of impeller shrouds, the advantage is that the full shroud diameter will minimize pump instability when it is operated below fifty percent of its best efficiency point. However, cutting the shrouds will reduce the impeller disc friction and improve efficiency.
Pump FAQsÂ® October 2006 Article #2 Q.
I keep hearing about suction recirculation but cannot find a good explanation. Can you help me?
A. When centrifugal pumps are operated at rates of flow below their best efficiency
Pump FAQ’s by Hydraulic Institute (UK) point (BEP), the excess flow produced by the impeller is recalculated on the suction side of the impeller as shown in figure 5-12. These eddy currents cause local vortices on the impeller vanes, which in turn cause cavitations resulting in noise, vibration, and damage to the impeller vanes
This action usually begins between 70% and 50% of the BEP flow and many pump manufacturers do not allow operation below the onset of recirculation. Furthermore, some impellers, which are designed for low NPSH Available applications, may begin the recirculation mode close to the BEP. An example of this might be condensate drain pumps in electric power plants.
Pump FAQsÂ® November 2004 Article #1(1) Q.
The first answer in the September issue of Pumps and Systems says that spring mounted baseplates can also work well to avoid pipe strains on pumps. How can I know if the base plate stiffness is sufficient to work without grouting?
the base plate must not be permanently deformed after the equipment is mounted at the manufacturing facility. in conjunction with proper installation procedure. How does a change in liquid viscosity affect the performance of a rotary pump? I have seen a viscosity correction graph for the performance of centrifugal pumps but nothing for rotary pumps. no general viscosity correction graph has been developed. 4 .005 inches/inch) angular misalignment when subjected to maximum motor and piping loads simultaneously. This base plate must allow for initial mounting and alignment of equipment. A.005 mm/mm (. It must be recognized that it is not necessary that an absolutely rigid base plate be designed to meet these requirements. be capable of being installed properly with minimum difficulty. Compliance with these design criteria. It is recommended that this type of baseplate have torsional stiffness of 1. Pump FAQsÂ® May 2006 Article #3 Q.25 mm (.13x10 4 Nâ€¢M/rad (105 inâ€¢lb/rad). and allow removal and reinstallation of equipment.3-2000 Centrifugal Pumps for Design and Application. 4 Whether to grout or not depends on the specific application and the design of the base plate.Pump FAQ’s by Hydraulic Institute (UK) A.010 inch) parallel coupling misalignment and . Additional information and calculation of baseplate stiffness can be found in Appendix A of ANSI/HI 1. At the same time. Applications that undergo wide temperature variation may do well with floating base plates in order to allow for movement of the pump and thereby minimize pipe strain caused by thermal expansion of the pipe. allow final alignment of the mounted equipment. Base plates may be designed to be installed free standing. Most pump manufacturers produce a range of performance curves for each pump at different levels of viscosity. the base plate in such cases must be sufficiently rigid and designed to avoid misalignment between the pump and driver shaft as the base plate moves. or to be installed using grout. Because of the variety of rotary pump designs. A grouted baseplate relies on the grout for the majority of its stiffness but it must be sufficiently rigid to permit handling and allow installation. The rigidity shall prevent no more than 0. However. The purpose of a base plate is to provide a foundation under a pump and its driver that maintains shaft alignment between the two. A free standing base plate must be rigid enough to maintain coupling alignment when subjected to loads from piping or motor torque. will contribute significantly to meeting the functional requirements. survive handling during transportation to the installation site.
but pump efficiency peaks at about one thousand SSU viscosity due to the increasing viscous drag at increasing viscosity. For more information see the HI standard ANSI/HI 3. Required pump input power increases with increasing viscosity.1-3. If the runaway speed exceeds the normal pump speed.5 Rotary Pumps Pump FAQsÂ® May 2006 Article #2 Q. Maximum allowable pump speed decreases with increasing viscosity. See figure 3.Pump FAQ’s by Hydraulic Institute (UK) 5 There are some general guidelines that can be used as follows: • • • • • Net positive inlet pressure required (NPIPR) increases with increasing viscosity. Pump volumetric efficiency increases with viscosity. If the pump is driven by a prime mover offering little resistance while running backwards. such speed may impose A. Reverse runaway speed occurs when a pump runs in uncontrolled reverse 5 . the reverse speed may approach a maximum or runaway speed. It is most likely to happen with Vertical Turbine Pumps when pumping from deep wells. and the pump will operate as a hydraulic turbine in a direction opposite to that of normal pump operation. A sudden power failure and/or discharge valve or non-return valve failure during operation against a static head may result in a flow reversal. What is reverse runaway speed? What is the cause? Is it dangerous and can it be prevented? direction due to the reverse flow of liquid from an elevated or pressurized source.31 below. such as a storage tank. Pump internal leakage or slip decreases with increasing viscosity.
Check valves on the pump discharge and/or suction may also help with the problem. and also show if excessive wear is taking place by the presence of metallic particles.Pump FAQ’s by Hydraulic Institute (UK) 6 high mechanical stresses on the rotating parts of both pump and driver. 6 . it will accelerate the normal wear of bearings. their application is not always desirable and a review should always be made with the pump manufacturer. Vertical pump drivers can be equipped with non-reverse ratchets to prevent reverse rotation. How can we monitor these pumps to eliminate or predict these failures? Lubricant analysis is a good way to keep an eye on pump bearings and prevent unexpected bearing failure. and sometimes causes unscheduled system shutdown. We operate about one thousand centrifugal pumps and find that ball bearing failure is a major cause of pump shutdown which requires repair. However. Figure 2.58B on the right provides a means for estimating reverse runaway speed for pumps of different specific speed designs. A. Figure 2.58B at€” Reverse runaway speed ratio versus specific speed (US units) Pump FAQsÂ® May 2006 Article #1 Q. If the lubricant is contaminated.
Pump FAQsÂ® May 2005 Article #3 Q. Samples should be withdrawn from within one half inch of the surface of the oil. see ANSI/HI 9.642Q/MA Where v = Average liquid velocity in the valve in feet per second. Until your experience provides statistics and consistency. but what about reciprocating pumps? Are there any limits to the viscosity of liquids that can be handled by reciprocating pumps? Theoretically there is no limit to the viscosity of liquids that can be handled by reciprocating pumps as long as they can be run slow enough.5 Centrifugal and Vertical Pumps for Condition Monitoring. to ensure well-mixed lubricant is obtained. I know that centrifugal pumps do not operate well on viscous liquids and rotary pumps are often recommended. Q = Rate of flow in gallons per minute. it is suggested that samples be taken monthly. or immediately after shutdown. Usually the lubricant turns white and emulsifies. A sample from the bottom of the oil sump is best to indicate the presence of water. A. For further detail on this subject. M = Number of suction valves.Pump FAQ’s by Hydraulic Institute (UK) 7 Quantitative analysis of metal particles are obtained from a particle counting analysis which will provide information on the number of particles in a sample within various size ranges and an analysis of the contaminants. Oil samples for the detection of particles should be taken while the pump is operating. The primary limiting factor is the velocity of liquid flow through the suction and discharge valves. This velocity can be calculated from the following equation: v = 0. or external sources such as leaking seals. Water can come from internal sources such as leaks in cooling systems and condensation. Water is one of the most common contaminates found in large quantities and is the easiest to detect. 7 .6. A description of the methods and codes used can be found in ISO 4402 and SAE ARP 598.
0 6. there are several solutions.300 600 350 Valve velocity ft/sec 4.0 7. One is to install one or more vertical flow dividers in the elbow which will guide the flow through the elbow and keep the flow to each side of the impeller equal.0 9. Another solution is to reduce the flow velocity prior to the elbow with an eccentric increaser and add a reducing elbow at the pump.000 1.000 2.5 Reciprocating Power Pumps. Is there another solution to this problem? Yes.0 More information on this subject can be found in ANSI/HI 6. I believe that the elbow on the suction is the major cause of the problem. the noise and cavitation damage should cease.0 5.Pump FAQ’s by Hydraulic Institute (UK) 8 A = Suction valve flow area in square inches. The process of accelerating the flow rate has a tendency to straighten A.0 10. Pump FAQsÂ® May 2005 Article #2 Q. It may also be practical to use a combination of a larger elbow followed by a straight pipe reducer.1-6. If the NPSH available is sufficient. 8 .0 11. Some guidelines in this regard would limit this velocity as follows: Viscosity SSU 20. but adding straight pipe in between is not practical. The pump operation is noisy and one side of the impeller shows cavitation damage and the other side does not.000 5. Our plant has a horizontal axially split case pump handling cooling water and the horizontal suction pipe includes a ninety degree elbow at the suction flange of the pump.0 8.000 9.000 3.
The simplest solution is the installation of a circular baffle plate with a diameter of four times the pipe diameter directly over the outlet pipe at a distance of two diameters above the pipe opening. A. For more information on this subject see ANSI/HI 9. but then it is protected from the surface air.Pump FAQ’s by Hydraulic Institute (UK) 9 the flow at the same time. We are operating an end suction centrifugal pump which takes suction from the bottom of an open tank. See the figure on the right.Pump Intake Design. thereby reducing the liquid velocity as it leaves the tank. If the baffle plate is supported by four to six vertical plates forming a star to a diameter of two times the pipe diameter. I understand that this can be corrected with baffle plates. a vortex is formed which allows air into the pump. they will further reduce the start of a vortex. The objective is to increase the apparent opening to the suction pipe. This changes the performance of the pump and upsets the process downstream. As the level in the tank drops. Pump FAQsÂ® May 2005 Article #1 Q. Are there any guidelines in this regard? Yes. and baffle plates are effective in correcting this problem. Of course the velocity increases under the baffle plate. It is the velocity of the liquid flow that creates the vortex as the liquid level drops. 9 .8 . This results in an apparent opening which is eight times the original opening and a corresponding reduction in flow velocity as the liquid moves under the baffle.
