ARG, Technical Training Centre Mirpur Mathelo Pilot - 7 Pumps UNIT: 1 - CENTRIFUGAL PUMPS‘ PILOT SEVEN — PUMPS * UNIT ONE: CENTRIFUGAL PUMPS SECTION 1 An Introduction to Centrifugal! Pumps 3 Centrifugal Pumps ‘ pe ae 6 How Centrifugal Pumps Are Rated... : 10 Capacity .. : coolly Pressure and Hend ; 1B Vapor Pressure ... zi 21 Net Positive Suction Head (NPSH) . 24 Friction . es 3 24 Horsepower ..-...ccsseeerveeees 21 Performance Curves ....sssseeeeee05+ Sogn ee SECTION 2 > Design and Construction of Centrifugal Pumps ....- nae Pump Types 7 eS ames pois, Tame Propeller Pumps 2 88 ‘Turbine Pumps 35 Vertical and Horizontal Pumps : Tan Pumps Operating in Series or in Parallel ~ 88 Regulating Pump Discharge 40 Mechanical Details . 4 Packing Box . 41 Lantern Rings ed - 48 Mechanical Seals ...... +++ t rl Impeller Thrust k : 46 Bulaneing Druin ‘i a1 Alignment and Vibration . 248 Lubrication ...+++++++ tee 49 * Wear Rings Go 0 - 49 ‘The Packing Box . 1 Ad Bearings anil Couplings : 49 Pump Cooling - lat + BA SECTION 3 Operation « 56 Startup : 56 Shutdown .. z Sty Common Pump Problems .. 60 Gradual Loss of Pump Capacity . 60 Reconditioned Pump Returned to Below Normal 62 Pump Functions Properly at Low Rates—Losee Suction at High Rates « 6a Motor Kicks Of, Engine Lugs, o” Turbine Will Not Get Up to Speed 62 Pump Continually Loses Suetion 68 + Cavitation 3 64 Features of the Centrifugal Pump . 65 712-78a ee ee INSTRUCTIONS ’ This is a programed learning course. Programed learning gives. information in a series of steps riled frames. Each frame gives some information and asks you to make use of it Here is how it works. First, cover the response column at the right with a mask. Read this frame and use the information it gives to fill in the blank. ‘A micrometer is an instrument designed to measure in ‘thousandths of an inch. ‘A micrometer is a good tool for measuring very small e differences in size. vy Move the mask down to uncover the word at the right of the frame, If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. ‘The drawing of a micrometer provides information that will help you fill in the next blanks. opsect 70 8€ s MEASURED ANVIL me IMBLE | spinoce Lis pa © —- can rn tex agent = FRAME a ~ Seven major parts are shown in the drawing, but only the —___and the contact the anvil; spindle object to be measured.nnn nnn ee ‘The next frame calls for a choice. Circle or underline the ap- propriate word. + Of the two parts that contact the object, only the (anvil/ spindle) moves. spindle ‘A program is a series of frames that work like the ones you haye just done: Read the frame. ‘Use the information to fill in the blanks or make a choice. ‘Move the mask down and check the response column. Go on to the next frame. Remember to cover the response column with a mask before you begin each page. Now, go on to Page $ and begin.SECTION 1 AN INTRODUCTION TO CENTRIFUGAL PUMPS Exhibits 1, 2, and 8 are placed in the center of the book 80 that they may be removed easily for reference. Please remove them now s0 that you will have them available when needed. The force of gravity causes a liquid to flow from one elevation to a (higher/lower) elevation. 2 Potential energy is stored energy. Liquid at higher pressure has more potential energy than liquids at lower pressure. Thus, liquid flows from to__ pressure area: Pressure areas 8 Liquid at higher elevations has (more/tess) potential energy than liquid at lower elevations. 4. In the drawings below, indicate the direction of flow with arrows. = 15 PSIG 30 PSIG lower higher lower more| j Within a system, liquids flow because there is a pres- Z gure difference in the system. __ There (is/is not) a pressure difference in this system: is 6. Look at this system. : Since both tanks have the salle pressure, the liquid (flows/does not flow) does net flow U7 A pump is a machine that. adds _< é A tiquid. toa presswte, oF energy 8. A pump moves 6 I uid by mechanical means. al a “PUNE B \ By installing @ pump in the piping between tank A 4 and tank B, liquid oat he Hl6ved from a__(pnaen elevation to a peep beh elevation 49, Look at the drawing. * = => i“ A PUMP B This pump is moving liquid trom a 2 lower pressure area to a! 21. pressure area higher JY19- Pumps are also used to move more liquid in a given ammount of time a a y 50 GALLONS/MINUTE 100 GALLONS/MINUTE * PUMP ‘The amount of liquid moving through the pipe may be increased by installing ® in the line. pufiip 11. In moving a liquid {6m a lower elevation to a higher elevation, the pump adds energy to the liquid at low elevation to provide the needed to lift enerif¥; or pressure it to the higher elevation. (22) Pumps are used to: move liquids from —— elevations to lowers higher elevations; move liquids from pressure areas to Giver dy areas of pressure; higher increase the rate of a liquid. flowCENTRIFUGAL PUMPS 13. Pumping adds energy to 8 liquid. ' The energy of a liquid may be_______by pumping it. vee C : ap When an object is spun around in a circle, it pushes (outward from, inward toward) the center of the circle. 15. One way to increase the energy of a liquid is to whirl the liquid around in circles. When a liquid is spun A¥Gtind, it pushes (inward to the center/outward from the Celiter) of the circle. 18, This outward forse ie called force 4 increased \/ outward from vutward frem the center centrifugal| how a centrifugal pump works. IL This i Liquid first comes in at the center. from the center. It is then forced ¥ 18, Pressure at the pump outlet is greater than pres ~~" at the inlet. Liquid leaving the pump has (more/less) energy than liquid entering the pump. ure 49. ‘The pump part that spins the liquid is called the im- peller. > IMPELLER BLADE EYE (Suction) Liquid flows through the pump inlet and into the & abe) — (centé) 9F the impeller. 20, ‘The impeller whirls the liquid a¥éiund in a circle, The liquid is forced from the center to the — as of the impeller. _ the 2LyThe faster the impeller turns, the liquid moves. 2B- The impeller 1s made up of guide vanes, or blades, The liquid’s path it ireeted by these, 2BeCentrifugal force push eye. fe liquid outward from the It enters the _________ when it leaves the outer edge of the impeller. ie ¥y- When the liquid enters thu casing, its speed (increases/ decreases), outward more outside, or rim faster Valeo, uF blades Sasiiig, oF Rousing téceuses| 25. Look at this impeller. As the speed of the liquid decreases, its pressure As centrifugal force moves the liquid away from the eye, n low-pressure area is formed (in the eye/ at the rim). 