305-Understanding The Operation of Pumps Missing Pages 139-140

Understanding the
Operation ofPumps
Contributors:
E. Elwin Arasmith
Terra West
Robert H. Fuller
Robert H. Fuller & Assoc. Inc.
Richard M. Hell
Industrial Training Consultant
John H. O'Neill
Editor:
Linda Warner
Graphic Design:
Robert A. Ravelo
TPC Training Systems 750 Lake Cook Road Buffalo Grove, Illinois 60089 U.S.A 847/808-4000
Table of Contents
Lesson One Pump Development and Application.
Lesson Two Basic Pump Hydraulics 19
Lesson Three End-Suction Centrifugal Pumps 35
Lesson Four Propeller and Turbine Fîmps 53
Lesson Five Rotary Pumps 69
Lesson Six Reciprocating Pumps 85
Lesson Seven Metering Pumps 101
Lesson Eight Special-Purpose Pumps 117
Lesson Nine Packings and Seals 133
Lesson Ten Pump Maintenance 149
© Copyright 1998, 1986 by TPC Training Systems, a division of Telemedia, inc.
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UNDERSTANDING THE OPERADON OFPUMPS
Lesson One
Pump Development
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Lesson
Pump Development
and Application
TOPICS
The Development of Pumps Waste Pumping Systems

Pumping Systems High-Vlscoslty Material Pumping Systems
Water Pumping Systems Solids Pumping Systems
Chemical Pumping Systems
OBJECTIVES
After studying this Lesson, you should be able to...
• Describe dead-end and recirculating hot water Tell the effects of heat on the pumping of high-
distribution systems. viscosity materials.
• List severai speciai considerations involved in List some special problems Involved in the pump
chemicai pumping systems. ing of soiids.
• Define the term viscosity and give examples of
high-viscosity materials.
KEY TECHNICAL TERMS
Archimedean screw 1.01 abroad-threaded Viscosity 1.28 the property of a material that
screw encased in a cylinder or in an open trough resists any fiow-producing force
Noria 1.02 a water-lifting device with open-ended
tubes around the edge of a wheel
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Pumps are used in almost every industrial plant. Water systems are the most
common pumping systems In Industry. Water supply and hot water distribution
systems are two examples of water pumping systems. After studying this Les
son, you will be able to explain how these systems work, Including the differ
ences between dead end systems and recirculating systems.
Chemical pumping systems have special design and construction requirements

because of the nature of the materials they handle. Many factors must be con
sidered when choosing the correct pump for such systems. This Lesson will
acquaint you with only some of the important factors.
High viscosity material pumping systems have special requirements, as do

solids pumping systems. This Lesson covers some of the problems Involved In
these pump applications.
The Development of Pumps 1.02 The first pumping device employing neither
human nor animal power was probably developed in
1.01 One of the earliest pumping devices in recorded China. The device, called a noria, consisted of many
history is the Archimedean screw, developed in Greece open-ended bamboo tubes attached around the edge
in the third century BC. The device is simply a broad- of a large wheel. As the current of a river caused the
threaded screw encased in a cylinder or in an open wheel to turn, each tube dipped into the river and car
trough. In ancient times, an operator at the top of the ried a small amount of water up to a channel located
screw turned a hand crank that turned the screw, raising near the top of the wheel. Here the tubes spilled their
the water higher with each revolution. The screw was water and returned to the river.
used for irrigation purposes and for raising water from
mines, ship holds, and other confined spaces. These 1.03 An early modification of the noria is illustrat
devices are still used today in water treatment plants. ed in Fig. 1-2 on the next page. This device employed
Figure 1-1 shows several screws in use at the Indianapo free-swinging buckets attached to a wheel by pins.
lis Advanced Water Treatment facihty. Their free-swinging nature prevented the buckets
Fig. 1-1. Archimedean screws

•• \ >1
r"* M
'■
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6 Lesson One
Fig. 1-2. Noria with free-swinging buckets Fig. 1-3. Chain of pots
V.
from dumping their contents before reaching the top pressure. Some pumps are even used to move cement
of the wheel. When a bucket reached the top of the and other solids. The remainder of this Lesson
wheel it struck a bar which caused it to tip and empty describes several applications of modern pumps in
its contents into a trough. The maximum lift of the typical pumping systems, perhaps like those used in
noria was limited by the diameter of the wheel, usual your plant.
ly 30 to 40 ft. Use of the noria was also limited by the
fact that it could not operate in wells or other con Pumping Systems
fined spaces.
1.07 Nearly all industrial plants use pumps in
1.04 Ancient Egyptians are credited with invent some way. The pumping of materials can create many
ing a device for pumping water from deep wells. It challenges for both operating and maintenance per
consisted of a series of buckets or pots mounted on sonnel.
an endless chain rather than on a wheel. The chain
was driven by humans or by oxen. This device is 1.08 Maintenance problems in pumping systems
shown in Fig. 1-3. Simple pumping machines like are usually caused by the pump itself, but can also be
these are still used today for irrigation in areas of the result of improper piping or poor selection of
the Far East. valves or accessories. Ejcf^ding or modifying an
existing pipiTig s}êm is a project often assigned to
1.05 Figure 1-4 is a drawing of an early posi the maintenance department.
tive-displacement pump. A positive-displacement
pump discharges a known quantity of fluid during a 1.09 Some pumping systems described in this
piston movement through a stroke distance. This Lesson probably resemble those located in your
pump remained substantially unchanged until the plant. Even if the systems are different, the basic
beginning of the Industrial Revolution in late eigh principles and operating procedures will be similar.
teenth-century England. At this time, a steam-pow The main objective of this Lesson is to describe
ered, positive-displacement pump was developed. various pump and piping systems used in industrial
The centrifugal pump first appeared in the mid plants.
1800s.
Water Pumping Systems
1.06 In industry today, pumps are second only to
electric motors as the most commonly used type of 1.10 Water systems are the most common pump
equipment.!^mps allow fluids to be moved through ing systeihTmTpiant. Although municipal water sys
pipes, raised to higher elevations, or stored under tems supply water to most plants, some plants have
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Pump Development and Applications 7
their own wells or other supply sources. Some plants Fig. 1-4. Early positive-displacement pump
have special requirements, such as water under high
pressure, chemically treated water, or water circula
tion within the plant.
1.11 A typical direct water supply system is

shown in Fig. 1-5. A pump withdraws water from a
reservoir, lake, well, or other supply source. A cen
trifugal pump is usually used for this purpose. The
water is then conditioned to make it usable for
drinking and other purposes. Conditioning can
include such processes as softening, filtering, set
tling, and chemical treatment. From the condition
ing tanks, pumps raise the water to an elevated
storage tank. After leaving the storage tank, a pip
ing system distributes the water to the required
points within the plant.
1.13 Industrial plants use many types of chemical

1.12 Plants with special water treatment require
additive systems that resemble the boiler feedwater
ments often use modifications of the system just
system. You might have one or more of these in your
described. For example,(water might be treated for plant. The feed pumps used in additive systems are
use with a specific piece of equipment and supplied
often metering pumps. If metering pumps are not
directly to the equipment without passing through a
used, some other means of control must be provided
conditioning tank.ôiler feedwater systems common to regulate the flow of the chemicals or other addi
ly use an arrangdmenl similar to this. The necessary
tives.
chemicals are added to the water in specific amounts
just before the water is pumped into the boiler. The
1.14 The pumping systems just described are rela
chemicals are often mixed in advance and held in a
tively easy to understand. Several application prob
small storage tank until they are added to the/boiler
lems exist, however, even in these simple systems.
feedwater system^
Fig. 1-5. Typical water supply system
storage tank
Conditioning lank
Reservoir
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Fig. 1-6. Hot water distribution systems
Dead-end system Recirculating system
One, of course, is choosing the right kind of pump. In either a dead-end system or a recirculating system.
addition, pump pressures must be sufficient to over Both types are shown in Fig. 1-6. The type used in
come changes in the elevation of the water and pres a particular case depends upon plant requirements.
sure in the piping. Also, the pumps and piping must If a large amount of hot water is required in dt
be constructed of materials that are capable of han specific area, a dead-end system is probably the
dling the water and chemical solutions without best choice. If hot water is required throughout the
becoming damaged or corroded. plant, a recirculating system might be more eco
nomical. In a recirculating system, unused hot
1.15 Another type of pumping system common water can be reheated along with a small amount of
to most industrial plants is the hot water distribu incoming cool water. This type of system not only
tion system. A hot water distribution system can be eliminates the need to heat all cool water, but also
Fig. 1-7. Chemical pumping system
Storage bins
Mixing tank
Filling
machine
Transfer
pump
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saves heat that would be wasted as water cooled in might be an in-plant operation limited to only a
the lines. small area, as shown in Fig. 1-7. In this case, dry
chemicals are stored in elevated bins on the second
Chemical Pumping Systems floor of the plant. Feed spouts or chutes extend
down to the first-floor mixing area. On the first
1.16 Chemical pumping systems are unique in floor, several dry chemicals are blended in a mixing
their design. Most of their special construction and tank, then combined with water or other liquids to
design requirements are necessary because of the produce the desired chemical solution. The chemical
nature of the materials they handle. The chemicals solution is then pumped to a filling machine, which
handled in one area of a plant might not require the dispenses it into bottles, cans, drums, or other con
use of special corrosion-resistant materials. The cor tainers. Similar operations take place in most bot
rosion-resistant material used in one pump for one tling plants.
chemical might not be suitable for use with another
chemical. In such cases, two separate systems must be 1.20 In another type of operation, a plant might
used. Piping requirements also vary with the material manufacture chemicals in a process similar to the one
being pumped. just described. But instead of filling containers,
pumps move the chemicals into large storage tanks
1.17 Another factor to be considered when select which are located either outside the building or with
ing a pump is the flow resistance of the chemical. If in. The fluid is later pumped from the storage tanks to
the chemical is a slurry, it might be necessary to use a rail cars or trucks for shipment to other plants, where
positive-displacement pump rather than a centrifugal it is processed further. Or, the chemicals might be
pump. The viscosity (resistance to flow) of the chemi pumped from one building to another within the plant
cal determines the kind of pump selected. Applica complex for further processing to make a different
tions in which chemicals must be metered or pumped product. A good example of this type of operation is
under high pressure require high-powered positive- an oil refinery.
displace-ment pumps.
1.21 Frequently, chemical products must remain
1.18 Chemical pumping systems often require spe within a specific temperature range while they are
cial gaskets, seals, and packing materials. The materi being pumped from one location to another. In such
als used to manufacture seals for pumps having a cor cases, the piping systems carrying the chemicals
rosion-resistant casing are not the same as those used must be fully insulated to maintain the properjgm-
for pumps without this casing. As a result, you must peiature. Insulated piping systems are also neces
give special consideration to the seals used. They sary for pjpjiigJiDL_wa^r or stgapl within an indus
must not only withstand the corroding action of the trial plant complex.
chemical, but must also be compatible with the corro
sion-resistant materials used in the pump. The Programmed Exercises on the next page will
tell you how well you understand the material you
1.19 Chemical handling, like water distribution, have just read. Before starting the exercises,
can involve a wide variety of pump and piping remove the REVEAL KEY from the back of the
arrangements. The plant layout and the requirements book. Read the instructions printed on the Reveal
of the particular application determine the arrange Key. Follow these instructions as you work
ment. For example, one chemical pumping system through the Programmed Exercises.
* r
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10 Programmed Exercises
1 -1. Fluids can be moved through pipes 1-1 PUMPS

raised to higher elevations, or stored
under pressure through the use of Ref: 1.06
1-2. Maintenance problems in pumping sys 1-2. PIPING

tems are usually caused by the pump,
but also can be the result of improper Ref: 1.08
1 -3. What is the most common type of 1-3. WATER SYSTEM

pumping system in industrial plants?
Ref: 1.10
1 -4. If a large amount of hot water is 1-4. DEAD-END

required in one specific area, a(n)
distribution system in the Ref: 1.15
best choice.
1-5. In a(n) system, unused hot 1-5. RECIRCULATING

water is reheated along with cool
incoming water. Ref: 1.15
1-6. Applications in which chemicals must 1 -6. POSITIVE-DISPLACEMENT

be metered or pumped under high pres
sure require high-powered Ref: 1.17
pumps.
1-7. Chemical handling arrangements are 1 -7. LAYOUT; APPLICATION

determined by the plant and
the requirements of the particular Ref: 1.19
1-8. Insulated piping systems are necessary 1-8. HOT WATER; STEAM
for piping chemical products, ,
and in an industrial plant. Ref: 1.21
Waste Pumping Systems

Fig. 1-8, Waste pumping arrangement
1.22 Waste pumping systems,like chemical pump
ing systems, have a variety of applications. For exam
ple, one system might handle roof runoff water,
another sewage wastes, and yet another chemical Discharge
wastes and radioactive wastewater, Generally, cen Motor
trifugal pumps are used to pump wastewater in a Float _ Sump

switch pump
plant. The low-head pumping requirements and the
pump's ability to pass small solid particles make the
centrifugal pump well suited to these applications.
Usually, the waste is piped directly to the pump.
Often, the pump is completely submerged in the liq
uid it is pumping, like the sump pump shown in Fig.
1-8.
•t 4=
1.23 If the pump is handling corrosive waste, the

pump impeller, housing, shaft, and supporting struc
ture must be made of CQiXQsion^gsistant materials. If
the pump is handling run-off water or other non-cor
rosive waste, it can be made of cast iron, bronze, or sump, only the internal parts of the pump come into
brass and will usually have good service life. When contact with the waste. Therefore, only the internal
sump pumps are used, intake screens must be pump parts must be able to withstand the action of the
installed to keep large particles from reaching the chemical. The pump discharges the waste into an ele
pump impeller. vated waste storage tank for temporary storage. From
this point, the waste is picked up by truck, rail car, or
other means and is disposed of where the waste
1.24 When pumping radioactive or chemical
chemicals will not harm or pollute any existing water
wastes, pumps are often connected to independent
sources or disposal facilities.
collection and discharge systems. Chemical wastes
might be pumped through one system, while floor
drainage and other wastewater are conveyed through 1.25 The pulp, paper, and canning industries
offer many examples of special waste disposal
a separate system to a second sump, as shown in Fig.
facilities. These industries produce large amounts
1-9. Since the chemical pump is located outside of the
Fig. 1-9. Separate waste systems
Waste storage tank
Plant waste -Chemical waste
Transfer pump
Sump
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the paint pigments. The water returns to the reser
Fig. 1-10. Typical paint spray booth voir, where the paint pigments settle to the bottom.
Water from the reservoir is supplied to the spray
To exhaust fan header pipe by a recirculating pump that is mounted
outside of the spray booth. The paint spray booth is
an example of a closed circulation system operating
Spray header in a small area.
1.27 Because spray booths require large quantities

