@ KASA Redberg GD Erinoees a Toameal Fare CENTRIFUGAL PUMPS 3.1 INTRODUCTION 32 3.4.1 Preview 32 3.1.2. Section Objectives 32 3.2 CENTRIFUGAL PUMP PRINCIPLE OF OPERATION 33 3.3. CENTRIFUGAL PUMP CLASSIFICATION a4 3.3.1 Classification By Type 34 3.3.2 _ Classification By Construction or Purpose 36 3.4 TYPICAL CENTRIFUGAL PUMP COMPONENTS. 347 3.4.1 General 347 3.4.2 Impellers 3-22 3.4.2.1 General 3:22 3.4.2.2 Open impellers 3:22 3.4.2.3 Semi-Open Impellers 3:23 3.4.2.4 Closed Impellers 3:23 3.4.2.5 Comparison Between Open and Closed Impellers 3:24 3.4.2.6 Impellers for Submersible Sewerage Pumps 3:25 35 SPECIFIC SPEED 327 3.6 CHARACTERISTIC CURVES 3:29 3.7 AFFINITY LAWS 3.34 38 SYSTEM CURVES 3:37 3.9 PUMPS IN PARALLEL 343 3.10 PUMPS IN SERIES 347 3.11 CENTRIFUGAL PUMP SELECTION PROCESS 3-50 3.12 TESTING OF CENTRIFUGAL PUMPS 3-55 3.13 PRIMING, STARTING AND TROUBLESHOOTING 3-59 3.13.4. Priming 3-59 3.132 Starting 3-59 3.13.3 Troubleshooting 3-60 3.14 DATAREQUIRED FOR BUYING OR SPECIFYING PUMPS 3-63 wicker japtllr ~ vada we fig Hemeber = bigna present P08 Water/Wastewater Pump & Piping Fundamentals ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NO incor Tract Famers 3.1. INTRODUCTION 3.1.1 Preview Some published sources claim that centrifugal pumps account for over eighty percent of the sold pump market on an annual basis. This being the case, it is essential that engineers involved in pumping systems have a thorough understanding of this class of pumps. The main purpose of this section is: To introduce the various classifications of centrifugal pumps. Outline pump affinity laws and explain how to use centrifugal pump characteristic curves. Explain how to match the pump to the system. Outline the purposes of series and parallel pumping circuits as well as provide example calculations. Provide common troubleshooting tips. 3.1.2 Section Objectives After completing this section, you should be able to: abs Water Wastewater Pump & Piping Fundamentals, Page Recognise various centrifugal pump types and components. Use centrifugal pump characteristic curves in-conjunction with calculated system curves so as to properly match the system to a pump. Perform calculations relating to series and parallel pumping circuits. Have a basic understanding of the common symptoms associated with poorly performing centrifugal pumps and how to go about remedying such a situation. ‘Section 3 Centrifugal Pumps for Water & Wastewater3.2 @ KASA Redberg 6 crane t Tec Tamers CENTRIFUGAL PUMP PRINCIPLE OF OPERATION The rotating element (impeller) is used to build up the kinetic energy of the fluid and this kinetic energy is then converted to static (pressure) energy. A useful analogy is to imagine yourself swinging an open bucket of water above your head. If you swing at a fast enough pace in a circular motion, centrifugal force prevents the water from spilling on you by forcing it outwards. So to with a centrifugal pump impelier. It serves the purpose of throwing the water out of the pump casing as it spins. If you tried this "bucket swinging” experiment, you would see that there would be an absence of water in the centre of the bucket and a vortex would be formed. This vortex indicates a low pressure region. So to with a centrifugal pump impeller, a low pressure region is formed at the impeller eye (pump inlet). When this pressure is lower than the atmospheric pressure, the atmospheric pressure being higher will force more fluid in to the impeller eye. So in real terms, the word “suction” causes much confusion. Centrifugal pumps do not "suck". Fluids flow from regions of high pressure to low pressure. That is, the higher pressure forces the fluid to flow. PB08 Water/Wastewater Pump & Piping Fundamentals, Pages ‘Section 3 Centrifugal Pumps for Water & Wastewater(fms KASA Redbi @ edberg 3.3. CENTRIFUGAL PUMP CLASSIFICATIONS 3.3.1. Classification By Type Centrifugal pump types can be classified primarily as: (i) Radial Flow (ji) Axial Flow (iii) Mixed Flow, or (iv) Peripheral. The shape of the impeller determines which one of these classifications the pump belongs to. ‘Axial Flow Single Stage [Stood impolier] Fixed Ph] Hurt Stage | Open Tipeler | Variable Pic | Sanaa eR oen Inape creo | wuteStage—|Cioea ier] ‘Self Priming Non-Pr 19 Peripheral Fig. 3.3.1.1 Classification of Centrifugal Pumps The two most common classes are Radial Flow and Axial Flow. Mixed Flow, as the name suggests, is a transition between the two. Radial Flow: The pump impeller imparts energy to the fluid primarily by centrifugal force. The fluid enters the impeller parallel with the impeller shaft and is then forced ninety degrees towards the outside of the casing and the discharge port. Radial Flow pumps are generally used for adding high pressure at low flow rates. Fig. 3.3.1.2 Radial Flow Impeller "F808 Waler/Wastewater Pump & Piping Fundamentals ae Page s+ Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NSP Engines & Technical Trane Radial and Mixed Flow pumps can be designed for either single suction or double suction operation. In a single suction pump, fluid enters from only one side of the impeller. In a double suction pump, the impeller is two sided and fluid therefore enters from both sides. The operation of a double suction pump is similar to having two single suction pumps in parallel (i.e. extra flow is added by the pump for a particular size and speed). Axial Flow: The pump impeller imparts energy to the fluid by forcing it axially from the fluid inlet to the fluid discharge just like a compressor. Axial Flow pumps are generally used for adding lower pressures at high flow rates Paeiee treet ee Pre \ —_——4 Fig. 3.3.1.3 Axial Flow Impeller All centrifugal pump types can be single staged or multi-staged. A multi-staged pump has two or more impellers within a single casing. The discharge from one stage feeds the input of the next stage and the operation is similar to having several pumps in series (i. extra head (pressure) is added). Centrifugal pump types can be further classified by the impeller shape — open or closed. The effect of impeller shape on pump performance and selection shall be outlined later in this section. The classification of ‘non priming” and “self priming’ is beyond the scope of this section. In the vast majority of instances and, as a general rule, centrifugal pumps are not able to prime themselves. That is, when the pump Is started for the first time, fluid must be available through the full length of the suction line right through to the discharge port of the pump. Also, entrained air must be bled out of the suction line and pump casing. This can only be done manually or by using another, smaller pump to force fluid through the suction line with the pump casing bleed valve, or another valve in the discharge line open to atmosphere. So called ‘self-priming” centrifugal pumps make up a small percentage of the water/wastewater pump market. They suffer from a reduction in efficiency compared to submersible pumps and horizontal end-suction pumps. “PB08 Water/Vastewaier Pump & Piping Fundamentals, oe Pages Section 3 Contritugal Pumps for Water & Wastowaier@ KASA Redberg NG incre octal Fares 3.3.2. Classification By Construction or Purpose Centrifugal pumps can also be classified by the way they are constructed or for the purpose that they are used. There are many of these classifications. A selection is presented as follows: In-Line (or Vertical) Pumps: An in-line pump has the suction port and discharge ports in the same plane and running along the same centreline. The pump impeller is orientated horizontally whilst the shaft is vertical, These pumps have a small footprint and are typically used where installation space is hard to come by, or for pre-packaged pump skids. They can be either single staged or multi-staged. The In-Line pump shown in Fig. 3.3.2.1 also has the advantage that the motor, mechanical seal and rotating element can be removed for maintenance without disturbing the pump casing or pipe-work (i.e. “top pull-out’). Rotating Assembly —— [— Totally Enclosed Fan- Fabicated stainless stes! Cooled Motor impelierfor sustained Provicies protection performance and nici agains! moisture and smooth, efficient vermin entry ‘operation Mechanical Shaft Seal ior fe Oars free :— Split Coupling for Operation, 3 Simple Servicing : y : Enables motor removal : - : and dismanting of pump Suotion/Diecherge— Unitto be carried out mber ickly and east Inne suction andl is ee are 7 cischarge ports ensure eesy pump instalation, Removable Baseplate Simmpified inexpensive = instalation, Fig. 3.3.2.1 Cut-Away View of an Single-Stage, In-Line Centrifugal Pump (Reproduced With Permission of Grundfos Pumps Pty Ltd) | P808 Waler/Wastewator Pump & Piping Fundamentals : “Page ss Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg iS Technical Tamers (—Grundies totally enclosed fan-cooled motor S7kWto 11K. (BHP 10 1SHP) Fine grained cast ron pumpheadwith ant. ‘corrosion coating Mecherical shaft seal [= Stainless steel impetiers. Intermediate ‘Chambers Shaft Fine grained cast iron pump base with ant orrosion coating Fig. 3.3.2.2 Vertical Multistage Pumps. (Reproduced With Permission of Grundfos Pumps Pty Ltd) End-Suction Pumps: As the name suggests, the fluid flows in to the end of the pump and is discharged at ninety degrees to the shaft centreline. These pumps can be single staged or multi-staged. Fabricaled sianioss sea impeler for sustzned perkermance andernaath | sion gpocion Amacai sat ne | eseatorlongtle and meinvenar | cpeeien reetes | ond csmanting of pump Unitobecaresoz Totally Enclosed casi wahoucistupton | Fan-Cooled Motor Proves priecion ‘agains mature and vermin erty, Enables fexble postioring of isonarge port and ‘iol terminal box Enables pump serving tbe eee Chamber ‘cared out Sngly wine estuaries ofthe Buen ‘ee poslioncéscharpeporensures easing co ppewark eraprumn texibiy for apevokisiaition, Fig. 3.3.2.3 Cut-Away View of a Single-Stage, Close-Coupled End-Suction Pump (Reproduced With Permission of Grundfos Pumps Ply Ltd) P08 Water/Waslewaler Pump & Piping Fundamentals as Pages? ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg The pump in Fig. 3.3.2.3 is known as a “close coupled pump” as the motor shaft is coupled directly to the impeller shaft and the motor mounting flange bolts directly to the pump housing. Smaller sized pumps are generally close coupled. The pump shown also has the advantage that the motor, mechanical seal and rotating element can be removed for maintenance without disturbing the pump casing or pipe-work (ie. "back pull-out”). For ‘long coupled" pumps of the end-suction type, a back pull-out design is a distinct advantage as the suction and discharge pipe-work can remain in-situ during maintenance activities. During maintenance, the shaft coupling is removed and the pump housing is slid towards the drive end. Fig. 3.3.2.4 A Long Coupled Pump of the Back Pull-Out Design (Reproduced With Permission of Ebsray Pumps Pty Ltd) End-Suction pumps can be belt driven or directly coupled to the drive. Manufacturers also design these pumps so that the pump discharge port can be orientated in a number of positions from vertical discharge, to horizontal (bottom) discharge, to horizontal (top) discharge. E08 Water/Wastowater Pump & Piping Fundamentals, oe Page so ‘Section 3 Centrifugal Pumps for Water & WastewaterKASA Redberg Engnoars @ Technical Treners Fig. 3.3.2.5 End-Suction, Long-Coupled, Vertical Discharge Pumps (Chilled Water Application) sy Fig. 3.3.2.6 Belt Driven, Radial Split Casing Centrifugal Slurry Pump (Reproduced With Permission of Weir Warman Ltd) On larger pumps, as shown in Figs. 3.3.2.6 and 3.3.2.7, the casing can be split in two halves for easier maintenance. Casings are either split in the horizontal (axial) or vertical (radial) plane depending on the suction and discharge port orientation. PEOS Water/Wastewater Pump & Piping Fundamentals Bae Pages ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NSSF Briginears & Tecnica Traners End-Suction pumps are one of the more common types of centrifugal pump. A number of industry bodies such as the American Petroleum Institute (API) and the Intemational standards Organisation (ISO) actually produce specifications which detail the construction of these pumps. These construction details include: dimensions, seal types, materials of construction, service factors etc, These specifications are frequently quoted by system designers or Plant Engineers in their tender documentation when specifying pumps for new installations or upgrades to existing plants. These specifications are mainly encountered in the petrochemical or processing industries. Fig. 3.3.2.7 Axial Split-Case Centrifugal Pump (Reproduced With Permission of Flowserve Thompson Kelly & Lewis Pty Ltd) Axial Split-Case Pumps: Have the advantage that there is no need to disturb either the suction and discharge pipe-work or remove the shaft coupling for access to the impeller, seal and bearings. These are usually larger capacity pumps for high volume water supply. "PE0E Watar/Wastewatar Pump & Piping Fundamentals Page 3-10 ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg_ Cd ‘FFechnical Trainers Submersible Pumps: There are many types of submersible pumps. Some only have the pump casing submerged whilst other designs are capable of having the drive submerged as well. Portable units are popular with mariners and builders for emptying ship bilges, drains or rainwater in trenches for example. The advantage of using these pumps is that there is no suction lift and therefore there is no need to worry about priming issues or the NPSHR (in the majority of instances). Built-in float switch for automatic operation.. Fig. 3.3.2.8 Compact Style Submersible Pumps (Reproduced With Permission of Grundfos Pumps Pty Ltd) Fig. 3.3.2.9 Portable Submersible (De-Watering) Pump (Reproduced With Permission of ITT Flygt Ltd) P80 Waler’Wastowator Pump & Piping Fundamentals Page sit Section 3 Centrifugal Pumps for Wetor & Wastewater@ KASA Redberg ss a Technical Taine Submersible pumps are used frequently in general water and wastewater applications. In these applications, the pump itself is mounted at the base of a pump pit (below ground level). A relatively large submersible pumping station is shown in Fig. 3.3.2.10. Fig. 3.3.2.10 Pump Station Utilising Submersible Pumps (Reproduced With Permission of ITT Fiygt Ltd) H] Mounting Plate Coarse Inlet Str Discharge Pipe Fig, 3.3.2.11 Submersible (Sump) Pump Prior to Installation (Note: Motor mounted above water level) "F808 Wator/Wastewator Pump & Piping Fundamentals ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NG iors & Technet Trees Bore Hole Pumps: Are another sub-classification of submersible pumps. There are two types of Bore Hole pumps: (i) Line Shaft (Turbine), and (ji) Electro- Submersible. + Line Shaft pumps are generally used for raising water from wells and are quite common in the irrigation sector of the pump market. The pump wet- end is fully submerged in the well whilst the drive is located above ground. This style of pump utilises single-staged or multi-staged, mixed-flow impellers. These impellers are each enclosed in a bow! with the lowest bow! having an inlet strainer. + Electro-Submersible pumps are used in similar applications to Line Shaft pumps. They operate on the same principle. The main difference is that the electric motor Is integral to the body of the pump and is also fully submerged in the well. Fig. 3.3.2.12 Schematic of a Borehole (Electro-Submersible) Pump Installation (Reproduced With Permission of Pentair Water Pty Ltd) "PB08 Watar/Wastowater Pump & Piping Fundamentals Page 313 Section 3 Centrifugal Pumps for Water & Wastewateral Taner: (a KASA Redb @ edberg One final addition to the “submersible” pump family is that of the so-called ‘axial propeller submersible motor pump". This particular type of pump has been gaining in popularity in recent years in applications where large vertical turbine, “submersible spindle” or mixed flow pumps were used. It is typically used in process water, large scale irrigation, water supply and stormwater pumping applications. In basic terms, this particular type of submersible pump resides in a steel discharge tube thereby alleviating the need for expensive civil works. The following figures illustrate the basic setup and construction of this type of pump. Fig, 3.3.2.13 Axial Propeller Submersible Fig. 3.3.2.14 Axial Flow Impeller Motor Pump. (Source: KSB Australia Pty Ltd) (Source: KSB Australia Pty Lid) Fig. 3.3.2.15 Typical Setups - Axial Propeller Submersible Motor Pump (Source: KSB Australia Pty Ltd) | PE08 Water Wastewater Pump & Piping Fundamentals Pages Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg C Eick 1 Evercleanblades 2 Casingweartingin stainless stee! 3. Shattsealingwith two mechanical seals in tandem arrangementand oll chamber 4 Pumpmotorunitis supportedby 245" inclination andbig O-ring 5. Submersiblemotor with low starting current. Suitable for D.O.L, starting, w/o gear box 6 Oversizedatease lubricatedbearings, maintenance free for25.000hours 7 Shatin stainless steel 8 Power andcontrolcableswith Epoxy encapsulatedDesign Fig. 3.3.2.16 Sectional View — Axial Propeller Submersible Motor Pump (Source: KSB Australia Pty Ltd) Pressure Units: These are not pumps but are generally used in conjunction with small, end-suction pumps for providing water at a set pressure for locations where reticulated pressure water is unavailable. For example, rural communities who may utilise rainwater tanks. In addition to the pump and motor, a typical set-up consists of a pressure tank, pressure switch and a constant pressure valve (for automatic operation). The pressure tank has a rubber diaphragm inside which separates the water from an air chamber. The pump discharges water in to the pressure tank until the set pressure is reached. This discharge compresses the air above the diaphragm inside the pressure tank. When water is called for (i.e. a tap is opened in the discharge line), the air expands and forces the water out as required. As the water pressure in the tank drops to the set pressure of the pressure switch, the pump starts again and forces more water in to the pressure tank and the cycle continues. P806 Waler/Wastewator Pump & Piping Fundamentals ag ‘Section 3 Centrifugal Pumps for Waler & Wastewater@ KASA Redberg Enginears & Technical Trane Fig. 3.3.2.17 Typical Pressure Unit (Reproduced With Permission of Grundfos Pumps Pty Ltd) P08 Water'Wastowator Pump & Piping Fundamentals Page 3-16 ‘Section 3 Centrifugal Pumps for Water & Wastewater3.4 3.4.1 P80 Water’Wastowator Pump & Piping Fundamentals @ KASA Redberg_ C= Engineers & Technical Trainers TYPICAL CENTRIFUGAL PUMP COMPONENTS General A DIN24255_ standard pump is shown over-the-page in Fig. 3.4.1 and will be used as an aid in described the various components that go in fo a typical centrifugal pump. Whilst on the subject of standard pumps, it should be mentioned that there are many manufacturers of pumps to API, ANSI, ISO and DIN standards. The advantage is that you can replace a particular API, ANSI, ISO or DIN pump from one manufacturer (for an existing installation) with one from a different manufacturer. This is because they will be dimensionally the same for a particular size. * Volute Casing (aka “Casing” or “Housing”): Houses the intemal rotating components and is used as an aid in converting the kinetic energy of the fluid in to static pressure. * Impeller: As described previously, the impeller provides the centrifugal force which is used to pump the fluid. More information on impellers will be given later in this section. x . weer Rings: On radial flow pumps, these rings are placed behind the impeller and prevent the impeller and housing from wearing excessively in this area. When this component is wom-out, it is replaced with another ae ci the expensive impeller and housing. nroraully £40 % pepe betwee EC ecege Sep petwes| + Stuffimly Box Is the trafitional nme for the section of the pump casing that houses the mechanical seal (or packing). The name is derived from the early years of pump design and construction when shaft sealing was achieved through “stuffing” ces agranal ele esweeg the haft pes ng.casi He te seh rast ere SB, «Shaft Sleeve: Just like waelpuee the shaft sieeve fs & Component designed to sacrifially wear to protect a more expensive component. In this case, the shat sleeve protects the impeller shaft from wear and damage in the area of gland packing. This is an important function as if the shaft becomes even slightly scratched, pitted or scored in the area of the gland packing, excessive leakage can result * Gland Packing (aka “Packing”): Is used to prevent the fluid in the pump housing from escaping between the housing and the shaft. The packing is constructed from multiple rings of braided, square-cross-sectioned material. These rings are inserted in