Definitions. ANSI-HI 6.Pump FAQ’s by Hydraulic Institute (UK) Pump FAQsÂ® May 2004 Article #3 Q. you will find that the cost of excess power will be significant. noise and vibration. At low rates of flow the impeller is also suffering from suction side recirculation in the impeller eye. Basic construction may be different from that for clear liquid applications. Pump efficiency at 50% of BEP will always be lower than at BEP. addition of surge chambers. are any special design changes necessary? A.1-6. The differences may be in types of valves. Another problem is the increase in radial forces on the impeller which reduce bearing and seal life and even cause shaft breakage from bending fatigue. 50% of BEP is outside the normal operating range allowed by most pump manufacturers. we find that for higher heads centrifugal pumps are limited in what they can do. The highest velocity should be below that which causes excessive erosion. fluid injection into the inner portion of the stuffing box or material for wearing parts. Hydraulic passages should be sized so that the lowest velocity of the fluid will be above the critical carrying velocity of 4 to 6 ft/s. In applications on handling slurries. If you do the math. which is timed to the position of the plunger during its stroke. A. 10 On low NPSH available applications it is often necessary to apply a centrifugal pump at 50% of its design flow rate to get a pump with low NPSH required values. external injection. Lubrication and flushing of packing are extremely important.5-2000 Reciprocating Power Pumps for Nomenclature. Metered. clear.3-1997 Centrifugal and Vertical Pumps for Allowable Operating Region. Reciprocating pumps are often used to handle slurries for in-plant process and pipeline applications. Can reciprocating pumps be used in these applications? If so. The vortex caused by recirculation further increases local cavitation which in turn causes impeller damage. 10 . The lower NPSHR values at 50% flow do not guaranty cavitation damage free operation. Application and Operation contains considerable information on this subject.6. Pump FAQsÂ® May 2004 Article #2 Q. This subject is discussed in detail in ANSI HI 9. or continuous flow injection is required. What is the downside of doing this? The most significant downside is in excessive power consumption.
This is most serious with single volute pumps and. it could overheat badly. Metal to metal ball valves may also be used. We are replacing a 30. impeller rubbing and shaft breakage. Pump FAQsÂ® May 1999 Article #3 Q. what criteria are used to determine this value? The factors which determine minimum allowable rate of flow include the following: • • Temperature rise of the liquid -. if a pump operates at shut off. Radial hydraulic thrust on impellers -. Rod and plunger packing requires special consideration when dealing with abrasive materials. a€ Is there a standard procedure for determining this limit? If not. Some centrifugal pump manufacturers show a vertical dotted line on their pump rating curves with the notation â€œminimum allowable flow.This can also occur below 50% of BEP causing noise.000 gpm vertical pump with a larger one.3-1997 Centrifugal and Vertical Pumps â€“ Allowable Operating Region discusses all of the factors involved and provides recommendations for the â€œPreferred Operating Region.6.â€ Pump FAQsÂ® May 2004 Article #1 Q. excessive shaft deflection. Valve construction usually has replaceable valve inserts that are made of an elastomer or polymer. In piston pumps. Piston rods and plungers are coated to resist wear. Total head characteristic curve â€“ Some pump curves droop toward shut off. the piston runs in a renewable metal cylinder or liner. Flow re-circulation in the pump impeller -. What guidelines are available to determine if enough 11 . A. it should be fitted with adequate connections so the liquid end passages can be flushed of the slurry with clear liquid. The liners are made of abrasion and corrosion resistant metals. and some VTP curves show a dip in the curve.This is usually established as 15Â°F and results in a very low limit. even at flow rates as high as 50% of BEP could cause reduced bearing life. To facilitate starting and stopping a slurry pump. and are concerned that the new pump will have enough submergence to prevent vortices at the pump inlet.Pump FAQ’s by Hydraulic Institute (UK) 11 Valves for use in slurry service are designed for velocities between 6 and 12 ft/s to reduce erosion and abrasion of the valve seat and other valve components. Operation in such regions should be avoided. cavitation and mechanical damage. • • There is no standard which establishes precise limits for minimum flow in pumps. but ANSI/HI 9. vibration. seal failures. However.
Highly non-uniform approach flows will require the application of vortex suppression devices.8-1998 Pump Intake Design. Submerged vortices are not believed to be related to submergence and are not addressed here. Approach-flow skewness and the resulting circulation have a controlling influence on free surface vortices in spite of adequate submergence. Pump FAQsÂ® May 1999 Article #2 12 . The recommended minimum submergence given here is for a reasonably uniform approach flow to the pump suction bell. Experimental analysis and field experience have resulted in the following empirical relationship: S = D + 0.26B taken from ANSI HI 9.8.Pump FAQ’s by Hydraulic Institute (UK) submergence is available? A.574Q/D1.5 Where S is submergence in inches D is bell diameter in inches Q is rate of flow in gpm The required minimum submergence can also be determined from figure 9. 12 This answer provides the recommended minimum submergence of a vertical pump inlet bell to reduce the probability that strong free-surface air core vortices will occur.
NPSHA should be 1. are discussed in a recently published 62 page standard. In order for a pump to operate cavitation free. The problem is also aggravated by the use of a cast iron impeller.8-1998 Pump Intake Design addressing this subject. NPSHR is measured when the pump total head is reduced by 3% due to cavitation. Increasing the liquid level over the pumps would be very expensive. • Add a downward opening flanged elbow to the inlet pipe. two suggestions could be tried. The pumps are mounted in a dry pit adjacent to the collecting tank. can be added to the collecting tank near the pump inlet pipe. use a reducing elbow to further increase the size of opening and flange diameter. These will inhibit the formation of vortices. titanium and nickel A.3 to 2. A. Attach a horizontal baffle plate to the wall directly above the pump inlet pipe. 13 We operate a sanitary sewage pumping plant.0 times NPSHR. For satisfactory operation. which is also defined in the standard. the NPSHA must be from 2 to 20 times greater than the NPSHR of the pump. etc. Assuming that the pump inlet pipe is in the wall between the collecting tank and pump pit. The standard provides design recommendations for a variety of different intakes for both solids bearing liquids and clear liquids. The vortices are reducing the pump flow and causing excessive vibration in the pumps. If possible. The pumps are operating close to the best efficiency point and the NPSH available is slightly higher than the NPSH required by the pump. ANSI/HI 9. The Hydraulic Institute has recently published a new standard on this subject namely. What else can be done to eliminate the vortices? Plates.6. Should there be cavitation damage in the pump impellers under these conditions? There is a common misconception among pump users that if the NPSH available from the system is greater than the NPSH required by the pump. and others. The plate should have a length and width equal to 4 times the diameter of the pump inlet pipe. This will lower the point where liquid enters and the flange on the elbow will reduce entrance velocity. for cooling tower service.Pump FAQ’s by Hydraulic Institute (UK) Q.1-1998 Centrifugal and Vertical Pumps for NPSH Margin. which frequently creates vortices at the pump inlet pipes. Pump FAQsÂ® May 1999 Article #1 Q. some NPSH margin over NPSHR must be provided by the system. This is not so. By definition. depending on suction energy level. Our plant is operating pumps on cooling tower service which are experiencing cavitation damage to the cast iron impellers. • These solutions. ANSI/HI 9. that the pump will operate free of cavitation. 13 . splitters. other materials such as stainless steel. In cooling tower service. vanes. According to this standard.
13 . 14 . Air consumed by the pump is given in terms of the mass flow rate of the air through the pump at standard atmospheric conditions (68 degrees F and a pressure of one atmosphere).Plotting test results Pump FAQsÂ® March 2006 Article #1 Q. Will you please explain it for me? The term â€œcanâ€ pump may be used to describe either VTP. The power required by the compressor to produce the motive air is beyond the Hydraulic Institute scope. lines of â€œconstant air consumptionâ€ are shown. or close coupled centrifugal pumps. Note that instead of input power. A. Air operated pumps generally do not show power or efficiency on their rating curves.Operated Pump Tests provides more detail on testing air-operated diaphragm and bellows pumps. Pump FAQsÂ® March 2006 Article #3 Q. See the typical curve on the right. The standard unit of air consumption is SCFM (standard cubic feet per minute). We are using a large number of air-operated reciprocating pumps and are concerned about the amount of power that they are using. However there is a big difference between them. which is well maintained. Measurement of air consumption by the pump can be made and compared with the pump performance curve to check for deterioration. ANSI/HI 10.6 Air. What is a â€œcanâ€ pump? I have seen this term applied to both centrifugal and vertical turbine pumps(VTP). Reciprocating pumps generally have good hydraulic performance.Pump FAQ’s by Hydraulic Institute (UK) 14 aluminum bronze will withstand cavitation damage much better than cast iron. How can we check the efficiency of these pumps? A. Figure 10.
Figure 5. ref. See ANSI/HI 5. the pump bowl assembly and column pipe are inserted in a vertical â€œcanâ€ with sufficient clearance between the â€œcanâ€ and bowl outside diameter to increase the submergence of the first stage impeller without friction loss in the downward flow of the liquid.2 â€” Canned motor pump: close coupled end suction. and is called the containment shell. ref.6. See figure 5. another cylinder. Sealless Centrifugal Pumps for more detail. number 221 on the right.Pump FAQ’s by Hydraulic Institute (UK) 15 When applied to a close coupled centrifugal pump. When the term â€œcanâ€ refers to vertical turbine pumps. 217 is attached to the inner diameter of the stator. overhung impeller 15 .15.2. In addition. This â€œcanâ€ design is also used with rotary type pumps. This design is more properly called a canned motor pump. the term â€œcanâ€ refers to a cylinder or can which surrounds the motor rotor to seal it from the liquid being pumped.
Pump FAQ’s by Hydraulic Institute (UK) 16 16 .
2. It must be understood that these are field vibration values for pumps in good 17 A. vibration measurements are very useful in predicting pump failure.6. I understand that pump vibration is an important parameter in predicting the imminent failure of a pump. and what is an acceptable level of vibration for ASME B73 Chemical pumps? Yes. . Vertical Pumps for Nomenclature and Definitions for more detail.64 above and ANSI/HI 2. unfiltered.1-2.Pump FAQ’s by Hydraulic Institute (UK) 17 Figure 2. Pump FAQsÂ® March 2005 Article #2 Q.4 shows the normally acceptable vibration level for ASME B73 pumps. Is this true? How is the vibration level measured.4. Such measurements should be taken on the outside of the pump bearing housing closest to the coupling. Measurements should be taken in both the horizontal and vertical direction perpendicular to the pump shaft with an instrument that measures in units of velocity in inches per second RMS. The graph from figure 9.2.64 â€” First stage impeller datum closed suction â€“ can pump See fig.
4. liquid pumped and more 3. We operate a small plant and would like to improve the reliability of our centrifugal pumps and minimize unplanned pump shutdowns. Figure 9. More detailed information on this subject can be found in ANSI/HI 9.6. Pump operating speed 12. take corrective action to upgrade the performance of the most troublesome pumps. Can you suggest a plan for monitoring pump performance to achieve our goal? To begin with. Input power Temperature of key components such as bearings. The frequency of recording these measurements depends on severity of the 18 . or pressure parts 5. Maintenance inspection of critical components 11.4. Vibration at pump bearings 7. Shaft runout at seal face 9. and exceeding them does not mean imminent failure.6. These include: 1. Corrosion of pressure containment parts 4. Rate of flow of pumped liquid 10. gaskets.Pump FAQ’s by Hydraulic Institute (UK) 18 condition. Your experience with pumps that have failed will help you determine an appropriate vibration level. Based on this review. Bearing wear A. we suggest a detailed review of each pumpâ€™s performance history to determine which are more likely to fail and why. Pressure of liquid at pump suction and discharge 6. Monitoring the performance of all of your pumps is the next step. There are twelve main parameters which can be measured to prevent failure. 2. seals. motor windings.4 Pump FAQsÂ® March 2005 Article #1 Q. Leakage from seals. Centrifugal and Vertical Pumps for Vibration Measurement and Allowable Values. Lubricant cleanliness or degradation 8.
