Overview of pump efficiency

A machine’s efficiency indicates its ability to convert one form of energy to another. If one unit of
energy is input to a machine and its output is one-half unit, the machine’s efficiency is 50%.

For a centrifugal pump, much of the work involves two very efficient machines: the pump itself and
the AC induction motor that drives it. The centrifugal pump converts mechanical energy into
hydraulic energy (flow, velocity, and pressure), and the AC motor converts electrical energy into
mechanical energy.

Medium and large centrifugal pumps generally operate with efficiencies above 75%, and smaller
ones usually fall into the 50% to 70% range. Large AC motors, on the other hand, approach an
efficiency of 97%.

The overall efficiency of centrifugal pumps is the ratio of the water (output) power to the shaft (input)
power, and it is described by the following equation:

Ef = PW / PS

Where: 
Ef = efficiency
PW = the water power
PS = the shaft power provided to the pump shaft in brake horsepower (BHP)

And:
PW = (Q x H) / 3,960

Where:
Q = Flow (gallons per minute, gpm)
H = Head (feet)
3,960 = converts to BHP

For example, a pump that produces 100 gpm at 30 feet of head and requires 1 BHP will have an
overall efficiency of 75.7% at that flow point.

The total efficiency of a centrifugal pump is the product of mechanical, volumetric, and hydraulic
efficiencies. Mechanical efficiency accounts for losses in the bearing frame, stuffing box, and
mechanical seals. Volumetric pump efficiency comprises losses due to wear ring leakage, balancing
holes and vane clearances (in the case of semi-open impellers). Hydraulic efficiency includes liquid
friction and other losses in the volute and impeller.

While mechanical and volumetric losses are important contributors to total efficiency, hydraulic
efficiency is the largest factor. There are various conditions that decrease the efficiency of a
centrifugal pump:
 Heat generated due to packing
 Rubbing between wear rings and maintaining impeller clearances
 Recirculation using a bypass line from the discharge of the pump to the suction
 Double volute design
 Throttled discharge valve
 Corroded internal pump passages that cause fluid turbulence
 Obstacles, hindrances, or any sort of restrictions inside the piping passages that might
include foreign particles or dirt
 Overlubricated bearings

A detailed record of preventive maintenance performed and required repairs should be kept to aid in
diagnosing problems and to eliminate or minimize any future equipment downtime. Operators who
adhere to a preventive maintenance program will reap the benefits of a facility that functions without
encountering breakdowns and out-of-service situations.

Pump manufacturers supply a manual with recommended maintenance procedures for their
centrifugal pumps. However, routine preventive and protective maintenance practices should, at a
minimum, include the monitoring of the following:
1. Bearing and lubricant condition. Monitor bearing temperatures, lubricant level, and vibration.
The lubricant should be clear with no signs of frothing. Excessive vibration and an increase in
bearing temperature may indicate imminent failure.
2. Shaft seal condition. The mechanical seals should show no signs of visible leakage. Some
packing leaking is normal, but this should not exceed a rate of about 40 to 60 drops per minute.
3. Overall pump vibration. Imminent bearing failure can be preceded by a change in bearing
vibration. Excessive vibration can result from a change in pump alignment or cavitation resonances
between the pump, its foundation, or the valves located in the suction and/or discharge lines.
4. Pump discharge pressure. A gradual decrease in the developed head pressure of the pump
may indicate that the impeller clearance has widened. An impeller clearance adjustment may be
required to restore the pump to its intended design performance.

Annual maintenance
 Once a year, the pump’s performance should be checked and recorded in detail. Performance
benchmarks should be established for a new pump during the early stages of a pump’s operation,
when the installation adjustments are correct. This benchmarking data should include:
 The head pressure developed, as measured by the suction and discharge gauges
 Centrifugal pump flow rate
 Motor amp draw
 Pump vibration signature

During the annual assessment of a pump’s performance, any changes in the benchmarks should be
recorded and used in determining the level of maintenance that may be required to get the pump
back to operating at its BEP.

Quarterly maintenance

The following maintenance tasks should be performed on a quarterly basis:

 Verify the integrity of the pump’s foundation and check the hold-down bolts for tightness.
 For oil-lubricated pumps, change the oil after the first 200 hours of operation for a new pump,
and then after every three months or 2,000 operating hours, whichever comes first. For grease-
lubricated pumps, bearings should be greased every three months or 2,000 operating hours,
whichever comes first.
 Check the shaft alignment.
 Grease the motor bearings according to the manufacturer’s instructions.

Bearing lubrication tips

About the Authors: David Holland and Ronald Burg
David Holland is vice president at Mahan’s Thermal Products. He has a degree in mechanical
engineering, which has helped him acquire an extensive background in general contracting and
mechanical contracting. He also has extensive experience in the design and construction of
mechanical systems and controls. Contact him at david.holland@mahans.com

Ronald Burg writes extensively for the Mahan’s blog and has worked extensively in the heat
exchanger industry. He was factory-trained at API BASCO in Buffalo, NY, and is factory-
certified as an authorized service provider for Alfa Laval.

