What is a pump?

“A pump is a device which helps fluid to move form one to another by mechanical action”

10 m3

Distance (m) Flow rate m3/h

Most Important Characteristic of a Pump

• Flow Rate (m3/h)

• How much water a pump can move in one hour

• Head (m)
• How far a pump can through specific amount of water
The centrifugal pump
Casing

• In 1689 the physicist Denis Papin invented

the centrifugal pump

• Mostly used around the world

• Construction is fairly inexpensive, robust

and simple

Impeller
Types of Centrifugal pump

• Radial flow pumps

• Mixed flow pumps

• Axial flow pumps

Pump Curves

• Flow and Head curve

Pump Curves

• Efficiency, the η-curve

𝑃𝑃4 𝜌𝜌 . 𝑔𝑔 . 𝑄𝑄 . 𝐻𝐻
ɳp= =
𝑃𝑃2 𝑃𝑃2 . 3600
Pump Curves

• Power consumption
Pump Curves

• NPSH-curve (Net Positive Suction Head)

“Cavitation occurs in a pump when the

pressure on the suction side of the impeller
falls below vapor pressure of the liquid.”

-More details will be in Pump Performance

Complete Pump Curves
Most common end-suction and in-line pump
types
OPERATION & ROUTINE MAINTENANCE

PUMP TYPE: GRUNDFOS NK

SYMBOLS USED IN THIS DOCUMENT

Warning
If these safety instructions are not observed, it
may result in personal injury!

Warning
The surface of the product may cause burns or
personal injury!

 If these safety instructions are not observed, it

may result in malfunction or damage to the
equipment!
 Notes or instructions that make the job easier
and ensure safe operation.
 GENERAL DESCRIPTION

Pump type and model are stated on the pump nameplate.

The pumps are fitted with Grundfos motors, type MG or MMG till 22Kw.

If the pump is fitted with a motor make other than Grundfos, please note that
the motor data may differ from the data stated in this booklet.

This may also influence the performance of the pump.

IDENTIFICATION - NAME PLATE
TYPE KEY
Technical Data
 PUMPED LIQUIDS
Clean, thin, non-explosive liquids without solid particles or fibres.

The liquid must not attack the pump materials chemically.

When pumping liquids with a density and/or viscosity higher than that of water,
motors with correspondingly higher outputs must be used, if required.

O-rings and the shaft seal chosen must be suitable for the liquid to be pumped.

at temperatures above 80 °C contSpecial shaft seals may be required if the pump is

used for pumping treated water aining additives to prevent system corrosion,
calcareous deposits, etc., for instance in heating and ventilating systems.

Another type of shaft seal may also be required for the pumping of glycol-
containing liquids.

For heating systems, the water quality should meet VDI 2035.

Contact Grundfos for further information.

 AMBIENT TEMPERATURE

AMBIENT TEMPERATURE

The ambient temperature and the installation altitude are important factors
for the motor life, as they affect the life of the bearings and insulation
system.

Maximum ambient temperature:

• EFF2 motors: +40 °C.
• EFF1 motors: +60 °C.

If the ambient temperature exceeds +40 °C (+60 °C), or the motor is installed
more than 1000 m (3500 m) above sea level, the motor must not be fully
loaded due to the low density and consequently low cooling effect of the air.

In such cases, it may be necessary to use a motor with a higher output.

 LIQUID TEMPERATURE
LIQUID TEMPERATURE
-25 °C to +140 °C.
The maximum liquid temperature is stated on the pump nameplate.
It depends on the shaft seal chosen.
For pump housing of cast iron EN-GJL-250 local regulations may not allow
liquid temperatures above +120 °C.

OPERATING PRESSURE
The maximum operating pressure is stated on the nameplate.
NK:
Maximum 1.6 MPa (16 bar).
DN 200: 1 MPa (10 bar).
NKG:
Maximum 1.6 MPa (16 bar).
 TECHNICAL DATA
MINIMUM INLET PRESSURE
According to the NPSH curve of the pump + a safety margin of minimum 0.5 m head.

MAXIMUM INLET PRESSURE

The actual inlet pressure + pump pressure against a closed valve must always be
lower than the maximum permissible operating pressure

MINIMUM FLOW RATE

The minimum flow rate must be at least 10 % of the maximum flow rate. The flow
rate and head are stated on the pump nameplate.

MAXIMUM FLOW RATE

The maximum flow rate must not exceed the values stated for the individual pump ,
as otherwise there is a risk of for instance cavitation and overload.

ELECTRICAL DATA
See the motor nameplate.
 ELECTRICAL CONNECTION
The electrical connections should be carried out by an authorized electrician in
accordance with local regulations.

Warning
Before removing the terminal box cover and before any removal/dismantling of
the pump, make sure that the power supply has been switched off.
The pump must be connected to an external mains switch.