Water curtain
of water, it is impractical to supply fresh, unused
water continuously. By using a recirculating system,
Air flow
far less water is used. The water is changed at regular
intervals, and the paint pigments are collected from
Recirculating
pump I c Reservoir the bottom of the reservoir.
High-Viscosity Materiai Pumping Systems
1.28 Viscosity is the property of a material that

of wastewater in a short time. Because of the resists any flow-producing force. High-viscosity
nature of the wastewater, it cannot be discharged materials include syrups, oils, and light cement
into municipal sewage systems, rivers, or lakes. In slurries. The degree of viscosity of materials varies
these cases, companies usually have treatment from plant to plant. The materials covered in this
plants installed on company property. The treat section are fairly thick but still flow whe^
ment plants process and purify the water before it pumped.
is discharged into municipal sewage facilities or
bodies of water. 1.29 Positive-displacement pumps (both rotary
and reciprocating) are generally used for pumping
1.26 Another example of chemical waste treat high-viscosity materials. The nature of the mater
ment is the paint spray booth shown in Fig. 1-10. ial being pumped frequently limits the area of
Air passes through the painting area into the water system operation. The length of pipe runs is lim
curtains of the spray booth. As the air and paint pass ited by the distance the material can be pumped
through several curtains of water, the water collects without using booster pumps, which add to ener-
Fig. 1-11. Paint spray systems
Paint recirculating lines Paint heater
Spray gun Spray gun
Air lines
Air line
Paint drum
Air compressor Air compressor
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Fig. 1-12. Cement slurry pumping system 1.34 Light cement slurries and glue are usually
pumped with piston pumps. In these applications,
heat need not be added. Because of the high water
content of these materials, they flow quite easily at
Receiving hopper room temperature. Heat applied to these materials
tends to set them or dry them out, causing problems
within the piping system.
Drive motor
1.35 Because of their weight, cement slurries are
usually withdrawn from a holding tank or hopper
located above the pump. Cement slurries can be
Large-diameter pumped long distances without encountering many
pipe problems. The piping through which the materials
flow should be large enough to allow them to flow
with a minimum of friction. An example of a cement
slurry pumping operation is shown in Fig. 1-12.
Notice that the receiving hopper is located above the
pump.
gy consumption. In some cases, the fluid being
pumped can be heated to lower its viscosity and Solids Pumping Systems
make it easier to pump. Pipe runs are then insu
lated to maintain the elevated temperature of the 1.36 Solids pumping systems are similar in
fluid.
nature to high-viscosity material systems. They dif
fer only by the characteristics of the material being
1.30 Paint is another example of a high-viscosity pumped. Solids pumping systems handle greases,
fluid. Piston pumps are usually used to handle paint. heavy mastics, cement, concrete, and similar mate
Often the paint is pumped directly from the drum, rials. The cement slurry pumping system previous
through a system of filters and strainers, to the spray ly described is equally effective for pumping dry
gun, as shown in Fig. 1-11. cement.
1.31 Some paint systems do not pump from a 1.37 When pumping concrete, a pump must be
drum but use compressed air to force the paint able to pass a large quantity of stone and gravel. For
from a pressurized storage tank. This arrangement this reason, pumps must be heavily constructed with
also is shown in Fig. 1-11. The paint moves large suction and discharge ports. Because of the
through a heater and then to the spray gun. When abrasiveness of the sand in the concrete, excessive
heaters are used, they usually contain small, air- wear is frequently a problem. Repair will therefore be
driven, circulating gear pumps to help keep the easier if cylinder liners and other replaceable compo
paint in motion. nents are used.
1.32 One of the problems involved with paint 1.38 Mastic and grease pumping systems are
pumping systems is the settling of pigments as they usually of the dead-end or non-circulating type
travel through the supply lines. To avoid pigment set shown at the right in Fig. 1-13 on the next page.
tling, the paint must be kept in motion and must move Recirculating systems are sometimes used when
relatively quickly. several stations demand large quantities throughout
the day. A recirculating system is shown at the left
1.33 Another problem in spray paint systems in Fig. 1-13.
involves the abrasiveness of paint pigment. Although
paint feels slippery when you rub it between your fin 1.39 Piston pumps are most often used to handle
gers, the pigment that gives paint its color is very materials like these. One common problem encoun
abrasive. This abrasiveness causes wear within the tered with a piston pump, however, involves the
pump. flow at the source of supply. The pump can usually
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14 Lesson One
Fig. 1-13. Grease or mastic pumping systems
Recirculating system Dead-end system
Dispensing points
Pump
Pump
a
Material drum
withdraw the material (grease, for example) faster equipped with 2l follower plate, as shown. This fol
than the material can flow down to the pump, as lower plate rides on top of the material being
shown in Fig. 1-14. To overcome this problem, pumped. The use of a follower plate is also shown
grease drums using piston pumps are usually in Fig. 1-14.
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Fig. 1-14. Use of a follower plate
1.40 The suction of the pump draws the level of the ets or voids between the pump suction and the grease
grease or mastic down toward the bottom of the drum. surface. A rubber gasket placed around the outer edge of
The weight of the follower plate helps force the material the plate scrapes the drum clean as it travels down and
down.The plate also prevents the formation of air pock ensures that most of the grease gets to the pump.
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1-9. When sump pumps are used. 1-9. INTAKE SCREENS

must be installed to keep large particles
from reaching the pump impeller. Ref: 1.23
1 -10. Because spray booths require large 1-10. RECIRCULATING

quantities of water, afnl sys
tems is best for such applications. Ref; 1.27
1-11. High-viscosity materials are materials 1-11. FLOW-PRODUCING

that resist any force.
Ref: 1.28
1 -12. What type of pump is usually used for 1 -12. POSITIVE-DISPLACEMENT

pumping high-viscosity materials?
Ref: 1.29
1-13. In some cases, a fluid is to 1-13. HEATED

lower its viscosity.
Ref: 1.29
1 -14. Two problems encountered in paint 1-14. PIGMENTS; ABRASIVENESS

pumping systems are the settling of
and pioment Ref: 1.32,1.33
1 -15. Systems handling greases, heavy mas 1-15. SOLIDS

tics, cement, and concrete are called
pumpinq systems. Ref: 1.36
1 -16. Repair of solids pumping systems is 1-16. REPLACEABLE

made easier if cylinder liners and other
components are used. Ref: 1.37
Self-Check Quiz 17
Answer the following questions by marking an "X'

in the box next to the best answer.
1-1 In boiler feedwater systems, metering pumps 1-6. High-viscosity materials are
regulate the flow of
□ a. thick
□ a. steam □ b. thin
□ b. solids □ c. lumpy
□ c. chemicals □ d. combustible
□ d. water
1 -2. Which type of distribution system is best suit 1-7. If a liquid is heated to lower its viscosity, the
ed for plants that require hot water through pipe runs must be
out?
□ a. made of aluminum
□ a. Conditioning □ b. short
□ b. Dead-end □ c. angled
□ c. Recirculating □ d. insulated
□ d. Boiler
1-3. high-powered positive-displacement pumps 1-8. To avoid pigment settling in paint pumping
are used to pump chemicals that are systems, the paint must be
□ a. under high pressure □ a. kept in motion

□ b. corrosive □ b. strained
□ c. used in water treatment □ c. heated
□ d. noncorrosive □ d. pressurized
1-4. Insulated piping systems are NOT necessary

for piping 1 -9. Adding heat to light cement slurries and glue
□ a. hot water □ a. makes them flow more easily

□ b. steam □ b. dries them out
□ c. chemicals □ c. lowers their viscosity
□ d. slurries □ d. destroys pipe insulation
1 -5. When sump pumps are used in a waste

pumping system, which of the following is 1 -10. Repair of solids pumping systems is easier if
used to keep large particles from reaching the
impeller? □ a. you work as a team
□ b. the system has small ports
□ a. Filter □ c. replaceable components are used
□ b. Intake screen □ d. pipe runs are kept short
□ c. Strainer
□ d. Large discharge pipe
18 Lesson One
SUMMARY
Water systems are the most common pumping require special gaskets and seals, and some must
systems used in industry. The direct water supply be insulated.
system and its modifications are used to supply
water to the plant. Metering pumps are often part Waste pumping systems generally use centrifugal
of the system when chemicals must be added to pumps. Depending on the materials to be han
the water. Hot water distribution systems can be dled, the pumps may be made of corrosion-resis
either dead-end or recirculating systems, depend tant materials and special screens may be used.
ing on how much water is needed in a given area.
Positive-displacement pumps are often used to
Chemical pumping systems have special design pump high-viscosity materials. Piston pumps are
and construction requirements. The viscosity of used to handle paint. Solids pumping systems
the chemical being pumped determines the type are similar to high-viscosity materials systems
and energy requirements of the pump selected. except in the materials each carries. Cylinder lin
Positive-displacement pumps are common in ers and other replaceable components make
chemical pumping systems. Such systems also repairs of solids pumping systems easier.
Answers to Self-Check Quiz
1-1. 0. Chemicals. Ref:1.13 1-6. a. Thick. Ref:1.28
1-2. 0. Recirculating. Ret: 1.15 1-7. d. Insulated. Ref:1.29
1-8. a. Kept in motion. Ref: 1.32

1-3. a. Under high pressure. Ret: 1.17
1 -9. Dries them out. Ref: 1.34
1-4. d. Slurries. Ret: 1.21
1-10. c. Replaceable components are

1-5. b. Intake screen. Ref: 1.23 used. Ref: 1.37
Contributions from the following sources are appreciated:
Figure 1-1. RQAW and Associates, Consulting Engineers, inc.
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UNDERSTANDING THE OPERATION OFPUMPS
fr.
^ J
Ô:
TPC Training Systems

20
Lesson
Basic Pump Hydraulics
TOPICS
Pumping Terminology Head Capacity Curves

Calculating Total Head Efficiency Curves
Horsepower Calculations Horsepower Curves
Total Energy vs Available NPSH Curve Families
Available NPSH vs Required NPSH Pump Selection
Pump Performance Curves
OBJECTIVES
• Describe suction head and suction lift pumping Define static suction head.
conditions. Contrast liquid, brake, and electrical horsepower.
• Tell what three elements make up total dynamic Tell what useful information can be gained from
head. pump curves.
KEY TECHNICAL TERMS
Suction lift 2.02 condition in which the eye of the Velocity head 2.07 energy required to put a liquid
impeller is above the fluid level into motion or to increase its speed
Suction head 2.02 condition in which the eye of NPSH 2.26 amount of energy remaining after all
the impeller is below the fluid level energy consumption conditions have been satisfied
21
This Lesson presents some fundamentals of pump hydraulics with which you
need to be familiar when maintaining a pump. It begins by introducing basic
pumping terminology, defining the concepts on which an efficient pumping sys
tem is built.
Many of these terms are used by the engineer who designs the system or
selects the pump for a particular application. However, maintenance and operat
ing personnel also need to have a working knowledge of these concepts in order
to check a pump's performance.
It is also important that you know how to read pump performance curves-
graphs that chart a pump's capacity, efficiency, and horsepower. Understanding
the principles of hydraulics and how they affect the operation of a pump will
help you perform your job more effectively and improve your knowledge of the
equipment you work with.
Pumping Terminology condition. In this case, the eye of the impeller is

below the liquid level, as shown in Fig. 2-2. Pump
2.01 A basic understanding of pump hydraulics is conditions are also referred to as static (when the
important for both maintenance and operating person pump is not running) and dynamic (when the pump
nel. You might need to evaluate the effect that rpm or is running).
suction condition have on horsepower requirements,
discharge pressure, or discharge quantity. Although 2.03 A column of liquid in a vertical pipe exerts a
you need not be able to do complex mathematics, certain pressure on the horizontal surface at the bot
some math background is helpful. tom of the pipe. This pressure can be expressed in
units of pressure (psi, for example) or as vertical dis
2.02 First, consider two classic pump installa tance (feet of head). Feet of head can be determined
tions. The first is called the suction lift condition. In from pressure as follows:
this case, the eye of the impeller is above the fluid
psi X 2.31
level, as shown in Fig. 2-1. The second is called the = ft of head
suction head, positive suction, or flooded suction specific gravity
Fig.2-1. Pump operating with suction lift Fig. 2-2. Pump operating with suction head
Static suction lift
Static suction head
Fig. 2-3. Illustration of static head
Static head
Static head
Static
Static
discharge
discharge head
head
Static
suction
head
Static suction lift
2.04 The power required to drive a pump is based on vation head. This static head can be broken down into
its capacity and on the head against which it operates. The two components, as shown in Fig. 2-3A. The vertical
total head against which a pump operates takes into distance from the suction liquid level to the eye of the
account several elements, including suction and dischaige impeller is called the static suction lift. The vertical
conditions. These elements are covered in die paragraphs distance between the eye of the impeller and the dis
that follow. We will examine the suction lift condition first. charge liquid level is called static discharge head.
2.05 With the pump shut off, the physical differ 2.06 Energy is needed not only to move the liquid
ence in elevation between the suction liquid level and being pumped, energy is also needed to overcome
the discharge liquid level is called static head or ele- friction due to pipe wall roughness and pipe fittings.
Fig. 2-4. Calculating total head-suction head Fig.2-5. Calculating total head-suction lift
condition condition
100 psi
(X)l5in. Hg
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Basic Pump Hydraulics 23
Standard tables of formulas are used to calculate these as in the suction lift condition. There is a change in
factors. The total is called head loss or friction head. terminology, however, on the suction side of the
Head loss is usually expressed in feet. It represents an pump. The distance between the eye of the impeller
additional effective distance that the pump must move and the suction liquid level is called static suction
the liquid. The normal method of looking at head loss head (instead of static suction lift). The dynamic
is to refer to the suction head loss and discharge head terms are also changed to indicate this changed condi
loss as separate components. In calculating head loss, tion.
these two must be considered individually. From an
operation standpoint, you can consider head loss a Calculating Total Head
single item.
2.11 When designing a pumping installation, an
2.07 There is one other factor related to total engineer would calculate theoretical total head by
head—the amount of energy that it takes to accelerate using formulas and tables for head loss. These calcu
the liquid. This energy input is referred to as velocity lations, which were briefly described in previous
head. Velocity head is directly related to the velocity paragraphs, are based on an assumed flow.
of the pumped liquid. That is, if the liquid in a pipe
were moving at 3 ft/s and you wanted to increase its 2.12 Once a pump is installed, however, the actual
speed to 5 ft/s, additional energy would be required. total head can be calculated. If you know this value
Velocity head is equal to the distance the liquid would and the diameter of the impeller and have a pump
have to fall to acquire the same velocity. It is curve, you can calculate the theoretical flow from a
expressed mathematically as: pump. You can then compare this value to a pump's
actual flow to determine overall pump conditions.
V- There are three typical conditions for which you can
— = ft
calculate actual total head —suction head condition,
suction lift condition, and submersible and lineshaft
where V = velocity, in ft/s turbines. In each of these examples, the liquid being
pumped is water. For other liquids, you will have to
g = acceleration due to gravity, which is find the specific gravity of the liquid on a table of
32.2 ft/s2. specific gravities.
In most pump installations, velocity head is 1 ft or 2.13 Suction head. In this arrangement, you must
less. From an engineering standpoint, however, it place a pressure gauge on each side of the pump and
must be calculated. record the two pressures while the pump is operating.
This arrangement is shown in Fig. 2-4. Under these
2.08 If suction and discharge pipes are the same conditions, the formula for total head is:
size in a particular application, the velocity head need
be calculated only once. In most installations, howev
(Pd - Ps) X 2.31 ft/psi ^
er, the discharge pipe is smaller in diameter than the specific gravity
suction pipe, even though the same amount of liquid
flows through both pipes. For this reason, the velocity where Pd = discharge pressure
of liquid in the discharge pipe is higher than the
velocity in the suction pipe. The result is an increase Pg = suction pressure.
in discharge velocity head.
From the example in Fig. 2-4, this is:
2.09 The sum of the total static head, head loss,
and velocity head is called total dynamic head(TDH) (100 psi - 50 psi)x2.31 ft/psi _ j 5
or simply total head. Total head can be divided into 1
dynamic suction lift and dynamic discharge head.
2.14 Suction lift. Under suction lift conditions, you
2.10 When dealing with a suction head condition, will need a vacuum gauge on the suction line and a
as shown in Fig. 2-3B, the calculations are the same pressure gauge on the discharge line, as shown in Fig.
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2.A \_ossor\ Tvmo
Fig. 2-6. Calculating total head-submersible pump (75 psi X 2.31 ft/psi)+(15 in. Hgxl.l3 ft/in.)
1
= 190.2 ft.
2.15 Submersible pumps and lineshaft turbines.