Any centrifugal pump operation and maintenance program must emphasize bearing lubrication.
Realistically, all pump bearings will eventually fail. When two surfaces rub together, whether
lubricated or not, friction will win in the end.
 For oil-lubricated bearings, use only non-foaming and non-detergent oils. Avoid over-
lubrication which can be just as damaging as under-lubrication.
 Excess oil will cause a slightly higher horsepower draw and generate additional heat, which
can cause frothing of the oil. If there is cloudiness when checking the condition of the lubricating oil,
it may be an indication of excessive water content from condensation. If this is the case, the oil
needs to be changed immediately.
 For pumps equipped with re-greaseable bearings, avoid mixing greases of differing
consistencies or types. Also, note that the shields must be located toward the interior of the bearing
frame. When re-greasing, confirm that the bearing fittings are absolutely clean to prevent
contamination, which can decrease bearing life.
 Over-greasing must also be avoided, as this can cause localized high temperatures in the
bearing races and create caked solids.

Additional parts examination

For cases where an operator needs to replace a part on a malfunctioning pump, take the opportunity
to examine the pump’s other parts for signs of fatigue, excessive wear, and cracks. Any worn parts
should be replaced if they do not meet the following part-specific tolerance standards:
 Bearing frame and foot. Inspect for cracks, roughness, rust, or scale. Machined surfaces
should be free of pitting or erosion.
 Bearing frame. Inspect all tapped connections for dirt. Clean and chase threads as
necessary. Remove all loose or foreign material. Inspect lubrication passages to be sure that they
are not blocked.
 Shaft and sleeve. Inspect for grooves or pitting. Check bearing fits and shaft runout, and
replace the shaft and sleeve if worn or if the shaft runout is greater than 0.002 inches.
 Casing. Inspect for signs of wear, corrosion, or pitting. If wear exceeds a depth of 1/8-inch,
the casing should be replaced. Check gasket surfaces for signs of irregularities.
 Impeller. Inspect the impeller for wear, erosion, or corrosion damage. If the vanes are bent or
show wear in excess of 1/8-inch deep, the impeller should be replaced.
 Frame adapter. Inspect for cracks, warpage, or corrosion damage and replace if any of these
conditions is present.
 Bearing housing. Inspect for signs of wear, corrosion, cracks or pits. Replace housings if
worn or out of tolerance.
 Seal chamber/stuffing box cover. Check for pitting, cracks, erosion or corrosion. Inspect for
any wear, scoring or grooves that might be on the chamber face. Replace if worn more than 1/8-inch
deep.
 Shaft. Check the shaft for any evidence of corrosion or wear and straightness, noting that the
maximum total indicator reading (TIR) at the sleeve journal and coupling journal should not exceed
0.002 inches.
 Severe service conditions. If the pump is used in severe service conditions, such as in highly
corrosive liquids, maintenance/monitoring intervals should be shortened.

Conclusion

Follow these recommendations to guarantee an efficiently performing centrifugal pump that meets
design expectations and provides service for an extended period of time with minimal repairs and
shutdowns. Consult the pump manufacturer’s manual for maintenance requirements that are specific
to certain models and may not be listed here.

Implementing these maintenance recommendations may seem daunting, but it is only through a
routine such as this that a fluid-handling operation can maximize the service life of the equipment
while enhancing the safety of plant personnel and the environment.
Tinjauan tentang efisiensi pompa
Efisiensi mesin menunjukkan kemampuannya untuk mengubah satu bentuk energi ke
bentuk lain. Jika satu unit energi dimasukkan ke mesin dan outputnya satu setengah unit,
efisiensi mesin adalah 50%.
Untuk pompa sentrifugal, sebagian besar pekerjaan adalah mesin yang sangat efisien:
pompa itu sendiri dan motor induksi AC yang menggerakkannya. Pompa sentrifugal
mengubah energi mekanik menjadi energi hidraulik (aliran, kecepatan, dan tekanan), dan
motor AC mengubah energi listrik menjadi energi mekanik.
Pompa sentrifugal menengah dan besar umumnya beroperasi dengan efisiensi di atas 75%,
dan yang lebih kecil jatuh ke dalam kisaran 50% hingga 70%. Motor AC besar, di sisi lain,
pendekatan dan efisiensi 97%.
Efisiensi keseluruhan daya adalah rasio air (output) daya ke poros (input) daya, dan itu
dijelaskan oleh persamaan berikut:
Ef = PW / PS
Dimana:
EF = efisiensi
PW = kekuatan air
PS = poros pompa dalam tenaga kuda rem (BHP)
Dan:
PW = (Q x H) / 3,960
Dimana:
Q = Aliran (galon per menit, gpm)
H = Kepala (kaki)
3,960 = mengonversi menjadi BHP

Misalnya, pompa yang menghasilkan 100 gpm pada 30 kaki kepala dan membutuhkan 1
BHP akan memiliki efisiensi keseluruhan sebesar 75,7% pada titik aliran tersebut.