The operating voltage and frequency are marked on the nameplate. Make sure
that the motor is suitable for the power supply of the installation site.

The electrical connections should be carried out as shown in the wiring diagram
inside the terminal box cover.

Warning
Whenever powered equipment is being used in explosive surroundings, the rules
and regulations generally or specifically imposed by the relevant responsible
authorities or trade organisations must be observed.
 MOTOR PROTECTION

Three-phase motors must be connected to a motor-protective circuit breaker.

All three-phase Grundfos MG and MMG motors of 3 kW and up incorporate a

thermistor. See the instructions in the motor terminal box.

Carry out the electrical connection as shown in the wiring diagram in the
terminal box cover.

Warning
Whenever motors incorporating a thermal switch or thermistors are to be
repaired, make sure,before starting to work, that the motors cannot start
automatically after cooling.
 FREQUENCY CONVERTER OPERATION

All three-phase motors can be connected to a frequency converter.

Frequency converter operation will often expose the motor insulation system to a
heavier load and cause the motor to be more noisy than usual due to eddy
currents caused by voltage peaks.

Large motors driven via a frequency converter will be loaded by bearing currents.
Start-Up
 START-UP
DO NOT START THE PUMP UNTIL IT HAS BEEN FILLED WITH LIQUID AND VENTED.

CHECKING THE DIRECTION OF ROTATION

The correct direction of rotation is shown by arrows on the pump housing. Seen
from the pump end, the direction of rotation must be counter-clockwise.
Before starting the pump, completely open the isolating valve on the suction side
of the pump and leave the isolating valve on the discharge side almost closed.
Start the pump.
Vent the pump during starting by loosening the air vent screw in the pump
head/cover until a steady stream of liquid runs out of the vent hole.

Warning
Pay attention to the orientation of the vent hole to ensure that the escaping
water does not cause personal injury or damage to the motor or other
components.

In hot-water installations, special attention should be paid to the risk of personal

injury caused by scalding hot water.
 START-UP
When the pipework has been filled with liquid, slowly open the isolating valve on
the discharge side until it is completely open.

Warning
If the motor is fitted with a motor with an output selected on the basis of a
specific maximum flow rate, the motor may be overloaded if the differential
pressure is lower than anticipated.

Check the overload by measuring the motor current consumption and comparing
the value with the nominal current stated on the motor nameplate.

In case of overload, throttle the valve on the discharge side until the motor is no
longer overloaded.

It is advisable always to measure the motor current consumption during starting.

At the moment of start, the input current of the pump motor is up to six times
higher than the full-load current stated on the motor nameplate.
MAXIMUM NUMBER OF STARTS/HOUR
REFERENCE READINGS OF MONITORING EQUIPMENT

It is advisable to take initial readings of these parameters:

• vibration level (use SPM measuring points)

• bearing temperature (if sensors have been fitted)

• inlet and outlet pressure (use pressure gauges).

They can be used as reference in case of abnormal operation

MAINTENANCE
 MAINTENANCE
Warning
Before starting work on the pump, switch off the supply voltage. It must be
ensured that it cannot be accidentally switched on.

PUMP

The pump is maintenance-free.

If the pump is to be drained for a long period of inactivity, inject a few drops of
silicone oil on the shaft at the bearing bracket. This will prevent the shaft seal
faces from sticking.

MECHANICAL SHAFT SEALS

Mechanical shaft seals are maintenance-free, working almost without any
leakages.
If any considerable and increasing seepage occurs, the mechanical shaft seal
should be checked immediately.
If the sliding surfaces are damaged, the entire shaft seal should be replaced.
Mechanical shaft seals should be treated with the greatest care.
 MAINTENANCE
PUMP BEARINGS

Depending on size, the pump is provided with

• maintenance-free, greased-for-life bearings. The pump has no grease nipples.

• bearings which should be greased via the grease nipples of the pump.

These bearings should be greased every 5000 operating hours.

Quantity of grease: 50 g.

MOTOR BEARINGS

Motors up to and including 7.5 kW are provided with maintenance- free,

greased-for-life bearings.

Motors of 11 kW and up should be greased in accordance with the indications

on the motor nameplate.
 BEARING GREASE SPECIFICATIONS

Lithium-based grease according to the following specifications must be used:

• NLGI class 2 or 3.

• Viscosity of basic oil: 70 to 150 cSt at +40°C.

• Temperature range: –30°C to +140°C during continuous operation

 ALIGNMENT

When a complete unit is supplied assembled from the factory, the coupling
halves have been accurately aligned by means of foil inserted under the pump
and motor mounting surfaces as required.

As the pump/motor alignment may be affected during transport, it must

always be checked when the pump has been installed.

It is important to check the final alignment when the pump has obtained
its operating temperature under normal operating conditions.
 ALIGNMENT
HOW TO ALIGN THE UNIT
It is very important that the pump/motor alignment is carried out correctly.
Follow the procedure below.