125 psi Under these conditions, the formula is as follows:
(Pd x2.31 ft / psi)+ lift

= total head (ft)
specific gravity
For the example shown in Fig. 2-6, the calculations

are as follows:
125 psi x2.31 ft / psi)+ 58 ft

= total head
288.75 ft+ 58 ft =346.75.
The accuracy of these calculations depends on the

accuracy of the gauges and measurements.
2.16 This type of calculation does not give you

the maximum possible total head but the actual
2-5.The formula for calculating total head is as follows: total head for the existing conditions. These calcu
(Pd X 2.31 ft / psi)+(in. Hg x 1.13 ft / in.) lations are a reflection of velocity head, head loss,
and static elevation heads. Besides being useful in
specific gravity comparing pump performances, the calculations for
total head can be used to determine horsepower
= total head (ft).
requirements.
The 1.13 ft/in. factor converts the vacuum reading to Horsepower Calculations
a height in feet. This should be the same value you
would obtain if a physical measurement were made 2.17 In a typical pump installation, there are three
between the liquid level and the eye of the impeller. related horsepower calculations that you should
For our example,the calculations are as follows:
understand (see Fig. 2-7). The hydraulic power that
the pump transfers to the pumped liquid is called liq
uid horsepower. The horsepower input to the pump
Fig.2-7. Three kinds of horsepower is referred to as brake horsepower. This value is
greater than the liquid horsepower by a factor repre
senting the efficiency of the pump. The electrical
Brake hp Liquid hp horsepower required to run the motor (to deliver the
required brake horsepower) is larger than the brake
Electrical hp
horsepower by a factor representing the efficiency of
the motor.
2.18 The calculations must start with the liquid

horsepower requirement. The amount of energy
required to raise liquid a given amount is measured in
foot-pounds (ft-lb). One ft-lb of energy is the amount
of energy needed to raise 1 lb of liquid 1 ft.
Th. material .s pmlecled by U. S. Copyngh, taw. Copying by any opttaal. electmnc. o,otrier means ,s illegal wthou. perm,sstan.
2.19 The energy required to move the liquid is

total head(ft) x flow(gpm)x 8.34 lb
affected by total head. The weight of the liquid Liquid hp =
moved is a reflection of the flow converted to 33,000 ft - lb / min / hp
weight in pounds. For example, moving 100 gallons
of water is the same as moving 834 lb of water, 2.23 To compute brake horsepower, you need to
since one gallon of water weighs 8.34 lb. know the efficiency of the pump. For example,
assume that the pump you were using in the previous
2.20 If you were to move 100 gallons of water example is 75% efficient. The brake horse-power is
through 200 ft of total head, the energy required calculated as follows:
would be:
liquid hp _ 5 hp
Brake hp = = 6.67
200 ft X (100 gal X 8.34 lb/gal) = 166,800 ft- % effciency of pump 0.75
Ib
This is the energy input required by the pump. It is
If you were to move this 100 gallons in 1 minute, also the energy output required of the motor.
the energy consumption would be 166,800 ft-
Ib/min. 2.24 The computation of electrical horsepower is
based on brake horsepower and motor efficiency and
2.21 Since the common method of expressing ener is determined as follows:
gy consumption is horsepower, you need to convert ft- brake hp
Ib/min to horsepower.The conversion is as follows: Electrical hp =
% efficiency of motor
1 hp = 33,000 ft-lb/min. If you assume for the above condition that the motor
Therefore, energy consumption is: is 90% efficient, then the electrical horsepower is as
follows:
166,800 ft - lb / min
= 5 hp
33,000 ft - lb / min / hp , 6.67 brake hp ^ , . ..
Electrical hp = = 1A electrical hp
0.90
2.22 This 5 hp is liquid horsepower, the true
energy transferred from the pump to the liquid. 2.25 It took 5 hp to get the job done, but you had
Now that all of these conversions have been made, to purchase 7.4 hp. The 2.4 hp increase is lost to heat
you can write a new equation for the calculation of in the motor and pump. In reality, this is not consid
liquid horsepower. ered to be an exceptionally large loss.
2-1. When the eye of a pump impeller is 2-1. SUCTION LIFT

above the level of the pumped fluid, the
condition is called Ref: 2.02
2-2. When a pump is not running, conditions 2-2. STATIC; DYNAMIC

are referred to as ; when a
pump is running, the conditions are Ref: 2.02
2-3. With the pump shut off, the difference in 2-3. STATIC HEAD or ELEVATION HEAD
elevation between the suction and dis-
charoe liquid levels is called Ref: 2.05
2-4. Velocity head is expressed mathemati- 2-4. V2/29

callv as
Ref: 2.07
2-5. In most installations, the discharge pipe 2-5. SMALLER

is than the suction pipe.
Ref: 2.08
2-6. The sum of total static head, head loss, 2-6. TOTAL HEAD
and dvnamic head is called
Ref: 2.09
2-7. You can calculate the theoretical flow 2-7. PUMP CURVE
from a pump if you know the total head
and impeller diameter and have a(n) Ref: 2.12
2-8. Brake horsepower is greater than liquid 2-8. EFFICIENCY

horsepower by a factor representing the
of the pump. Ref: 2.17
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Basis Pump Hydraulics 27
Total Energy vs Available NPSH Fig. 2-8. Available NPSH - suction lift condition
2.26 When a pump is in a suction lift condition,

the only energy available is the atmospheric pres
Vapor pressure
sure— 14.7 psia, or approximately 34 ft of water. Sev
eral factors combine to reduce the effect of this Friction loss in suction
atmospheric pressure. The amount of energy remain
ing after the energy consumption factors have been I Velocity head loss
satisfied is called available net positive suction head
(NPSH).
2 o
2.27 When liquid in a column is placed under a
^ i"
vacuum, a portion of the liquid will evaporate and CO „
3 7a
form vapor, which will reduce available energy. This
z:
vapor pressure increases with an increase in liquid
temperature.
2.28 Energy is required to overcome the distance

that the liquid must be lifted, to make the liquid move
(velocity head), and to overcome the friction of the
pipe and fittings (friction head or head loss). The
available NPSH, then, is the atmospheric pressure
minus vapor pressure, static suction lift, and head loss
due to friction. The pressure in psia at the eye of the
impeller is the NPSH minus velocity head. Figure 2-8
illustrates this concept.
2.29 The largest single contributing factor to the

reduction of pressure at the impeller is the lift itself.
least as large as the required NPSH in order for the
Even small changes in the height of liquid below the
curves to be valid.
eye of the impeller will have a drastic effect upon the
amount of liquid pumped.
2.33 Under a suction lift condition, the NPSH
should be calculated. However,for suction head condi
2.30 From an absolute pressure standpoint, the liq
tions, the usual practice is to measure the height of liq
uid must enter the impeller eye under positive pres
uid above the eye of the impeller. If this distance meets
sure in order for the pump to function. The higher the
or exceeds the required NPSH,the pump conditions, as
positive pressure, the greater the pump discharge.
defined by the curve,can be used. The assumption here
is that atmospheric pressure will be sufficient to over
2.31 When the eye of the impeller of a pump is
come losses due to friction, velocity head, and vapor
below the level of the liquid source which supplies
pressure.
the suction (suction head condition), the available
NPSH is the sum of atmospheric pressure and the
Pump Performance Curves
height of the liquid above the eye of the impeller
minus vapor pressure and minus friction loss.
2.34 A pump performance curve is a vital piece of
information that can be essential to operators and main
Available NPSH vs Required NPSH
tenance personnel alike. Each combination of pump
2.32 The NPSH discussion so far has been aimed
and impeller has a unique set of performance curves.
Any new pump should come with installation, opera
at determining the available NPSH. Most pump
tion, and maintenance data and with pump curves.
curves will give a required NPSH as a part of the
Files should contain curves on every pump in the plant.
curve. It is necessary that the available NPSH be at
28 Lesson Two
2.35 Pump curves can be used to select a pump for 2.41 From the curve, it is easy to see how the
a set condition, or they can be used to help determine pump responds to changes in head. If the head
the effects of changes in impeller diameter, speed, and increases, the flow automatically decreases. If the
suction lift on horsepower requirements, flow, and head decreases, the flow increases. The pressure
efficiency. developed by a pump is also dependent on its speed.
For that reason, as speed decreases, the head capacity
2.36 There are three basic types of curves used for curve sinks straight down toward the bottom of the
centrifugal pumps—the head capacity curve, the effi graph. As speed increases, the curves rise toward the
ciency curve, and the horsepower demand curve. top of the graph. The curve always maintains its same
Some pump curves also include a curve for NPSH. basic shape. The same is true for the impeller diame
Before looking at specific curves, you must know: ter. As diameter decreases, the curve sinks.
• the speed of the pump Efficiency Curves
• the diameter of the pump's impeller. 2.42 It is important that pumps be operated so that
the most amount of work can be done for a given
2.37 Figure 2-9 shows a typical pump curve. amount of expended energy. The efficiency curve will
Notice that a series of curves depicts various impeller tell you at what total head the best energy transfer
diameters. A series of curves also shows efficiency will take place.
and another brake horsepower. At first glance, this
information can appear very confusing. If you analyze Horsepower Curves
each type of curve individually, however, pump per
formance curves are much easier to understand. 2.43 The horsepower curve gives information on
the horsepower required by the pump, not necessarily
Head Capacity Curves the horsepower output of the motor. For example,
suppose you required 17 hp in a certain pumping situ
2.38 The head capacity curve is the most basic and ation. Motors are manufactured in 15 hp and 20 hp,
useful of all the pump curves. It is a graphic display but not 17 hp. Therefore, a 20 hp motor is needed.
of the relationship between total head and flow condi While pumping, however, the motor would be
tions. Notice that the curve shown in Fig. 2-10 is for required to produce only the 17 hp. The horsepower
one 9-in. impeller and running at one speed—3200 requirement increases as flow increases. Maximum
rpm. Notice that for any given head, one and only one horsepower is required at maximum discharge. Mini
flow condition exists, and vice versa. Also, notice that mum horsepower is required when the discharge is
for a given head, a flow can be found and for a given closed.
flow, a head can be found.
Curve Families
2.39 Refer to Fig. 2-10 for the following example.
If a head of 300 ft is required, what flow can the 2.44 In reality, curves are usually plotted in fami
pump produce? First, enter the curve from the left at lies. For example, the bold lines in Fig. 2-9 are curves
300 ft. Continue to the right in a straight line until you developed for various impellers that might be installed
meet the 9-in. diameter impeller curve. Now move in one particular volute case. AU of these curves have
down in a straight line to read a flow of 230 gpm. been plotted from an actual pump test. All tests were
conducted at 1155 rpm. Notice from the impeller
2.40 From the curve, you can see that the maxi curves that as the diameter of an impeller is reduced,
mum total head to be expected is about 380 ft using the msiximum capacity is also reduced. The effect on
the 9-in. impeller at 3200 rpm. Remember that this the head,however,is much more drastic.
head includes suction lift (if you have one), discharge
static pressure, and friction losses on both the suction 2.45 Rather than having a single efficiency
and discharge side of the pump. This maximum pres curve, it is common to plot efficiency curves in
sure or head is reached when the pump is shut down families. These are shown by the thin lines in Fig.
and is referred to as shutdown head. 2-9. Each curve connects points of common effi-
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Fig.2-9. Typical pump curve
60
10 in. diameter
1155 rpm
9 in. diameter
8 in. diameter
\
NPSH required
15ft
7 in. diameter
71/2 hp
3 hp
100 200 300 400 500 600 700 800
Gallons per minute
ciency. The greatest efficiency for this particular 2.46 Horsepower curves are also commonly plot
pump is in the area of 500 gpm at 30 to 35 ft of ted in families, corresponding to available motor
head. At a flow of 350 gpm and a total head of 35 sizes. Figure 2-9 shows, in dashed lines, curves for
ft, the efficiency is 70% four motors, from 2 to 7V2 hp. For heads of less
Fig. 2-10. Head capacity curve
450 -
400 - 9 in. diameter 3200 rpm
350 -
300 -
■D
<0
a> 250 -
£
75 200 -
o
H 150 -
100 -
50 -
1 1 1 MM 1 1 1 1
50 100 150 200 250 300 350
Gallons per minute
30 Lesson Two
than 35 ft and flows less than 225 gpm, a 3 hp one type typically available from manufacturers.
motor can be used. If, however, you have a flow of Some pump curves are plotted for a single impeller
400 gpm and a head of 30 ft, the point of intersec diameter at various speeds rather than various
tion is about halfway between a 3 hp and a 5 hp impeller diameters at a single speed. Both types are
motor. In such a case, the larger motor would be usually available from manufacturers.
required.
2.49 For pumps that have more than one impeller
2.47 There is one important curve that has not and in which all impellers are identical, one set of
yet been discussed —the NPSH curve. This can curves is usually given for one impeller. Since the
appear as a single curve or as a family of curves. capacity of a pump is dependent upon the first
The NPSH shown by the curve is required NPSH, impeller that the liquid encounters, the addition of
not available NPSH. The required NPSH influences impellers adds energy to the liquid. This additional
capacity more than head. Notice that for 9-in. energy results in a direct increase in head and horse
impellers, flows less than 550 gpm require a NPSH power. For example, suppose a pump operating at
of 10 ft or less, while a flow of 625 gpm would 1460 rpm has one impeller with a diameter of 7 '/8 in.
require at least 15 ft of head. At a flow rate of 350 gpm, the head is 25 ft and 2 hp
2.48 The pump curve shown in Fig. 2-9 is only is required. If the pump contains two impellers, the
head is increased to 50 ft and the required horsepower directly with the speed. You will need to use the manufac
to 4 hp. turer's capacity charts to help you determine the pump
capacity at a given speed.
Pump Selection
2.52 The altitude at which a pump operates has a defi
2.50 Although it might not be your job to select a nite effect on its capacity and performance. Because of the
pump for a particular application, it might be useful to reduced amount of air pressure at the higher altitude, less
know some of the things that must be considered when suction lift is available for the pump.
selecting a pump.Besides the suction lift or total dynamic
head, one of these requirements is the capacity of the 253 The temperature of the liquid being pumped is
pump. Normally, the capacity is given in gallons per another determining factor when selecting a pump. Liq
minute or cubic feet per second. The liquid used to rate uids pumped at low temperatures will show different
pump capacity is water. pump capacity than the same fluids at high temperatures.
In addition to the temperature and viscosity of the liquid,
25\ The speed of the pump is another factor that the specific gravity of the material is also important. The
determines the capacity and suction lift capability of a specific gravity and temperature of the material being
pump. The capacity of a centrifugal pump does not vary pumped have a direct result on the NPSH.
2-9. Under suction lift conditions, available 2-9. STATIC LIFT, HEAD LOSS
NPSH is equal to atmospheric pressure
minus vapor pressure, and Ref: 2.28
2-10. Most pump curves give a(n) 2-10. REQUIRED

