PUMP USER GUIDE

USER GUIDE TO PHS SELF PRIMING PUMPS

 Disclaimer

Disclaimer
This information is not intended as a reference source for the design of pumping
or associated systems, but to promote interest and further investigation by
individuals and companies into the provision of reliable pumping equipment. Due
to the complexities of pumping systems in various industries it is difficult to
predict the applications encountered.

PHS makes no representations or warranties with respect to the completeness or

accuracy of the data or information contained herein, and assumes no liability for
losses or damages resulting from the use or application of the data or information
contained herein.

This information has been compiled by PHS from various reference sources, and
with the assistance of the Sykes Group of companies. Some elements of this
user guide are under the protection of copyright laws, and as such can not be
copied without the express permission of PHS and the Sykes group.
 Pump Selection

To ensure the correct pump is selected for your application the following detail
are required. If you can not supply some of the information, just ask for help
from PUMP HIRE SERVICES, we can assist in identifying your requirements.
See pump terms for more info. These details required for all applications

• Flowrate required
• Static suction head
• Suction pipe inside diameter
• Footvalve or open pipe
• Suction pipe length & material
• Static discharge head
• Discharge pipe inside diameter
• Discharge pipe length & material
• Discharge pressure required
• Temperature
• Details of solids
• Height above sea level
 Pump Selection

• Details of application ie:

- mine pit dewatering, dam transfer, fire fighting???
Full liquid description
Specific gravity
Viscosity
pH value
• Other details or data sheet

Variations of pump drives can be:

• Electric? - voltage/phase/Hz
• Electric? - hazardous location?
• Diesel? – preferences
• Petrol? – preferences
• Hydraulic? - system available
 Pump Selection
TERMS USED

HEAD
The term used to describe the pressure a pump produces. Centrifugal pump curves
show 'pressure' as head, which is the equivalent height of water with S.G. = 1.

STATIC HEAD
The vertical height difference from surface of water source to centreline of impeller is
termed as static suction head or suction lift ('suction lift' can also mean total suction
head). The vertical height difference from centreline of impeller to discharge point is
termed as discharge static head. The vertical height difference from surface of water
source to discharge point is termed as total static head.
TOTAL HEAD / TOTAL DYNAMIC HEAD
Total height difference (total static head) plus friction losses & 'demand' pressure from
nozzles etc. ie: Total Suction Head plus Total Discharge Head = Total Dynamic Head.
NPSH
Nett positive suction head - related to how much suction lift a pump can achieve by
creating a partial vacuum. Atmospheric pressure then pushes liquid into pump. A
method of calculating if the pump will work or not.
S.G.
Specific gravity. weight of liquid in comparison to water at approx 20 deg c (SG = 1).

PUMP SPEED
RPM of the pump shaft. Normally the same as engine/drive speed unles a gearbox or
similar is used

VAPOUR PRESSURE
If the vapour pressure of a liquid is greater than the surrounding air pressure, the liquid
will boil.

VISCOSITY
A measure of a liquid's resistance to flow. ie: how thick it is. The viscosity determines the
type of pump used, the speed it can run at, and with gear pumps, the internal clearances
required.

FRICTION LOSS
The amount of pressure / head required to 'force' liquid through pipe and fittings.
 HELPFUL HINTS

Pump pressure is called in HEAD and

is most commonly measured in:
• Metres (m)
• Kilopascals (kpa)
• Bar
• Pounds per square inch (psi)
Approximate equations are:
• 1m = 10kpa • Vacuum pressure is measured in
• 10m = 100kpa negative eg. -40 kpa
• 100m = 1000kpa • When calculating total head from
pressure and vacuum gauges, add the
to numbers together. Eg Pressure
• 10m = 1 bar
gauge reads 100 kpa and vacuum
reads -40 kpa, the total pressure is
• 1 PSI = 6.89 kpa 140kpa