to the stuffing box and then a plate is secured behind and tightened by bolts until the correct amount of leakage obtained. Note that a controlled and minimal amount of leakage will still be obtained through the use of gland packing. This leakage is necessary and aids in cooling the packing so it does not wear or bum out too quickly due to friction. If this small amount of leakage cannot be tolerated, a mechanical seal should be used. Vats Meine ul Page S17 ‘Section 3 Centrifugal Pumps for Water & Wastewater veg ethodd on Sactic athe A Layaebor.KASA Redberg Streamline pump range fully complies to the Intemational ‘Standard DIN 24255, which isa performance and ‘dimensional standard. This range has 33 models with grease lubricated bearings and a further four models with ol lubricated bearings which give a wide hydraulic coverage at both 2 and ‘4'pole speeds for 50 Hz and 60 Hz. Most models are suitable for 16 bar working pressure. ‘SUPT SLEEVE ‘STUFFING BOX Thesis eng box inert psn rg hear Tonal thie The ag tox SScomeciod br animal ato er or ang *cjsne separa Puno canbe supped va ‘rothaneal sal anf oye bole covarson ‘repack sing brio mri 2a rfecnrnshanea bee pace esee BEARING HOUSINGS nun argon seroauee tte cat re setts tee eae Seance MECHANICAL SEAL, ‘SHAFT ‘The sales sel cat [Goad atthe iepalor bbymeans of dome Ting ms Bearings ae grease brcatas oare edn groase ‘pos whch alow poe Sarees cae | vowure case youuTe casi Sea maser ae neers urronr Foor oer TOOT emnreaemt | opm nats ue guartsteeye —————__/ _/ ‘oplacoablestanlos cool postvalyorven | Schemes | Bega Generac succes! aoa SL ore amon / sesrantit, wean ans Hecseeuwanae Fesaoedia Wea ngs are fed mal exongs angaso "placate wea roger chon ‘feo nag renee in oer somh Senet ober tnateranc cosa a stn. andng sien patomants a eS erey. shut yale tr Ekle ead prAsiene , (sre ick 1h Yepe oh wants reper. IP tresseue fas Fig. 3.4.1.1 Schematic of a DIN24255 Standard Centrifugal Pump Aewyn~- (Reproduced With Permission of Ebsray Pumps Ply Ltd) eer wee set, "PB08 Water/Wastewator Pump & Piping Fundamentals Page 18 Section 3 Centritugal Pumps for Water & Wastewater@ KASA Redberg NS) Eras eect Tres Mechanical Seal: Is used as an alternative to gland packing in pumps where a slight amount of leakage cannot be tolerated. Mechanical seals come in numerous types and styles. * Bearing Housing: As the name suggests, the shaft bearings are housed in this part of the pump. For end-suction and in-line pumps, the bearings are housed on the drive side of the pump only. For axial split pumps, the bearings are housed either side of the impeller. Using the correct bearing type is oritical, especially on the larger pump types and for axial flow pumps where large thrust loads are encountered. Litting Device Cable Entry ——~ Motor (Squirrel-Cage Induction Type)” 7 Fig. 3.4.1.2 Sectional View of a Submersible Pump (Reproduced and Modified With Permission of ITT Flygt Ltd) F808 Water/Wastewater Pump & Piping Fundamentals Pages Section 3 Centritugal Pumps for Water & WastewaterKASA Redbs @ edberg ore & Pechnical Stones steal mounting studs tal hate Exectrica lead Ob tubvicated bal bearings a ice decay i Tiga a Rotey Me ees ve wh Soeory mont sone hve Catia teat Dveroad protection Rotor estembiy rotates smocthiy at highspeed Stator eore and cl seem 2 wire motors up to 20d Ineloding Precision moulded ° Tap The switch bow only 2 ale twical leads down Searing sich and aecuator ‘Sleeve beating ‘sites ste! parm shell, tiotar conte sick sevieing tate Stoinlest steel motor eousting Stonios soe! Saapemelananion neon Dee 5: Capacitor Balances dapdragrn The pressure inside the motor the sare a5 that ‘acide hs Oinfied moter Fig. 3.4.1.3 Sectional View of a Borehole Pump (Reproduced and Modified With Permission of Pentair Water Pty Ltd) "PROS Water Wastewater Pump & Piping Fundamentals a Page 5-20 ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg WP Engineers & af Trainers Fig. 3.4.1.4 Cut-Away View of an Open Impeller Process Pump (Reproduced With Permission of American Seal and Packing Inc) Fig. 3.4.1.5 Cross-Sectional View of a Double Suction (Axial-Split) Pump (Reproduced and Modified With Permission of ITT Flygt Ltd) 808 Water/Wastewater Pump & Piping Fundamentals Page S21 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg ND crgnenrs & Tecmial Wane 3.4.2 Impellers 3.4.2.1 General ‘The component that has the most influence on the performance of a centrifugal pump is the impeller. The diameter and shape of the impeller determine the head added by the pump for a particular flow rate. There are a number of impeller types with various sub-classifications and these can be tabulated as follows: Table 3.4.2 Classification of Centrifugal Pump Impellers [Flow Type] Impeller Entrance Type | Overall Design Type Radial Flow Single or Double Suction Open, Semi-Open or Closed Mixed Flow Single or Double Suction ‘Open, Semi-Open or Axial Flow Single Suction Radial Flow, Mixed Flow and Axial Flow impellers have been outlined previously. These three types can all have single of double suction fluid entry and can be of the open or closed style. The impeller entrance type refers to whether fluid enters from one side of the impeller only (Single Suction) or from both sides (Double Suction). Finally, the overall style of the impeller can be either open, semi-open or closed. 3.4.2.2 Open Impellers As fluid enters the eye of the impeller, the turning vanes direct it to the discharge port. A very small running clearance between the vanes and the pump casing (volute), or in certain designs, the ‘back plate’, prevents most of the fluid from recirculating back to the eye of the impeller. Fig. 3.4.2.2.1 A Typical Open Impeller (Radial Flow) (Reproduced With Permission of ITT Flygt Ltd) P06 Water/Wastewator Pump & Piping Fundamentals, ee Page 322, ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NEO aginst Techea Taner 3.4.2.3 Semi-Open Impellers These impellers are almost identical to open impellers with the exception that they have a wall or shroud on one side. This makes them structurally stronger than open impellers. They are not encountered any where near as frequently as open or closed impellers for non sludge/slurry applications. They are typically used in waste-water applications for fluids containing solids and fibres. Fig. 3.4.2.2.2 A Typical Semi-Open Impeller (Reproduced With Permission of ITT Fiygt Ltd) 3.4.2.4 Closed Impellers As fluid enters the eye of the impeller, the turning vanes direct it to the discharge port. These impollers have a wall or shroud on both sides. There is no running Clearance to set between the vanes and the pump casing (volute) or back plate. Wear rings restrict the amount of fluid recirculating back to the suction side. Fig. 3.4.2.4.1 A Typical Closed Impeller "P08 Water/Wastowator Pump & Piping Fundamentals Page s25 Section 3 Centrifugal Pumps for Water & Wastewater3.4.2.5 Comparison Between Open and Closed Impellers KASA Redberg Tiginonrs & Technical Waivers « Table 3.4.2.5.1 outlines the relative advantages and disadvantages between open and closed impeller types. In Australia for the pro cess industries (i.e. not the waterwastewater industry), the majority of impellers are of the closed type. This is also the case in Europe but in the United States the majority of impellers are of the open type. The petrochemical industry almost always use closed impellers because the fluids that are pumped are often explosive or flammable. Open impellers are not used with these fluids as there is a risk that the impeller could interfere with the casing (volute) if the clearance has not been set properly thereby causing a spark. Table 3.4.2.5.1 Comparison Between Open and Closed Impellers CONDITION OR CLOSED IMPELLER OPEN IMPELLER ATTRIBUTE Pumping of High Temperature Fluids (ie. Heating Oil) ‘Generally handle shaft thermal ‘expansion without problems. However, if there is too much shaft axial expansion, the impeller vanes may not line up directly with the discharge nozzle. The impeller may interfere with the casing due to shaft racial and axial expansion. This is due to the olose running clearances found in these types of pumps. Pumping of Volatile or Explosive Fluids ‘Generally handle these fluids without problems. The wear rings are the only parts that will contact the impelier if the shaft expands or is displaced. Not good. Tight running clearances mean an increased risk of interference between the impeller and the casing (volute) which could cause sparking. Pump Efficiency Pumping of fluids containing solids or pulp-like materials. Initialy, when the pump is new. efficiency is very high. As the ‘wear ring clearance increases: through wear, efficiency will érop. ‘As a general rule, once the ‘wear ring cleerance has doubled, replacement is required. The pump has to be disassembled to achieve This impeller design is prone to “clogging” and once clogged is difficult to clean. Efficiency is less but can always be maintained at optimum leveis by adjusting the running clearances, ‘The pump does not have to be disassembled to adjust these clearances, This impeller type is less likely to become clogged and is easy fo clean. Relative Cost ‘Shear Forces This impeli ‘complicated in design and therefore more expensive to produce thereby increasing the ‘overall pump cost, ‘These impellers apply smaller shear forces on the pumped fiuid P8086. WateriWastewater Pump & Piping Fundamentals Section 3 Centrifugal Pumps for Water & Wastewater This impeller is simple to produce and therefore allows for 2 lower cost pump, ‘These impeliers apply higher shear forces on the pumped fluid Page &:24@ KASA Redberg NO Fiaiaear Facial Tres 3.4.2.6 Impellers for Submersible Sewerage Pumps The pumping of sewerage has its own nuances and the design of the impellers used in submersible sewerage pumps are quite different to those found in other industries. Impellers will almost always be of the open or semi-open type (to prevent clogging) and rely on clearances in the order of 0.5 mm to maintain efficiency. There are three main variations of the standard open/semi-open impeller in use in Sewerage pumping applications. These are as follows: Fig, 3.4.2,6.1 Single Channel Impeller for ‘Sewerage (Source: Grundfos Pumps Pty Ltd) Fig. 3.4.2.6.2 Double Channel Impeller for Sewerage (Source: Grundfos Pumps Pty Ltd) Fig, 3.4.2.6.3 Vortex Impeller for Sewerage (Source: Grundfos Pumps Pty Ltd) Single Channel Impeller: Has very good resistance to