NPSH, which should be at least as
large as the available NPSH. Ref: 2.32
2-11. What are the three basic types of 2-11. HEAD CAPACITY, EFFICIENCY,
curves used for centrifugal pumps? HORSEPOWER DEMAND
Ref: 2.36
2-12. Before using a specific pump curve, you 2-12. SPEED; DIAMETER
must know the of the pump
and the of the impeller. Ref: 2.36
2-13. A head capacity curve is a graphic rep 2-13. TOTAL HEAD

resentation of the relationship between
and flow conditions. Ref: 2.38
2-14. Pump curves are usually plotted in 2-14. FAMILIES
Ref: 2.44
2-15. The liquid used to rate pump capacity is 2-15. WATER
Ref: 2.50
2-16. Because of the reduced amount of air 2-16. SUCTION LIFT

pressure at high altitudes, less
is available for the pump. Ref: 2.52
Self-Check Quiz 33

2-1, When a pump is not running; it is said to
be in a 2-6. What IS the largest single contributing factor
to the reduction of pressure at a pump
□ a. flooded condition impeller?
□ b. static condition
□ c. lift condition □ a. Vapor pressure
□ d. dynamic condition □ b. Velocity head
□ c. Friction
2-2. With the pump shut off, the difference □ d. Required lift
between the suction and discharge liquid lev
els is called 2-7. For a pump curve to be valid, available NPSH
must be
□ a. elevation head
□ b. net positive suction head □ a. larger than the required NPSH
n c. friction head □ b. at least as large as the required
□ d. velocity head NPSH
□ c. the same as the required NPSH
2-3. The sum of the total static head, head loss, □ d. less than the required NPSH
and dynamic head is called
2-8. Which of the following is NOT a basic type of
□ a. NPSH centrifugal pump curve?
□ b. GPM
□ c. TDH □ a. Speed curve
□ d. PSI □ b. Head capacity curve
□ c. Efficiency curve
2-4 The horsepower input to a pump is called □ d. Horsepower demand curve
□ a. liquid horsepower 2-9. A head capacity displays the relationship

□ b. brake horsepower between total head and
□ c. suction horsepower
□ d. electrical horsepower □ a. shutdown head
□ b. efficiency
2-5. To calculate brake horsepower, you need to □ c. flow conditions
know the □ d. impeller diameter
□ a. liquid horsepower and motor 2-10. The temperature of the liquid being pumped
efficiency
will affect
□ b. electrical horsepower and motor
efficiency
□ a. pump capacity and NPSH
□ c. liquid horsepower and pump
□ b. NPSH and pump speed
efficiency
□ d. electrical horsepower and pump □ c. pump speed and TDH
efficiency □ d. TDH and pump capacity
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34 Lesson Two
SUMMARY
This Lesson explains the concept f ^

In a suction lift condition,The eye of the pump required NPSH-one is "characteristic of a Pu p
impeller is above the level of the liquid being and one a function of the system in which it oper
pumped.In a suction head condition,the eye of t e asIn addition,the methods of calculating pump
pump impeller is below tbe level of the liquid and motor efficiency (expressed as percentages)
being pumped.This Lesson examined many of the were described.The Lesson concluded with an
basic principles of pump hydraulics and related explanation of how to read pump performance
them to these two system configurations.
curves.
Liquid pressure may be expressed either in psi or

in ft of head.In order to calculate the total head in Understanding these pump terms and what they
a pumping installation, you must have a thorough actually mean relative to a pump's operating char
knowledge of such concepts as velocity head,fric acteristics is important to satisfactory pump main
tion loss,suction lift, static discharge head,and tenance. Without such knowledge,pump problems
others. Determining horsepower requirements that are of a design nature may appear to be
calls for an understanding of the three horsepower equipment failures.
calculations and their mathematical formulas.
2-1. b. Static condition. Ref: 2.02 2-6. d. Required lift. Ref: 2.29
2-2. a. Elevation head. Ref: 2.05 2-7. b. At least as large as the required
NPSH. Ref: 2.32
2-3. c. TDH. Ref: 2.09
2-8. a. Speed curve. Ref: 2.36
2-4. b. Brake horsepower.
Ref: 2.17 2-9. c. Flow conditions. Ref: 2.38
2-5. c. Liquid horsepower and pump 2-10. a. Pump capacity and NPSH.
efficiency. Ref: 2.23 Ref: 2.53
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Lesson Three
End-Suction
ContrifugalPumps
co
36
Lesson
End-Suction CentrifugalPumps
TOPICS
Introduction to Centrifugal Pumps Split-Case Centrifugal Pumps

Pump Operation Double-Volute Pumps
Pump Part Definitions Impeller Types
Pump Casing Materials Wearing Rings
End-Suction Casing Configurations Shafts, Bearings, and Sleeves
OBJECTIVES
• Describe the function of the following: pump cas Give characteristics of fluids pumped with open,
ing, shaft, impeller, wearing rings, and stuffing semi-open, and closed impellers.
box. Name an advantage and a disadvantage each for
• Contrast frame-mounted and close-coupled end-suc stainless steel and brass shaft sleeves.
tion pumps.
KEY TECHNICAL TERMS
Casing 3.10 the enclosure surrounding the pump Impeller hub 3.12 the portion of the impeller that
impeller, shaft, and stuffing box mounts on the shaft
Impeller 3.12 the part of the pump that supplies Suction intake 3.13 the passage through which
energy to the fluid to give it velocity and momen fluid enters the pump
tum Discharge outlet 3.13 the passage through
Impeller vanes 3.12 devices that direct the flow which the pump discharges fluid to the piping sys
of fluid within the pump tem
37
End-suction centrifugal pumps account for almost 80% of the pumps used in
industrial plants. There is a good chance that some of the pumps used in your
plant are of the end-suction centrifugal type. Therefore, after studying this Les
son, you will have some of the basic information necessary to work with end-suc
tion centrifugal pumps.
This Lesson describes the internal parts, construction, and operation of the several
kinds of end-suction pumps in common use. By using the information presented in
this Lesson, you will be able to explain the operation of centrifugal pumps, and
name the main components of such pumps. You will also be able to describe vari
ous kinds of pump casings, explain the function of wearing rings, and know how to
select the correct pump parts for a particular application.
introduction to Centrifugal Pumps next Lesson will cover vertical and regenerative
turbine pumps, which are also considered cen
3.01 Centrifugal pumps normally have capacities trifugal pumps.
from 5 to 500 gpm and produce heads up to 250 ft.
These pumps are relatively inexpensive, quiet, and 3.05 Because end-suction centrifugal pumps are
dependable. They are compact and simple in con available in a great variety of styles and have many
struction. When pumping fluids that contain more different uses, they do not always resemble each
than a small amount of vapor, however, their capacity other. They all have the same operating characteris
is reduced. tics, however.
3.02 Unlike positive-displacement pumps, cen 3.06 Because of their many applications, low ini
trifugal pumps will not continue to produce a head tial cost, and ease of maintenance, about 80% of the
when operating against a closed discharge. Centrifu pumps used in industrial plants are end-suction cen
gal pumps perform best when pumping low-viscosi trifugal pumps. They are used to move water and
ty fluids. Their capacity is greatly reduced when many other fluids. These centrifugal pumps can also
they are used to pump heavy oils and other viscous be adapted for pumping slurries, wood pulp and
fluids. chips, and other heavy materials. When pumping
these materials, however, the pumps are made of spe
3.03 Centrifugal pumps can be classified in several cial materials and require specially constructed
ways. They can be divided according to: impellers.
• the kind of impeller they contain 3.07 You might have helped repair a centrifugal
pump at some time, or maybe you have watched
• the number of stages they have the job being done. You probably found that, after
the piping and casing were removed, work on the
• their axis of rotation internal parts of the pump was relatively simple.
This Lesson describes the internal parts, construc
• the method used to drive them tion, and operation of end-suction centrifugal
pumps.
• their configuration or appearance.
Pump Operation
3.04 This Lesson will divide centrifugal pumps
by the last method, configuration or appearance. 3.08 The operation of a centrifugal pump is
This Lesson in particular will cover a major con based on centrifugal force. As the fluid being
figuration of centrifugal pump called the end-suc pumped enters the inlet or center section of the
tion pump. These types of pumps can be further pump, the rotating action of the impeller vanes
subdivided as close coupled or frame mounted, forces it to the outside of the pump casing, as
and can be mounted vertically or horizontally. The shown in Fig. 3-1 on the next page. Because the
Fig. 3-1. Fluid flow in a centrifugal pump for reference with the following definitions of
pump parts. Even if the pumps in your plant do
not look exactly like the ones shown in this Les
son, definitions for the various parts will be the
3.10 The casing is the enclosure surrounding

the pump impeller, shaft, and stuffing box. It
directs the flow of fluid into and out of the pump.
Casings are usually of the volute or increasing-
radius type.
3.11 Depending upon the type of motor connec

tion used, the pump shaft might be part of the
motor rotor, or it might be independent and cou
pled to the motor shaft. The shaft can be support
ed by its own bearings or by the motor bearings.
The method used depends upon the design of the
pump.
fluid moves faster at the outer edge of the
impeller, momentum increases. As more fluid 3.12 The impeller is the part of the pump that sup
enters the pump suction, more fluid momentum is plies energy to the fluid to give it velocity and
built up in the casing that encloses the impeller. momentum. The open area in the center of the
This momentum forces the fluid out of the pump impeller, called the impeller eye, partially determines
discharge port. the pump capacity. Impeller vanes or blades direct the
flow of fluid within the pump. Impeller shrouds
Pump Part Definitions enclose the blades of the impeller and contain the
flow of fluid in the impeller area. The portion of the
3.09 Figure 3-2 shows a cross section of a sin impeller that mounts on the shaft is called the
gle-stage, end-suction centrifugal pump. Use it impeller hub.
Fig. 3-2. End-suction centrifugal pump parts
Sbfnng box
Pump shaft
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End-Suction Centrifugal Pumps 39
3.13 The suction intake is the passage through Fig, 3-3. Double-suction centrifugal pump
which fluid enters the pump. It is normally located
near the center of the casing. The diameter of the pas
sage at this point partially determines the pump
capacity. The pump discharges fluid to the piping sys
tem through the discharge outlet.
3.14 Wearing rings are not always included in

the design of a pump. The main function of these
replaceable rings is to maintain the small clearance
between the impeller and the casing. Because even
this small clearance allows some fluid leakage,
abrasives in the pumped fluid can cause wear to the
pump parts. Wearing rings- protect the impeller and
casing from damage by the abrasives. Replacing
wearing rings is usually much simpler and more
economical than rebuilding or replacing pump
impellers or casings.
3.15 A pump seal seals the fluid in the pump.