Efisiensi total pompa sentrifugal adalah produk efisiensi mekanis, volumetrik, dan hidraulik.
Perhitungan efisiensi mekanik untuk kerugian dalam bingkai bantalan, kotak isian, dan sil
mekanik. Efisiensi pompa volumetrik terdiri dari kerugian akibat kebocoran cincin aus,
lubang balancing dan jarak bebas vane (dalam kasus impeler semi terbuka). Efisiensi
hidrolik termasuk gesekan cair dan kerugian lain dalam volute dan impeller.
Sementara kerugian mekanis dan volumetrik merupakan kontributor penting untuk efisiensi
total, efisiensi hidraulik adalah faktor terbesar. Ada berbagai kondisi yang menurunkan
efisiensi pompa sentrifugal:
• Panas yang dihasilkan karena pengepakan
• Menggosok antara memakai cincin dan mempertahankan kelonggaran impeller
• Resirkulasi menggunakan jalur bypass dari pembuangan pompa ke hisap
• Desain double volute
• Throttle discharge valve
• Corroded internal pump passages yang menyebabkan turbulensi fluida
• Hambatan, rintangan, atau segala bentuk pembatasan di dalam saluran pipa yang
mungkin termasuk partikel atau kotoran asing
• Bantalan yang terlalu dilubangi
Catatan rinci pemeliharaan preventif yang dilakukan dan perbaikan yang diperlukan harus
disimpan untuk membantu dalam mendiagnosis masalah dan untuk menghilangkan atau
meminimalkan downtime peralatan masa depan. Operator yang mematuhi program
pemeliharaan preventif akan memperoleh manfaat fasilitas yang berfungsi tanpa
menghadapi gangguan dan situasi di luar layanan.
Produsen pompa menyediakan manual dengan prosedur perawatan yang disarankan untuk
pompa sentrifugal mereka. Namun, praktik pemeliharaan pencegahan dan pelindung rutin
harus, minimal, termasuk pemantauan hal-hal berikut:
1. Kondisi bantalan dan pelumas. Monitor suhu bantalan, tingkat pelumas, dan getaran.
Pelumas harus jernih tanpa tanda-tanda buih. Getaran yang berlebihan dan peningkatan
suhu bantalan dapat menunjukkan kegagalan yang akan segera terjadi.
2. Kondisi shaft seal. Segel mekanis seharusnya tidak menunjukkan tanda-tanda kebocoran
yang terlihat. Beberapa kemasan bocor normal, tetapi ini tidak boleh melebihi laju sekitar 40
hingga 60 tetes per menit.
3. Pompa getaran keseluruhan. Kerusakan bantalan yang segera dapat didahului oleh
perubahan dalam getaran bantalan. Getaran yang berlebihan dapat dihasilkan dari
perubahan dalam perataan pompa atau resonansi kavitasi antara pompa, fondasinya, atau
katup yang terletak di garis hisap dan / atau pembuangan.
4. Tekanan discharge pompa. Penurunan bertahap dalam tekanan kepala yang
dikembangkan dari pompa dapat menunjukkan bahwa izin impeller telah melebar.
Pengaturan izin impeler mungkin diperlukan untuk mengembalikan pompa ke kinerja desain
yang diinginkan.

Pemeliharaan tahunan

Setahun sekali, kinerja pompa harus diperiksa dan dicatat secara rinci. Tolok ukur kinerja
harus ditetapkan untuk pompa baru selama tahap awal operasi pompa, ketika pengaturan
instalasi sudah benar. Data pembandingan ini harus mencakup:
• Tekanan kepala dikembangkan, sebagaimana diukur oleh pengukur hisap dan
pengosongan
• Laju aliran pompa sentrifugal
• Motor amp menarik
• Tanda tangan getaran pompa
Selama penilaian tahunan kinerja pompa, setiap perubahan dalam tolok ukur harus dicatat
dan digunakan dalam menentukan tingkat pemeliharaan yang mungkin diperlukan agar
pompa kembali beroperasi di BEP-nya.

Perawatan tiga bulanan

Tugas pemeliharaan berikut harus dilakukan setiap tiga bulan:
• Verifikasi integritas pondasi pompa dan periksa baut penahan untuk keketatan.
• Untuk pompa yang dilumasi oli, ganti oli setelah operasi 200 jam pertama untuk pompa
baru, dan kemudian setelah setiap tiga bulan atau 2.000 jam operasi, mana saja yang lebih
dulu. Untuk pompa berpelumas gemuk, bantalan harus diberi oli setiap tiga bulan atau
2.000 jam operasi, mana saja yang lebih dulu.
• Periksa perataan poros.
• Lumasi bantalan motor sesuai dengan instruksi pabrik.