clogging with maximum pump éfficiencies in the range of 70 to 75%. Double Channel Impeller: Not as resistant to clogging when long, stringy fibres are present but provide an excellent pump efficiency in the range of 80 to 85%. Vortex Impeller: The solids do not come into contact with the impeller as it creates a strong vortex action, It is therefore an “indirect” pumping action and as such P08 Water/Wastewater Pump & Piping Fundamentals Page 325 ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NG incre & Facies’ Tse: pump efficiencies are greatly reduced and are in the order of 50% in pumps of flow rates greater than 15 litres per second. Below 15 litres per second, the pump efficiency is roughly the same as that of single channel impellers. It should be noted that three and four channel impellers are also available but only for the largest sizes of submersible sewerage pumps. One final point on sewerage pump impellers is that they are typically designed for a free passage of at least 80mm and are typically in the range of 80 to 120mm, Fig. 3.2.6.4 A Typical “Dry Well” Sewerage Pumping Station ‘"Ba0R Water/Wastewater Pump & Piping Fundamentals Pee Page 3-26 ‘Section 3 Ceninfugal Pumps for Weter & Wastewater3.5 @ KASA Redberg Engineers & Technical Wramners SPECIFIC SPEED From the preceding discussion, it should be clear that the design of the impeller is one of the most significant factors in determining the performance characteristics of a pump. A quantitative index exists which is used to determine the most ideal impeller design for a particular application. This index is known as the “Specific Speed”. The specific speed has been derived on the basis that for a given desired flow rate and head, there will be one optimum impeller design. The Specific Speed is calculated as follows: Specific Speed Shaft Speed (rpm) Flow Rate (m*/s) Head Added (rm) Ns = Ne Where: N, Note: For double-suction inlet condition, half of the flow, Q, should be used. Whilst Specific Speed is not dimensionless, the units do not mean anything. It is generally expressed as a dimensionless number. Table 3.5.1 lists the impeller designs that are the most ideal for a particular specific speed range. Table 3.5.1 Specific Speed and Impeller Design ‘SPECIFIC SPEED RANGE IMPELLER DESIGN (Sl. units) 8-22 40-60 80 - 140 780 and above Radial Flow Francis Vane Mixed Flow Axial Flow *A“Francis Vane” impeller is a specific type of Mixed Flow impeller. + Highest head added per stage is developed at low specific speeds. «For the best efficiency, Specific Speeds should be greater than 13 approximately. «Ifthe Specific Speed is less than 13, a multi-stage pump should be used. «Maximum suction lift, pump efficiency and NPSHR can all be correlated with Specific Speed. P808_ Water/Wastowater Pump & Piping Fundamentals, PERSE age 27 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NO cngneen 8 Teownes anes EXAMPLE PROBLEM 3.1 Given: A pump is required to discharge 350 /min at a total head of 30 metres. Various centrifugal pumps and motors are available in your site stores. Your site standard for drives for this application is (i) direct driven, and (ii) 3 phase, 2 pole, 50Hz motor (i.e. 3000 rpm synchronous speed) To Find: The type of centrifugal pump required. Assumptions: The motor slip (2. deviation from synchronous speed at full load) is less than 5%. No speed reducer is required. The motor is fully loaded at the design conditions Relevant Equations: a nm Solution: Poe Ns = 3000 \J (0.35/60) = 18 30078 From Table 3.5.1, a Radial Flow pump should be chosen. ro lotes: If the slip of the motor is 5%, n = 0.95 x 3000 rpm = 2850. Therefore, Ns = 17 which gives the same result as above. “PROS Walorastonstor Pump & Piping Fundamentals SSS Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg ND ciara Tecincal Trarers 3.6 CHARACTERISTIC CURVES Assume that a centrifugal pump has a discharge port that can be orientated anywhere from the vertical (90°) right through to the horizontal (0°). Also assume that pipe friction losses are negligible. Now, if the discharge port is fully vertical, for a given diameter impeller and for a given rotational speed, the pump would throw the fluid straight up to some maximum height. This maximum height is known as the “shut-off head”. At this head there would be no fiuid coming out of the pipe and therefore the fluid would have zero velocity. As mentioned earlier in this section, if you were to increase the rotational speed or the impeller diameter, then the shut-off head would increase. Maximum Height (Shut-Off Head) —> Zero Velocity Maximum Velocity or Capacity (Zero Head) Fig. 3.6.1 Graphical Explanation of Centrifugal Pump Characteristic Curves Now, if the discharge port is rotated to the horizontal position, the fluid would be discharged at maximum velocity and there would be zero head added by the pump. It should be apparent that as the head increases, the velocity decreases. Similarly, if the velocity is increased, the head decreases. Therefore, the centrifugal pump can give a pumped fiuid: velocity, head or a combination of both. From Fig. 3.6.1., it can be seen that as the discharge nozzle is rotated from the horizontal through to the vertical, a curve of head versus velocity is developed. The shape of this curve is determined by the type of impeller employed. This curve is identical to a “characteristic curve" with the exception that the flow rate is plotted along the horizontal axis rather than velocity. Pa06 WaleriWastewaler Pump & Piping Fundamentals Page 3-29 ‘Section 3 Centritugal Pumps for Waiar & Wastewater@ KASA Redberg NSD Enginsers & Technical Pump characteristic curves are generated through testing. That is, when a manufacturer designs and builds a particular pump, they check the performance by testing with water at various flows. The results are plotted on a curve and this is called the “characteristic curve’ or "head versus capacity curve’. Additional information is also plotted on the same curve which includes: * Efficiency Curves: Which show the internal losses of the pump at different capacities. The curves are shown as percent efficiency. The point of highest j efficiency is called the “best efficiency point’ (BEP). The BEP can also be defined as the point where the least amount of shaft deflection occurs and the | power input is closest to the power output. That is, the shaft is not bending and ! the least amount of power is being used. As a general rule, the head at the BEP is usually around 80 to 85 percent of the shut-off head for larger pumps. » Power Curves: Which show the power that the pump requires at various flow rates. * Net Positive Suction Head Required Curves: Which show the NPSHR the pump required to prevent the on-set of cavitation. As outlined in Section 2.4.6.2, the manufacturer's test defines the NPSHR as the head at which the total pump. head has decreased by 3 percent due to a low suction head and resultant cavitation in the pump. The following general points should be noted: * The shape of the characteristic curve is determined by the impeller type (i.e. radial flow, axial flow, mixed flow etc). Radial flow pumps generally have flat head versus capacity curves whilst the head drops quite sharply against capacity for axial flow pumps. Mixed flow pumps fall somewhere in-between. * The pump manufacturer usually shows at least three different characteristic curves on the same sheet for each model. The different curves represent the different sized impellers that fit within a particular pump case. Altematively, curves for different rotational speeds for a particular impeller size are shown. + Ifa fluid of a different density to that shown on the curve is to be pumped, as long as the viscosity of the fluid is similar then the same head versus capacity curve can be used. However, the pumping power depends on fluid density. If the pump characteristic curve is used to find the operating point, multiply the power shown on the power curve by the specific gravity of the fluid, The pump efficiency does not change with fluid density, only with viscosity changes. + If the viscosity of the fiuid is higher to that on the curve then correction factors will need to be applied, or the pump will have to be tested with that particular fluid. The Hydraulics Institute publishes various correction factors for fluids of different viscosities. Pump manufacturer's themselves also have data on their ‘own pumps for different fluids. The pump will have a reduced performance of head versus capacity, more power will be required and the efficiency will reduce. "P8308 Water/Wastewator Pump & Piping Fundamentals Page 30 Section 3 Centritugal Pumps for Water & Wastewater@ KASA Redberg NO gress Tina Tames ; aos FEEEEEEEE, $Peeo: 14somm SH ISOspee 40% 2p 8S Fig. 3.6.2 A Typical Centrifugal Pump Characteristic Curve Set (Reproduced With Permission of Davey Pumps Pty Ltd) Fig. 3.6.2 depicts a typical characteristic curve set. The following points should be noted: P08. Water/Wastewater Pump & Piping Fundamentals, There are five individual “head versus capacity” curves which correspond to five different impeller diameters. These diameters are: 274mm, 291mm, 308mm, 325mm and 342mm. The total head added by the pump is shown on the vertical axis whilst the flow rates corresponding to various heads are shown on the horizontal axis. The Net Positive Suction Head Required (NPSHR) for various flow rates is shown for the smallest and the largest diameters only. Lines of constant efficiency are superimposed on the "head versus capacity” curves. The Best Efficiency Point (BEP) is the intersection of head and flow at the highest efficiency for a particular curve. In this case, the BEP corresponds to just over 47 percent efficiency for the 342mm diameter impeller. Sometimes the efficiency is shown as a group of curves on a separate section of the chart. Lines of constant power have also been superimposed on the “head versus capacity’ curves. These lines are shown for standard motor sizes only (ie. 1.5kW, 2.2kW, 3kW and 4kW. If the operating point fell in-between these lines, you would use the next largest sized motor. Sometimes the power is shown on a separate chart just like the efficiency. Fig. 3.6.3 depicts thi P ‘Section 3 Centritugal Pumps for Water & Wastewater@ KASA Redberg NG sapicass & Techn Trane So, using Fig. 3.6.2, if a pump was required to add a total head of 30 metres for a flow rate of 5.4 litres/second, then: A 308mm diameter