These are approximate figures and are rules of thumb only

 Section 1 - Strainer

Section 4 - Centrifugal Pump

Section 3 - Self Priming

Section 2 - Suction Hose

Section 5 - Discharge Pipe

Section 6 – Pump Dynamic System

Section 1 - Strainer Section 7 – Troubleshooting

 Section 1 - Strainer
Area of suction hose

Recommended Strainer Features
• Corrosion protection
• Robust construction
• Generous flow path to minimize
intake restrictions
– Total open area of strainer =
4 x Area of suction hose

• Match pump solid handling

Capability (∅d)

∅d
Open area of strainer
 Section 1 - Strainer

 Vortex Motion Vortices created at pump suction

• Reason’s to avoid
Vortices
– Air drawn into intake
– Creates ‘Air Gulping’
– Loss of Prime
– Cavitation Vortex
– Vibrations
– Loss of efficiency
 Section 1 - Strainer

 Prevention of Vortices & Clogging D

• Position of strainer
– Suction hose diameter (D)
– Minimum Depth = 3 x D
– Minimum Height off bottom = 2 x D

3D
2D
 Section 2 – Suction Hose

Recommendations
• Locate pump as close to water as possible
• Minimize static suction lift (Hs)
• Minimize suction hose friction losses
– Short and straight as possible
– Diameter (D) equal or one size larger
than pump inlet flange size
– Minimize restrictions
• Rises continuously to avoid air
entrapment Hs
• Free from air leaks
• When pump inlet diameter is less D
than D, use eccentric reducer Eccentric reducer
• Non collapsible type of hose
 Section 2 – Suction Hose

Recommended
 Section 2 – Suction Hose

 Not Recommended Trapped Air (Undulating Suction)

• Excessive static lift (Hs)

• Diameter (D) < pump inlet
diameter
• Excessive length
• Bends,elbows & restrictions
• Concentric reducer Hs
• Trapped air conditions
D
– Falling Suction
– Undulating suction Concentric reducer
– Concentric reducer
• Elbow directly to pump inlet
 Section 2 – Suction Hose

 Not Recommended
• Pump is close to water, however… Trapped Air (Undulating Suction)
 Section 3 – Self Priming

 Concept of Self Priming  Pump does not suck

• Atmospheric Pressure (A)=101.3kPa
• NRV seals pump discharge from atmospheric pressure
• Priming system evacuates pressure
• Creates Vacuum Pressure (V)
• The pressure in the suction hose
is less than the atmospheric
pressure causing a pressure A
V
differential
A
V A
A
V

A A
NRV

Liquid
 Section 3 – Self Priming

Reduction in Suction Lift (m)

 Other Conditions
Affecting Priming 10
8
6
• Suction Lift loss 4
2
– If the fluid temperature 0
is increased, the suction 15 20 30 40 60 80 100
lift will be reduced Temperature (C°)
– If the altitude is
increased, the suction
lift will be reduced Reduction in Suction Lift (m)

• For explanation of 10
suction lift please refer 8
6
to Section 6 – Dynamic 4
System 2
0
0 500 1000 1500 2000 3000 3500
Altitude (m)
 Section 3 – Self Priming

 Compressor Priming (CP) Venturi system C

• Compressed air (C)

– Through venturi system
– Venturi effect creates a
vacuum in Priming Tee
and suction system Priming Tee

• Priming Tee fills with fluid

and the pump is primed
 Section 3 – Self Priming

Venturi
Compressor Hose System

Compressor

Priming
Tee
 Section 4 – Centrifugal Pump

Pumping Concepts
• Impeller transfers mechanical energy to the liquid
• Impeller throws the water outwards with sufficient
force to generate a head (Pressure)
• Pumping at the best efficiency Impeller
point (BEP) in any application is
the ideal combination of head &
flow (Velocity)
• When pump operates at BEP,
balanced radial forces act on the
impeller

Radial Force
 Section 4 – Centrifugal Pump

Operating at BEP – Why is it important !