At 90 percent of full speed the efficiency of the drive may be reduced by about ten percent of that at full speed and power.9 / 0. then: electrical power = pump power / driver efficiency = 100 / 0.5.0 horsepower A.6. Centrifugal and Vertical Pumps for Condition Monitoring.2 below for the recommended frequency measurement. If we assume the full load efficiency of the driver is 92%. This depends on the design of the drive. the power required by a 100 horsepower pump is reduced by the cube of the speed so at ninety percent speed the power required is 0. I understand that the efficiency of variable speed drives is reduced as operating speed and power is reduced.92 X 0. Implementation of this program requires considerably more information that is available from ANSI/HI 9.92 = 108. Assuming a change in demand results in a reduction in pump speed of ten percent. 19 . Pump FAQsÂ® March 2004 Article #2 Q.Pump FAQ’s by Hydraulic Institute (UK) 19 results of failure and the likelihood of failure of the weakest performers.90 cubed times 100 horsepower or 0. Does this negate the power saving from the accompanying reduction in pump speed? The difference in the power consumption with and without the variable speed drive must be evaluated. The power savings from the reduction in speed of the pump is typically greater than the loss in efficiency of the driver.9 horsepower.729 times 100 which equals 72.90 = 88.6.7 horsepower At 90% of full speed: electrical power = 72. See table 9.5.
the problem disappeared. One of our customers installed a 500-hp double suction axial split case pump with horizontal discharge and a right angle elbow mounted horizontally on the discharge of the casing. both high rate of flow and high horsepower are 20 . When operated near the best efficiency point.5 Vertical Pumps and ANSI/HI Vertical Pump Tests. the pump bearing housings flexed vertically about Â¼ inch. The pump bearings failed quickly as a consequence.pump. You may also wish to look at ANSI/AWWA E-101 Vertical Turbine Pumps which was developed by the American Water Works Association.org] will be up and running in mid-April. a supplier finder with manufacturer names crossmatched to specific products and hyperlinks to member websites. 20 We are trying to standardize on a manufacturer of vertical pumps at our plant. Can you explain why? We cannot provide a precise explanation of what took place inside this pump casing. I can appreciate your interest in wanting to standardize on a vertical pump manufacturer and understand the wisdom of finding a GOOD pump which is suitable for your applications.1 â€“ 2. but before doing so we are trying to figure out what is critical in the design of the pumps. The website will include information regarding the HI. elbows or other fittings attached directly to the pump discharge port will not effect what happens inside the pump impeller and casing. When the discharge piping was changed to add ten diameters of straight pipe between the pump and the first elbow. Another right angle elbow was bolted to the first elbow. I take issue with the second question in FAQs in the February 2000 issue. Pump FAQsÂ® June 2006 Article #3 Q. These standards should help you to define what constitutes a GOOD pump design for your service requirements. Any suggestions of where to look would be greatly appreciated. Since you have indicated an interest in vertical pumps please refer ANSI/HI 2. When very large pumps. In other words. We use them for pumping liquids from one tank to another part of the plant. We thank you for your input and ask if anyone else can explain what was happening. which cause severe vibration in the impeller. what makes a vertical pump a GOOD vertical pump? The vertical pumps we use here are mainly in service all the time. but apparently the discharge elbows created a hydraulic feedback. The phenomenon is probably similar to that caused by suction side circulation in the impeller.Pump FAQ’s by Hydraulic Institute (UK) Pump FAQsÂ® March 2000 Article #2 Q. and the pump rotor was shuttling back and forth axially. You state that valves. You may be interested to know that the HI Website [www. A. Pump FAQsÂ® March 2000 Article #1 Q. A.
5 Q1/Q2 = (D1/D2)2(H1/H2)0. Pump FAQsÂ® June 2006 Article #2 Q. any difference in vapor pressure is compensated by a change on the surface of the liquid. the rate of flow through the pump is kept constant and the liquid level in the tank is gradually lowered while total head measurements are recorded. if a different specific weight of liquid is used. If a liquid other than water is used. and I do not find information on how to correct this for other liquids. this is done by exhausting air or gas from the tank with a vacuum pump. the reduced pressure due to the column height is compensated by the reduced weight of a given volume of A. The model test speed n1 and rate of flow Q1 shall be determined by the following relationship: n1/n2 = (D2/D1)(H1/H2)0. for example. In a similar manner. a smaller model may be built and tested to prove the proper performance of the design.6 Centrifugal Pump Tests.122 on the right.Pump FAQ’s by Hydraulic Institute (UK) custom built. The simplest NPSHR test is conducted using a closed tank to which the pump is directly connected and the space above the liquid level in the tank is kept equal to the vapor pressure of the liquid. Under these conditions. When testing with cold water. Is this true? Specific gravity and vapor pressure do not change the NPSHR of a centrifugal pump. the NPSHA (available) is equal to the height of the liquid above the pump impeller. NPSHR is determined by test and is selected as the value when the total head of the pump is reduced by three percent due to blockage of the flow through the impeller by the formation of vapor bubbles. Hydrocarbons. I understand that NPSHR (required) by a pump is measured by the manufacturer using cold water. All dimensions of the model hydraulic passages. What are the rules for building such a model? A. By definition. 21 The model impeller should not be less than twelve inches outside diameter. have a wide range of specific gravities and vapor pressures which must affect the NPSHR performance of a pump. should be in accordance with the model to prototype ratio. The plot of test points will look like Figure 1. When conducting the test.5 Where D = diameter and H = head More detail is available in ANSI/HI 1. 21 . including the relative roughness of the hydraulic passages in the impeller and casing.
Accuracy is a compound definition composed of steady state accuracy. Steady state accuracy is the variation in the rate of flow over a specific period of time. repeatable and adjustable rates of flow. How accurate are these pumps and does accuracy change with different conditions? Controlled volume metering pumps are reciprocating positive displacement pumps and are used in applications requiring highly accurate. There is another characteristic of liquid that does affect NPSHR. 22 .NPSH Test with Rate of Flow Held Constant Pump FAQsÂ® June 2005 Article #1 Q. Figure 1. under fixed pump and system conditions.122 . Specific values for your pumps can be obtained from the manufacturer. linearity and repeatability. Some high vapor pressure liquids produce a lower volume of vapor when they boil and therefore less blockage in the impeller vanes. We use several metering pumps in our blending operation and are concerned about their accuracy. See ANSI/HI 1. Linearity is an expression of maximum deviation (plus or minus) of a series of measured rates of flow values versus rate of flow setting points to A. That is its thermodynamic properties.Pump FAQ’s by Hydraulic Institute (UK) 22 pumped liquid.3 Centrifugal Pumps for Design and Application for more information. expressed as a percent of the maximum calibrated rate of flow. Steady state accuracy applies over a defined turndown ratio.
23 . Is there a simple guideline for allowable misalignment measurements? There is no single answer to this question. This requirement is clearly stated in every pump manual.Pump FAQ’s by Hydraulic Institute (UK) 23 corresponding points on a theoretical best fit straight line drawn through the points on a graph.1-7. how carefully aligned is seldom answered. followed by a return to that set point. Pump FAQsÂ® June 2004 Article #3 Q.5 Controlled Volume Metering Pumps. expressed as percent of maximum calibrated rate of flow. I am aware that pump shafts must be carefully aligned with the driver shaft before start-up. Linearity is expressed as percent of maximum calibrated rate of flow. More information on this subject can be found in the soon to be published standard. However. Misalignment often occurs in any of the following ways: • parallel offset A. See the figure on the right. Repeatability is the rate of flow variation resulting from a specific excursion from a rate of flow set point. ANSI/HI 7.
metallic couplings usually are supplied in pairs separated by a coupling spacer.Pump FAQ’s by Hydraulic Institute (UK) • • • angular offset combination of both axial movement 24 The extent of the misalignment in these modes depends on the tolerance of the driver. Pump FAQsÂ® July 2006 Article #2 Q. The allowable misalignment acceptable by the metallic couplings will depend on the length of the spacer. and 24 . Pumps on hot applications should be realigned while the pump is at operating temperature. Most single metallic couplings such as gear. By far. the coupling has the greatest ability to tolerate misalignment. The coupling supplier can provide the allowable misalignment values for each type and size of coupling. plate or grid type can tolerate only angular misalignment. What is an API pump? I assume it is related to pumps used in the petroleum industry. Heavy Duty Chemical. Parallel alignment can also be affected by thermal expansion during operation. pump and coupling. Pumping hot liquids or even heat from the summer sun can affect the alignment. Space between the shaft ends must also be provide to permit free axial movement of the shafts. an API pump is one that was built in accordance with standards published by the American Petroleum Institute. A. Five different pump types are described by the following standards: API 610 Centrifugal Pumps for Petroleum. Petrochemical and Natural Gas Industries API 674 Positive Displacement Pumps â€“ Reciprocating API 675 Positive Displacement Pumps â€“ Controlled Volume API 676 Positive Displacement Pumps â€“ Rotary API 685 Sealless Centrifugal Pumps for Petroleum. but what is special about it? As you guessed. The most forgiving is the universal joint when supplied as a pair with a spacer shaft. especially with pumps on hot applications which will cause axial expansion of the pump shaft. Elastomeric couplings can tolerate all forms of misalignment by the distortion of the elastomer. To accommodate parallel offset.