impeller would be fitted. NPSHR would be approximately 1 metre. Efficiency would be approximately 45.5% Motor size would be 4kW (as the operating point falls between a 3kW and a KW motor). If the operating point cannot be achieved with one of the standard impeller diameters, the pump supplier may include a dotted curve that represents a trimmed impeller that it proposes to use. so Hean | 45 520mm es 0 1 2 SEEEEe Eee eee: * paver 30 eed 0 1 2 5 6 7 Fig. 3.6.3 Example Centrifugal Pump Characteristic Curve Set (With Trimmed Impeller) "P808 Water/Wastewater Pump & Piping Fundamentals Page 332 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NSE) Signears Coane Trane. From Fig. 3.6.3, the operating point corresponds to an added head of 37 metres at corresponding flow of 4.6 litres/second. The power absorbed is approximately ABKW. It should also be noted from this figure that the operating point has been chosen so that itis close to the Best Efficiency Point. if a pump is to operate at the same duty point all the time, then always select a pump so that the operating point corresponds with the BEP. The BEP is not only the point of highest efficiency, it is also the point where velocity {and therefore pressure) is equal at all points around the impeller and pump casing (volute). As the operating point moves away from the BEP, the velocity changes which in-turn changes the pressure acting on one side of the impeller compared to the other. This uneven pressure on the impeller results in radial thrust which causes shaft deflection. Shaft deflection promotes: (i) Excessive load on the bearings, or (i) Excessive distortion to the mechanical seal, or uneven wear on gland packing. The resulting damage can include: * reduced bearing life * reduced seal life © damaged shaft. A pump should never be operated outside the manufacturer's recommended operating range. Severe damage due to excessive velocity and turbulence can occur if this guideline is not adhered to. The resulting vortexes can create damage due to cavitation. Also, it is important when selecting a pump to not add excessive safety margins or base selection on inaccurate information. The normal operating range for most centrifugal pumps is between 50 and 120 percent of the BEP. ‘Shaded area depicts recommended pumy operating range ‘Maximum Radial Thrust Minimum Radial Thrust Radial Thrust 10% 50% 100% 120% Porcont of Bost Efficiency Point Fig. 3.6.4 Typical Radial Thrust Curve for a Centrifugal Pump 'PE08 Waler/Wastewater Pump & Piping Fundamentals Page 3-33 Section 3 Centrifugal Pumps for Water & Wastewater37 P08 Wator’Wastewater Pump & Piping Fundamentals ct Page a4 @ KASA Redberg SS AFFINITY LAWS The affinity laws are a set of formulas that express the mathematical relationship between various centrifugal pump variables. They can be used to find a new set of operational variables if the set-up of the pump is changed or if an identical pump of a different size is used as replacement. These laws only apply to centrifugal pumps. They are only accurate for two different sized of pumps if the efficiencies are similar. In practice, this means that they should only be used with similar sized pumps as larger pumps have greater efficiencies than smaller pumps. + Ifthe impeller diameter is held constant and the speed is varied... Q@ = m Where: Q; Qa m4 Q 2 2 ne ho = Q ha hy a Py 3 PB = |m Py m4 [3 Ifthe speed held constant and the impeller size is varied... Original flow rate New fiow rate Original speed New speed Original head Original power New power 28 @ = Where: D; = Original diameter a Di D2. = Newdiameter 2 he = [Dm hy Dy 3 a (2) Py Dy, Generally, the affinity laws will be used by Process, Design or Project Engineers to determine a “head versus capacity” relationship if a desired operating point does not lie on a standard manufacturer's published curve set. This is most common with pumps driven by variable speed drives. Fig. 3.7.1 shows a typical set of characteristic curves. In this case, the ‘head versus” capacity curves are plotted for different speeds with the impeller diameter held constant. If a variable speed drive was to be considered, this curve set, in conjunction with the affinity laws, would be useful in determining various operating points. Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg SE EXAMPLE PROBLEM 3.2 Given: To Find: Assumptions: Relevant Equations: Notes: A manufacturing plant has a centrifugal pump operating at 1450rpm producing a flow rate of 6 litres/sec at a total head of 36 metres for a particular process line. The set-up of the process line will be changing and you have been advised that the pump will now be required to add 45 metres of head. ‘What changes will be required for this pump. The new flow rate is not critical. There are two choices, increase the speed or increase the impeller diameter. The speed increase is easier as it just requires a drive change (ie. pulley diameters, gearbox, inverter or motor change). It is doubtful that an impeller of larger diameter would be available at short notice (if one was suitable at all) Now, 45m = nme 36m 1450 rpm) Therefore, nz = 1621 rpm ¢ ‘* The absorbed power should also be calculated as a larger motor may be required. * The NPSHR should also be checked. "P808 Water/Wastowator Pump & Piping Fundamentals Page 36 ‘Section 3 Centrifugal Pumps for Water & WastewaterKASA Redherg Engineers & Technical Tamers ° 1 2 6 ’ e 2 4 Flaw ‘vs Fig. 3.7.1 Centrifugal Pump Characteristic Curve Set (For Different Operating Speeds) "PaOE WaterMWastewaler Pump & Piping Fundamentals ——SSSSSSSCSCS~S~S~S~«é US ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NG) rnaiiean # Technica Panes 3.8 SYSTEM CURVES A system curve (aka “system performance curve") is a graphical representation of the relationship between flow rate and the hydraulic losses (i.e. pipe friction) in a pumping system. The system curve depends only on the configuration of the suction and discharge lines and is independent of the pump used. From the Darcy Formula (presented in section 2.4.7.2), it can be seen that system head losses due to friction are proportional to the square of the velocity. As flow rate is directly proportional to velocity (i.e. Q = VA) then it follows that system friction losses vary with the square of the flow rate. This means that the shape of the system curve will be a parabola. If the friction loss for one flow rate is known, friction losses at other flow rates can be found. 2 he = | Qh he Q The intersection of the system curve and the pump characteristic curve will be the operating point. If changes to the system are made (ie. a discharge valve is partially closed) or if the pump speed is changed, the intersection of these two curves will shift and a new operating point will be established. 2900rpm HEAD System Curve (Valve Throtted) /” System Curve (Valve Open) FLOW RATE Fig. 3.8.1 Example System Curves “P05 Water Wastewater Pump & Piping Fundamentals a ST ‘Section 3 Centrifugal Pumps for Weter & Wastewater@ KASA Redberg NS? Engineers & Technica anes In Fig. 3.8.1 there are four possible operating points shown. Point 4: This is the first operating point. When the discharge valve is fully ‘open and the pump is operating at 2900 rpm,, Point 2: Assume now that the discharge valve is throttled but the pump speed is unchanged (i.e. 2900 rpm). The system friction losses will increase with flow rate as the valve is partially closed and therefore, the operating point will move along the pump curve to Point 2 (i.e. reduced flow rate but a higher head). Point 3: Assume now that the pump speed is reduced and the discharge valve Is fully open. Point 4: The pump speed is reduced and the discharge valve is throttled. Therefore, it should be clear that the operating point is dependent on: System set-up (i.e. shown by the system curve), and «Pump characteristic (i.e. speed or impeller diameter). If any of these variables change, a new operating point will be established. One further point of note from Fig. 3.8.1 is this... assuming that points 1 and 3 lie on the line of the Best Efficiency Point (BEP), then it can be seen that throttling takes the pump operating point away from the BEP thereby increasing radial thrust. Various typical system set-ups are presented in Figs. 3.8.2 to Fig. 3.8.6. "PROS Water Wastewater Pump & Piping Fundamentals Page 338 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NSS Enginears & Tochnical Trainers Pump Characteristic Curve HEAD System Curve, (Valve Throttled) / / 7 / ~~ System Curve (Valve Open) FLOW RATE Fig. 3.8.2 System Curve — No Static Head No Static Head: When the fluid supply level is the same as the discharge level, there is no static head and therefore the system curve represents pipe and fitting friction losses only. The curve will therefore start at zero flow and zero head. Fig. 3.8.2 depicts this particular set-up. Point 1 depicts the operating point when the discharge valve is fully open. Point 2 depicts the operating point when the discharge valve is throttled. Note that suction line valves should never be throttled as this may cause cavitation. P808 Water/Wastewator Pump & Piping Fundamentals a4 Page s-30 ‘Section 3 Centritugal Pumps for Water & WastewaterKASA Redberg @2sars Pump Characteristic Curve System Curve, (Valve Throttled) / HEAD System Curve (Valve Open) FLOW RATE Fig. 3.8.3 System Curve — Positive Discharge Head Positive Discharge Head: In this set-up, the static head, h., has to be overcome before fiuid will start to flow. Once fiuid is flowing, friction head losses come in to play. Therefore, the system curve is plotted with all friction head losses added to the static head as shown in Fig. 3.8.3. P08 Water/Wastewator Pump & Piping Fundamentals Page 40 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg SS Engineers & Technical Wraners Pump Characteristic Curve HEAD ° FLOW RATE Fig. 3.8.4 System Curve — Negative (Gravity) Head Negative (Gravity) Head: Without the pump, a certain flow rate will be achieved due to the force of gravity. However, to obtain higher flows, a pump is required to overcome friction head losses in excess of the static head, The system curve is plotted as per normal with the difference that the static head is now a negative value. Fig. 3.8.4 depicts this set-up. P08 Water/Wastowater Pump & Piping Fundamentals ————~—SCSCSCS~*~S~S~S« GT Section 3 Centrifugal Pumps for Water & WastewaterPump Characteristic Curve HEAD FLOW RATE Fig. 3.8.5 System Curve — Variable Static Head Variable Static Head: Often the static head will vary as the fluid supply tank or reservoir is drained or as the destination tank or reservoir fils. The system head is then defined by a pair of matching system curves. There will be two operating points which show the extreme operating conditions. Fig. 3.8.5 depicts this scenario. P08 WaterWastevater Pump & Piping Fundamentals Page 3-42 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg Sagineare & Technical Traiers 3.9 PUMPS IN PARALLEL A parallel arrangement is defined when two pumps discharge in to a common manifold. This type of set-up is used when: + The system demand (flow rate) varies greatly and cannot be handled by one pump. «High reliability is required. With two pumps operating in parallel, one can be shut-off during periods of low demand. This allows the running pump to operate at close to its optimum efficiency point. Parallel pump operation increases the flow rate of the system whilst maintaining the same total head. Fig. 3.9.1 Schematic of a Parallel Pumping Set-Up For parallel pumping set-ups, the combined characteristic curve is obtained by drawing the characteristic curves for both pumps on the same sheet. The flow that each pump delivers at the same head is then added together to produce a third curve. This is the combined characteristic curve. Fig. 3.9.2 depicts this. Once again, the operating point for two pumps in parallel is obtained from the intersection of the system curve with the combined characteristic curve. Do not make the mistake of assuming that if you put two identical pumps in parallel, they will deliver twice the flow rate. This will not be the case. Often, two pumps in parallel will only deliver slightly more flow than one pump on its own. This is because as the flow rate increases, the friction head loss increases as a square of the flow rate. “P08 Water Wastewater Pump & Piping Fundamentals Page 345 Section 3 Centrifugal Pumps for Wator & Wastewater@ KASA Redberg NG rears # Fecha Fn Parallel piping arrangements should always have non-return valves fitted. When two dissimilar pumps are arranged in parallel, it should be noted that the flow rate does not increase at heads above the maximum head of the smaller sized pump. Also, a second pump will only operate when its discharge head is greater than the discharge head of the pump already running. Pumps 1&2 (Parallel) HEAD ‘combined ‘System Curve Sm 8 OB FLOW RATE Fig. 3.9.2 Pumps Operating in Parallel From Fig. 3.9.2, it can be seen that the combined characteristic curve for pumps operating in parallel is of a “humped” appearance for two different sized pumps. Pump 1 operating on its own will produce a flow of Q; and Pump 2 operating on its own will produce a flow rate of Qz. However, when both pumps are operating together, the combined flow rate is not the algebraic sum of Q; + Qz. Instead, it is the flow rate at the point where the system curve intersects the combined characteristic curve. It should be noted that pumps with “drooping” characteristic curves are not acceptable for use in parallel pumping circuits. This is because pump operation can be unstable and fluctuate between two operating points on the curve as shown in Fig. 3.9.3. This is also the case for series pumping circuits. "F808 WatoriWastewater Pump & Piping Fundamontals, Page 5. Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NR Eginaais & Technical Traes HEAD FLOWRATE Fig. 3.9.3 Pumps in Parallel - Unstable Operation With reference to Fig. 3.9.3, it can be seen that when two pumps are operating in parallel and one pump has a “drooping” characteristic curve, it is possible that the pump can fluctuate between points A and B. This can happen if the System Curve (shown by the dotted line in Fig. 3.9.3) is flat and crosses the characteristic curve twice. This is typical of systems that have short pipe runs and the system curve is primarily made up of Total Static Head (i.e. lift). It is common for parallel pumping arrangements to be considered problematic by many Plant Operators. Three points should be noted which may help the Plant Operator better understand the reasons for parallel pumping system problems. .. * If only one pump is running in a parallel pumping system, it will be susceptible to cavitation because it is forced to operate to the right of its BEP. Refer to point ‘Qy' on Fig. 3.9.2. Because of this, double mechanical seals should be used. This is because they can withstand cavitation better than single mechanical seals and will therefore be less likely to fail prematurely. ‘If only one pump is running in a parallel pumping system, it will require a larger motor. This is because the hydraulic power required increases as you move from left to right on the pump performance curve. This single pump may be running far to the right of its BEP in an area of higher power than that at the design duty point. One pump will always be the more dominant in a parallel pumping system (of two or more pumps). Therefore, always start the weaker pumps first otherwise they will do no useful pumping if they are started after the more dominant pump. That is, the weaker pumps may “dead-head” against their discharge check valves. Premature bearing failure may result. ~Pa0E WalerWastonator Pump & Ppiig Fundamentals Rr ‘Section 3 Centrifugal Pumps for Wator & Wastewater@ KASA Redberg Fig. 3.9.4 A Typical Packaged Parallel Pumping Arrangement for Vertical In-Line Pumps (Source: Lowara Pumps Pty Ltd) The figure above illustrates a typical packaged, parallel pumping arrangement. This type of system quite commonly features integral variable speed drives so that the operating point can be kept as close as possible to the Best Efficiency Point thereby saving energy and minimising maintenance issues. Fig. 3.9.5 A Typical Parallel Pumping Installation in an Industrial Environment Pa06 WatarWastewater Pump & Piping Fundamentals, Page 3-46 ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NSD Engineare & Techaioal Trainers 3.10 PUMPS IN SERIES A series operation is achieved when one pump discharges in to the suction of the next. This arrangement is generally used to increase the delivered head. A small increase in capacity also results. Fig. 3.10.1. Schematic of a Series Pumping Set-Up For series pumping set-ups, the combined characteristic curve is also obtained by drawing the characteristic curves for both pumps on the same sheet. The head that each pump adds at the same flow rate is then added together to produce a third curve. This is the combined characteristic curve. Fig. 3.10.2 depicts this. From Fig. 3.10.2, Pump 1 produces a head of hy operating on its own. Similarly, Pump 2 produces a head of hz. However, when the two pumps are operated in ' series, the new total head is determined at the operating point which is the intersection between the combined characteristic curve and the system curve. “Pa08 Water/Wastowaler Pump & Piping Fundamentals, Page S47 Section 3 Centritugal Pumps for Water & Wastowator@ KASA Redberg GD incase Tashncat Tamers Ptr P2+P34PA Combined Characteristic Cure (metres) PITP2+ PS ‘Syotem Curve fakaFretion Curve") Identical pumps operating atthe same speed and same impeller darnster Each pump adds an equal amount of heed as shown (at the same flowrate) Aten Flowilirestsec) PEO WalerWastewater Pump & Piping Fundamentals, ‘Section 3 Centritugal Pumps for Water & Wastewater FLOW RATE Fig. 3.10.3 Non-Identical Pumps Operating in Series Page 348@ KASA Redberg ND rraanes Techical Tames High pressure, high volume pumps such as boiler feed pumps require a high NPSH. One way of achieving a high NPSHR is to install a pump in series to feed the main pump or one or more pumps in parallel which are then series connected to feed the main pump. The feed pumps (aka “booster pumps") are chosen so as to deliver the same required flow rate as the main pump whilst adding a head sufficient enough so that the main pump's NPSHR requirements are met. JS! warning: For series pumping applications, the combined head should always be ——~ compared to the pressure ratings of the second pump as there could be a risk of bursting the pump casing or damage to the shaft and seals. Bole Yo pel Yb on vont pop batten fo~ Supe pressitmes dlr Uectee Yectane~ P8G6 WateriWastewater Pump & Piping Fundamentals Page o-49 ‘Section 3 Centrifugal Pumps for Water & Wastewater(fa KASA Redb @ ‘edberg Engineers & Technical Trainers 3.11 CENTRIFUGAL PUMP SELECTION PROCESS In practice, the selection of the pump and piping for new systems is a concurrent process. That is, various pipe sizes are analysed so as to give the best trade-off between installation cost, velocity and friction head losses whilst various pump set- ups (ie. impeller diameter, speed, pump models etc) are analysed so the operating point falls on the selected system curve. There are many permutations and combinations on this basic selection process. Generally speaking, the following steps are carried out when selecting a new pump and/or system set-up. Determine the static heads (i.e. how high does the fluid need to be lifted). ‘* Determine the required flow rate. Create a ‘short list’ of various pipe sizes for the suction and discharge line and plot a system curve for each size on the same sheet. Determine the specific speed of the type of centrifugal pump. «Use a Manufacturer's “family of curves” to begin preliminary investigation o. a pump model. Refer to Fig. 3.12.1 for a typical set of pump family curves. * Plot the selected pump’s "head versus capacity” curve on the same sheet as. the previously generated system curves. Alternatively, plot the proposed short list of system curves on the pump characteristic curve sheet. © Determine which pipe and pump combination to use based on a trade-off between Best Efficiency Point, installation cost and pipe-line velocity. For existing systems, the pipe-work may already been in place, or an existing pump may be used in a modified process arrangement. These systems are usually easier to analyse as more of the variables are fixed. Hr} Qin gem §0 490150250 590 4900 1500 20 2900rpm. | ss = a Z tmsohY lynese pela] 00 540.450 ; ™ 300, 80x50-250 123 A 100x85-250 ~~ 25r100-250 200 cs) 9) ‘50x32-200 erat 0) '30x50-200, 100x85-200 40] aa] Hay — 251090200 150 50x32-160_ tla . Re ea Sy 2a] 45) eee abe ws 45 340 0 4080 00150 9, ___, 3, (cummin) 10 2 «0 60 too 1500. 