• Uniform Pressures act on the impeller (balanced radial
forces) when the pump is operating at BEP
• Impeller & volute are operating at their design
conditions
• Most reliable and economical operation
• Lowest pump running cost
• Minimises
– Noise
– Vibration
– Temperature
– Bearing Loads
• Maximises pump life…
 Section 4 – Centrifugal Pump

 Running outside Recommended Operating Range

• Dramatically reduced pump life
• Unbalanced radial forces are generated that will
attempt to bend or deflect the shaft
• Shaft deflection can cause mechanical seal leakage
• Flow becomes turbulent
• Damage to impeller, volute, wear plates and shaft
• Vibration & Noise
• Low efficiency
• Temperature rise
• Recirculation & Cavitation
• High bearing loads
• Expensive unplanned maintenance issues
 Section 4 – Centrifugal Pump

 Consequence of running left of ROR

• Low flow rates Low pressure 60°
– Low pressure at 60° from
cutwater
– Net radial thrust at 240°
from cutwater
• Potential issues
– Shaft deflection
– Contact of impeller on front
wear plate
– Suction recirculation
initiates cavitation Wear plate Cutwater
contact
Suction
Net radial thrust 240° Recirculation
 Section 4 – Centrifugal Pump

 Consequence of running right of ROR

Net Radial thrust 60°
• High flow rates
– Low pressure at 240° from Wear plate
cutwater contact
– Net radial thrust at 60° from
cutwater
• Potential Issues
– Shaft deflection
– Contact of impeller on front
wear plate
– Discharge recirculation
initiates cavitation Cutwater
– Increase NPSHR
Discharge
Low pressure 240° Recirculation
 Section 4 – Centrifugal Pump

 Cavitation
• Will obstruct the pump, impair performance & damage pump
components – THE PUMP HAS A HEART ATTACK
• Lower pressures in the impeller eye are caused by friction losses
and variations in velocity of the liquid as it enters the impeller
• If pressure within the pump falls below the vapour pressure of the
liquid, vaporization or cavitation will occur
• Classical Cavitation
– When the liquid pressure is reduced to its vapour pressure
(NPSHA = NPSHR)
– The bubbles are formed and swept out along the vanes
– When the liquid pressure exceeds its vapour pressure it will cause
the bubbles to implode
 Section 4 – Centrifugal Pump

Discharge
 Cavitation Recirculation
(right of ROR)
• Suction Recirculation
– Eddy currents form in the eye of
the impeller
– The pressure falls below the
liquid vapour pressure
– Initiates cavitation
• Discharge Recirculation
– Reversal of flow at the discharge
tips
– Produce vortices through the Suction
impeller vanes Recirculation
– Initiates cavitation (left of ROR)
 Section 4 – Centrifugal Pump

 Cavitation
• Resulting effects include:
– Pitting of material surfaces due to the continual
hammering action of the collapsing vapour cavities
– Crackling noise, like gravel going through the pump
• Severe cavitation usually results in excessive
noise, vibration and damage to the pump
• Mild cavitation may produce nothing more than
a small reduction in pump efficiency and
moderate wear of pump components
 Section 4 – Centrifugal Pump

 Cavitation Damage
Results of mild Discharge
Classical cavitation
Discharge Recirculation Damage
Recirculation Pitting

Suction
Recirculation
 Section 5 – Discharge Pipe

Recommendations
• Hose diameter should be at least the same diameter as
the pump
– 8” hose = 8” pump
• Correctly rated discharge hoses and fittings
• Suitable non return valve, refer following slides
• Avoid excessive bends, elbows & restrictions
• Free from air leaks
• Good discharge piping control valve & pressure gauge
• Suitably rated pressure bleed valve
 Section 5 – Discharge Pipe

 Examples of Suitable Non Return Valves

Flapper Style
Non Return Valve
Section 5 – Discharge Pipe

Ball Style NRV

Ball Seat
 Section 5 – Discharge Pipe

 Non Return Valves

• Recommended Features
– Correctly rated for pump discharge pressure
– Corrosive resistant seating arrangement
– Minimal flow restriction at full capacity
– Access for maintenance
– Holds prime
– Prevents reverse rotation of impeller
 Section 5 – Discharge Pipe

 Example of suitable Control Valve

• Butterfly Valve
– Correctly rated for pump
discharge pressure
– Fine Adjustment
– Between flange
mounting
– Designed for throttling
conditions
– Resilient Seating
 Section 6 – Dynamic System