27. The low-pressure area in the eye causes liquid to flow 7 into the 28. In the centrifugal pump, liquid is moved by centrifugal force from a_____-pressure area at the eye to a_ ressure area at the pump's dit charge, For frame numbers 29 through 51 look at Exhibit 1, which shows a centrifugal pump with all its parts. 29. Find the impeller. Energy is added to the liquid as it moves through the rotating vanes of the ‘The rotating liquid in » elvoular path. of the impeller move the 81,-The impeller ts housed in the —_ FH Hiawia enters the pubip through the pump inlet, or suction, It comes into the eenter of the impeller through the impeller — When the liquid has moved to the outer rim of the impeller, it enters the casing and moves from the im- Peller to the. nozzle. increases in the eye eye low high impeller vanes casing eve discharge| 4K 34,_ As the liquid leaves the impeller, its velocity decreases. oe Velocity is partially converted to pressure in the casing. ‘The liquid’s velocity decreases, and part of this velocity shows up as an increase in pressure 35. The impeller is rotated by an outside power source (pump driver, or prime mover) connected to the pump Be shaft 36- The rotating shaft ______ the impeller. turns, or rotates 37The parts of the pump fit together closely. A pump is apt to leak where the shaft passes into the on), a casings Find the packing box. Where the shaft passes into the casing, packing pro- vides a seal to reduce a leakage 39. The packing box may be filled with a flexible packing 7 material. ‘This packing material presses around the. shaft 40, A mechanical seal may be used instead of flexible ee EB, packing Where the packing rubs against the shaft, the shaft may — excessively. wear 42, In most centrifugal pumps, part of the shaft is pro- tected by a removable sleeve. Find the shaft sleeve. ‘The shaft sleeve can be _____more easily replaced and less expensively than the whole shaft, 43, Liquid leaks from the high-pressure area (discharge) back into the suction area, Find the wear rings. ‘The space between the eye (suction section) and the casing (discharge section) is fitted with __ wear rings 44, ‘The casing wear ring is stationary, and the impeller wear ring rotates with the 45, The close fit between the stationary wear ring and the rotating wear ring (increases/decreases) the amount decreases of high-pressure liquid leaking back into the inlet stream.x e.)°"_|(\\" 46, Some leakage is necessary for lubrication. 7 Yiquid leaking between the wear rings acts as a lubri- ‘cant and coolant, and keeps the rings from ‘against each other. 47, Worn wear rings are removed and replaced more easily and less ____ than a casing or an impeller. 48, As the rings become worn, clearance between them (inereases /decreases), and more liquid flows from the discharge back into the suctior 49, The wear rings are lubricated and cooled by the being pumped. 60, Without proper lubrication, the wear rings can come “into with each other, get hot, and seize. 51, For this reason, a centrifugal pump is never started unless it is filled with HOW CENTRIFUGAL PUMPS ARE RATED 52, Pumps are rated partly according to their pumping characteristics. For example, a certain pump delivers 100 gallons per minute (GPM). This pump has a rated capacity of —____ GPM. 53, Capacity is usually a factor in_____a pump. 54. Suction and discharge pressure also affect the rating of a pump. For example, a pump produces a discharge pressure of 30 PSIG. It has a rated discharge pressure of ______ PSIG Pumps are rated according to the things you need to know to operate the pump efficiently. Ratings help you select the ________ pump for your operation. 56. For example, you need to pump out a huge tank quickly. If all other conditions are equal, a pump with a capacity of (100 GPM/500 GPM) is preferred. Capacity 82, The capacity of a pump is the amount of liquid that the pump moves in a given length of time. Capacity is usually measured in gallons per minute, abbreviated 10 rubbing expensively increases liquid contact liquid 100 rating 30 best, or right, or proper 500 GPM GPMeO0O00—0—§—§ B-Gallone, pounds, and cubic feet are measures of (amount/time) . ea ‘Minutes, hours, and days are measures of ___ 60. Check the measurements that are measures of both amount and time, _———allons per minute pounds per square inch cubie feet barrels per day 61, -Pump capacity ean be changed by changing the speed of the impeller (RPM, or revolutions per minute) Increasing pump speed also (increases /decreases) pump capacity ‘The pump and its prime mover usually run best within a range of specific speeds. To increase the pump speed, you must also increase the speed of the 63,_Increasing pump capacity by increasing pump RPM's (ix/is not) always practical, 64. In a centrifugal pump, the liquid moves outward from the __________of the impeller toward the rim of the impeller. 65,-Liquid travels from the inlet into the eye of the im- paler. ‘The liquid is forced to move in a circular path by the rotating ________of the impeller. §§, Centrifugal force propels the liquid (inward /outward) through the rotating vanes, 67, Because the impeller is rotating, the liquid in the — impeller is also 68, Circumference is the distance around a circle. he distance across a circle is called the (circumfer- ‘ence/diameter). st amount. time gallons per minute barrels per day increases prime mover is not vanes outward rotating diameter63 Look at the drawing. @ IMPELLER ‘The circumference of impeller is less than the circumference of impeller. 70, Because the shafts of both impellers rotate at the same © ‘speed, they both travel the same number of revolutions in a given length of time. But, liquid traveling around the outer edge of impeller B travels (farther/the same distance). 