The seal might be either a packed stuffing box, and multistage designs. The amount of fluid to be
which is replaceable and adjustable, or a mechani pumped and the required pressure determine the kind
cal seal, which consists of two polished, lubricat of pump used.
ed, mating parts running in contact with each
other. 3.17 A double-suction pump is shown in Fig. 3-3.
Its operation is similar to that of the single-suction
3.16 A single-stage, single-suction pump has been pump, except that fluid is drawn in on both sides of
described here for simple illustration of pump parts. the impeller and passes out through a single discharge
Centrifugal pumps are also made in double-suction outlet in the casing.
Fig.3-4. Multistage,single-suction pump
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3.18 Multistage pumps are available with either internal passages in the pump casing. Each stage
single or double suction. In a multistage pump, fluid builds up the velocity of the fluid until the desired
is discharged from one impeller to the next through head is reached. The additional impeller does not
Table 3-1. Material recommendations for corrosive substances
Pump Pump Pump

materials materials Liquid materials
Acetic Acid SS Creosote Cl, SS Picric Acid SS, SI

Acejpne Cl, BR _Ethyl Acetate SI, SS. Cl Potassium Bisulfate _BR,_SS_
Alcohol, Ethyl (grain) Cl, BR Ethylene Chloride SS, si Potassium Chloride BR, SS
Alcohol, Methyl (wood) Cl, BR Fatty ^cids SS, SI Potassium Nitrate _SS, Cl
Ammonia "Cl, SS Ferric Chloride R, SI, Ti Sea Water BR, Cl, SS
Ammonium Hydroxide Cl, SS Formaldehyde SI, Ti, K Sodium Carbonate Cl, BR, SS
Ammonium Nitrate SS. SI Formic Acid SI, k Sodium Chloride BR, Cl
Ammonium Phosphate SS. SI Hexane Cl, SS Sodium Hydroxide SS
Barium Nitrate Cl, SS, SI Hydrogen Peroxide SS Sodium Nitrate SS, Cl, SI "
Barium Sulfate SS^SI_ _ Isopropyl Alcohol Cl _ _ Sodium Phosphate Cl, SS, BR
Benzyl Acetate SS, SI Lye SS Sodium Sulfide SS, SI
_BoricAcic^ SS, M,SI Magnesium Sulfate SS, BR, Cl Stearic Acid ^S,Si
Brine "BR, Cl, M, SS Mercuric Nitrate SS Sulfite Liquors SS
Calcium Oxide (lime) BR, Cl, SS Methyl Chloride _CI, BR, SS_ Tannic Acid ^S,SI
Carbolic Acid (phenol) BR, Cl, SS Naphthalene Cl, BR, SS Titanic Sulfate si, BR
Carbon Tetrachloride SS, M, BR Naphthenic Acid SS Toluene (toluol) Cl, SS, BR
Caustic Soda SS Nitric Acid SS,Si,Ti Trichloroethylene CI,"SS, BR
Chromic Acid Ti, SI 0)^lic Acid SS, SI, K Xylene ^S
Copper Chloride Ti. SI Phenol SS78R Zinc Phosphate SS
Copper Sulfate SS, SI Phosphoric Acid SI, K Zinc Sulfide SS
Material abbreviations BR — Bronze SI — Silicon iron

Cl — Cast iron SS — Stainless steel (usually 316SS)
K — Karbate (impervious Graphite) Ti — Titanium
M — Monel
Fig. 3-5. End-suction centrifugal pumps
Close coupled Frame mounted
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End-Suction Centrigugal Pumps 41
increase the volume output of the pump. A multistage, eliminates the need to disconnect the piping. Both
single-suction pump is shown in Fig. 3-4 on the previ configurations are shown in Fig. 3-6.
ous page. 3.22 On most end-suction pumps, it is easy to
change the piping connections, since the volute case
Pump Casing Materials can be rotated a full 360°. This feature allows almost
unlimited positioning of the pump discharge.
3.19 The end-suction centrifugal pumps used in
industrial plants vary considerably in application. For 3.23 End-suction pumps can be either frame
this reason, pump casings are constructed in many mounted or close coupled. Both types are shown in
different styles and types. In addition,the pump cas Fig. 3-5. In the frame-mounted pump, the pump shaft
ings are made of many different materials. Cast iron, is coupled to the motor shaft. In the close-coupled
steel, and bronze are frequently used, as are many pump, the impeller is mounted directly on the motor
noncorrosive and abrasion-resistant alloys. A few of shaft. The close-coupled pump itself has no bearings.
the casing materials used with various fluids are The motor bearings support the entire load of the
shown in Table 3-1. impeller and motor rotor. The close-coupled pump
has several advantages:
End-Suction Casing Configurations
It occupies less space.
3.20 End-suction pumps are easy to recognize
because their suction and discharge ports are normally It eliminates vibration problems.
at 90° angles to each other. They are usually single-
suction, single-stage pumps with solid casings. Two It eliminates pump and motor shaft alignment
examples are shown in Fig. 3-5. problems.
3.21 Most end-suction pumps have a removable 3.24 End-suction pumps can be mounted either
faceplate or cover that gives access to the impeller on vertically or horizontally. Both of the pumps pictured
the shaft. Removing the faceplate involves removal of in Fig. 3-5 are mounted horizontally. Figure 3-7 on
the suction piping and possibly the discharge piping the next page shows a vertically mounted, close-cou
as well. Some pumps have a back pullout, which pled centrifugal pump.
Fig. 3-6. Back-pullout pump
Normal configuration Back pullout
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Programmed Exercises 43
3-1. The operation of a centrifugal pump is 3-1. CENTRIFUGAL FORCE

based on
Ref: 3.08
3-2. The casing of a pump encloses the 3-2. IMPELLER: STUFFING BOX
Dumo . the shaft, and the
Ref; 3.10
3-3. The is the part of the pump 3-3. IMPELLER

that supplies energy to the fluid.
Ref: 3.12
3-4. In afn1 Dumo, fluid is drawn 3-4. DOUBLE-SUCTION

in on both sides of the impeller and
passes out through a single discharge Ref: 3.17
outlet.
3-5. Does the additional impeller in a multi 3-5. NO

stage pump increase the volume out
put of the pump? Ref: 3.18
3-6. End-suction pumps are easy to recog 3-6. SUCTION AND DISCHARGE PORTS
nize because their are at 90-
degree angles to each other. Ref: 3.20
3-7. In the oumo. the imoeller is 3-7. FRAME-MOUNTED

coupled to the motor shaft.
Ref: 3.23
3-8. In the pump, the impeller is 3-8. CLOSE-COUPLED

mounted directly on the motor shaft.
Ref: 3.23
This material is protected by U. S. Copyright law. Copying by any optical, electronic, or other means is illegal withoLrt permission.
Fig. 3-8. Fluid flow in a single-stage,split-case This arrangement is shown in Fig. 3-8. Notice that
pump once the fluid enters the impeller, it moves as it would
in any other end-suction pump.
3.26 The main advantage of the split-case design

is that it eliminates the need to disconnect the suction
and discharge piping to gain access to the pump
impeller, shaft, and bearings. The upper half of the
casing can be removed completely for inspection and
repair purposes.
3.27 Figure 3-9 shows a horizontally split

pump. Notice that the split is made on the center-
line of the shaft. The term horizontal does not
refer to the position of the pump. If this pump
were mounted vertically, it would still have a hor
izontally split casing. Horizontal split indicates
the method of the split rather than the position of
the pump. A horizontal split is sometimes called
Split-Case Centrifugal Pumps an axial split.
3.25 Some end-suction pumps have casings that 3.28 Horizontally split pumps are available with
are split rather than solid. Horizontally split pumps single or double suction. They are also available as
are easy to recognize in that their suction and dis multistage pumps. The pump shown in Fig. 3-9 is a
charge ports are commonly parallel but opposite each two-stage, single-suction pump. As is the case with
other. Fluid enters the pump perpendicular to the other centrifugal pumps,the additional impeller of the
drive shaft, is turned 90° into the eye of the impeller, multistage pump increases pressure, but not volume
and leaves the pump perpendicular to the drive shaft. output.
Fig.3-9. Horizontally split pump
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3.29 Like other end-suction pumps, split-case Fig.3-10. Vertically mounted split-
models can be mounted vertically to save floor space. case pump
Their heavy construction gives these pumps long life.
A vertically mounted split-case pump is shown in Fig.
3-10.
3.30 Pump casings can also be split radially. At

one time, a radial split was commonly called a verti
cal split, meaning perpendicular to the centerline of
the shaft. Because the term was found to be confus
ing, it is now usually referred to as a radial split.
3.31 When manufactured with a radial split, cas
ings can be made up in segments and bolted together
to form a single pump, as shown in Fig. 3-11. This
feature simplifies construction and reduces casting
costs involved in making a multistage pump.
Double-Volute Pumps
3.32 Although the general principles involved in

the operation of end-suction pumps do not change the fluid passage. It also splits and balances the inter
from pump to pump, internal pump designs can vary nal radial force of the fluid, which reduces the load on
considerably. For example,the internal fluid action in the pump impeller, shaft, and bearings. Double-volute
volute casings tends to produce an unbalanced radial pumps are sometimes called vane pumps.
force. To reduce this imbalance, some pumps use a
double-volute casing, as shown in Fig. 3-12 on the 3.33 Double-volute guide vanes also help reduce
next page. This double volute adds a guiding vane to some of the stress on the casing walls. Double-volute
Fig. 3-11. Radially split multistage pump
Thismatenal is protected Dy U . S. Copyrigtit law. Copying by any optical, electronic, or other t

46 Lesson Three
Fig.3-12. Double-volute pump casing 3.38 The closed impeller has a shroud on both
front and back. Closed impellers are used to pump
fluids containing few or no solids. The closed
impeller is the most efficient of the three kinds in
terms of energy transfer.
Radial force 3.39 Impellers can have straight or curved vanes.

Straight-vane impellers are commonly used in small
industrial pump applications. They can be of semi-
Impeller open or closed design. Curved-vane impellers (also
called radial-vane impellers) are frequently used for
handling fluids containing lumpy solids or heavy par
ticles. Curved-vane impellers impart a higher velocity
to the pumped fluid than do straight-vane impellers.
Double
'volute Curved-vane impellers are available in open, semi-
open, and closed designs.
3.40 A type of double-suction impeller is shown in

Fig. 3-14. The double-suction type is similar to the
single-suction type, except there is no backing
guide vanes are available on both solid- and split- shroud. Instead, the center of the double-suction
case pumps. Guide vanes are also used on multi impeller has what might be called partial shrouds.
stage pumps to balance the discharge head and When joined, they have a curved shape that guides
guide the fluid to the suction area of the next stage. the fluid from the sides of the impeller to the tips of
the vanes. The vanes on each side are placed in
3.34 To strengthen pump casings, many high- matching positions and join to form a single vane
head pumps are manufactured with ribs around the near the outer edge of the impeller. The outer shrouds
casing exterior. These ribs are usually placed at form an enclosure for the material being pumped.
right angles to the direction of fluid flow.
3.41 The impellers discussed so far have been only
Impeller Types for single pumps. In multistage pumps, impeller
design must be worked out carefully to avoid increas
3.35 The impeller is the most critical part of a ing radial and thrust loads at each stage. To offset this
pump because its size, shape, and speed determine loading, impellers are frequently mounted back-to-
the pump s capacity. It is important to understand back, even though they are several inches apart. Some
that the impeller does not cup the fluid it is pump pump impellers are equipped with small vanes on the
ing, but slides throupThe fluid and throws it. This back of the shroud to pump any fluid that gets behind
throwing action was illustrated in Fig. 3-1. the impeller. This action also helps counteract the
thrust from normal impeller wear.
3.36 Figure 3-13 shows three impellers. The
open impeller has no shrouds. These impellers are 3.42 Like pump casings, pump impellers can be
used primarily for pumping fluids containing large made of cast iron, cast steel, fabricated steel, bronze,
solids. brass, molded rubber, fiberglass, or nearly any other
material compatible with the material being pumped.
3.37 The semi-open impeller has a back shroud,
but no front shroud. When seen from the back, the Wearing Rings
shroud forms a complete circle. Semi-open
impellers are most often used to pump fluids con 3.43 For a pump to operate correctly, there must
taining medium-sized solids. Both open and semi- be a physical separation between the high- and low-
open impellers are used in high-volume, low-pres pressure sides. Otherwise, fluid would simply circu
sure applications. late from the high-pressure side to the low-pressure
5 material is protected by U. S. Copyright law. Copying by any optical, electronic, or other means is illegal withoul permission.
Fig.3-13. Centrifugal pump impellers
Semi-open
Closed
side and be repumped. Although the impeller sepa corrosion-resistant materials are expensive, it is usu
rates the high- and low-pressure sides, a small clear ally good practice to install a high-quality shaft
ance exists between the impeller and the pump cas despite the higher initial cost.
ing. Even though this space is small, some fluid still
passes. 3.48 Shaft bearings can be of the sleeve, single- or
double-row ball, or roller bearing type. In addition,
3.44 When this fluid passes, some solids pass as some pumps use special thrust bearings to counteract
well. These solids can cause the pump impeller and high end thrust. Thrust bearings are normally used on
casing to wear. Wearing rings prevent damage to the
impeller and casing. They are usually made of the
same material as the impeller and casing and can be Fig.3-14. Cross section of a double-suction
installed on the casing (both front and back) and on impeller
the impeller edges. Some typical arrangements are
shown in Fig. 3-15 on the next page.
Discharge vane edge or tip
3.45 If both the casing and impeller have wearing

rings, you can replace both rings without having to
replace the impeller. If wearing rings are used only on Suction eye
the volute case, you must replace the rings and
impeller at the same time.
3.46 If pumps do not have wearing rings, worn

parts must be replaced or rebuilt. On some small
pumps, parts replacement is fairly inexpensive. On
large pumps,however, the cost of wearing rings is far Suction vane
less than the cost of replacing the worn parts. edge or tip
Shafts, Bearings, and Sleeves
3.47 Pump shafts are normally made of stainless

steel or other corrosion-resistant materials. Although
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48 Lesson Three
Fig.3-15. Wearing ring arrangements
No rings Flat ring Ring in

casing groove
Rings on casing and impeller
on casing
multistage pumps that have high pressures and deliv ing box. The sleeve protects the shaft from wear by
eries. On small horsepower pumps, the impeller and the packing or seals.
shaft frequently overhang the motor bearing. In such
cases, all radial and axial thmst must be taken up by 3.51 Shaft sleeves are usually made of high-carbon
the motor bearings. steel, stainless steel, or brass. Stainless steel is the
most expensive, but will outlast the other types. Brass
3.49 On large pumps, the motors are usually has the shortest life, but is easier to replace than the
coupled to the pump shaft. The shaft is indepen others. High-carbon steel is the hardest of the three to
dently supported by one or two bearings, depend remove, and has a life span between the other two.
ing upon the design. Oil-lubricated bearings are
usually provided with a separate oil sump. Some 3.52 A shaft sleeve must be secured to the shaft on
pump manufacturers use bearings that require which it is installed in order to keep it turning with
grease. Bearings will be discussed in more detail in the shaft. Also, the sleeve must fit tightly enough to
Lesson Ten. prevent leakage between the shaft and sleeve. Some
sleeves are threaded onto the shaft. Others are keyed
3.50 Shaft sleeves are located on a pump shaft at to the shaft with the key used to keep the impeller
the point at which the shaft passes through the stuff from rotating independently.
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3-9. The main advantage of the split-case 3-9. PIPING

design is that there is no need to dis
connect the to Gain access to Ref: 3.26
the pump components.
3-10. A double volute casing adds a(n) 3-10. GUIDING VANE

to the fluid passaae.
Ref: 3.32
3-11. The impeller does not cup the fluid it is 3-11. THROWS
pumping, but slides through the fluid
and it. Ref: 3.35
3-12. The impeller is the most effi 3-12. CLOSED

cient in terms of energy transfer.
Ref: 3.38
3-13. Which impeller imparts a higher veloci 3-13. CURVED-VANE

ty to the pumped fluid, curved-vane or
straight-vane? Ref: 3.39
3-14. A physical separation between the high 3-14. WEARING RINGS

and low pressure sides of a pump is
maintained by Ref: 3.43-3.44
3-15. If wearing rings are used only on the 3-15. IMPELLER

volute case, you must replace the rings
and the at the same time. Ref: 3.45
3-16. What kinds of bearings are normally 3-16. THRUST

used on multistage pumps that have
high pressure and deliveries? Ref: 3.48
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Self-Check Quiz 51