The values for ø and s2 can be found in the following table.

The value for s1 is 0.1 mm.

ALIGNMENT
ALIGNMENT
ALIGNMENT
ALIGNMENT
ALIGNMENT
ALIGNMENT
ALIGNMENT
 FAULT FINDING

Before removing the terminal box cover and

before any removal/dismantling of the pump,
make sure that the power supply has been
switched off and that it cannot be accidently
switched on.
FAULT FINDING CHART
FAULT FINDING CHART
FAULT FINDING CHART
OPERATION AND ROUTINE MAINTENANCE

CR, CRI,CRN
PUMPS

47
OPERATION AND ROUTINE MAINTENANCE

CR, CRI,CRN
PUMPS

48
TYPE IDENTIFICATION
TYPE IDENTIFICATION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
GENERAL DESCRIPTION
MINIMUM INLET PRESSURE
MINIMUM INLET PRESSURE
MAXIMUM INLET
PRESSURE
PRESSURE TEST DATA
MINIMUM FLOW RATE
MAXIMUM NUMBER OF START PER HOUR
INSTALLATION
ELECTRICAL CONNECTION
ELECTRICAL CONNECTION
TERMINAL BOX POSITION
FREQUENCY CONVERTER OPERATION
START-UP
START UP
START-UP
START-UP
MAINTENANCE AND SERVICE
MAINTENANCE
FAULT FINDING
FAULT FINDING
FAULT FINDING
75
 TEN PROVEN WAYS
TO
MURDER YOUR PUMP
 1. OVERWORK IT

 Work it continuously at higher capacities, flows, heads,

or speeds than originally specified or ordered for.
 The pump will one day die of a broken shaft, worn out
impeller, or a burned out bearing.
Impeller Washout - Over pumping
 2. STARVE IT

 Never give the grease cup a good turn.

 Never grease or oil.
 3. CHOKE IT

You can choke your pump in three ways:

Lower the water level in the sump.
Let the suction strainer clog, and never clean it.
Let the temperature of fluid rise without raising the suction
pressure.
Ignore the complaint, and you’ll soon have eroded impeller
vanes, which should really warm your heart.
 CAVITATION facts:

 Implosion has been measured up to 145,000,000 PSI.

 Life of vapor bubble is est. 0.003 seconds.
 Pump suffers loss of head
 Sounds like you are “Pumping Rocks”
 Results in Impeller & Casing Damage!!
Damage due to Cavitation
Damage due to Cavitation
NPSH(A) Calculation Chart
 4. FRY IT

 Operate it at shutoff for a long time, and make sure the

bypass line is closed tight.
 All that expensive power is converted to heat. You’ll have a
lovely hot pump in no time.
 As an added bonus, all the liquid will be flashing to vapor in
the suction areas.
Pump Operating with Closed Discharge
Pump Operating with Closed Discharge
Pump Operating with Closed Discharge
 5. POISON IT

 To poison the pump, just change the fluid you’re pumping

without checking with the manufacturer.
Adding chemicals.
 You’ll hit on just the right chemical to initiate corrosive action,
 6. STAB IT

 Your pump is made of metal, so nothing can harm it. Go

ahead, remove the suction strainers.
 Put plenty of grit, sand, scale and the like into the fluid.
Pipe Strain
 7. SHAKE IT TO PIECES

 It’s easy--- just misalign it at the coupling. This will subject the
shaft, seals, and bearings to alternating forces that’ll slowly but
surely shake it apart.
This can be achieved in a couple of ways:
 Don’t align it at installation.
Or
 Install it on a flimsy foundation. (This’ll make it easy for your
pump to move out of place and shake itself to a frazzle.)
Broken Shaft Due to Mis-alignment
 Alignment and Pipe Strain

The # 1 and # 2 causes of Pump Failure are Seal Failure and

Bearing Failure.

1. Alignment, (of Coupling)

and
2. Alignment (of Piping)

These issues MUST be properly accomplished at initial

installation--- Fixing after the fact is next to impossible.
 8. DROWN IT

Let’s assume you have a packed box, with a drain for the gland
leakage. It’s easy enough to plug the drain.
Or, you can remove the water shield.
Or, line up the splits on the packing rings.
Just make sure its easy for water to get to the bearings, and you
can painlessly drown your pump. (Painless for you, but not for
your pump.)
 9. NEGLECT MEDICAL CHECKUPS

 This is the final way to murder your pump. It’s not quick, but it
works well.
 Ignore the manufacturer’s recommendations for “check-ups”
 Don’t check packing, gaskets, o-rings, or other small parts.
 Don’t ever repaint it, or lubricate the coupling if called for.
 Don’t check vibration, or if you do, ignore the doctor’s advise.
 Just let the pump die slowly.
 CONGRATULATIONS

You now have 10 proven ways to kill your pump.