71, The distance traveled around a circular path in a given © length of time is the tangential velocity. Any point on the rim of impeller the greuter tangential velocity. has 73, As a drop of liquid moves outward from the eye, th circular path it travels continually in size. 78, Because the size of the circular path continually in- creases, the tangential velocity —as the Niguid moves outward from the ey 74, Thus, the larger the diameter of the impeller, the aa the final tangential velocity for a given RPM. ay. After the high-velocity liquid leaves the rim of the im- eller, it enters the casing where its velocity decreases, A large part of the velocity is converted to___ in the casing, 76., Increasing the tangential velocity increases the pres- 7 sue at the pump's discharge. Without changing impellers, tangential velocity is in- creased by (increasing/decreasing) pump speed. fp Without changing pump speed, liquid can be pumped to higher elevations or higher pressures by the size of the impeller. 13 Fump capacity can be increased by increasing pump ———_—, or by using a larger wb farther increases increases greater pressure increasing increasing speed, or RPM; impellyrPressure and Head 1g, Pressure is the force acting on a unit of area (usually ‘one square inch). When force is measured in pounds, pressure may be stated as ________per square inch (PSI) pounds 89 Head is the height of a liquid. 10 FEET ‘The head of this liquid is__ feet. 10 81. The pressure exerted by a head of liquid does not depend on the diameter of the container, HEAD piawerer-- — L__pianeter At atiy point on the bottom of the container, pressure depends only on the ______of liquid above that head, or height point, 82, Pressure gages are set to read 0 at atmospheric pres- sure (14.7 PSIA). ATMOSPHERIC PRESSURE ‘This gage is showing a pressure of. = SPsic, 10 18| 2 86. ‘This pressure (includes/does not include) the pressure 7 of the atmosphere on the liquid. Atmospheric pressure is_______ PSIA (pounds per square inch absolute). j. An instrument that measures atmospheric pressure as ~~ well as tank pressure is measuring absolute pressure. 87. 88, 89, . PSIA = PSIG + __ ‘This is written as pounds per square inch absolut PSIA is an abbreviation for pounds per square inch The pressure gage in frame 82 records only pressure. Since a gage reads atmospheric pressure as 0, it is measuring gage pressure. PSIG is an abbreviation for pounds per square inch PSIA is always a (larger/smaller) number than PSIG. Pressure in this tank is 43 PSIG. Atmospheric pressure is 14.7 PSI. 43 PSIG Absolute pressure in the tank is (more/less) than 43 PSIA. . Absolute pressure is actually ___ sta. 43 PSIG and 57.7 PSIA are (the same amount/ different amounts) of pressure, PSIG = PSIA ~ ___ a A gage reads 30 PSIG, ‘The absolute pressure in the tank is____ PSIA. 14 does not include 147 absolute tank, or liquid gage larger more 43 + 14.7, or 82.7 the same amount. 149 14.7 44.795. Suppose a 10-foot head of water makes a pressure gage read 4.33 PSIG. 100 FEET 4.33 PSIG 43.3 PSIG 10 FEET 1 ‘A 100-foot head of water makes the gage read __ PSIG. 96, By dividing 435 or 45% we can see that, for each foot of water, 0.483 PSIG is exerted. A L-foot head of water exerts PSIG. 97, A 15-foot head of water exerts 6.49 PSIG (15 x 0.433) We can find out how much pressure a column of water exerts by multiplying the — of the water by 0.433. 98, Because oil weighs less than water, a 10-foot head of oil exerts (more/less) pressure than a 10-foot head of water. 99. A 100-foot head of crude oil and 100-foot head of water produce (the same pressure/different pressures) 10). The spoviic sravity of a substance isthe weight of the substance divided Ly the weight of the same volume of water. The specific gravity of water is 1 A liquid with a specific gravity of less than 1 weighs (more/less) ‘than the same volume of water. 101, A 1-foot head of water exerts 0.483 PSIG. 2S A 1-foot head of liquid with a specific gravity of 0.5 exerts_____ PSIG. 102, Water and a liquid with a specific gravity of 0.5 have the same height. But the liquid with the 0.6 specific gravity exerts as much pressure as the water does. Now look at Bxhibit 2, 103. Exhibit 2 is a chart for converting head to pressure, or pressure to 15, 43,8 0.433 head, or height less different pressures less 0.5 x 0.438, or about .216 half, or 1% head104, To read the chart, you must know the —___ of the liquid being pumped. 105. Suppose the head of a liquid is 200 feet and the specific gravity is 0.5. Using a straightedge, find the line between 0.5 on the specific gravity scale and 200 feet on the head scale. ‘The pressure exerted by this liquid is about ___. PSIG. 106) Head can be changed to pressure; pressure can also ~~ be changed to head. By reading a gage at the bottom of a closed tank, you can tell the _____of the liquid im the tank (if you know what the liquid is). 107. Compare these two tanks of liquid, A B ‘There is a greater head of liquid in (tank A/tank B). 108. Look at the pressure gages to fiud which of these tanks has the greater head of liqui A B He on With the same liquid in each tank, (tank A/tank B) has the greater head. 16. specific gravity 43 height, or depth, or head tank A tank BEXHIBIT 1 @ BARRIS LAVHS avis. {I ZION F9avHOSICHIBIT 2 10,000 100,000 50,000 5000 4000 3000 2000 1000: L— 30,000 20,000 10,000 5000 1o—4 PRESSURE, PSIG [=— 3000 2000 1000 500 300 200 100 E—s0 -=— 30 E—20 19 HEAD, FEET OF LIQUID eT a Trt) [rit LIQUID SPECIFIC GRAVITY eS ee109, ‘These tanks contain liquids of the same specific gravity. Ele Lis ‘The pressure reading would be higher on (gage A/ gage B) Heal spre 0.008 Pressure = head x sp. gr. x 0.438 lead may be expressed in terms of — and pressure may be expressed in terms 0 Pressure = 30 PSIG Specific gravity = 0.5 oie 30 Head = 95 0.433 = 0216 = about 139 feet For this liquid to exert 30 PSIG, the column must be about ________ feet high. [xe J ena 10 feet Specific gravity = 0.5 10 x 0.5 x 0.433 5 x 0.433 2.16 PSIG Pressure This liquid exerts (twice as much/half as much) pres- sure as the same head of water does. 118. Suction head is the sum of the pressure changed to head, plus the velocity changed to head, at the inlet to the pump, Discharge head is the sum of the pressure changed to head, plus the velocity changed to head, at the of the pump. 114. Velocity head is normally very small and is not used in pumping calculations. Suction head, then, is the _____at the suc- tion, changed to head. WW gage A pressure head 139 half as much discharge, or outlet pressure116. Discharge head is the pressure at the discharge, changed to. ____ head 116, Gages record the pressure at the pump suction and at the pump discharge. —“ ‘The height of water in the suction tank exerts pressure, which is recorded on the (P./Pa) gage. Be discharge sure, Pa 117, Since the height of water is higher on the side, the (P. Py) gage records the higher pr 118. The pump adds pressure to the liquid as it passes through the pump. ‘The discharge pressure is actually the suction pres- sure plus the that the pump adds. pressure 119. Even without « pump in the line, the liquid rises until it is equal on both sides. POINT 3—+ PoINT 2——-] 1 Without pumping, the liquid rises to point 2 120. To move the liquid from point 2 to point 8, a___ pump may be used. 121. The pump provides the _______ needed to move energy, or pressure the liquid above point 2. 