• 25 . (Insert figure 18 from the Student Workbook for the Energy Reduction Video . but the figure below can be used as a guide. the presence and size of abrasive solids. During the maintenance of centrifugal pumps. There are other API standards covering data sheets. Pump FAQsÂ® July 2005 Article #2 Q. the head developed by the impeller and the operating speed. the term API pump usually refers to an end suction centrifugal pump which is designed in conformance to API 610 for high temperature and pressure petroleum products.HERE. A primary feature is the support system which is at the centerline of the pump casing to minimize the effects of thermal expansion. Magnetic containment shells shall be designed for the maximum allowable working pressure within the stress values for the materials in â€œSection VIII of the ASME Boiler and Vessel Codeâ€. Pump FAQsÂ® June 2004 Article #1 Q. viscosity of the liquid. The containment shell between the inner and outer magnet assemblies is very thin. Normal wear of centrifugal pump clearance depends on many factors such as cleanliness of the liquid. We have concerns about wear in the shell and leakage of the liquid. In common usage. You can take the following precautions regarding magnetic drive pumps: • The containment shell material must be selected to resist corrosion and erosion from the liquid being pumped. how much wear of the wearing rings is considered normal. and what is the normal wearing ring clearance for a new pump? A simple answer is not available. Is our concern valid.Pump FAQ’s by Hydraulic Institute (UK) 25 Gas Industry Services. and what can be done to protect against leakage? Leakage of toxic liquid from any type of pump is a valid concern. We are considering the use of a magnetic drive pump for handling toxic liquids. There shall be a minimum ratio between bursting pressure and design pressure of 2 to 1 for the pressure/temperature range in the pump. sealing systems and sucker rods. The gasket between the containment shell and the pump cover casing shall A. Stainless steel impellers typically require greater clearance than bronze or iron to avoid galling and seizing. The normal clearance range of a new pump can be obtained from the manufacturer or his representative.) A.
casing. This is usually done by the outer housing which surrounds the outer magnet assembly. A secondary containment shell shall also be provided.6-2000 Sealless Centrifugal Pumps. part 239) to detect loss of primary containment. Sensors should be provided to measure and monitor the position of the inner and outer magnet assemblies to prevent them from rubbing on the containment shell. 26 .Pump FAQ’s by Hydraulic Institute (UK) be confined on the atmospheric side to prevent blowout. For further information see ANSI/HI 5. See the figure below: 26 • • • Provide a leak detector or pressure sensor at an appropriate location in the outer containment shell (frame. The design shall consider thermal cycling which may occur as a condition of service. and a suitable sealing device around the input shaft on the pump side of the inboard bearing (Ref 16). part 19 or cover.1-5.
The answer to your question is not that simple. The members of the Hydraulic Institute and a team of international experts put their collective experience 27 . How can this performance change be calculated? A. I have been told that the performance characteristics of centrifugal pumps are changed when pumping viscous liquids such as hydrocarbons.Pump FAQ’s by Hydraulic Institute (UK) 27 Pump FAQsÂ® July 2006 Article #1 Q.
6.7 Effects of Liquid Viscosity on Rotodynamic (Centrifugal and Vertical) Pump Performance. How can the shaft fail in fatigue under these conditions? The existence of torsional vibration rarely shows itself in the pump column or driver housing vibration. pump shafts.6.Pump FAQ’s by Hydraulic Institute (UK) together and prepared a thirty-page document on this subject which was approved as an American National Standard.6. It is designated as ANSI/HI 9. Rotor torsional critical speeds can be present any time there are two rotating masses connected by a shaft that is not infinitely stiff. The correction factors used in this standard are based on in-depth hydraulic design calculations proven by extensive laboratory test data of many pumps on liquids with a wide range of viscosities. coupling or gears can fail without the usual (radial) vibration monitoring equipment indicating any danger. The correction factors are used to adjust the performance on water as shown below in Figure 9.7.1 a and b.7. Figure 9. This implies that any pump rotor coupled to a driver has a torsional natural frequency of vibration. An analysis of the break pointed to torsional fatigue as the cause but the pump was operating under full load in a steady mode and vibration monitors did not show excessive vibration. We recently experienced line shaft failure in a multistage vertical turbine pump with ten-inch diameter bowls. Torsional critical speeds are associated with torsional or angular deflection of the rotor and are not to be confused with lateral critical speeds associated with A. 28 . Thus.1 â€” Modification of pump characteristics when pumping viscous liquids 28 Pump FAQsÂ® July 2006 Article #3 Q.
is it better to grout the pump baseplate or let it float free? Different sources provide opposing views on this subject. the inaccuracies in the gear teeth can provide the exciting force and high torsional critical speeds at tooth meshing frequencies. The resulting stresses and angular deflections can cause premature equipment failure. not to the entire performance curve. It is recommended that the contractual agreement contain the agreed upon acceptance level.4 Centrifugal and Vertical Pumps for Vibration Measurements and Allowable Values. the primary hydraulic exciting force is generated by the impeller vanes passing the bowl vanes. with resulting negligible vibration amplitudes. When installing a horizontal pump. the head variation at the rated flow is +5% to -0%.6 Centrifugal Pump Tests. "A" or "B" which must be agreed to by both customer and manufacturer. when a pump is driven through a gear. How much deviation from the manufacturerâ€™s rating curve is normal? The Hydraulic Institute Standard contains two performance test acceptance tolerance levels. The energy level of this force is typically low. An alternate tolerance in rate of flow at rated head is +10% to -0%. The tolerance for total head has four different categories that depend on the total head and rate of flow. When checking the performance of a new centrifugal pump. There is an alternate tolerance for rate of flow at the rated total head. All of this is dependent on an agreement with the pump manufacturer to perform a factory test to determine the true performance and take any necessary corrective action before the pump is shipped. engines can also cause high torsional vibrations at higher frequencies. Similarly.Pump FAQ’s by Hydraulic Institute (UK) 29 lateral deflection. Pump FAQsÂ® July 2004 Article #1 Q. For more information on pump vibration. Pump FAQsÂ® July 2005 Article #3 Q. 29 .6. On the other hand. A. Field tests are seldom accepted as reliable due to the difficulty of meeting the proper test procedures in the field and making corrections. see ANSI/HI 9. The acceptance tolerance applies to the specified condition point only. Assuming acceptance level â€œAâ€ is applicable and the rated conditions are 3500 gpm at 300 feet. With vertical pumps. Additional details are available in ANSI/HI 1. the plot of the resulting head versus rate of flow curve appears to be lower than the manufacturerâ€™s rating curve.
the baseplate must not be permanently deformed after the equipment is mounted at the manufacturing facility.Pump FAQ’s by Hydraulic Institute (UK) A. be capable of being installed properly with minimum difficulty. It must be recognized that it is not necessary that an absolutely rigid baseplate be designed to meet these requirements. allow final alignment of the mounted equipment. However. Functional requirements: The purpose of a baseplate is to provide a foundation under a pump and its driver that maintains shaft alignment between the two.94. survive handling during transportation to the installation site. Free standing baseplate: A free standing baseplate is a design which is intended to be elevated off the floor or deck and supported by stilts or shims.3-2000 Centrifugal Pumps for Design and Application Pump FAQsÂ® July 2005 Article #1 30 . Applications that undergo wide temperature variation may do well with floating baseplates in order to allow for movement of the pump and thereby minimize pipe strain caused by thermal expansion of the pipe. Compliance with these design criteria. This type of baseplate must be designed to provide its own rigidity as there is no grout for support. 30 Whether to grout or not depends on the specific application and the design of the baseplate. and allow removal and reinstallation of equipment. See Figure 1. will contribute significantly to meeting the functional requirements. the baseplate in such cases must be sufficiently rigid and designed to avoid misalignment of the shaft coupling as the baseplate moves. Additional information and calculation of baseplate stiffness can be found in ANSI/HI 1. in conjunction with proper installation procedure. This baseplate must allow for initial mounting and alignment of equipment. At the same time.
1978.2 ft/sec2 L = a characteristic length (usually bell diameter or submergence) in ft. 32. we are concerned that the pump intake structure may not provide a good hydraulic design and are considering whether to build and test of a model of the intake. Knauss. but the same parameter must be used for the model and prototype when determining the Froude number. the Froude number shall be equal in both the model and prototype and solving for the velocity in the model will answer your question. The choice of the parameter that is used for velocity and length is not critical. it is important to select a reasonably large geometric scale to minimize viscous and surface tension scale effects. the scale selection based on vortex similitude considerations is a requirement to avoid scale effects and unreliable test results. Hecker. representing the ratio of inertial to gravitational forces. Because of local restrictions on the size.. Fluid motions involving vortex formation have been studied by several investigators (Anwar. can be defined for pump intakes as: F = u/(gL)0. Realizing that larger models. How do we select the appropriate rate of flow for the model test? Models involving a free surface are operated using Froude similarity since the flow process is controlled by gravity and inertial forces.5 Where: u = average axial velocity (such as in the suction bell entrance) in ft/sec g = gravitational acceleration.Pump FAQ’s by Hydraulic Institute (UK) Q. In modeling a pump intake to study the potential formation of vortices. the model shall be large enough to allow visual observations of flow patterns. et al.. and to reproduce the flow pattern in the vicinity of the intake. However. H. 1984. and Hecker. J. 1981. a balancing of these factors is used in selecting a reasonable model scale.O.E. G. accurate measurements of swirl and velocity distribution. G. 1987) ANSI/HI 9.E. though more accurate and reliable. Padmanabhan. 31 We are designing a circular sump for the installation of three sewage pumps. Pump FAQsÂ® July 2002 Article #3 31 . and sufficient dimensional control. The Froude number. M.. A.8 Pump Intake Design includes additional information on this subject. In addition. For similarity of flow patterns.. are more expensive.