 Dynamic Head Hv
Conditions Hf
• Static Suction Lift (Hs)
• Static Discharge Head (Hd)
• Total Static Head (Hst)
• Friction Head (Hf)* Ht
Hst Hd
• Velocity Head (Hv)*
– Usually negligible
• Total Dynamic Head (Ht)
* Information to determine Hf Hs
and Hv can be sourced from
the Australian Pipe Friction
Handbook
 Section 6 – Dynamic System

 How to read a Performance Curve

• Required Pump Duty

– 100L/s at 95m
• Draw a line up from Flow at
100L/s (point A)
• Draw a line across from
Total Head at 95m (point B)
B
• Point C determines the
pump speed and power C
required at this duty
• Pump speed = 1400rpm
• Power required = 150kW

A
 Section 6 – Dynamic System

 How to read a Performance Curve

• To obtain the suction lift,

draw a line across from the
intersection at point D
• Maximum Dynamic Suction
Lift = 6m (point E)
• NPSHR = 4m (point F)
B
C

E D
F
A
 Section 6 – Dynamic System

 Typical control valve setup

Suction Vacuum Pump Operating Chart Discharge Pressure Gauge
Gauge

Butterfly Control Valve

 Section 6 – Dynamic system

XH100 OPERATING CHART

THIS PUMP MUST BE OPERATED BETWEEN THE GIVEN TOTAL PRESSURE READINGS AT
THE NOMINATED PUMP SPEEDS
NOTES:
TOTAL PRESSURE READING IS THE SUM OF THE DISCHARGE GAUGE READING AND THE
SUCTION VACUUM GAUGE READING

EG If pressure gauge reads 1150 kpa and vacuum gauge reads -26 kpa, then the total is 1176 kpa

PUMP MAXIMUM BEST MINIMUM

SPEED RPM PRESSURE KPA PRESSURE KPA PRESSURE KPA
1400 1029 902 823
1500 1176 1034 956
1600 1352 1176 1078
1700 1529 1343 1196
1800 1715 1489 1323

FAILURE TO OPERATE THE PUMP WITHIN THE PRESSURE RANGE FOR

THE NOMINATED RPM MAY RESULTS IN PUMP FAILURE
 Section 6 – Dynamic System

 Pump Suction Lift

• Maximum Allowable Dynamic Suction Lift
SL(max) = Atmospheric pressure – Vapour Pressure – NPSHR
• Water at 15°C
– One standard atmosphere = 101.3kPa (10.3m)
– Vapour Pressure = 1.704kPa (0.2m)
• Therefore, an ideal pump with zero NPSHR will give you a
Maximum suction lift of 10.1m
• For general pumping applications it is common to assume
atmospheric pressure to be 10m
– SL(max) = 10m – NPSHR
 Section 7 - Troubleshooting

• Pump Does Not Prime

• Not Enough Liquid

• Not Enough Pressure

• Pump Ceases to Deliver Liquid After a Time

• Pump Takes Excessive Power

• Pump Vibrating or Overheating

• Pump Leaking at Mechanical Seal Housing

• Pump Bearings Have Short Life

 Section 7 - Troubleshooting

• Pump Does Not Prime

– Suction lift too great
– Inlet of suction pipe insufficiently submerged
– Suction inlet or strainer blocked
– Excessive amount of air or gas in liquid
– Viscosity and / or S.G. of liquid being pumped too high
– Suction line not air tight
– Suction hose collapsed
– Non return valve ball not seating
– Mechanical seal / Packing drawing air into pump
– Pump’s priming system blocked or badly worn
– Separation tank cover blocked
– Pump’s priming hose leaking air
– Pump’s priming system not delivering sufficient air
– Pump’s priming system belt drive faulty
 Section 7 - Troubleshooting