3-1. Which part of the end-suction pump directs 3-6. What does an impeller in a centrifugal pump
fluid flow into and out of the pump? do to the fluid being pumped?
□ a. Suction intake □ a. Cups it

□ b. Wearing rings □ b. Sprays it
□ c. Shaft □ c. Laps it
□ d. Casing □ d. Throws it
3-2. The function of a pump's impeller is to 3-7. Which kind of impeller is used mainly for
pumping fluids containing large solids
□ a. supply energy to the fluid
□ b. direct fluid flow within the pump □ a. Open impeller
□ c. support the pump shaft □ b. Semi-open impeller
□ d. allow fluid into the pump □ c. Semi-closed impeller
□ d. Closed impeller
3-3. In which pump is fluid drawn in on both sides
of the impeller and discharged thorugh a sin 3-8. A physical separation between the impeller
gle outlet? and the casing is maintained by the
□ a. Single-suction pump □ a. bearings

□ b. Double-suction pump □ b. shaft sleeves
□ c. Multistage pump □ c. packing glands
□ d. Frame-mounted pump □ d. wearing rings
3-4. The close-coupled pump has no 3-9. Multistage pumps that have high pressure
and deliveries usually use special
□ a. impeller
□ b. vanes □ a. sleeve bearings
□ c. bearings □ b. thrust bearings
□ d. ports □ c. roller bearings
□ d. ball bearings
3-5. Which of the following statements about
close-coupled pumps is false? 3-10. Which shaft-sleeve material lasts the
longest?
□ a. They take up less space than frame-
mounted pumps □ a. Copper
□ b. They can only be mounted horizon □ b. Brass
tally □ c. Stainless steel
□ c. They present no shaft alignment □ d. High-carbon steel
problems
□ d. They elminate vibration problems
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52 Lesson Three
SUMMARY
Centrifugal pumps operate by centrifugal force. Wearing rings maintain a small clearance between
They are made in single-suction, double-suction, the impeller and the casing and protect those parts
and multistage designs. The pumps can either be from damage by abrasives in the pumped fluid.
frame mounted or close coupled.All end-suction
centrifugal pumps do not look alike, but all have Shafts, bearings,and sleeves are other components
essentially the same parts. Casing,impellers,and of centrifugal pumps.Shafts should be made of
some kind of seal are common to all end-suction high-quality,corrosion-resistant materials. Bear
centrifugal pumps.Pump casings can be solid or ings may be of the sleeve,single- or double-row-
split,impellers can be of the open,semi-open,or ball, or roller bearing type. Special thrust bearings
closed design. Impeller vanes can be straight or are required in some applications. The shaft sleeve
curved. protects the shaft from wear.
3-1. d. Casing. Ref:3.10 3-6. d. Throws it. Ref: 3.35
3-2. a. Supply energy to the fluid. 3-7. a. Open impeller. Ref: 3.36
Ret: 3.12
3-8. d. Wearing rings.
3-3. b. Double-suction pump. Ret: 3.17 Ref: 3.43-3.44
3-4. c. Bearings. Ref; 3.23 3-9. b. Thrust bearings.

Ref: 3.48
3-5. b. They can only be mounted
horizontally. Ref: 3.23-3.24 3-10. c. Stainless steel. Ref: 3.51
Figure 3-2. Worthington Division, McGraw-Edison Gomapny Rgure 3-6. Environmental Training Consultants, Inc.
Figure 3-3. ITT Bell & Gossett Figure 3-7. Aurora Pump, A Unit of General Signal
Figure 3-4. Worthington Division, McGraw-Edison Company Figure 3-9. Aurora Pump, A Unit of General Signal
Figure 3-5. Price Pump Co. and Worthington Division, McGraw- Figure 3-10. PACP Pumps
Edison Company Rgure 3-11. Carver Pump Company
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UNDERSTANDING THEOPERATION OFPUMPS
irt
V
54
Lesson
Propeller and Turbine Pumps
TOPICS
Turbine Pump Introduction Mixed-Flow Propeller Pumps

Lineshaft Turbines Special Propeller Pumps
Can Turbines Turbine Pump Construction
Submersible Turbines Vertical Turbine Pump Applications
Flow Patterns Regenerative Turbine Pumps
Axial-Flow Propeller Pumps
OBJECTIVES
• Explain the construction of a line-shaft turbine Define electrochemical corrosion and state its
pump. cause.
• Name the two types of flow possible in a propeller Describe fluids that can be pumped by a regener
pump. ative turbine pump.
• Tell the function of diffuser vanes in an axial-flow
propeller pump.
KEY TECHNICAL TERMS
Thrust bearing 4.14 the top bearing in a hollow Mixed flow 4.30 fluid moving with a swirling
shaft motor motion
Radial bearing 4.14 the bottom bearing in a hol Electrochemical corrosion 4.40 a phenomenon
low shaft motor causing pitting and material buildup in a pump
Axial flow 4.30 fluid moving parallel to the pump
shaft
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Turbine pumps, because of their size and capacity, are often used where other
centrifugai pumps are unsuitabie. To operate or maintain a turbine pump, you
need to understand the specifics of turbine pump operation and recognize the
differences among the various kinds of pumps.
Each kind of pump has its own advantages and disadvantages, which make
each kind suitable for different applications. You must know what kind of
flow pattern each turbine pump produces and what volume and discharge
head each is capable of handling.
When selecting a pump for a particular application, you must be sure its parts
are made of materials appropriate for the conditions under which the pump will
be used. After studying this Lesson, you will have some of the basic informa
tion necessary to select, operate, and maintain turbine pumps.
Turbine Pump Introduction • lineshaft turbines
4.01 The previous Lesson presented quite a bit of • can turbines

information about end-suction and split-case centrifu
gal pumps and their applications. Although more end- • submersible turbines
suction centrifugal pumps are used in industry than
any other type, they do have certain limitations. In • propeller pumps.
some situations, such as in deep wells, their size lim
its their use. They also have limited capacity and effi An example of each is shown in Fig. 4-1 for compari
ciency. For certain applications, one of the various son purposes.
styles of turbine pump might be chosen.
Lineshaft Turbines
4.02 Vertical turbine pumps are classified both by
physical configuration and by flow pattem. The com 4.03 Lineshaft turbines are composed of four
mon physical configurations are: major parts, as shown in Fig. 4-2 on the next page.
Fig.4-1. Common vertical turbine pumps
I IS illegal without permission.

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56 Lesson Four
pump can handle depends upon the capabilities of the

Fig.4-2. Llneshaft turbine first impeller.
4.07 The ability to add bowls to obtain high pres

sures makes this kind of pump very popular for use in
deep wells in industry, irrigation, and municipalities.
— Discharge head
4.08 The entire bowl assembly of a lineshaft tur
bine is usually submerged. Fluid travels from the
<1 Water column bowl assembly through the water column. The col
umn contains the drive shaft and radial bearings.
These bearings help to keep the shaft aligned. They
can be made of bronze or rubber.
4.09 Rubber bearings are usually water lubricated.

Bronze bearings are usually oil lubricated. The oil-
Pumping unit
lubricated bearing generally works better in deep
wells (over 300 ft). Some state regulatory agencies
insist that oil-lubricated pumps not be used in munici
pal wells.
4.10 The column is secured to the discharge head.

The pump discharge piping is connected to the dis
They are, starting at the bottom of the illustration: charge head. The discharge head contains the stuffing
box. In water-lubricated pumps, the stuffing box con
• the pumping unit tains either packing or a mechanical seal. Either can
be used to control leakage around the shaft.
• the water column
4.11 Because of the high pressures at which line-
• the discharge head shaft turbines often operate, it is a common practice
• the motor or drive unit.
4.04 The pumping unit (Fig. 4-3) consists of a Fig. 4-3. Lineshaft turbine pumping unit
bowl assembly and a suction bell. Fluid enters the
pumping unit at the suction bell. It then passes to the
bowl assembly, which consists of an impeller and a
bowl or casing. The bowl surrounds the impeller and
serves the same function as the volute of an end-suc
tion centrifugal pump. Bowl
assemi
4.05 If the pump contains more than one bowl, as

Bearing
in Fig. 4-2, the pumped fluid passes upward through
each bowl assembly. The amount of energy and pres
sure added to the fluid is directly proportional to the
number of bowls. For example, if one bowl produces Impeller
50 psi, then two bowls will produce 100 psi, and three
will produce 150 psi.
4.06 The amount of fluid pumped is not changed

by the addition of pump bowls. The amount of fluid a
Th. i. prc.ec.ed by U. S. Cppyr.gh, Copying ^
Propeller and Turbine Pumps 57
to use metal-core or metal-fiber packing. Such Fig.4-4. Can turbine pump

packing allows ample tightening of the packing
without squeezing the lubricant from the packing.
Shafts packed in this way last much longer than
those packed with conventional packing.
4.12 When the pump uses oil-lubricated bear

ings, the drive shaft is fitted inside of a protective
sheath that contains the bearings. With this
arrangement, there is no packing material and no
mechanical seal in the stuffing box. There should
be no leakage from this type of stuffing box.
4.13 The motor is located above the discharge

head. The common practice is to use hollow shaft
motors on lineshaft turbines. The pump drive shaft
passes through the motor shaft and is secured to
the top of the motor by the head nut. This arrange
ment places the entire load of the drive shaft and
impellers on the top bearing of the motor.
4.14 The motor's top bearing is referred to as

the thrust bearing and is often a spherical-roller
thrust bearing. The bottom bearing in this type of
motor is commonly called the radial bearing. It is
usually a single-row, deep-groove ball bearing.
4.15 The impellers used most often in lineshaft

turbine pumps are either closed or semi-open. The
4.18 This configuration can be confusing at first
semi-open impeller can be raised or lowered after
glance, because the inlet and outlet lines are commonly
pump installation to alter the pump capacity and
directly opposite one another. The incoming fluid is
discharge pressure. This adjustment is made by
fed down into the can. The turbine inside the can
adjusting the head nut. It is for this purpose that
pumps the fluid up and out the discharge port.
the hollow-shaft motor was designed.
Submersible Turbines
4.16 Adjustment of the impeller setting on
semi-open impeller pumps can be critical. On one
particular pump, for example, a change of 0.001
4.19 Another version of the vertical turbine pump
in. on the head nut can alter the discharge head 10 is the submersible turbine. This kind of pump is used
in many individual homes and in municipal and
ft.
industrial wells. A submersible turbine pump is shown
Can Turbines
in Fig. 4-5 on the next page. The pump portion of this
unit is similar to that of the lineshaft turbine. The
major difference is that the motor is located under the
4.17 The can turbine is an adaptation of the
pump instead of above it. The entire assembly is low
lineshaft turbine. It is often used as a booster
ered into the fluid to be pumped. The fluid is used to
pump, especially in municipal water systems. A
cool the motor.
can turbine pump is shown in Fig. 4-4. In this
design, a lineshaft turbine is placed inside a metal
4.20 This pump's configuration eliminates the
or concrete "can." Fluid enters the can under pres
sure. The pump simply moves the fluid out of the problems commonly associated with long drive lines
can at a higher pressure. and their bearings. It does cause other problems, how-
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58 Lesson Four
Fig. 4-5. Submersible turbine pump ever. If fluid enters the motor, the motor will fail.
Also, you lose the ability to adjust the impeller clear
ance as you can with a lineshaft turbine.
Flow Patterns
4.21 As was mentioned earlier in this Lesson, ver

tical turbines can be classified both by physical
description and by flow pattern.
4.22 The lineshaft turbine, can turbine, and sub

mersible pump are all classified as mixed-flow
pumps. Mixed flow indicates several things:
• The fluid inside the pump does not flow

straight up the shaft, as in an axial-flow
pump.
• The fluid inside the pump does not make a

right-angle turn as it flows through the
impeller.
• Energy is transferred to the fluid being

pumped in two ways—by centrifugal force
and by a wedging action.
4.23 Another major style of vertical turbine is

called a propeller pump. Propeller pumps can be
classed as axial-flow or mixed-flow pumps. Mixed-
flow propeller pumps move fluid partly by cen
trifugal force and partly by the lift of the blades or
vanes on the fluid. Axial-flow propeller pumps
move fluid only by the propelling or lifting action
of the blades on the fluid.
4.24 The two separate designs, although they

resemble each other outwardly, have different oper
ating characteristics. Both axial-flow and mixed-
flow propeller pumps are commonly installed with
the entire pumping unit submerged.
Axial-Flow Propeller Pumps
4.25 Axial-flow propeller pumps are often used

to supply water for municipalities and irrigation
purposes. They are also used for pumping out
ponds or areas having excess amounts of water.
These pumps normally deliver a high volume at
low head, and are supported from the drive area. A
typical axial-flow propeller pump is shown in Fig.
4-6.
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Fig.4-6. Propeller pump
Thrust bearing
Labyrinth
seal
Sieeve
bearing —
flush lines
Mounting
plate
Sieeve bearing
Shaft sleeve
Flanged
connection
Propeller
keyed to shaft
Propeller
nut
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60 Lesson Four
Fig.4-7. Axial-flow propeller pump bowl
Diffuser
"vanes
C D
steady _
bearing
Propeller
Suction bell
4.26 The propeller pump bowl, as shown in