Pump FAQsÂ® July 2002 Article #2 Q. which is about 30 feet long. This up thrust is usually less than the heavy down thrust from the weight of the rotor and hydraulic forces so that no net up thrust occurs. to supply cooling water. A. In this case there is little down thrust from the impeller and maximum up thrust from the change in momentum resulting in a net up thrust which disengages the motor clutch. What causes this to happen and what can be done to prevent it? Vertical turbine pumps are designed so that the downward thrust due to the weight of the rotor and hydraulic force from pressure on the back of the impellers is carried by a high thrust tapered roller bearing on the top of the motor. A. Pump FAQsÂ® April 2002 Article #2 Q. How can this safe thickness be determined and what are the potential consequences of operating with less than proper thickness? The minimum casing thickness for a pump is determined by the manufacturer based on the maximum casing working pressure and temperature and the material of the casing. which is capable of resisting the momentary up thrust. This bearing is not capable of carrying any thrust in the upward direction. However. Pump manufacturers also add a corrosion allowance to the minimum wall thickness so the casing as manufactured can safely be eroded by the amount of the allowance. during pump operation there is also an upward thrust on the pump rotor caused by the change in momentum of the flow as it changes direction from axial to radial at the entrance to the impeller blades.Pump FAQ’s by Hydraulic Institute (UK) Q. the pump will not immediately fail because of the factor of safety and possible operation below the maximum working pressure. However. Operating a pump with less than minimum wall thickness should be avoided. 32 We operate a vertical turbine type well pump that has a clutch at the top of the motor that often disengages when the pump starts. This is done using finite element analysis or empirical calculations based on test. To correct this problem the pump rotor needs to be fitted with a thrust collar. there is no resistance to flow and the pump operates momentarily at a very high rate of flow. Normal pump operation will eventually corrode and erode the inside of a pump casing until the thickness of the casing wall is too thin for safe operation. The requirements have been changed and we need an 32 . The consequences of failure will range from a leak in the casing wall to total fracture. Our plant uses a 10-inch vertical turbine pump. at the moment of start up. However. The ASME Pressure Vessel Code is used to determine the proper factor of safety for the casing material and the manufacturer publishes the resulting minimum thickness.
a€ Pump FAQsÂ® April 2004 Article #1 Q. resulting in sudden failure. I understand the importance of monitoring pump performance in order to prevent unexpected pump failures. Ultrasonic thickness measurement can also be used. But you know this. stress corrosion can occur without any visible signs. However this is not useful in detecting localized forms of corrosion such as pitting. What else can be done? We cannot increase the impeller diameter due to power limitations. Most pump manufacturerâ€™s performance curves are limited to the bowl assembly performance. According to the pump rating curve. But how do we know when corrosion or erosion have reduced pump casing wall thickness to the point at which casing failure may occur? The casing wall thickness must be measured periodically to know when failure is imminent. but we cannot reach the rating curve performance. We have renewed the impeller wearing ring clearances. To use this method the casing surface must be cleaned to bare metal. Linear polarization is another method that involves measurement of a current response to an applied potential through probes that are inserted in the system.Pump FAQ’s by Hydraulic Institute (UK) increase in flow of about 10%. Measuring the casing wall thickness is the problem. rate of flow. Electrical resistance measurement of the casing wall using a metal probe shows an increase in resistance as the casing thickness is reduced by corrosion. The last three methods lend 33 . To this end. This was included in an educational video titled â€œSystems. input power. but it does not. Ultra sound is not as accurate as the other methods. We have difficulty in getting wearing ring data for several older pumps. 33 Increasing the pump column pipe diameter will certainly help. In addition. several methods can be used: • Visual inspection is the easiest and may be the most economical method. A. since the length and diameter of the column pipe represent an unknown variable. Performance parameters such as discharge pressure. • • • The frequency of wall thickness measurement depends on the expected corrosion rate of the pump on the application. and vibration are straight forward. Is there a general guideline on recommended wearing ring clearance that we can use? In 1997 the Hydraulic Institute published a listing of recommended clearances for a range of wearing ring diameters. A. However it is cumbersome and messy when dealing with corrosive liquids. To use this method a conductive liquid is required. Pump FAQsÂ® April 2002 Article #3 Q. A. the pump should satisfy our needs.
Verify the NPSHA to ensure there is sufficient margin to operate at the high rates of flow. See the figure for an example.5 Centrifugal and Vertical Pumps for Condition Monitoring. This design allows the solids to collect at the pump inlet where they can be swept away with the flow. This allowance can be supplied by the pump manufacturer. How can this be? When are rubbery materials best used? 34 . According to ANSI/HI 9. The pump should be periodically operated at its maximum rate of flow to more effectively carry away the solids. Is there a better way? It is often practical to build the pit with sloping sides to minimize the horizontal floor area. Pump casings are designed with a built in allowance for corrosion. Contact the pump manufacturer or his representative when the allowance has been reduced by 50% or if a significant change in process conditions causes rapid reduction in wall thickness. A. This requires draining of the pit or removal of the pump to remove the solids. I understand that hard material for the impeller and casing is recommended to resist erosion. The visual method is more difficult. portable devices. I also hear that soft rubbery material is also used.8 Pump Intake Design includes considerable detail on this design. If two or more pumps are in the pit.Pump FAQ’s by Hydraulic Institute (UK) 34 themselves to continuous monitoring or frequent checks by use of small. Pump FAQsÂ® April 2004 Article #2 Q. ANSI/HI 9. Pump FAQsÂ® April 2004 Article #3 Q.6. especially slurries. the pump should be â€œShutdownâ€. Pumps operating in wet pit applications often suffer from the accumulation of grit or other solid material which accumulates near the pump inlet. but the first measurement should be made no longer than 3 months after start up. when measurements show that 70% of this corrosion allowance has been lost. When pumping liquids with entrained solids. the one farthest from the inlet to the pit may be run alone to remove the solids. The sloped walls should be a minimum of 60 degrees from the horizontal for concrete or 45 degrees for steel.
use caution and do not over lubricate the bearing. We operate a number of end suction centrifugal pumps on a chemical process application. pump bearings are usually selected to provide a minimum of two years continuous operation before failure and the average bearing life is about five times longer. Pump speed is also a factor. as distinct from rotational speed. Check the bearing manufacturerâ€™s catalog for the recommended shaft dimension. • • • 35 . but the anti-friction bearings fail in less than twelve months. Verify that the internal preload of the bearing meets the recommendation of the pump manufacturer.chrome irons or elastomers are used for their corrosion resistance.115 ft/sec higher slurry concentrations and larger solids-100 ft/sec pumps fitted with elastomer impellers. what can be done to increase bearing life? No. Make sure the bearing cover seals are replaced each time. Follow the manufacturerâ€™s recommended lubrication intervals. Impeller tip speed. In special applications with low head requirements. the nozzle loads are within acceptable levels. or solids in the oil will attack the bearings and reduce life. water. hard metals are often used in applications characterized by large. however. is often used as a guide for wear in the selection of slurry pumps. solid ceramic-lined pumps are used for pumpages containing fine material. and cleanliness: Corrosive chemicals. 35 As a general guideline. Pump FAQsÂ® April 2005 Article # 1 Q. hot alignment checks are recommended. make sure that the pressing force is applied evenly to the A. Normally. Lubricant amount. check for the following during the bearing replacement process: • Shaft coupling alignment: Poor alignment imposes additional loads on the bearings which will reduce bearing life. Where grease lubrication is used.Pump FAQ’s by Hydraulic Institute (UK) A. sharp edged solids. Either high. poor alignment will also lead to premature seal failure. and elastomers for smaller round-edged solids. Shaft alignment can be affected by nozzle loads. For pumps operating in higher temperature service. Also make sure that the shaft-mounted rotating flingers are close to the bearing seals to help keep contaminants away. and if necessary retrofit the pumps with more elaborate labyrinth bearing seals. Bearing assembly procedure: When the replacement bearing is pressed onto the shaft. Is this normal? If not. ANSI/HI 1. Be sure that when the pump is running.3 Centrifugal Pumps for Design and Application recommends the following maximum impeller tip speeds: • • • • dirty water-130 ft/sec medium slurries up to 25% solids and 200 micron solids. The next time the bearings fail.85 ft/sec. Bearing fit on the shaft: If the shaft diameter under the bearing is too large it will expand the ID of the inner race of the bearing excessively and preload the rotating elements of the bearing beyond the recommended levels. condition. The seals operate well.
Is there similar information on rotary pumps handling liquid with solids or slurries? Yes. clutches and other mechanisms are necessary to allow safe operation in this condition. providing uniform contact with all shoulders. With air operated pumps. The December 2004 issue of P&S included a question and answer on air entrainment in rotary pumps which I found to be useful. Bypass valves. when the discharge valve is closed. 36 • Finally. Be sure to follow the manufacturerâ€™s recommendations when preheating the bearing is required. 36 A. A. it is true. Coupling half assembly: Most couplings are designed with a light interference fit on the shaft. ANSI/HI 3. I have been told that reciprocating pumps must be protected against operation with a closed discharge valve. If the coupling half is assembled to the shaft with a hammer or press. the pump cannot be damaged. The closed valve prevents the fluid from exiting the pump. . ANSI/HI 10.Pump FAQ’s by Hydraulic Institute (UK) inner race only and not to the outer race. when back in operation check that the pump is operating within the manufacturerâ€™s allowable operating region. Rotary pumps may be used for in-plant process and pipeline transfer of slurries when metered flow or medium-to-high discharge pressures are required.110. There is little additional stress generated because the pressures on both sides of the diaphragm are equal. rings.5 Air Operated Pumps contains much useful information on these pumps. Motor driven reciprocating pumps continue to rotate when the discharge valve is closed. Pump FAQsÂ® April 2005 Article #3 Q. Pump FAQsÂ® April 2005 Article # 2 Q. which will transfer the load to the bearings. The Hydraulic Institute standard.1-3.5 Rotary Pumps includes several good pages on this subject. Since volumetric efficiency and therefore mechanical efficiency are normally dependent on the clearances between the pumping elements of a rotary pump. and checknuts on the shaft and in the bearing housing. the air and fluid pressures equalize and the diaphragm or bellows stops reciprocating. care must be taken in the selection and application of the pump in slurry service. subjecting the motor and other pump components to excess internal stress due to the high torque that is generated by the motor as load increases and speed is reduced by that load. The pump end is designed to withstand the force generated by the maximum rated air pressure so as long as the air pressure is below the rated air pressure. Verify that the bearing temperature and vibration levels are within acceptable limits. Care shall be taken to install the bearing square with the pump shaft. Is this true and why? Yes. the restraining force should be applied to the impeller end of the shaft and not to the pump frame. but that is not necessary with air operated diaphragm pumps.
Generally.Pump FAQ’s by Hydraulic Institute (UK) 37 Slurries containing hard particles can cause abrasive wear in rotary pumps. Many types of slurry similar to paper stock require open porting and clearances and definite minimum velocities of flow. In some pumps. configuration and interaction and operating clearance. What is a balancing disc or drum? I understand that multistage pumps. rotor cavity size. Figure 3. Thus. the rotor configuration will accept large particles as long as the size. the size must be related to porting. distribution and shape are controlled. such as on boiler feed service. as the percentage and size of the solids increase at given conditions of operation. speed and pressure.34 .21 below shows the last two stages of a multistage pump with a 37 . Figure 1. Usually the clearances must be greater than particle size. control. etc.Differential Pressure vs. The size and general shape of the solids in slurry normally govern whether a particular rotary pump configuration and/or clearances can be used for the slurry in question. Although rotary pumps are capable of limited slurry handling. usually use such a device to balance hydraulic thrust. Low concentrations of fine non-settling solids in a Newtonian fluid carrier may have no appreciable effect on either the power requirements or the pump rate of flow. The effect on rotary pump performance can vary widely as slurries change with time. Pump Input Power Pump FAQsÂ® April 2006 Article # 2 Q. Clay slurries require low shear rate. the particular rotor and housing configuration make the various rotary designs more or less adaptable to specific types of slurry.34). character. the pump input power curve increases (see Figure 3.