50 Fig. 3.11.1 A Typical Family of Curves For Preliminary Pump Selection (Reproduced With Permission of Davey Pumps Pty Ltd) "Pa08 Water/Vrastewater Pump & Piping Fundamentals Page 350 ‘Section 3 Centritugal Pumps for Water & Wastewater@ KASA Redberg_ CE Engineers @ Yechnical Trainers EXAMPLE PROBLEM 3.3 Given: To Find: Assumptions: Solution: A centrifugal pump is required to raise water at 20°C from a storage tank to a buffer tank. Both tanks are open to atmosphere and the pipe selected is Medium Stee! Pipe to AS1074. Other pertinent details are: 10 litres/sec -3m (i.e. suction lift condition) 25m Required Flow Rate, “Q” Static Suction Head, “hzs)" Static Discharge Head, "hz" Total Suction Line Length 8m Total Discharge Line Length 50m Atmospheric Pressure, "hes" 101.3 kPa Vapour Pressure of Water, "hyp" 1.7 kPa @ 20°C Density of Water, “p” = 998 kgim* () — Assuitable pipe size for the suction and discharge lines (i) Assuitable pump and motor combination for the duty No details on valves or fittings are given so it shall be assumed that the friction losses associated with these items are negligible when compared to the Total Dynamic Head. Calculation of Trial Pipe Diameters and Velocities: From Tables 2.4.8.1 and 2.4.8.2, recommended pipeline velocities should be in the order of 0.50 to 2.0 mis. Trial pipe diameters should be selected for the suction and discharge line. It is normal practice for the suction line to be at least one pipe size larger than the delivery line. Therefore, selecting an 100NB suction line and 80NB discharge line, Discharge (80NB): Q = VA => 0.010 = V x xx 0.080? = V = 1.99 m/s 4 Suction (100NB): Q= VA => 0.010 = Vx xx 0.100? => V = 1.27 m/s 4 We will continue to use these trial diameters for the purposes of this example problem. In reality, pipe size selections would take in to account: recommended velocities, acceptable friction losses and cost of installation. Therefore, in practice, further trial diameters should be selected and individual system curves plotted for each. P808 Wator/Wastewater Pump & Piping Fundamentals Page sot Section 3 Centrifugal Pumps for Water & WastewaterSolution: EXAMPLE PROBLEM 3.3 CONTINUED neers & Technical Wane KASA Redbi @ edberg Calculation of NPSHA: hp == Po = 101.3x10° = 10.3m Pg 998 x 9.81 bp = Po = 17x10? = 0.2m Pg 998 x 9.81 From Table 10.5, for a 100NB pipe @ 10 I/sec, hy= 1.71 m/100 m hy) = 8mxt.7im400m= 0.1m NPSHA = hap + hay) — hye) — ap =NPSHA = = 10.3+(3)-041-02 = 7.0m Calculation of Specific Speed: From Table 10.5, for a 80NB pipe @ 10 Vsec, hy= 6.17 m/100 m hw = S0mx6.17m100m= 3.1m The total head required by the pump (Le. total dynamic head) ha = gays) * hss * hea) = 25-(-3)+ 0.4434 = 312m Assuming 2900 rpm is the site standard for motor speed, then The Specific Speed,Ns = my /Q = _2900\/0.010 hae” 34.2078 > N = 2 Therefore, a radial flow, single stage centrifugal pump should be chosen. Using a pump manufacturer's family of curves such as that depicted in Fig. 3.14.1, for Q = 10 lisec @ h = 31.2 m, a Davey 65x50-160 looks to be suitable when operating at 2900 rpm. The characteristic curve set for this pump is shown in Fig. 3.11.2. Calculation of Total Static Head: = Neo) = Ay fey = 25-3) = 28M Paaa WatorWastonater Pump & Pipmg Fundamentals SSSCSCS~C~ ag Section 3 Contnfugal Pumps for Water & WastewaterEXAMPLE PROBLEM 3.3 CONTINUED Solution: @ KASA Redberg GD erica TTecial Fanos Calculation of System Curve for 100NB suction and 80NB Discharge: From Fig. 10.5, friction losses for both the suction and discharge line can be found. These losses are then added together for the same flow rate and then added to the Total Static Head so that a system curve can be plotted (i.e. curve of Total Dynamic Head versus flow rate). Aitotan* Bs) * Br (Total Dynamic Head) 28+0+0=28 28 + 0.01 + 0.16 = 28.2 28 + 0.03 40.57 = 28.6 28+ 0.05 + 1.20=29.3 28 + 0.09 +2.04 = 30.1 28+0.14+3,09=31.2 28+ 0.29 + 6.53 = 34.8 This data from the table above is then plotted on the characteristic Curve Set (Fig. 3.11.2). The operating point is Q = 10 sec @ h = 31.2 m. Therefore, a 164 mm diameter impeller would be fitted. The efficiency is 68%. Calculation of Power Required: Hydraulic Power = Q x p xg x Ep When both the supply and delivery reservoir are at atmospheric (or the same) pressure, Ep = the Total Dynamic Head. Therefore, Hydraulic Power = 0.010 x 998 x 9.91 x 31.2 = 3.06 kW Brake Pump Power = Hydraulic Power = 3,06 = 4.5kW ™ 0.68 Therefore, the next largest standard motor size should be selected and that is a 5.5 kW motor. Cavitation Check: From Fig. 3.11.2, the NPSHR is approximately 2 metres, Previously, the NPSHA was calculated at 7 metres. As NPSHA > NPSHR + safety margin (i.e. 10%) , cavitation is not and issue. F808 Wator/Wastewater Pump & Piping Fundamontae Page 383 Section 3 Centnfugal Pumps for Water & Wastewator@ KASA Redberg hgineers & Technical Tamer (5x50-160 SPEED: 290mm ISOspec ape wh a Fig. 3.11.2 Davey CF Series 65x50-160 Characteristic Curve Set (Reproduced With the Perfissionef Ravey Pumps Pty Ltd) Sine areciael — Haneten ae you lat 30 Shine taepcllem wif mee Ha~ is PaG6 Waer/Wastewater Pump & Piping Fundamentals Page 354 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg_ CE Engingors & Technical Tamers 3.12 TESTING OF CENTRIFUGAL PUMPS There are a number of pump testing procedures in use around the world. Such testing procedures are published by a number of industry bodies such as: The International Standards Institute (ISO), The American Petroleum Institute (API) and The Hydraulics Institute. In Australia, tests are generally conducted in accordance with Australian Standard AS2417 “Pumps — The International Acceptance Test Codes’. Regardless of the test procedure, the aim of any testing is to establish a characteristic curve set for the particular pump in question. Such a curve set would also include curves of efficiency, power and NPSHR versus flow rate as well. Pump manufacturers have an advantage over Plant or Process Engineers as they generally have dedicated testing facilities complete with expensive equipment such as magnetic flow meters, pressure transducers, torque bars and data acquisition systems which make testing procedures much easier. However, pumps can be tested in-situ in a plant situation without too much difficulty as long as some basic equipment is available. The general procedure for pump testing is as follows: i. Prime the pump by filing the suction piping and pump casing with water until all air has been expelled. ii. Start the pump with the suction valve fully open and the discharge valve almost, but not quite closed (so that the least possible torque is applied to the drive). ili, Run the pump for at least one hour at the design operating point. During this time it should be possible to determine whether the bearings are likely to become overheated due to insufficient lubricant, too tight a fit in the bearing housing or by excessive thrust. The “rule of thumb” is that the ideal temperature of the bearings should be warm but not so warm that you can't hold your hand on them for 10 seconds. iv. The pump characteristic curve sets can then be generated by varying the discharge valve setting between the maximum discharge and shutoff. Sufficient time should be allowed after each valve setting so steady flow conditions can be established. The Net Positive Suction Head Available (NPSHA) can be controlled by (i) varying the suction line throttle valve for basic tost set-ups, or (ii) by varying the height of the fluid in the delivery tank for suction lift set-ups, or (i) by varying the pressure in the delivery tank for pressurised (or vacuum) set-ups. Pa08 Water Wastewater Pump & Piping Fundamentals : Page s-55 ‘Section 3 Centriiugal Pumps for Water & Wastewater@ KASA Redberg NO) Eigreon & Tecinan Tames If you were to be testing pumps on a regular basis, it is recommended that a pressure or vacuum tank be used in a closed circuit arrangement. The advantages Of this set-up are: * The absolute pressure in the system can be varied. Testing under positive pressure eliminates air leaks in any of the pressure transducer tapping points. * Changes in the system pressure do not effect the total head developed by the pump, but lowering the pressure in the system lowers the NPSHA which facilitates suction testing. Drawing water from an open tank requires fluid level to be varied or the tank to be lowered when suction testing and this increases the testing time. A typical (basic) test set-up is shown in Fig. 3.12.1. The following variables are measured during testing at each flow rate... * Measurement of Flow: There are several methods available to measure the fiow rate and the one selected will depend on the equipment available as well as the required accuracy. Some of these methods are: (i) Route the discharge pipe to a tank of known volume and measure the time to fill it (ii) use a calibrated flow meter such as a magnetic flow meter (ji) use a weir, or (iv) use a venturi meter. + Measurement of Total Head: The static heads can be determined by the pressure gauges in the suction and discharge piping. These readings should be corrected to the pump centreline (if there is any difference in elevation). The velocity heads can be calculated using Bernoulli's Theorem and the flow rate in conjunction with the suction and discharge pressure gauge readings. These days, it is more practical and cost effective to use pressure transducers rather than Bourdon Tube Gauges or manometers. « Measurement of Pump Rotational Speed: Instruments such as tachometers, strobe lights or revolution counters can be used to measure the rotational speed of the pump. «Measurement of Torque or Power: Pump manufacturers and those who test pumps frequently have expensive equipment such as a “torque bar” which, as the name suggests, measures the shaft torque from which the power can be determined. Torque bars are precision instruments but suffer from the disadvantage that a special coupling is required to fit the torque bar to the shaft and because of the expense, they are only used on the smaller pumps. Pa08 WaterWastowaler Pump & Piping Fundamentals Page 3-56 Section 3 Centrifugal Pumps for Weter & Wastewater@ KASA Redberg RD craic Fecal Tas Nhe ) Measurement of voltage and current 1 (Gdatorminaton of power) ‘pmme_— Rev. Counter ope) PLAN VIEW Sictonand iste owt ae pasture Tt ave eee |\ (for regulating head versus flow rate) scson Ml va \ \ " enamine f YO \ SSI \ cea) ELEVATION Fig. 3.12.1 A Basic Centrifugal Pump Testing Set-Up “808 Water/Wastowater Pump & Piping Fundamentals Pagoso7 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg | NG res 2 Foams Famers For in-situ testing of pumps driven by three phase electric motors, the voltage and current drawn by the pump motor can be easily measured. If the power factor of the motor is known, then the power input to the motor (i.e. Brake Pump Power) can be determined from the following equation: Brake Pump Power = \/3 xVxAxPF (kW) 1000 Where: V —-= _ Three Phase Voltage (volts) A Three Phase Current (amps) Power Factor Ifit is desired to determine the hydraulic power (i.e. the power at the pump shaft) or the efficiency of the pump alone, motor losses must be taken in to account. To determine the motor losses, the motor has to be tested with a dynamometer unde identical electrical input conditions and at the same speed as when the motor is driving the pump at the required operating point. The actual hydraulic power is then taken as the actual power input to the motor. The value obtained would have to be modified further to take in to account any losses in any belt drive, coupling or gearbox if they were fitted between the motor and the pump shaft. PROB Water/Wastowater Pump & Piping Fundamentals, Page 358 ‘Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg GD crscer t Facil Tners 3.13 PRIMING, STARTING AND TROUBLESHOOTING 3.13.1 Priming With the exception of ‘self priming” type pumps, all centrifugal pumps need to be “primed” before starting. That is, the suction pipe and pump housing need to be completely filled with fluid so no air bubbles exist. Priming can be achieved in various ways. Some of the more common methods are: + For systems with a “suction lift” condition, install a foot valve at the suction entry and then fill the pump housing and suction piping with fluid. Leave a bleed valve open in the top of the pump housing or discharge pipe and continue filling until fluid flows from this bleed valve. ‘+ For systems with a “suction lift” condition, use another pump such as a hand- operated diaphragm pump installed on the discharge side of the pump to draw fluid up in to the suction pipe and casing. Employ a bleed valve for the removal of entrapped air as above. * For systems with a “flooded suction’ condition, open all valves in the suction line. Employ a bleed valve for the removal of entrapped air as above. Wherever possible, it is important to design pumping systems so that any installed centrifugal pump is continuously primed. This is best achieved by ensuring that the pump is always lower than the fluid source. Obviously, this is not always practical so the use of foot valves becomes a necessity for systems with a suction lift condition. Warning: Apart from not being able to pump, failing to fully prime a centrifugal pump before starting may cause damage to the pump itself. 3.13.2 Starting Unless instructed otherwise by the pump supplier or manufacturer, a centrifugal pump should be started as follows: * Adjust the discharge valve so that it is almost closed. This is to allow the least possible torque to be applied to the drive, «Ensure that flushing fluid is available if the pump has a flushed mechanical seal or packed gland, * Start the drive. * Once the drive has reached the required operating speed, gradually open the discharge valve until the required operating point has been obtained. P806 Water/Wastewater Pump & Piping Fundamentals, Page 3-59 Section 3 Centrifugal Pumps for Water & Wastewater@ KASA Redberg NED) asiears t Teanct 3.13.3 Troubleshooting Centrifugal pumps, like all rotating mechanical devices are prone to wear and tear which may show in performance changes. Once the pump is installed and properly commissioned, the major causes of pumping problems can usually be traced back to ‘ear and tear” or changes in the system set-up. Table 3.14.3.1 shows some typical symptoms of poor performance as well as recommended remedies. Table 3.13.3.1 Centrifugal Pump Troubleshooting POSSIBLE CAUSE AND REMEDY Pump not sufficiently primed: Check suction pipe and pump housing for fluid. No fluid is delivered. ‘Speed too low: Check electrical connections, belt drives for correct pulley diameters and belt slip, inverter settings, engine condition and performance. Discharge head too high: Check lift heights, pipe diameters etc and compare with the design. Check pipe work for obstructions or closed valves. Suction lift too high: Check lift height and compare with the design. Raise the fluid source or lower the pump so as to reduce the suction lift. Clogged Impeller: Flush impeller with a compatible, clean fluid. Disassemble and inspect impeller and volute. Wrong Direction of Rotation: Change the drive direction of rotation (i.¢. swap any two phase wires in a three-phase motor set-up). Reduced amount of flow. ‘Air-leaks. Check suction piping, packed gland and pump housing and seal. ‘Speed too low: Check electrical connections, belt drives for correct pulley diameters and belt slip, inverter settings, engine condition and performance. Discharge head too high: Check lift heights, pipe diameters etc and compare with the design. Check pipe work for obstructions or closed valves. Suction lift too high: Check lift height and compare with the design. Raise the fluid source or lower the pump so as to reduce the suction lift. "P06 Water/Wastewater Pump & Piping Fundamentals Page 350 Section 3 Centritugal Pumps for Water & Wastewater@ KASA Redberg NO cnansars a Technica Tamers Table 3.13.3.1 Centrifugal Pump Troubleshooting (Continued) POSSIBLE CAUSE AND REMEDY Clogged Impeller: Flush impeller with a compatible, clean fluid. Disassemble and inspect impeller and volute. Reduced amount of flow. Wrong Direction of Rotation: Change the drive direction of rotation (i.e. swap any two phase wires in a three-phase motor set-up). Wear and Tear: Worn impeller, wear rings, housing ete. Check and replace as required. Impeller Diameter: An incorrectly sized impeller may have been installed. Check against the design. Gavitation: Check suction line pressure, listen for “rumbling” noises. Replace foot valve with a larger size. Insufficient pressure _ | Speed too low: Check electrical connections, belt drives, (head) developed. for correct pulley diameters and bolt slip, inverter settings, engine condition and performance. Wrong Direction of Rotation: Change the drive direction of rotation (.¢. swap any two phase wires in a three-phase motor set-up). Wear and Tear: Worn impeller, wear rings, housing etc. Check and replace as required. Impeller Diameter: An incorrectly sized impeller may have been installed. Check against the design Entrapped Air or Gases in the Fluid: Check the fluid for frothing or entrapped air/gases. Pump intermittently | Suction lift too high: Check lift height and compare suffers performance _ | with the design. Raise the fluid source or lower the pump losses. 80 as to reduce the suction lift. Air-leaks: Check suction piping, packed gland and pump housing and seal. Entrapped Air or Gases in the Fluid: Check the fluid for frothing or entrapped air/gases. PaO Water Wastewater Pump & Piping Fundamentals aT Section 3 Centrifugal Pumps for Water & Wastewaterneers & Trainers (fa, KASA Redb @snnses Table 3.13.3.1 Centrifugal Pump Troubleshooting (Continued) Pump intermittently _ | Speed too low: Check electrical connections, belt drives suffers performance | for correct pulley diameters and belt slip, inverter losses. settings, engine condition and performance. Excessive Power Consumption. ‘Speed too high: Check belt drives for correct pulley diameters, inverter settings, engine condition and performance etc, Head lower than expected: The pump will produce a higher flow rate than necessary. Reduce the impeller diameter or reduce the speed. Fluid density higher than expected: Install a new drive with a higher rating. Fluid viscosity higher than expected: Install a new drive with a higher rating. Mechanical Defects: Check for shaft distortion, binding impeller, binding wear rings, gland packing too tight, 808 Waler/Wastewater Pump & Piping Fundamentals, Page 362 Section 3 Centrifugal Pumps for Water & Wastewater(faa KASA Redbi @ edberg 3.14 DATA REQUIRED FOR BUYING OR SPECIFYING PUMPS As a minimum, the flow rate required, head required and fluid to be pumped are required when asking a supplier or manufacturer to select a pump for a particular duty. However, in the majority of instances, much more information would be required so a cost effective and reliable selection can be made. — Typical information required is listed below. Such information is typical for all pump types, not just centrifugal. * Required flow rate (m*/hr, I/min, V/s etc). If the pump will run in parallel, confirm that the required flow rate is for one pump only or for two or more pumps. © Total Head (m). Flooded suction or suction lift condition. * Fluid type and properties such as: specific gravity, vapour pressure, materials compatibility, shear sensitivity, contaminants and solids content. * Net Positive Suction Head Available (NPSHA). «Fluid temperature range. * Ambient temperature range. * Elevation of pump above sea level (if the installation will be above 500 metres). «Preference for type of pump (i.e, end-suction, in-line etc). * Preferred materials of construction. «Preferred paint specification. * Preferred motor and gearbox manufacturer (so as to fit in with site standard spares). © Motor Electrical Protection (IP) Rating (e.g. IP56 is standard on mine sites in Australia). + Is hazardous area duty required? + [san inverter (variable speed drive) going to be used for speed changes? Note that most suppliers or manufacturers would be more than happy to help you find such data and do work from basic sketches of the proposed or existing layout. However, it is in your best interests to know as much about your pumping system as possible so expensive mistakes don't get made. The goal of any engineer involved in specifying a pump should be to take the decision making away from the pump supplier. This will allow a more accountability in the design process and will allow you to compare “apples to apples” when comparing makes, models and types. for a particular application. PE0E Water/Wastewater Pump & Piping Fundamentals Page 53 ‘Section 3 Centrifugal Pumps for Water & Wastowater@ < This Page Left Intentionally Blank> P08 Water Wastewater Pump & Piping Fundamentals Section 3 Centrifugal Pumps for Water & Wastewater KASA Redberg Ereineers & Technical Trainers Page 64