cross section in Fig. 4-7, frequently resembles a
short length of pipe. Generally, it is slightly smaller
in diameter than the discharge pipe to which it is
bolted. Often the pump bowl contains a set of dif
fuser vanes. The diffuser vanes reduce the stirring
action caused by the pump propeller and thus
straighten the flow of fluid into the discharge pipe.
4.27 In addition, the pump bowl contains one or

two steady bearings. These bearings keep the shaft
and impeller turning in a true line.
4.28 The suction bell is usually flared at the bot

tom. The bell might have diffuser vanes. Occasional
ly, an additional shaft steady bearing is built into the
suction bell. The type and construction of the bell are
determined by the application and by the manufactur
er of the pump.
4-1. In a lineshaft turbine, fluid enters the 4-1. SUCTION BELL

pumpina unit at the
Ref: 4.04
4-2. The amount of pressure in a lineshaft 4-2. BOWLS

turbine pump can be increased by
addino Ref: 4.05
4-3. The water column of a lineshaft turbine 4-3. DRIVE SHAFT, RADIAL BEARINGS
contains the and the
Ref: 4.08
4-4. The turbine is often used as 4-4. CAN

a booster pump.
Ref: 4.17
4-5. In a submersible turbine pump, where 4-5. UNDER THE PUMP

is the motor located?
Ref: 4.19
4-6. Which kind of propeller pump moves 4-6. AXIAL FLOW

fluid only by the propelling or lifting
action of the blades on the fluid? Ref: 4.23
4-7. What kind of propeller pump moves 4-7. MIXED FLOW

fluid partly by centrifugal force?
Ref: 4.23
4-8. The function of diffuser vanes is to 4-8. REDUCE; STRAIGHTEN

the strino action and to
the flow of fluid into the dis ReF: 4.26
charge pipe.
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62 Lesson Four
Mixed-Flow Propeller Pumps This feature is especially convenient when the pumps
are down 20 ft or more and removing the piping and
4.29 A variation of the axial-flow propeller pump is casing would require a great deal of time and special
the mixed-flow propeller pump. Although these two machinery. The smaller casing is connected to the
pumps are similar in design and in the type of materials larger discharge pipe by a split adapter ring. When the
used in construction, the impellers are quite different. An ring is removed, the casing can easily be pulled up
example of each type of impeller is shown in Fig.4-8. through the discharge pipe.
4.30 Unlike axial-flow impellers, which move the Special Propeller Pumps
fluid parallel to the shaft, mixed-flow impellers give a
slight swirling motion to the fluid as it leaves the 4.34 Although most axial- and mixed-flow pro
impeller blades. The combination of axial and radial peller pumps operate with the impeller submerged in
motion led to the mixed-flow classification. fluid, some propeller pumps are mounted horizontally
and are located above the fluid's surface. Even when
4.31 Because of their design and the centrifugal mounted in the horizontal position, the pump still has
action they impart, mixed-flow impellers are capable an end or bottom suction. Horizontally mounted
of attaining a slight suction lift. They are restricted, pumps are limited in application and are only men
however, to impeller speeds above 4200 rpm. When tioned at this point to make you aware of their avail
operating at speeds below 4200 rpm, their operating ability. Such a pump is shown in Fig. 4-9.
efficiency decreases considerably.
4.35 In applications involving high discharge
4.32 The vanes of a mixed-flow impeller, which heads, propeller pumps can be used in double or triple
are enclosed in shrouds, discharge the fluid outward stages. Each stage will have the same propeller
ly, much like an end-suction centrifugal pump. design. In operation, diffuser vanes direct the fluid
Although this kind of mixed-flow pump resembles a discharged from one impeller into the suction of the
vertically mounted end-suction centrifugal pump,it is next stage. This action boosts the fluid's pressure and
designed to handle much larger volumes of fluid. velocity until it overcomes the head.
4.33 Frequently the bowl assembly of a mixed- 4.36 Although small, fractional horsepower sump
flow or axial-flow pump is cast slightly smaller than pumps are usually of the end-suction centrifugal type,
the discharge pipe. This construction permits the bowl the larger sump pumps for sewage and slurry applica
and impeller to be removed up through the discharge tions are often propeller pumps. Propeller pumps can
pipe without dismantling the piping and supports. handle much larger volumes of fluid than can end-
suction pumps and generally are driven by motors of
5 to 10 hp or more.
Fig.4-8. Propeller pump impellers
Turbine Pump Construction
Axial f ow
4.37 Vertical turbine pump suction bells and bowl
assemblies can be made from a variety of materials.
Usually, they are made of cast iron or steel. Pumps
handling brine or chemically polluted water are usual
ly made of stainless steel, bronze, or other noncorro-
sive alloys. Abrasion-resistant alloys are frequently
used when the pumped fluid contains gritty material.
Mixed flow
4.38 Pump impellers are usually made of cast

materials similar to those used for the bowls. The
choice of material depends upon the pump application
and the compatibility of the impeller with the bowl
material.
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Fig. 4-9. Horizontally mounted propeller pump
4.39 Because the impeller, bowl, and suction bell

are usually located under water at all times, the
selection of materials is important. If the wrong Fig.4-10. Turbine pump drive shaft and bearings
materials are selected, pump parts will corrode
quickly, and unnecessary repairs will be required to
keep the system in operation and pumping at peak
efficiency. Coupling
4.40 In addition, if incompatible materials are

Bearing
used, a phenomenon called electrochemical corrosion
can occur. Electrochemical corrosion causes pitting
and material buildup on the pump's internal parts. It is
Drive shaft
most often a problem when the pumped fluid is high
in dissolved solids. To counteract corroding and elec
trochemical action, special paints or surface coatings
can be used.
Bearing
4.41 The discharge head of a vertical turbine pump

is usually made of fabricated or cast steel. Occasion
ally, more expensive alloy steels are used. Fabricated
Coupling
bronze or brass pipes are also used. The material
selection depends upon the application.
Bearings
4.42 The drive shaft, as shown in Fig. 4-10,
extends down through the discharge pipe from the
drive motor coupling. The drive shaft can be coupled
directly to the drive motor by a splined hollow shaft, Impeller
Bowrl assembly
or with a flexible coupling. Depending upon the

Suction bell
length, the shaft can be made of a single piece of steel
or it can be made in sections.
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4.43 Support bearings are sometimes located along well in which it is placed. When used in wells, the
the shaft to maintain alignment and to keep the shaft pumps are also limited in capacity by the amount of
from deflecting as it rotates. The supporting bearings are fluid they can withdraw without depleting the supply
often fastened to sides of the discharge pipe by diffuser in the pipe. The pumps are usually made up of two or
vanes. These bearings can be made of rubber or bronze. more segments or stages, depending upon the well
and the head requirements.
4.44 The shaft is normally sealed at the point at which
it passes through the bend in the discharge pipe. The shaft 4.48 In addition to direct mounting in wells, verti
might be sealed with packing or with a mechanical seal. cal turbines are frequently mounted in a wet sump
In addition to the shaft seal, there are probably several with a steady inflow of water. In these applications,
guide vanes in the bend area to direct the flow of fluid the can turbine discussed earlier is used. The pump is
around the bend smoodily. These guide vanes also direct often used to handle steam condensate and fresh
the fluid pressure away from the shaft seal. water, and in so doing, frequently must pump against
a high discharge head.
4.45 In some applications, the drive shaft is sup
ported or contained within a separate housing in the Regenerative Turbine Pumps
discharge pipe. In such cases, the shaft and bearings
operate in a dry atmosphere, except for the lubricant 4.49 Regenerative turbine pumps, also called
provided at the bearings. periphery pumps, are a unique version of centrifugal
pump in which the impeller is a wheel with a large
Vertical Turbine Pump Applications number of small vanes on both sides of the rim. A
close-coupled, regenerative turbine pump is shown in
4.46 Vertical turbine pumps vary in output capaci Fig. 4-11. Figure 4-12 shows the pump's impeller and
ty from 10 to over 25,000 gpm. In addition to pump inner casing. The impeller rotates at a high speed
ing large quantities, these pumps are designed to (3600 rpm and up) in a ring-shaped channel in the
operate under heads up to approximately 1000 ft. pump's casing.
4.47 The size and capacity of a vertical turbine 4.50 Some people refer to this kind of pump sim
pump are usually restricted by the diameter of the ply as a turbine pump. The term regenerative, howev-
Fig.4-11. Regenerative turbine pump
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Fig.4-12. Regenerative turbine impeller Fig.4-13. Flow in a regenerative turbine pump
Suction Discharge
Stripper-
Impeller
■Impeller
Casing
er, describes more fully the action of the pump during shown in Fig. 4-13. When the fluid reaches the dis
its operation, and the method it uses to build up the charge port, it is forced out by a stripper between the
required head. Component parts of these pumps are suction and discharge ports.
constructed of materials similar to those used in the
pumps discussed previously. 4.54 Because of the close clearances between the
impeller and the casing, regenerative turbines cannot
4.51 Regenerative turbines are usually easy to be used to pump fluids containing grit or other solid
recognize. Unlike the eccentric volute of an end-suc particles. They can, however, pump fluids containing
tion centrifugal pump, the case of a regenerative tur vapors or gases, providing there is enough liquid pre
bine is perfectly round. The suction and discharge sent to seal the close clearances.
are usually close together and of the same size pipe.
These pumps can be either frame mounted or close 4.55 Regenerative turbines can be used only to
coupled. pump fluids with relatively low viscosities. Their life
span is usually only a quarter that of a conventional
4.52 A relief valve is usually provided on the dis centrifugal pump under similar operating conditions.
charge side of the pump because of the high head Foreign materials in the pumped fluid or corrosion
pressures that can develop within the pump. The relief cause a rapid loss of capacity.
valve usually directs the discharged fluid back to the
suction side of the pump. 4.56 Regenerative turbine pumps are considered self
priming, but are restricted in their capacities. Usually,
4.53 As fluid enters the pump, a separator sends they are manufactured as small pumps of less than 100
half of the fluid to each side of the impeller. The gpm with heads up to 500 ft. In applications requiring
clearance between the edge of the impeller and the high-head capacities, the fluid delivery in gpm is rela
outside of the case is the same all around the case. tively low. The horsepower required to drive the pump
The rotating impeller throws fluid toward the case, is higher at the high head pressures with low gpm. The
which directs it back to the impeller. This process is horsepower drops, however, when the head pressure
repeated as the fluid travels around inside the case, as drops and the fluid delivery increases.
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4-9. The vanes of a mixed-flow impeller dis 4-9. OUTWARDLY

charge the fluid
Ref: 4.32
4-10. If incompatible materials are used in a 4-10. ELECTROCHEMICAL CORROSION

pump. can cause oittino and
material buildup. Ref: 4.40
4-11. The discharge head of a vertical turbine 4-11. FABRICATED or CAST STEEL
pump is usually made of
Ref: 4.41
4-12. Vertical turbine pumps can handle 4-12. 25,000 gpm

capacities up to cpm.
Ref: 4.46
4-13. In a regenerative turbine pump, the 4-13. VANES

impeller Is a wheel with a large number
of on both sides of the rim. Ref: 4.49
4-14. The case of a regenerative turbine is 4-14. ROUND

in shape.
Ref: 4.51
4-15. Regenerative turbines cannot pump 4-15. GRIT or SOLID PARTICLES

fluids containinc
Ref: 4.54
4-16. When the head pressure drops and 4-16. DECREASES

the fluid flow increases, the horsepow
er required to drive a regenerative tur Ref: 4.56
bine pump
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Self-Check Quiz 67

4-1. The lineshaft turbine's bowl assembly and 4-6. In an axial-flow propeller pump, which of the
suction bell together are called the following straightens the flow of fluid into the
discharge pipe?
□ a. pumping unit
□ b. water column □ a. Diffuser vanes
□ c. discharge head □ b. Steady bearings
□ d. drive unit □ c. Suction bell
□ d. Impeller
4-2. If one bowl of a lineshaft turbine produces a
pressure of 30 psi, three bowls will produce 4-7. Which of the following is NOT a characteristic
□ a. 10 psi
□ b. 30 psi □ a. It imparts a swirling motion to the
□ c. 45 psi fluid
□ d. 90 psi □ b. It can attain a suction lift
□ c. It can handle larger volumes of fluid
4-3. Which of the following is often used as a than end-suction pumps
booster pump? □ d. It operates best at speeds below
4000 rpm
□ a. Lineshaft turbine
□ b. Can turbine 4-8. Pump suction bells and bowl assemblies are
□ c. Submersible turbine usually made of
□ d. Propeller pump
□ a. bronze or cast iron
4-4. How is a submersible pump's motor cooled? □ b. cast iron or steel
□ c. steel or brass
□ a. By a fan □ d. brass or rubber
□ b. By circulating oil
□ c. By the pumped fluid 4-9. As fluid enters a regenerative turbine pump,
□ d. By a graphite solution
□ a. it turns a 90° angle
4-5. The fluid inside a mixed-flow pump □ b. it moves up the shaft
□ c. half is sent to each side of the
□ a. flows straight up the shaft impeller
□ b. moves in a circular spiral □ d. it is compressed
□ c. moves by centrifugal force and by a
wedging action 4-10. Regenerative turbine pumps CANNOT be
□ d. makes a 90° turn at the impeller used to pump
□ a. fluids containing solid particles

□ b. fluids containing vapors
□ c. clear fluids
□ d. low-viscosity fluids
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68 Lesson Four
SUMMARY
Vertical turbine pumps are often used in applica essentially a lineshaft turbine placed inside a metal
tions where end-suction centrifugal pumps cannot or concrete "can."
be used. Vertical turbine pumps are classified
according to physical configuration and by flow Submersible turbines are used in municipal and
pattern as lineshaft turbines,can turbines,sub industrial wells.The motor is located under the
mersible turbines,and propeller pumps. pump,and the entire assembly is lowered into the
fluid to be pumped.Propeller pumps can be axial-
Lineshaft turbines can obtain high pressures, flow or mixed-flow devices.The pumps are common
which makes them suitable for use in deep wells. ly installed with the entire pumping unit submerged.
The high pressures are obtained by adding pump
bowls to the pumping unit.A hollow shaft motor, Regenerative turbine pumps can pump vapors or
located above the discharge head,is generally used. gases, but not fluids containing solid particles. The
capacity of the pump is limited,and its life span is
The can turbine is often used as a booster pump in considerably shorter than that of a conventional
municipal water systems and in wet sumps.It is centrifugal pump.
4-1. a. Pumping unit. Ref. 4.04 4-6. a.

a. Diffuser vanes. Ref: 4.26
4-2. d. 90 psi. Ref: 4.05 4-7. d.