The resulting force can be very large. The space between the last impeller and the balancing drum is under full discharge pressure which creates a force to the right over the area of the impeller eye. and an appropriate thrust bearing will be required. Figure 1. There is a close clearance bushing between the impeller and disc so as liquid flows the pressure on the disc drops and the space between the disc and stationary member closes.21 shows a balancing disc which is slightly larger than the wearing ring. This makes the rotor self adjusting so the net thrust is always zero. This reduces the net axial unbalance to practically zero.21 .Pump FAQ’s by Hydraulic Institute (UK) balancing disc shown on the left. If a cylindrical drum is used in place of the disc. but as the disc moves. thereby balancing the force on the impellers. with the same diameter as the impeller wearing ring. the thrust can be effectively balanced. 38 To counterbalance this force a disc or cylindrical drum. but the self adjusting feature will be lost. Figure 1. which at the suction end is under suction pressure.Multistage Pump with Balancing Disc 38 . The hydraulic pressure acting on this device creates a force in the opposite direction from the impeller thrust. and difficult to restrain with a thrust bearing. the space between the disc and stationary member opens with a resulting flow of liquid which is pipe back to the suction. is mounted on the shaft. A. The pressure here will push the pump rotor to the left.
Pump FAQ’s by Hydraulic Institute (UK)
Pump FAQsÂ® April 2006 Article #1 Q. A.
We need to replace several pumps handling paper stock, and need to know what special problems we should look out for. Can you help with such information? Paper stock varies considerable depending on the wood source that is used and the consistency of the stock. Low-consistency stock usually refers to a class of products with 1 to 7 percent fiber content by weight. These paper stocks are normally handled by end-suction centrifugal pumps equipped with semi-open impellers and contoured wear plates. Medium-consistency stocks are made of 8 to 15 percent paper fiber. The rheological properties of fiber-water suspensions in this range are dependent on 39
Pump FAQ’s by Hydraulic Institute (UK)
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 example, some form of â€œshear generatorâ€ is needed at the inlet to create turbulence and reduce the effective fluid viscosity. Special impeller design and air-extraction devises are also required to prevent air binding. An end-suction centrifugal pumping unit must be specifically designed to handle medium consistency stock mixtures without clogging the device, or dewatering the stock. A large suction-eye and unobstructed waterways 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 clogging to improve its reliability. High consistency paper stocks contain more than 15 percent paper fiber, and are found in the bleaching operation. Centrifugal pumps cannot handle such high consistency, 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. More information on this subject can be found in ANSI/HI 1.3 Centrifugal Pumps for Design and Application.
Pump FAQsÂ® August 2004 Article #2 Q.
Our company operates a high pressure process during which the liquid is throttled to low pressure after processing. We are considering the use of a power recovery turbine to recover some of the energy lost by throttling. Can a typical centrifugal pump be used as a turbine, and if so, what precautions must be taken? Yes. A typical centrifugal pump can be used as a turbine, however, selection and installation must be done carefully. While operating in the turbine mode, the performance characteristics of a pump as turbine (PAT) differ significantly from operation in the pump mode. The PAT should be selected by the pump manufacturer to insure that the selection is both hydraulically and mechanically suited for the application. Precautions must also be taken to insure that the PAT will operate without cavitation. The turbine industry uses the terminology TREH (Total Required Exhaust Head) and TAEH (Total Available Exhaust Head) in place of NPSH. Some of the other factors which affect the use of pumps as turbines include:
Pump FAQ’s by Hydraulic Institute (UK)
• • • • • •
Runaway speed Liquid flow at runaway speed Required solids passage Liquid borne abrasives Torque reversals during start-up or shut-down Overspeed trip and control
Pump FAQsÂ® August 2004 Article #3 Q.
One pumping system in our plant makes a load bang when it is shut down. I have been told that this results from water hammer. What causes water hammer and what can be done to correct it? Water hammer may have severe effects and damage parts of the pumping system. It results when liquid flowing through a relatively long length of pipe is suddenly stopped. The velocity energy of this large mass of liquid is suddenly converted to pressure energy with a resounding bang. Itâ€™s like trying to stop a long railroad train within in a short distance. Some suggestions for correction include the following:
• • • •
Reduce the liquid flow gradually before stopping the pump Add a liquid chamber with an air cushion to absorb the energy Reduce the pump speed slowly by using a variable speed drive or by adding a flywheel Install a check valve that closes slowly to minimize shock
Pump FAQsÂ® August 2005 Article #1 Q.
When purchasing pumps for water supply systems, is there a simple way to determine the maximum allowable speed for a specific application? If so, what factors should be considered? The primary factor to be considered when estimating the maximum pump speed for water supply systems is minimizing the potential for cavitation damage. Experience has shown that cavitation risk is minimized when the pump suction specific speed is equal to or lower than 8500 in US units. Suction specific speed is a characteristic of a pump, which is determined by the following equation: S = nQ0.5 / NPSHR0.75, where: S = suction specific speed n = speed of pump in rpm
Again.Pump FAQ’s by Hydraulic Institute (UK) 42 Q = pump rate of flow in gpm for single suction pumps and half total flow for double suction pumps NPSHR = net positive suction head required in feet If we solve this equation for n.3 Centrifugal and Vertical Pumps for Design and Application for additional details.75 where: NS = specific speed n = speed of pump in rpm Q = pump discharge rate of flow in gpm for both single suction and double suction pumps H = pump total head in feet. Q can also be varied by changing the number of simultaneously operating pumps in the system Another consideration is maximizing pump efficiency. we get: n = ((8500) x (NPSHA)0. 42 . substitute 8500 for S and NPSHA for NPSHR.5 Substituting the systems values for NPSHA and Q will give the maximum recommended speed for this application. Refer to ANSI/HI 1.5 / H0. The figure below shows the efficiency correction or reduction as a function of specific speed.75) / Q0. Specific speed is determined by the following equation: NS = nQ0. experience has shown that centrifugal pump efficiency is maximum when pump specific speed is between 2000 and 4000 in US units.
and the following equation was developed: Where: RT = radial thrust in pounds K = thrust factor from figure 1. When the rate of flow is reduced by throttling. The flow velocity is higher in the vicinity of the volute tongue and the pressure is lowest at that point.Pump FAQ’s by Hydraulic Institute (UK) 43 Pump FAQsÂ® September 2006 Article #1 Q. there is little if any unbalance of forces around the impeller and very low net radial force. some of the liquid from the impeller is forced back into the casing volute causing an unbalance of flow and an unbalance in pressure distribution. Consequently. I understand that the radial force on a centrifugal pump impeller increases as the pump is throttled to lower rates of flow. In a properly designed centrifugal pump. the distribution of flow and pressure around the impeller is uniform at the design rate of flow.81 below H = pump head per stage in feet s = specific gravity of the liquid 43 . This phenomenon was studied experimentally in the early 1950s. The result of this is an unbalance in pressure distribution around the impeller and a net force or thrust in the radial direction. Why does this occur and how can this force be calculated? A.
More detail on this subject can be found in the American Standard â€œANSI/HI 1. Higher radial thrust loads may contribute to shorter bearing life and deflection at the pump seals causing premature seal failure. that does not seem to be the case since the bearings are clean. To avoid this problem. and the bearings look clean after they fail. This is also consistent with the regularity of the failures. How can we get longer life from the ball bearings in our pump? Our process uses an end suction centrifugal pump to circulate heat transfer liquid at 750 degrees F. That leaves the matter of excess bearing load. they will usually move out of alignment as the pump heats up. shut down the pump when it reaches operating temperature and recheck the coupling alignment. Pump FAQsÂ® September 2005 Article #1 Q. all of the flow from the impeller A. Realign the coupling if necessary. At low flow rates. One common cause of high bearing load is coupling misalignment. the bearing cooling is a big help. What else should we look for? Pump bearings are most likely to fail due to contamination and poor lubrication. However.3 Centrifugal Pumps for Design and Applicationâ€. 44 . If the coupling halves are aligned when the pump is cold.Pump FAQ’s by Hydraulic Institute (UK) 44 D2 = impeller diameter in inches b2 = impeller width at discharge including shrouds in inches The radial thrust must be supported by the pump shaft and bearings. some movement from pipe stains is still possible. The bearing housing is cooled. Another cause of high bearing load is operation below fifty percent of the pumps best efficiency rate of flow. Even with the pump supports at the shaft centerline. In addition.
45 . How do pump manufacturers determine the design rate of flow and total head for each pump in the series? The horizontal spacing between pumps is determined by a reasonable flow velocity for the discharge opening of the pumps. To guard against this. This makes the designerâ€™s job easier. 1Â½.6 for head also result in diagonally spaced pumps having the same design specific speed (NS). The popular pipe sizes. This allows an acceptable cut down range between pumps without an excessive reduction in efficiency at the lower end of the pumps coverage. experience. Total head between pumps usually increases by a factor of 1. A. Such bearings may also be referred to as C3 Fit bearings. The hydraulic coverage charts for standard pump lines published by manufacturers form a rectangular grid with pump size varying with rate of flow horizontally and total head vertically. a 3 inch discharge pump with a 10 inch impeller has the same NS as a 4 inch with 13 inch impeller and is therefore geometrically similar. This heat causes the shaft diameter and the inner raceway of the bearing to expand which in turn squeezes the rotating balls in the bearing. heat is transmitted to the bearing through the pump shaft. Finally.Pump FAQ’s by Hydraulic Institute (UK) 45 cannot exit from the pump casing so it recirculates in the impeller. This causes an uneven distribution of pressure around the impeller resulting in a high radial force on the impeller which must be supported by the bearings. 4. One of the laws says that Q1/Q2 = D1/D2. Many sources. also double in area in progression. The result is shorter bearing life which can be corrected by using bearings with greater internal clearance. 1. pumps increase in rate of flow in a doubling progression. Even with bearing cooling. Another problem which is unique to high temperature applications is excessive expansion on the bearing inner race. Design and Application. determine the actual rate of flow through the pump and make sure it is close to the pumps best efficiency flow.6-2000 Centrifugal Pump Tests says that at a given speed. These factors of 2 for rate of flow and 1. Pump FAQsÂ® September 2004 Article #3 Q. 6 inch etc. Pump FAQsÂ® September 2004 Article #2 Q.6. ANSI/HI 1. 2. where Q is the rate of flow and D is the impeller diameter. competition and standards play a big role as each manufacture attempts to compete with all others. describe the use of Affinity Laws which are used to predict the performance of a centrifugal pump when the impeller diameter is reduced or cut down. including the Hydraulic Institute e-learning program Centrifugal Pumps: Fundamentals. Hence. 3. For example. However.