18EXHIBIT 3 S3AuND sett tie| FStriaa4 Ni HSaN?122. The pump raises the liquid from the level of the suction tank into the discharge tank. DISCHARGE ‘SUCTION HEAD HEAD ‘The distance which the pump lifts the liquid is called the —____ head. total 123, The total head is the discharge head (minus/plus) the minus suction head. 46 FEET 124, This pump is lifting water. 23 FEET | Discharge head = , 71} 434 = 46 foot Suction head = 7? 28 feet Tx 048 Total head = 46 ~ 23 = 25 feet ‘Actually, the pump only has to lift the water 28 feet. 125. Total head can be estimated by measuring the height of liquid in the suction and discharge tanks and (adding/subtracting) these heads, subtracting 126. Or, total head can be calculated by reading the pres- sures at the pump suction and discharge and convert- ing these pressure measurements to——_____ head measurements. 19127. TOTAL DISCHARGE HEAD HEAD 128. 129. 130. ‘This drawing shows a suction-lift system. SUCTION LieT If the pump is located above the suction tank, the liquid must be —_______ to the pump. ‘The distance the liquid must be lifted to the pump is called the suction ______. ‘The pump must supply enough energy to raise the liquid a distance equal to the suction lift plus the dis charge head. Suction lift plus discharge head is the —___ head. ‘The prescure acting on the surface of a liquid is trans- mitted throughout the liquid. ‘The gage on top of the suction tank records the pres- sure acting on the______of the liquid. 20 lifted litt total surface131. This pressure is 10 PSIG. The gage at the pump sue- tion reads — PSIG. 15 132, Of the 15 PSIG on the suction gage, 10 PSIG is due to pressure acting on the surface of the liquid. ‘The remaining 5 PSIG is due to the _____of height, or head the liquid in the tank. 133, Look at the drawing. ‘The actual height of the liquid in the suction tank is or about 11.5 feet. 1X 043s But, the suction head is: 15 ; v 7x 0493 about 34 feet. The suction head is greater than the actual height of liquid in the tank because of the —_ — exerted pressure ‘on the surface of the liquid. 134. For liquid to flow into the pump, there must be some Pressure at the pump suction, The pump \(works/eannot work) if absolute suction cannot work pressure in 0 PSIA. 135. In a suction-lift system, suction pressure is provided by (the head of liquid/atmospheric pressure) atmospheric pressure 136. If there is no atmospheric pressure, then there (can/ cannot) be a suction lift. cannot Vapor Pressure 137. Sometimes, when the absolute suction pressure is not high enough, liquids vaporize or evaporate at the pump suetion. To understand why this happens we must understand what makes liquids evaporate, or vaporize a1nn ee 138, Heat is a form of energy (thermal energy). Heating a liquid (increases/decreases) its energy. increases 139. When ice is heated sufficiently, the added energy melts the ice, and the solid ice becomes = water, or liquid 140, If even more heat is added to this water, the liquid water becomes steam, which is a See vapor 141. When the liquid absorbs so much heat that vapors can , escape from the liquid surface, the liquid evaporates. Evaporation occurs when _____ escapes from vapor the surface of a liquid, 142. Vapors need energy to escape the liquid. — in the liquid. heat ‘This energy comes from the 143. Liquids and gases also exert a pressure on everything they touch: Heating a fluid causes it to exert (more/less) pressure. more 144, In a liquid, the vapors exert a pressure before they escape. [LIQUID SURFACE le als Vapor pressure is the pressure of the vapor that is trapped (above/in) the liquid. in 227aa | 145. 146. 17. 148. 149. 150. 151. 153. Vapor pressure causes the liquid to vaporize, or evapo rate, ‘The higher the vapor pressure, the (more/less) rapidly the liquid vaporizes. ‘The vapor pressure of a liquid is measured by finding the pressure that the liquids vapor exerts in a closed container. At room temperature, gasoline has a higher vapor pressure than water. ‘Therefore, the —_ will, will evaporate before the Heating a liquid (increases/decreases) its vapor pres. sure. At higher temperatures, the same liquid--for example, water—has a (higher/lower) vapor pressure, At the same temperature, different liquids have (the same/different) vapor pressures, ‘The higher the vapor pressure of a liyuid, the (more/ less) heat it needs to vaporize, ‘There is also a pressure that is exerted om a liquid's surface by the gases and vapors above the liquid. a | x 4 Liguip ! a — (VAPOR PRESSURE) pA The pressnre on a liquid tends to (eause/prevent) the escape of vapors from the liquid. To keep the liquid at the pump from vaporizing, the absolute suction pressure must be (higher/lower) than the vapor pressure of the liquid at that temperature. Hf the suction head of a pump is 8 feet, and the vapor Pressure of the liquid (changed to equivalent head) is 9 feet, liquid (vaporizes/does not vaporize). 2B more gasoline water inereases higher different less prevent, higher vaporizesSe Net Positive Suction Head (NPSH) 154, Net positive suction head (NPSH) is the absolute suction ‘head minus the vapor pressure head. If suction head is 50 feet and vapor pressure head is 35 feet, NPSH is feet. 16 155. Or, NPSH available is the absolute pressure at the pump suction, changed to head, (plus/minus) the minus vapor pressure of the liquid being pumped, changed to at 5 head 156. NPSH required is tho minimum head needed at the suction to get the liquid into the impeller without vaporizing 157. If NPSH available is equal to NPSH required, the pump may lose suction due to slight variations in pump design. If the NPSH available falls below the NPSH required, the pump loperates/does not operate} properly. does not operate 158. NPSH available must be (more/less) than NPSH re more quired. 