• Not Enough Liquid

– Incorrect engine speed
– Discharge head too high
– Suction lift too great
– Suction inlet or strainer blocked
– Suction line not air tight
– Suction hose collapsed
– Mechanical seal drawing air into pump
– Obstruction in pump casing / impeller
– Impeller excessively worn
– Delivery hose punctured or blocked
– Pump not primed
– Air pockets in suction line
– Inlet of suction pipe insufficiently submerged
– Excessive amount of air or gas in liquid
 Section 7 - Troubleshooting

• Not Enough Pressure

– Speed too low
– Excessive amount of air or gas in liquid
– Incorrect direction of rotation
– Viscosity and / or S.G. of liquid being pumped too
high
– Impeller Damaged
– Impeller out of balance
 Section 7 - Troubleshooting

• Pump Ceases to Deliver Liquid After a Time

– Suction lift too great
– Insufficient water at suction inlet
– Suction inlet or strainer blocked
– Suction hose collapsed
– Excessive air leak in suction line
– Mechanical seal / Packing drawing air into pump
– Obstruction in pump casing / impeller
– Delivery hose punctured or blocked
 Section 7 - Troubleshooting

• Pump Takes Excessive Power

– Engine speed too high
– Obstruction between impeller and wear plates
– Viscosity and / or SG of liquid being pumped too
high
– Incorrect direction of rotation
– Misalignment
– Shaft bent
 Section 7 - Troubleshooting

• Pump Vibrating or Overheating

– Engine speed too high
– Obstruction in pump casing / impeller
– Impeller damaged
– Cavitation due to excessive suction lift
– Suction or discharge re-circulation of fluid within the pump
– Impeller out of balance
– Shaft bent
– Shaft running of centre because of worn bearings or misalignment
– Misalignment
– Bearings worn
– Pump not primed
– Pump or suction pipe not completely filled with water
– Inlet of suction pipe insufficiently submerged
– Excessive thrust caused by mechanical failure inside pump
 Section 7 - Troubleshooting

• Pump Vibrating or Overheating

– Lack of bearing lubrication
– Incorrect assembly of stacked bearings, i.e.
angular contact ball bearings fitted front-to-front
instead of back-to-back
– Dirt in bearings
– Rusting of bearings from water in housing
 Section 7 - Troubleshooting

• Pump Leaking at Mechanical Seal Housing

– Mechanical seal damaged or worn
 Section 7 - Troubleshooting

• Pump Bearings have Short Life

– Obstruction in pump casing / impeller
– Impeller out of balance
– Shaft bent
– Shaft running of centre because of worn bearings or
misalignment
– Misalignment
– Bearings worn
– Excessive thrust caused by mechanical failure inside pump
– Lack of bearing lubrication
– Incorrect assembly of stacked bearings, i.e. angular contact
ball bearings fitted front-to-front instead of back-to-back
– Dirt in bearings
– Rusting of bearings from water in housing
 ENQUIRIES

REMEMBER THE FOLLOWING WHEN MAKING ENQUIRIES. PLEASE

FEEL FREE TO CONTACT YOUR NEAREST PHS BRANCH SHOULD
YOU REQUIRE FURTHER ASSISTANCE.

• Specifics/Details:
• Suction lift M (vertical distance) =
• Suction hose M length =
• Delivery head M (vertical distance) =
• Delivery hose M length =
• Type of delivery hose/pipe req =
• Liquid to be pumped =
• Liquid ph =
• Flow rate required =
• Pressure required at given flow rate =
• DATE REQUIRED:
• TIME REQUIRED:
 CONTACT

• Portsmith cairns@paramounthire.com.au 07 4052 4488 07 4052 4400

• North Cairns northcairns@paramounthire.com.au 07 4053 4488 07 40531732
• Townsville townsville@paramounthire.com.au 07 4775 2600 07 4779 3933
• Mackay mackay@paramounthire.com.au 07 4952 8000 07 4952 8099
• Gladstone gladstone@paramounthire.com.au 07 4970 3444 07 4972 8444
• QNI qni@paramounthire.com.au 07 4720 6359 07 4751 1359
www.pumphire.com.au www.paramounthire.com.au

PHS WOULD LIKE TO THANK THE CONTINUED SUPPORT OF THE SYKES GROUP

www.sykesgroup.com