They are also used by pump designers when they design a new pump based on the geometry of an existing pump of a different size. I understand that pipe strains are bad for pumps and should be avoided. the axial force caused by 150 psi pressure in a six inch pipe is 4. and the effect on rate of flow is linear. 46 Both are correct for their intended use. This force is usually restrained by the pipe.241 pounds. and to some degree up to ten percent.5 which is equivalent to Q1/Q2 = (D1/D2)3. This is a true three dimensional comparison. Vertical-inLine pumps are a variation of the close coupled design and are available for many process applications. For example.1 pump is 3500 pounds according to ANSI/HI 9. At 150 psi. The Affinity Laws are used to predict the performance of an existing impeller of known performance when its diameter is cut or reduced in the order five or ten percent. However.6. Typical expansion joints do not restrain the axial forces in the piping due to the liquid pressure. ANSI/HI 9. so the rate of flow changes as the third power of the impeller diameter. 46 . The modeling laws as described in the HI Test Standard are used to compare the performance of two distinct pumps which are of different size but geometrically similar. The maximum allowable force on the discharge flange of an 8X6X13 ANSI B73. This is an empirical relationship and is reasonably accurate for diameter reductions up to five percent.3 shows and A. no other dimensions change. the pipe do not do this. but what else can be done to solve this problem? Expansion joints have a problem too. Which is correct. In addition to the impeller dimensions the casing dimensions are modeled as well. Close coupled pump designs can facilitate this approach. On the other hand. Such forces must be carried by the pump if the expansion joint is close to the pump. The modeling laws are very accurate provided that the surface roughness of the waterways as well as all other dimensions of the impeller are kept to the same proportions as the original. VIL pumps can transmit substantial forces through the casing between the discharge and suction pipe. or is there some explanation for the difference? A. when the diameter of an existing impeller is cut down.Pump FAQ’s by Hydraulic Institute (UK) Q1/Q2 = (D1/D2)2 (H1/H2)0. Pump FAQsÂ® September 2004 Article #1 Q. Expansion joints are designed to relieve such forces.3-2000 Centrifugal and Vertical Pumps for Allowable Nozzle Loads. this allowable limit would be exceeded. but with an expansion joint. some installations inherently have this problem due to temperature changes which result in thermal expansion of the piping. Another approach to this problem is a free floating pump or a spring mounted baseplate.6.
Pump FAQ’s by Hydraulic Institute (UK) 47 allowable force between discharge and suction of a 4 inch discharge pump to be 18. Pump FAQsÂ® September 2002 Article #3 Q. 47 . Additional guidance on this subject may be found in the Hydraulic Institute Standard ANSI/HI 1. Above 10. I understand that centrifugal pumps are not well suited to handle viscous liquids. but the baseplate must have sufficient stiffness to maintain coupling alignment without relying on a concrete foundation. Is there an easy way to evaluate the viscosity value above which centrifugal pumps are not recommended? Centrifugal pump performance is significantly impaired when pumping liquids with viscosities that exceed 1000 SSU. A.704 pounds.000 SSU they are almost useless.3â€”2000 Centrifugal Pumps for Design and Application. Page 25 of this standard contains the correction chart that appears in Figure 2 below. Spring mounted baseplates can also work well.
We are operating an end suction pump with an elbow connected to the suction 48 .Pump FAQ’s by Hydraulic Institute (UK) 48 Pump FAQsÂ® September 2002 Article #2 Q.
One of our utility pumps takes suction from a river that frequently becomes muddy. If the existing suction line will not permit this. 2. The bronze impeller and wearing rings become badly eroded more quickly than anticipated. What do you recommend to increase useful impeller life? There are several approaches you may want to consider: 1. one pump manufacturer designed a special elbow that looked similar to the one shown in Figure 1. This will help to optimize the angle with which the vane and liquid meet thereby minimize erosion. Operate the pump close to its best efficiency point (BEP).Pump FAQ’s by Hydraulic Institute (UK) flange. Pump FAQsÂ® September 2002 Article #1 Q. 49 An improvement can be achieved by using a reducing elbow at the pump. A few years ago. Reduce the solids content from the liquid by installing a settling chamber or cyclone separator upstream of the pump suction. Is there a simple solution? A. Tests showed that this design provided a more uniform flow output. it should be increased to 2 sizes larger than the connection at the pump. 3. Upgrade the impeller material to something more abrasion resistant such as A. Reducing two pipe sizes is better than one. 49 . The suction connection is eroded on one side due to the uneven flow coming out of the elbow.
A.6. Excessive stress in the pump nozzles â€“The suction and discharge A. I know that pumps should not be subjected to excessive forces and moments from the system piping. It results in reduced bearing and mechanical seal life and may cause premature fatigue failure of the pump shaft. and high vibration of the pump rotor. The pump efficiency at 50% of the BEP is considerably lower than at the BEP. • • 50 . Replace the pump with one that is specifically designed for abrasive service. excessive noise. Pump FAQsÂ® September 2001 Article #1 Q. but how do excessive forces damage the pump and what is the weakest link in this regard? Pump damage due to excessive forces and moments from system piping can cause damage in the following ways: • Shaft coupling misalignment â€“ Excessive pipe loads can distort the pump or its baseplate such that the alignment of the driver and pump shaft is forced beyond that which the coupling can tolerate without transmitting unacceptably high loads to the shafts. Unbalanced radial forces.pumps. You can locate abrasive pump suppliers on Supplier Finder section.3-1997 Centrifugal and Vertical Pump for Allowable Operating Region.org under the Pump FAQsÂ® September 2001 Article #2 Q. which act on the outside diameter of the impeller. Is it an acceptable practice to select centrifugal pumps at rates of flow that are less than 50% of the Best Efficiency Point (BEP) in order to get a pump. This phenomenon is typically more severe in single volute designs. Operating a pump in this manner will require more energy (higher operating costs). which could be offset by selecting a pump which may have a greater initial cost and operates at a lower speed and has a lower NPSH requirement. Holddown bolt failure â€“ This can include elongation of the holddown bolts resulting in shaft movement at the coupling as well as reduced friction between the pump and baseplate causing the pump to move relative to its baseplate. bearings and mechanical seals. www. The result is shortened life of the coupling. • This subject is covered in greater detail in ANSI/HI 9.Pump FAQ’s by Hydraulic Institute (UK) series 400 stainless steel. 50 4. Continuous operation of centrifugal or vertical pumps below 70% of the BEP may result in the following problems: • • Recirculation in flow occurs on both sides of the impeller. thereby affecting the shaft coupling alignment. which causes cavitation damage to the impeller. increase as the rate of flow is reduced. which requires lower values of Net Positive Suction Head Required (NPSHR)? Most pump curves indicate lower values of NPSHR at lower rates of flow.
This is particularly dangerous with casings produced from a brittle material. which is found in Hydraulic 51 . We are designing a system with nine horizontal centrifugal pumps that will take suction from a common header. which provides information and design recommendations for suction piping. Premature seal failure and wearing ring damage may occur. This equation is for impellers with no back wearing ring and applies to operation A. ANSI/HI 2. A recently published document. Additional stress from the system piping can result in excessive stress in the casing structure.6.8 â€“ 1998 Pump Intake Design. This may result in contact between these parts as well as misalignment of the mechanical seal faces. can be distorted by excessive piping strain which affects the internal alignment between the rotating and stationary parts. Is there a simple way of calculating this? Institute Standard.â€ â€œThe suction piping should be designed such that it is simple with gentle transitions in changing pipe sizes. Pump FAQsÂ® September 2000 Article #3 Q. â€œThe ideal flow entering the pump inlet should be of a uniform velocity distribution without rotation and stable over time.â€ â€œThe maximum recommended velocity in the suction piping is 2. such as cast iron.3 Vertical Pump for Design and Application. Velocities may be increased at the pump suction flange by the use of a gradual reducer. 51 • Which of these problems becomes the weakest link depends on the specific pump design configuration and the direction or plane in which the forces and moments act. ANSI/HI 9. Internal pump distortion â€“End suction pumps. Due to a recent thrust bearing failure in one of our deep well pumps. Is there a design standard or good practice that will provide information on the maximum water velocity in the suction header? The Hydraulic Institute publishes ANSI/HI 9.0 ft/sec.2â€“2001 Centrifugal and Vertical Pumps for Allowable Nozzle Loads contains recommended allowable loads for specific pump types and further explains the problem. Following is a simplified version of this calculation. Pump FAQsÂ® October 2006 Article #1 Q. Bearing life may also be affected. Transitions resulting in flow deceleration at the pump shall not be used.Pump FAQ’s by Hydraulic Institute (UK) connections of the pump are already under stress due to the internal pressure in the pump case.4m/sec or 8. which are built with supports under the bearing housing. we would like to determine the down thrust on the bearing from the pump.â€ A.
Pump FAQ’s by Hydraulic Institute (UK) at BEP only.45 Adf= Area of impeller front wearing ring minus shaft area in in2 B = Number of bowls W = Total weight of all impellers and shaft in pounds Figure 2. which includes the impeller flow momentum change. A pump manufacturerâ€™s specific design 52 . The approximate down thrust at BEP in pounds is calculated as follows: 52 Where H = Single stage head at BEP in feet s = Specific gravity of pumped liquid C = Experimental coefficient from figure 2. This coefficient was obtained from a number of tests on vertical pumps with specific speeds from 1700 to 12000. The lines represent an average of these tests.45 provides the experimental coefficient â€œCâ€.
Approved pumps may then carry an FM or UL label when shipped. what can be done to decrease the operating cost of existing pump systems? With existing pump systems. If you do the math. what special requirements must we look for in their replacement? The purchase and installation of fire pumps must comply with strict regulations established by the National Fire Protection Association (NFPA) as published in their â€œPamphlet 20. At the same time. end suction. Donâ€™t allow for excess margin in rate of flow or head. Standard for the Installation of Stationary Pumps for Fire Protectionâ€ and â€œPamphlet 25. head at 150% of rated flow. • • • • Other opportunities for power savings include: Maintain pumps close to new condition to avoid efficiency loss. Pump FAQsÂ® October 2004 Article #3 Q. including the fire protection system.pumps. A list of approved fire pump manufacturers can be found on the Hydraulic Institute web site www. These requirements include the following: • • • • Pump type: Axially split case. Pump FAQsÂ® October 2005 Article #1 Q. We are expanding our building. Mechanical requirements: shaft strength. materials of construction and hydrostatic test pressure. A. you should see a one or two year payback on the cost of conversion. With the ever increasing cost of oil and resulting increases in the cost of power. Design approval by UL or FM based on their review of the pump design and witness of factory tests to insure that the pump performance meets their criteria. A. Review the pump selection and use a more efficient pump design if possible.â€ More specific pump design requirements are also enforced by â€œUnderwriter Laboratoriesâ€ (UL) and â€œFactory Mutualâ€ (FM). bearing life. Standard for Inspection. the most cost effective change that can be made is converting to variable speed drives for your pumps. See the figure on the right for an example of this effect. 53 . Performance requirements: shut off head. vertical-in-line or vertical turbine pump. Testing and Maintenance of Water Based Fire Protection Systems. existing control valves must be removed. no mechanical seals.org under Supplier Finder. suction lift capability and maximum horsepower requirement.Pump FAQ’s by Hydraulic Institute (UK) 53 may have a slightly different â€œCâ€ value. The result will be a reduction in the head loss in the system and lower operating speed for the pumps. If the existing fire pump must be replaced.