159. psi Absolute pressure at pump suction—vapor pressure at pump temp. sp. gt. X 0.433, Specific gravity = 1 5 PSIA, Vapor pressure = Suction pressure = 5 PSIG Absolute suction pressure = 5 + 14.7 = 19.7 PSIA NPSH available = 127 1x04 = about 10.8 fect If the NPSH required is 8 feet, the pump (operates does not operate) properly. operates: 160. NPSH available = 7.8 feet ~ NPSH required = 15 feot « ‘The pump (operates /does not operate) properly. does not operate Friction 161, Liquid fs flowing through this line. A B Pressure must be greater at (A/B). A mu| 162. 163. 165, 166. 167. Li, 169. 170. During flow, pressure is being converted to velocity. As velocity increases during flow, pressure (increases, decreases). ‘The pressure difference between A and B is called the pressure drop. To increase the flow rate, = the pressure drop. Fluid flowing through a pipe creates friction, Friction is a (driving foree/resisting force) for fluid flow. For fluid to flow, the driving force must be (sreater/ less) than the resisting force. sure drop must be greater than the amount Or, the pr ioe As flow rate increases, friction inereases. To overcome this friction, a— e drop is needed pressure ‘The more resistance the pipe offers to flow, the sr the pressure drop needed to move the liquid, —— A small pipe offers (more/less) resistance than a larger pipe. The pressure drop needed is greater in the (large/ small) pipe, When the flow rate of liquid into a pump is increased, friction increases. Increasing the flow rate ————— the available suction pressure, 25 decreases increase resisting force greater friction higher more small decreases,171, A smaller pipe is used on the suction of pump B. Resistance to flow is greater in pump (A/B). 172. The availuble suction pressure is lower at (A/B). 173. This means that NPSH available may be too (high/ low) for the pump to operate properly. 174. With increased resistance to flow at the pump suction, liquid may 175. As the flow rate of the liquid increases, the suction ses with ise the friction iner pressure decr fluid velocity. ses, bee Some pressure ix lost in overcoming —_ 176. An increase in flow rate increases friction and decreases suction pressure. ‘The NPSH available (increases/decreases) . 177. Look at the drawing. 10 FEET 0.5 ‘The gage above the liquid reals ______ PSIG. 178. The height of the liquid is feet, 26 low vaporize friction decreases 30 10inn ee 179. Pressure due to the liquid level is: Pressure = 0.433 ¥ 10 x 06 = 216 PSIG. The gage at the pump suction should read 30 + 2.16, or _—_ PSIG. 92.16 180, The gage at the pump suction actually reads 91.16 PSIG. The gage records a lower pressure beeause some pres- sure has been used to overeome— feietion 181. If there is no NPSH, liqi at the eye vaporizes 182, ‘Absol Rae 0.483% sp. er Or, when the absolute suction pressure increases, the NPSH available ____; increases when the vapor pressure increases, the NPSH available : decreases decreases ass. head are Or, when the suction head increases, the total head ae; : decreases when the discharge head increases, the total head ee increases Horsepower 184. A centrifugal pump is operated by coupling its —_______to the shaft of an outside power source shaft (prime mover, or driver). 185. Horsepower (HP) is a unit used for measuring rate of work. Horsepower necessary to overcome friction and other losses and to move the liquid is provided by the prime mover, or driver ees amount of useful work that a pump delivers is the difference between the pressure the liquid has as it enters the pump and the pressure it has as it the pump, leaves 187. Part of the horsepower put into the pump is used to overcome friction and other losses; part goes to in- crease the pressure of the liquid being pumped. The horsepower applied directly to the liquid is called fluid horsepower 2eee nn 188. The horsepower input is always (more/less) than the more fluid horsepower, or horsepower output. 189, The overall efficiency of a pump is the percentage of the HP input that is transferred to the liquid leaving the pump. ‘A pump that operates at 100 HP input and 75 fluid HP has an overall ______—_of 16%. efficiency 190. The overall efficiency of a pump is found by dividing the HP output of the pump by the HP input, or HP output, HP inpat If the HP input is 6 and the fluid HIP is 4, then the elliciency of the pump is ——_____ 80 191. If two pumps have the same capacity, a low-eificiency pump requires (more/less) horsepower than a high- mare efficiency pump to move the same amount of liquid at the same pressure and rate of flow. 192. The volumetric efficiency of a pump is a measure of its internal leakage. suree of internal leakage is the liquid Mlow- the wear rings from the discharge of the pump. suction The mai ing back betwe into the — 193. Volumetric efficiency is found by dividing the amount of liquid pumped by the amount of liquid pumped plus internal leakage: amount pumped _ A ‘amount pumped + internal leakage In a pump discharging 45 GPM, 5 GPM leaks between the wear rings. The volumetric efliciency is —— 98 194, As the wear rings become worn, the volumetric effi- ciency decreases and the overall efficiency — = decreases Performance Curves For frame nwabers 195 through 221 look at Exhibit 3, which shows a sample set of performance curves for a cen- trifugal pump. 195. In the exhibit there are four curves which show the relationship of capacity to: — hen; total aeeeshap, NPSH Be ee elficiency UP, or horsepower 28 —acl | 196. The graph in the exhibit is set up so that capacity is read at the bottom. Efficiency, horsepower, and total head are read at the (left side right side) of the graph. left side 197, NPSH is read at the __side. right 198. Find the line on the graph for 200 GPM. ‘PSH curve at about — 28 ‘This line crosses the » on the NPSH scale. 199. If the pump is pumping 200 GPM, the minimum NPSIL required for this pump is about 3-8 __ feet. 38 200. Find where the 200 GPM line crosses the efficiency From the efficiency scale on the left, you can read th this pump pumps 200 GPM at about efficiency. 65 201. The 200 GPM line and the HP curve show that the horsepower required for this pump at 200 GPM is about 42 202. Look at the efficiency curve, 84 Maximum efficiency on this curve is about 203, At maximum efficiency, this pump is pumping 400 GPM. 204. Find the other performance values at 400 GPM. ‘The HP required is about —___ ‘The total head is about NPSH is __ feet. 42 205. This pump is more efficient when it is pumping (200/ 300) GPM. 300 206. ‘These pump performance curves were made up for a pump moving water. For more viscous, thicker, liquids like oil, which resist flow more than water does, the curves should be adjusted for (higher/lower) efficiency, head and rate. lower 207. All centrifugal pumps come with a set of performance curves. ‘These curves can be used to find the NPSH, total ee _. efficiency, and for each, head; HP pump at different capacities. 29| 208, 209, au ou. 216, 217. 218. ‘The performance curves can also show some sreneral principles of centrifugal pump performance, For example, look at the relationship hetween the total head curve and the capacity line. When the total head decreases, the pump capacity except at very low capacity. Suppose the discharge valve of a pump is pinched down and the discharge head increases. ‘The total head increases, and the capacity [As the level in the tank falls, the suction head decreases. ‘The total heal Miereases, and the rate of flow Look at the NPSH curve and the capacity line, ‘As the pumping rate increases, the NPSH required Suppose the pump is operating at a point where the NPSHI available and NPSH required are about euual and you ry to Increase the flow rate. ‘The pump will lose . Look at the efficiency curve. ‘The efficiency of a pump is relatively at high and low flow rates. For every pump, there is a capacity where the pump operation is most and therefore must economical. . Look at the HP curve. ‘As the How rate increases, the horsepower required Other factors affecting the performance of 4 centvifu- gal pump are not shown on the chart. For example, a viscous (thick) liquid resists flow and is (ensier’harder) to pump. If the tiquidl being pumped becomes more viseous (for a given total head), the pump capacity is less. ‘The horsepower ed to pump a viseous liquid is Impellers of different sizes can be installed in a pump. An impeller of diameter ean pump to 8 higher head. 30 increases decreases, decreases increases suction, or prime low efficient inereases: harder greater larger| 219, To pump at a higher rate to a higher head requires more horsepower, When the size of the impeller is changed. neither the suction casing nor the size of the impeller eye changed. As the rate increases, the NPSH required increases 220, The speed of turbine-driven pumps can be controlled, Increasing the speed has the same effect as installing an impeller of larger diameter in a motor-driven pump. Decreasing specd has the effect of installing an im- peller of —_____diameter in a motor-driven smaller pump. 221, If the specific gravity of a material being pumped changes, the horsepower required changes. The capacity and head characteristies of a pump do not change when the asd ae eatin specific gravity material being pumped changes, but the horsepower required does change,Section 2 Design and Construction of Centrifugal PumpsSECTION 2 DESIGN AND CONSTRUCTION OF CENTRIFUGAL PUMPS PUMP TYPES 1. Pumps are classified according to impeller design and the number of impellers. ‘A multistage pump has more than impeller. A two-s age pump has. impellers. 8. A two-stage pump has the same effect as joining — single-stage pumps in series. 4, The first pump discharges into the — _— pump. 5, A multistage pump has two or more impellers mounted 6. The head at the discharge of the second impeller is greater than the head at the discharge of the first. ‘The greater the number of impellers, the (higher: lower) the final discharge head is. 7. Since liquids are nearly incompressible, ull the impellers in the pump are designed for about the same capacity. ‘The impellers of « multistage pump are all about the __ size. 8. Pumps are also classified as single-suction or double suetio In a single suction pump, liquid enters from (one side both sides) of the impeller. 9. Ina double-suction pump, liquid enters through (one side/both sides) of the impeller. 10. Since liquid enters at both sides of the impeller, a double-suetion pump is used for (high/low) capueity operations. 11, Double-snetion pumps have lower NPSH requiver When the NPSH available is low, a — pump is probably better suited for the pumping job. a | one two two second shaft higher same one side both sides. high double12, Impellers may be open, partially open, or enclosed. 13, 14. 15, 16. OPEN PARTIALLY OPEN ENCLOSED Tn ull three designs, the is open. of the impeller On an open impeller, the sides of the vanes (are/are nut) covered, ‘More liquid leaves the rim of the (open/partially open/ enclosed) impeller. Plow is least controlled in the impeller. ‘The ___________ impeller is the least likely to be- come clogged. Yropeller Pumps 17. A propeller pump works very much like an impeller pump. Instead of an impeller, the ________ whips the liquid passing through it to high speed. 33 eye are not enclosed open open propeller18. 19. 20. 21. 22. eat 24, In this way the propeller adds to the energy, or pressure liquid. ‘There are differences between impellers and propellers. PROPELLER i as yr IMPELLER For example, liquid leaves the (propeller/impeller) in propeller the same direction as it entered. Liquid leaves the (impeller/propeller) at right angles impeller to the way it entered. Liquid enters the impeller only through the eye in the (impeller/propeller) pump. impeller In the propeller pump, liquid enters the pump (through the eye/through the blades) through the blades ‘The area through which liquid enters the pump is smaller in the (impeller/propeller) pump. impeller ‘Therefore, the ________ pump ean handle larger propeller ‘capacities.Turbine Pumps 25. The best features of the impeller pump and the pro- peller pump are combined in the turbine pump. \ G 7 PROPELLER TURBINE IMPELLER The turbine pump is a mixture of the —___ propeller pump and the _____ pump. impeller 26. The flow of liquid through a turbine pump is like the flow through a centrifugal pump. like the flow through a propeller pump. halfway between the flow through a centrifugal pump and the flow through a propeller pump. halfway between 27. The turbine pump, like a propeller or an impeller pump, can be single- or multistage. ‘The multistage pump is used when you need a higher discharge (capacity /head). head Now 1uin the page, 35 — turn the book over, and go 628. Name the following pump designs. 