The reduction of NPSH A. Ideally. The Hydraulic Institute publishes an education program on this subject titled. How does this work. â€œEnergy Reduction in Pumps and Pumping Systems. When the load on the electric generator is reduced. and does it cause damage to the pump? Submergence control is sometimes used in applications where NPSH Available to the pump is limited and the pump would naturally be operating with marginal NPSH. I have heard that the rate of flow through centrifugal pumps can be regulated by submergence control instead of by throttling.org for details. 54 . Use pumps operating as turbines to recover pressure energy that would otherwise be wasted. Condensate pumps take condensed steam from the bottom of the steam condenser (hotwell)." Visit the e-Store at www. the steam required is reduced and the amount of condensed steam entering the condenser hotwell is reduced. producing the design rate of flow.pumps. This reduction in condensate causes the pump to draw down the level of liquid in the condenser.Pump FAQ’s by Hydraulic Institute (UK) • • 54 Use two or more smaller pumps instead of one larger pump so that excess capability can be turned off. thereby reducing the NPSH available to the pump. the liquid level in the condenser hotwell provides sufficient NPSH to the pump so that it operates on the head curve. A good example is condensate pumps in steam power systems. when operating at the design conditions. Pump FAQsÂ® October 2004 Article #2 Q.
but how can I determine the minimum rate of flow through the pump to avoid excess temperature build up? A commonly accepted practice limits temperature rise through a pump to 15Â°F. the pump will operate in this mode until the load is increased back to normal. gpm.Pump FAQ’s by Hydraulic Institute (UK) 55 available to the pump causes it to cavitate. The continuous cavitation in the impeller can be damaging to the pump. 2. the power input is approximately the same as at shut-off. but this can be compensated for by selecting a more cavitation resistant impeller material. hp. a flow must be maintained through the pump which will keep the liquid below its saturation temperature. 55 . To prevent flashing. resulting in a reduction in the rate of flow. If the load on the generator does not change. input power at the minimum flow. At the minimum flows calculated using the above equation. s = specific gravity.95 = constant. Pump FAQsÂ® October 2004 Article #1 Q. I know that a centrifugal pump can overheat badly if run at shut off for some time. and using a more rugged design of the pump shaft and bearings. this is adequate and minimum flow may be calculated with this equation: A. BTU/lb-Â°F. Cp = specific heat. For most installations. The bypass should not lead directly back to the pump suction. Minimum flow is guaranteed by installing a bypass from the discharge line to some low-pressure point in the system. Catastrophic failure of the pump and associated equipment may result if the liquid within the pump casing is allowed to vaporize. Where: Q = Pp = minimum flow rate.
Pump FAQ’s by Hydraulic Institute (UK) 56 An orifice installed in the bypass line breaks down the differential pressure between the pump discharge and the low-pressure point in the system. Typical locations monitored are joints.3 Centrifugal Pumps for Design and Application. Mechanical seal failure represents most of the causes for pump repair in our plant. Pump FAQsÂ® November 2006 Article #3 Q. Leakage from installed pumps is detected in a number of ways depending on the hazard posed by the liquid being pumped and the surrounding environment. Leakage through the inboard seal of a dual tandem seal arrangement may be detected by a change in pressure in the seal reservoir containing the buffer fluid. The bypass may be manually or automatically operated but must be open during periods of light load or when starting or stopping the pump. Improved seal life can result from a review of failures with your seal supplier 56 . This subject is discussed in greater detail in ANSI/HI 1. This is accomplished by blocking off the reservoir from the flare (vent) for at least 10 minutes and noting the increase in pressure. Concentrations can be measured to determine the severity of the leak. Pressure buildup in secondary containment areas of sealless pumps may also be used to indicate leakage past the primary containment. The proper sniffer must be used for the compound pumped. All single seal installations handling VOCs must use this method of monitoring. Leakage through the inboard seal of a dual tandem seal arrangement may be A. Visual monitoring is commonly used for single and dual outboard double and tandem seals. Larger leaks of volatile light hydrocarbons such as propane may form ice deposits on the outside surface of the seal gland plate. These leaks may be in the form of liquid or vapor. Reducing unscheduled shutdown can be done by appropriate leakage detection to identify imminent failures before they occur. Following are several means of monitoring leakage. with unscheduled shutdown and loss of production. leakage is often detected visually from joints or seal drains. Leakage detection is monitored to identify the failure mode of the seal or pressure boundary. Sniffers are used to detect minute leakage of volatile organic compounds (VOCs). What can be done to relieve this problem? and making some changes to improve the seal designs and operation. For less-hazardous liquids. Continued operation will cause the ice to melt and be replaced by carbon wear debris from the seal faces. connections and seal drains.
Is this possible? If so. it simple increases the available inlet pressure.59. A. which is from ANSI/HI 1. However.6. When properly designed and matched to the impeller. see HI Standard ANSI/HI 9. 57 . The consumption of barrier gas through a dual double gas-lubricated seal will vary with changes to pressure. most manufacturers do not make them available.3-2000 Centrifugal Pumps for Design and Application. little can be done to reduce NPSH Required. there is so much available that it is difficult to identity a starting point. Even this device does not change the basic function or NPSH Required by the impeller. Regarding further reading on this subject. See figure 1. In our power plants we have several applications where we need to reduce the NPSH Required by the pumps by as much as fifty percent. how can this be done? The NPSH required by a pump is a function of the pump operating speed and rate of flow required.5 Centrifugal and Vertical Pumps for Condition Monitoring Pump FAQsÂ® November 2004 Article #2 Q. For more detail on this subject.Pump FAQ’s by Hydraulic Institute (UK) 57 detected by monitoring the gas flow from the seal to the flare system. Inducers are devices designed to benefit the functioning of the impeller by increasing the liquid pressure before it enters the impeller. Leakage through the inboard seal of a dual double seal arrangement may be detected by measuring the loss of barrier liquid from the circulation system and reservoir. When these criteria are set in a given design. temperature and speed. A literature search service or an internet search should be able to help. The only thing that can make a significant is the addition of an inducer. the NPSH Required by the pump with the inducer can be reduced by as much as 50%.
The system provides 23. The noise sounds like the pump is handling sand.Pump FAQ’s by Hydraulic Institute (UK) 58 Pump FAQsÂ® March 2000 Article #3 Q. We have a new water system pump which operates with the excessive noise with smaller existing pumps. and all mechanical devices are inherently noisy to some extent.5 feet of NPSH and only 18 feet is required by the pump. The pump produces 7300 gpm and is driven by a 900hp motor. A pump is a hydraulic machine. . What is the cause of the noise. Recent studies by Hydraulic Institute members show a strong 58 A. examination shows no impeller damage. and can it be eliminated? After nine months of operation.
0). If there was no apparent impeller damage after nine months of operation. In order to measure the bowl performance. 59 . However. the pump can be expected to operate indefinitely. The total head with water can then be calculated as follows: Hba = 2. Do you have any suggestion for increasing the pump head? A.Pump FAQ’s by Hydraulic Institute (UK) correlation between noise and pump power.31pgba + Zd â€“ Zw + vd 2/2g where: Hba = bowl assembly head â€“ feet of water pgba = discharge gage pressure-psi Zd = height of discharge pressure gage above first stage impeller datum â€“ feet Zw = height of water level above first stage impeller datumâ€“ feet vd = liquid velocity in column pipe â€“ feet/second An alterative to this approach is to calculate the losses in the column pie and discharge elbow using published data on flow friction losses. The pump is thirty feet long so we put a test gage two pipe diameters downstream of the discharge elbow. The pump is handling water at ambient temperature (S=1. the gage can be located above ground and connected to the lower column pipe with a small diameter (1/4 inch ) tube. the discharge pressure gage must be connected to the pump column pipe two diameters above the outlet from the bowl assembly. However. The performance curve for vertical turbine pumps is usually for the bowl assembly only and does not include the head losses in the pump column pipe and discharge head. Note that the height of the gauge above the first stage impeller must be measured as well as the inside diameter of the column pipe. such as the Hydraulic Institute Engineering Data Book or computer software programs and adding such values to the measured pump head. We recently rebuilt a vertical turbine pump with new impellers and wearing 59 rings and tested its performance. the result showed total head performance which was lower than the published curve as the rate of flow was increased. See figure. The shut off head nearly matches the published curve. Pump FAQsÂ® June 2006 Article #1 Q. Higher horsepower pumps are naturally more noisy.
This is usually accomplished with the discharge pipe empty or with an air release valve on the pump. Pump FAQsÂ® April 2002 Article #1 Q. During the pumping cycle. or can they do better? During the priming cycle. I understand that this curve is based on tests. self-priming pumps are handling 100% air which is at much higher percent than a centrifugal pump could handle. but not at the same head as when pumping water. self-priming pumps must be vented to the atmosphere to allow the air to be expelled . A. Do self priming pumps perform the same way when pumping liquid with entrained air.Pump FAQ’s by Hydraulic Institute (UK) 60 Pump FAQsÂ® June 2005 Article #3 Q. Most industrial pump manufacturers publish centrifugal pump performance curves that include a curve for NPSHR. which determine the NPSH value when the total head is reduced by 3%. the self priming pump will suffer a similar reduction in total head as a regular pump but it should be able to handle a greater percentage of air before pumping stops. The FAQ in the February 2004 issue of P&S showed the performance curve of a centrifugal pump when handling entrained air. When priming. Isnâ€™t it better to publish NPSHR curves with higher values based on 0% reduction in total head or zero cavitation? 60 .
Pump FAQ’s by Hydraulic Institute (UK) 61 A. values as great as 10 to 20 times the NPSHR are required. In many applications such high values are impractical to design for. In order to reach a level of zero cavitation. the severity of the cavitation forces actually increases until NPSHA is about 2 times NPSHR. As NPSH available to a centrifugal pump increases. The severity of cavitation damage to a pump also depends on the properties of the liquid pumped and 61 .
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