29. Which of these purnps are not centrifugal pumps? (4/B/C/D/B) 36 A. single-suction B. double-suction C. multistage D. propeller pump E. turbine pump Dand EVertical and Horizontal Pumps 30. This pump must move liquid up out of a water well, or 31. 82, 33, pit, or any other source of liquid. There (isis no) suction head available. The pressure needed to move liqu tion must come from d into the pump sue- pressure. If the well is deep, atmospheric pressure (can/eannot) push the liquid all the way up into the pump suction. One way to increase the NPSH available is to (in- crease/decrease) the distance liquid has to move up to get to the pump suction. Here the pump has been placed in the well liquid, This gives the pump (more/less) NPSH available, aT is no atmospheric cannot decrease more| 85. Since the well is deep and narrow, the pump must he put in it (horizontally /vertically). vertically 86. To provide better NPSH, the pump is installed (hori- zontaily/vertically) and (above/below) the level of the vertically; below liquid. Because of the large amount of discharge head needed to lift liquid from a well, the turbine vertieal pump is generally (single-/multi-) stage. multi- Pumps Operating in Series or in Parallel 37, When the discharge of one pump is fed into the suction of another pump, the two pumps operate in series, Pumps (A/B) are operating in series A 38. When the pumps are connected in series, the second bump takes liquid from the first and increases the discharge head. Putting pumps in series inereases the discharge a of the system. head 89. The second pump cannot discharge more liquid than it receives from the first Thus, pumps in series (should should not) have about should the same capacities, 38| 40. Pumps that discharge into the same line are operating in parallel. = = A a (Qa —== =~» => = B Pumps af are operating in parallel, RB 41. Operating pumps in parallel of the system, the capacity inereases. 42, With pumps operating in parallel, the total amount discharged equals the amount discharged from the first pump —___ the amount discharged from the second, plus, or + 43. Since liquid discharged from the first pump does not enter the second, the discharge head produced by the two together is (greater than/the same as) the head the same as Produced by each one separately. 44, Pumps operated in parallel should have about the total head characteristics, same 46. Pumps are operated in parallel to increase —______, capacity 46. Pumps are operated in series to increase — head 47. Two pumps with similar capacity and head charac- teristics at a given speed may be connected in either or. parallel; series 48. To increase capacity, connect pumps in, parallel 49. To increase head, connect pumps in - series 39| Regulating Pump Discharge 50, The amount of liquid discharged from a pump can be changed in a variety of ways. VALVE A closed. discharge can be open or valve 51. By partially closing the valve, more pressure needed to get liquid out of the pump. 52. Partially closing the valve (increases/decreases) the decreases discharge volume. 53. Here is another way to regulate the discharge volume. BYPASS LINE A ~ line is connected to the discharge line. bypass 4064, 55. 56. 57. 58, | An open in the bypass line allows liquid valve to flow through the bypass line as well as through the discharge line. When this valve is opened, some of the liquid from the flows into the bypass. discharge ‘Then it flows back to the pump's ae suction This means that (more/less) liquid is actually dis- less charged from the pump into the discharge line. Being able to adjust the pump discharge is impor- tant when the pump may be moved and used for a _— operation. different MECHANICAL DETAILS Packing Box 59. 60. ‘The rotating shaft of a centrifugal pump extends out through the casing so that the impeller may be coupled to the — eG prime mover, or driver ‘The drawing shows a typical packing box. PACKING CASING GLAND at SHAFT SHAFT | f SLEEVE F PACKING RINGS | PACKING GLAND NUT ‘The packing is formed around the ___to mini- shatt 61. The packing box surrounds the shaft where it en the 2 mize leakage of liquid from the pump. casing, or housing 4163. 64, 65. 66. 67. 68. 69. 70. i. 2. 73. 14. Normally, the packing is formed into rings which con- form to the shape of the ‘ion material which is non- Packing must be a low- abrasive. Abrasive material damages the —_ ‘To minimize leakage along the shaft, the packing is _against the shaft, If the shaft is permitted to rub directly against the packing, the section of shaft in the packing box To keep from replacing the whole shaft due to packing wear, a is used to cover the section of shaft inside the packing box. Packing must be a material that is uot attacked and weakened by the liquid being pumped, Packing which is weakened by the liquid permits some of the liquid being pumped to_____ to the atmos- phere Packing is chosen for the _— being pumped and its temperature. A packing gland at the (inner/outer) end of the pack- ing box holds the packing in place, ‘The pressure necessary to compress the ‘against the shaft sleeve and control leakage is supplied by the packing gland nats. A small amount of leakage between the packing and the shaft is necessary for ‘The amount of _______is usually determined by company practices. ‘The packing gland holds the in place and controls the amount of If the nut is tightened too much, the rubbing sur- faces may not be sufficiently — —, and there may be excessive wear on the and the Since Insufficient lubrication may cause overheating, Packing gland nuts must be_______ to allow the amount of leakage specified by company practices. 42 ee shaft shaft pressed, or tightened wears sleeve escape, or leak liquid outer packing lubrication leakage packing leakage lubricated shaft, or sleeve packing adjustedLantern Rings %. 6. 7. 78. 79. 80. Look at the drawing. LUBRICATING OR SEAL OIL. LANTERN RING The lantern ring is a metal cage about the size of a packing ring that fits around the _______ sleeve inside the packing box. The lantern ring provides a space between the packing rings near the center of the packing box which ean be supplied with lubricating or seal____. ‘The lantern.ring arrangement shown differs from ring Packing in the way itis—__ The lubricating fluid can be liquid from the pump or liquid from outside the pump. When a corrosive or erosive liquid is being pumped, lantern-ring. lubrication from (another source/the Pump) is used, Lubricating fluid is pumped into the packing box under Pressure higher than the pressure inside the casing. ‘This pressure keeps the liquid in the pump from enter- ing the Lantern-riig packing is also used in a pump operating at less than atmospheric pressure. When the pump ‘operates under vacuum, air may be pulled into it during operation, To keep air out, the pressure of the sealing-lubrivating fluid must be (above/below) the pressure of the atmos- phere, 43 shaft oil lubrieated ‘another source packing box aboveSt In a pump operating under vacuum, the lubricating Niquid is usually the liquid being pumped, if that liquid is noncorrusive. Te ls pumped into the packing box at a pressure above —— pressure, 82. Pump A is pumping a light oil, Pump 1 is pumping acid. (Pump A/Pump B) is fitted with a lantern ving, 8S. Liquid leaking from the pump is a hazard, especia if it vaporizes at a low temperature. Leakage can also be expensive, Therefore, pump packing should be —tre quently to make sure it is operating properly. Mechanical Seals 84. Mechanical seals are more widely used than shaft packing because they require less maintenance and hold leakage to SPRING SEAL OIL STATIONARY HOLDER OUTLET SEAL RING (Corben) COMPRESSION RING SEAL OIL SEAL ROTATING SEAL RING INLET FLANGE (Hord.Surface Metal) ‘The other element rotates with the —___ : 85, The stationary seal ring is usually made of 85. ‘The rotating seal ring is faced with special metal where it comes in contact with the é seal ring, 44 atmospheric Pump B checked shaft carbon stationary87. The spring holder is held in place on the shaft by a set serew. The compression ring and the rotating seal ring are free to move along the 88. The springs push against the compression ring and compress the flexible O-ring against the shaft and the rotating seal members, to prevent pe at this point. 89. The O-ring is made of rubber or some other flexible material, depending on the liquid being pumped. It makes @ tight ________ between the rotating elements and the shaft, 90. Heat is generated between the stationary and rotating faces. Oil is circulated in the packing box to cool and the seal 91. The lubricant also helps to keep corrosive or material out of the seal. 92. A single seal has one set of sealing faces. ‘This seat has two sets of sealing faces. PUMP CASING COMPRESSION SEAL OIL. RINGS OUTLET O-RING LJ SEAL OIL ROTATING INLET SEAL RINGS STATIONARY STUFFING SEAL RING BOX FLANGE Minis aca, i ee shaft leakage seal lubricate erosive doubleImpeller Thrust 98. During operation, pressure in the discharge portion of the casing is greater than the pressure in the suction portion, SUCTION PH fi mms piscHarce PRESSURE PRESSURE —>) | ene ‘The discharge pressure acts on the right side of the impeller, exerting a force to the (left/right) 94. The discharge pressure acting on the right side of the impeller exerts a force to the left. Th ox n pressure acting on the left side of the impeller force to the 95. Since the suction pressure is less than the discharge Pressure, the total force acting to the left is than the force acting to the right. 96. This imbalance of forces creates thrust along the shatt ‘To overcome this thrust and hold the ——___ in its proper position, a thrust bearing is used 97. Both sides of the impeller maintain close clearance with the casing. HOLE: THRUST BEARING COLLAR WEAR RING WEAR RING Wear rings at the eye minimize leakage from the back to the suction, 46 left right greater impeller dischargeccc 98, A collar at the back of the impeller has the same inside dimension as the suction eye. Wear rings between the collar and the casing minimize into the e leakage 99. Any leakage into the collar flows back into the suction through a hole in the impeller. This hole equalizes pressure between the left and right sides of the impeller 100. Since the on both sides of the impeller Pressure is about equal, there is almost no thrust. 101. In multistage pumps, several methods can be used to minimize thrust, Some pumps are constructed so that some of the im- pellers face one way on the shaft and the others face the other way. One set of impellers offsets the of the others. thrust Balancing Drum 102. When all impellers are installed in the same direction on the shaft, thrust may be reduced with a balancing drum, BALANCING DRUM ATTACHED TO SHAFT i aL - baie 3 BALANCE LINE TO SUCTION The thrust ereated by each impeller acts to the (left/ right), lett a7| 108. The total impeller thrust is the sum of the thrust of all the impellers, The pressure acting on the left side of the balancing drum is the pump pressure, discharge 104. The space on the right side of the balancing drum is open to the suction, This space is at_______ pressure. suction 105. The pressure difference across the balancing drum creates a force acting to the right, The drum is sized so that this force balances the impeller thrust 106. The small clearance between the balancing drum and the cusing minimizes leakage from the discharge back to the suetion, As wear increases, this clearance increases, and the volumetric efficieney of the pump —__ decreases, ALIGNMENT AND VIBRATION 107. ‘The pump and prime mover are joined by couplings, ‘The pump and __ ——- must be prime mover, or driver properly aligned. 108. If the pump is handling hot liquid, then the pump should be heated to near operating te temperature check alignment. 109. Improper alignment of the pump and prime mover puta a strain on the shaft and may wear or break the shaft or couplings. Improper alignment may also cause bearings and seals to excessively or fail, wear 110. Improper alignment may also damage wear rin; Permit the impeller to____ against other parts. rub 211. Any improperly balanced rotating assembly may cause excessive vibration, Misalignment of pump and prime mover or partially. blocked impellers may also cause ie vibration 112. Cavitation in the impeller is the continual forming and collapsing of vapor bubbles in the liquid. Cavitation may cause the pump to vibrate 48