4000 rpm. Ref: 4.31
4-3. b. Can turbine. Ref: 4.17
4-8. b.
4-4. c. By the pumped fluid. Ref: 4.19
4-9. c. Half is sent to each side of the
4-5. c. Moves by centrifugal force and by a impeller. Ref: 4.53
wedging action. Ref: 4.23
4-10. a. Fluids containing solid particles.
Ref: 4.54
Figure 4-1. Peerless Pump and Burks Pumps Figure 4-6. Lawrence Pumps Inc.
Figure 4-2. Byron Jackson Pumps Figure 4-8. Peerless Pump
Figure 4-4. Byron Jackson Pumps Figure 4-9. Lawrence Pumps, Inc.
Figure 4-5. Byron Jackson Pumps Figure 4-11. Burks Pumps
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Lesson Five
RotaryPumps
,M.S
^ J
^ V
V ^-

70
Lesson
Rotary Pumps
TOPICS
Introduction to Rotary Pumps Vane Pumps

External-Gear Pumps Rotary Piston Pumps
Internal-Gear Pumps Flexible-Member Pumps
Lobe Pumps Rotary Pump Installations
Screw Pumps
OBJECTIVES
After studying this Lesson, you should be able to..
• Describe the fluids that can be pumped by a Compare and contrast timed and untimed screw
rotary pump. pumps.
• Explain the operation of external- and internal- Tell why sealed bearings might be used in a
gear pumps. vane pump.
• Describe the parts and construction of a lobe
pump.
KEY TECHNICAL TERMS
Crescent 5.16 separates the gears of an internal- Progresslng-cavity pump 5.25 single-screw
gear pump pump
Timing gears 5.22 transmit torque from driving Power rotor 5.26 the driving screw in a multiple-
rotor to driven rotor screw pump
71
Rotary pumps have many applications in the plant. These positive-displacement

pumps have certain characteristics that make them more suitable then centrifu
gal pumps for some purposes. However, there are also some restrictions that
apply to the use of rotary pumps.
A variety of pumps are manufactured under the classification of rotary pumps. In

order to choose a pump that is suitable for an application, you must be able to
identify the needs of the application and then match those needs to the capabili
ties of each kind of rotary pump.
After studying this Lesson, you will be able to explain how each kind of rotary
pump works, and you will have an understanding of the applications for each
pump. You will be able to name and describe the moving elements and other
essential components of rotary pumps.
Introduction to Rotary Pumps this Lesson will examine several types of rotary
pumps—their construction,operation,and application.
5.01 Rotary pumps are widely used for pumping
high-viscosity fluids in marine fuel-oil service, fluid External-Gear Pumps
power applications, and crude oil and chemical pro
cessing. Although they are often thought of as viscous- 5.05 External-gear pumps are probably the most
fluid pumps, rotary pumps can handle fluids of all vis widely used type of rotary pump in industry today.
cosities. They can deliver from less than 1 gpm to more Fluid power systems are frequent users of external-
than 5000 gpm at pressures of up to 10,000 psi. gear pumps. Many machine tools use external-gear
pumps to supply bearing lubrication and cutting fluid
5.02 Rotary pumps are positive-displacement to various points on the machine. The oil pumps in
machines that move fluid from pump inlet to pump the engines of many vehicles are external-gear
outlet by trapping a portion of fluid between one or pumps. In addition, many pumps used in the chemical
more moving elements and a fixed casing. The mov industry are external-gear pumps.
ing elements can be gears, cams, screws, vanes, or
similar devices. Because rotary pumps deliver a given 5.06 The operation of an external-gear pump is
quantity of fluid with each revolution of the pump shown in Fig. 5-1. At first glance, you might think
shaft, they can be adapted for metering applications. that the fluid being pumped is forced between the
5.03 Unlike centrifugal pumps, rotary pumps are

usually self-priming and their delivery is not affected Fig.5-1. Operation of an external-gear pump
by pressure variations. They operate at much higher
speeds than do reciprocating pumps, and are suitable
for pumping nearly all nonabrasive fluids. They are
usually simple, compact, and lightweight. Unlike rec
iprocating pumps, rotary pumps are capable of pro
ducing a flow that is free of pulsations.
Suction Discharge
5.04 The methods used to calculate rotary pump lift
and head are similar to those used for centrifugal pumps.
The fluid discharge is given in pounds per square inch Spur gear
rather than in feet of head, however, and the suction lift
is given in inches of mercury. Impellers, casings, and
shafts perform the same functions in both pumps,
although their appearances may differ. The remainder of
teeth of the two gears and pushed out the discharge made of cast iron or cast steel, although other metals
port. As shown by the arrows in the illustration, how can be used. Chemical pumps are often made of stain
ever, the fluid is drawn into the space between the less steel.
gear teeth and forced out of the discharge port. The
meshing of the gears keeps fluid from flowing back to 5.11 Because external-gear pumps normally han
the pump's suction side. dle hydraulic or oily fluids, the bearings are lubricat
ed not by external means but by the material being
5.07 Although spur-gear impellers are the most pumped. If the material being pumped is nonlubricat-
common kind used in gear pumps, helical and her ing, seals and a method of external lubrication are
ringbone gears are sometimes used. Figure 5-2 shows used in the pump.
pumps containing spur and helical gears. The pump
shown in Fig. 5-3 contains herringbone gears. The 5.12 An exploded view of an external-gear pump
kind of impeller used in a pump is determined by the is shown in Fig. 5-3. Notice that only one shaft
pump manufacturer. extends beyond the end of the pump casing. This
extended shaft is the driving shaft. The other is the
5.08 Helical and herringbone gears provide a shaft of the driven gear.
smoother transfer of power than do spur gears, thus
establishing a smoother fluid flow. For most applica 5.13 It is important to note that external-gear
tions, however, spur-gear impellers are satisfactory. pumps, like most rotary pumps, are reversible. Most
They cost less to manufacture and maintain than other can operate in either direction without any modifica
types. Helical and herringbone gears are used in large tion in the internal parts of the pump or to the casing.
pumps, which handle larger capacities and operate at If you are not sure which is the suction side of an
higher speeds than do spur-gear pumps. operating pump,look to see which way the drive shaft
is rotating. If you remember that the fluid being
5.09 In most applications, the slight discharge pul pumped is being carried around the outer edges of the
sations produced by spur gears do not warrant the use gear impellers and not between them, you will be able
of specially designed gear impellers. Often the pulsa to figure out which way the pump is pumping.
tions are damped by the fluid, which is being dis
charged under pressure. 5.14 Because the pump casing encloses the operat
ing parts of the pump, shaft seals are needed only at
5.10 The construction of an external-gear pump is the extended drive shaft. Shaft seals can be of the
relatively simple when compared to that of a centrifu mechanical or packing-gland type. The kind of shaft
gal or turbine pump. Basically, the gear pump casing seal used is determined by the fluid being pumped,
forms the external housing of the pump. It is usually the design of the pump,and the application.
Fig. 5-2, External-gear pump impellers
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Fig.5-3. Exploded view of an external-gear pump
Internal-Gear Pumps er's design. A single bearing supports the shaft

where it comes through the casing. The shaft car
5.15 Another kind of gear pump is the internal- ries the driving gear. A bearing in the end cover
gear pump. This pump is entirely different in con supports the driven or internal gear. Bearings for
struction than the standard or external-gear pump. the two gears are positioned at the time of manu
facture so as to allow for smooth meshing of the
5.16 The internal-gear pump, the construction gears within the housing.
of which is shown in Fig. 5-4, contains two mesh
ing gears. The outer gear of the set is the driving 5.20 Because the driving gear contains and
gear. The inner gear is the driven gear. The cres rotates around the driven gear, the housing is
cent keeps the gears separated and reduces eddy round and compact. This kind of housing is quite
currents, thus increasing the pump's efficiency. In different from the elongated shape of the external-
some models the crescent is movable, allowing gear pump housing.
the pump to operate in either direction.
Lobe Pumps
5.17 During operation, the rotating inner gear
opens the space between the teeth of both gears at 5.21 Lobe pumps are similar to external-gear
the intake port area. Fluid is drawn in through the pumps in both construction and operation. The
intake port and passes around the crescent area of
the pump, as shown in Fig. 5-5 on the next page.
As the gear teeth again come in contact with one
Fig. 5-4. Construction of an internal-gear pump
another near the exit port, the fluid is discharged.
5.18 Even though the inner gear has fewer teeth Suction Discharge
than the outer gear, the gears mesh smoothly at all
times without causing interference. This meshing
occurs because the spacing of the gear teeth is
equal, even though the pitch diameters are
unequal.
5.19 The materials used in the construction of

internal-gear pumps are similar to those used in
Inner
(driven)-
gear
i I Outer
|-«-H— (driving)
I ■ gear
external-gear pumps. The driving gear is usually - Crescent

made of steel. The driven gear can be made of Casing
steel or a softer metal. The pump casing is usually
cast iron or steel, depending on the manufactur-
This material is protected by U. S. Copyright law. Copying by any cptical, electronic, or other means is Illegal without permission.
Fig.5-5. Fluid flow in an internal-gear pump gears, however, are replaced by two rotors, each
having one, two, three, or four lobes. One rotor is
driven externally. Because a lobe pump delivers
fluid in a smaller number of larger quantities than a
gear pump, flow is less constant. Figure 5-6 shows
four types of lobe pumps.
5.22 The shape of lobed rotors does not allow one

rotor to drive the other. For this reason, lobed rotors
must be timed by separate means. Timing gears are
used to transmit the torque from the driving rotor to
the driven rotor. External timing of the lobe pump is
necessary not only to drive the idler rotor, but also to
maintain the proper angular relationship of the
rotors.
Fig.5-6. Lobe pump construction
Suction Discharge
Single lobe Two lobe Three lobe Four obe
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5-1. Rotary pumps can handle fluids of all 5-1. 10,000

viscosities at pressures of up to
□si. Ref: 5.01
5-2. Rotary pumps move fluid by trapping a 5-2. MOVING; FIXED

portion of fluid between one or more
elements and a Ref: 5.02
casing.
5-3. In an external-gear pump, fluid is drawn 5-3. GEAR TEETH

through the space between the
and forced out of the dis Ref: 5.06
charge port.
5-4. Gear pumps are normally lubricated by 5-4. THE MATERIAL BEING PUMPED
Ref: 5.11
5-5. The operation of most external-gear 5-5. REVERSED

pumps can be without modi
fication. Ref: 5.13
5-6. The external gear of the internal-gear 5-6. DRIVING; DRIVEN

pump is the aear.The inter
nal oear is the aear. Ref: 5.16
5-7. In internal-gear pumps, the Internal 5-7. FEWER

oear has teeth than the
external gear. Ref: 5.18
5-8. Lobe oumos use to transmit 5-8. TIMING GEARS

torque from the driving rotor to the dri
ven rotor. Ref: 5.22
Thts matenal is protected by U. S. Copyright law. Copying by any optjcaj, electronic, or other * illegal without permissiort.
Fig. 5-7, Single-screw pump
Suction
Discharge
Drive shaft
Screw Pumps ings are often located within the pump casing, as
shown in Fig. 5-8. In this arrangement, the fluid being
5.23 Screw pumps can have one, two, or three pumped lubricates the gears and bearings. Because
screws or rotors operating within a close-fitting cas many fluids are nonlubricating or abrasive, external
ing. The fluid being pumped flows between the screw timing gears and lubrication are used most often. In
threads or between the screw and the casing, along screw pumps, timing gears transmit power from the
the axis of the screws. Screw pumps can handle liq driving shaft to the driven shaft without the necessity
uids of nearly any viscosity and can be operated at of screw contact. By eliminating the need for screw
higher speeds than most other rotary pumps. contact,timing gears promote long screw life.
5.24 Like other rotary pumps, screw pumps do not 5.27 Three-screw pumps have two idler screws.
handle abrasives well. Abrasive particles can cause The idlers are threaded to mesh with the power rotor.
jamming or accelerated wear between the rotors as Three-screw pumps are often referred to as untimed
the fluid moves along their mating surfaces. Abrasive
materials can also damage the casing because of the
small clearances between the casing and screws. Fig.5-8. Two-screw timed pump
5.25 The simplest screw pump is the single-screw

pump. It consists of a spiral-shaped rotor that turns in Discharge Driving shaft
an intemal-helix liner. The rotor is usually metal. The
liner is rubber. Figure 5-7 shows a single-screw
pump. The rotation of the screw traps fluid between V/M/m
the rotor and liner and moves it along the axis of the
screw until it is discharged. Single-screw pumps are
often called progressing-cavity pumps.
5.26 Multiple-screw pumps are driven by a single

rotor called the power rotor. Two-screw pumps are
Timing gears
often called timed screw pumps because they require Suction
timing gears. If the pump will be used for pumping
clean, lubricating fluids, the timing gears and bear
This rnatenal is proteOed by U. S. Copyright law. Copying by any optical, electronic, or other r illegal without permission.
Rotary Pumps
screw pumps, because the driving force is transmitted pumps are also used for solvent and chemical transfer.
by the rotors themselves, not by timing gears. In a Vane pumps are often used for paint and other viscous
three-screw pump, the center screw is the driving materials and for other heavy fluids containing abra
rotor. Often, the close-fitting housing provides the sive particles. For abrasive applications, the vanes are
only support for the idler rotors. made of a softer material than the pump casing.
5.28 Figure 5-9 shows a cutaway view of a three- 5.32 The vane pump shown in Fig. 5-10 on the
screw pump. As the power rotor turns, fluid is drawn next page, called a sliding-vane pump, is simple in
into the pump. Because the threads of the power rotor operation. As the impeller rotates, its offset position
mesh with the threads of the idler screws, the fluid is above the pump centerline allows the vanes to slide
forced along the openings in the threaded area toward outward and draw fluid in on the inlet side. The open
the center discharge section of the pump. spaces between the vanes, impeller, and housing at
the bottom of the pump allow movement of the fluid
5.29 A multiple-screw pump is manufactured with through the pump. As the impeller continues its rota
a solid center casing made from cast iron or steel. The tion, the vanes are pushed back into their slots as they
interior of the casing is machined precisely to contain near the top of the pump. This constriction of avail
the rotors. The power rotor extends beyond one of the able space forces the fluid out the discharge port.
casing ends. The idler rotor shafts usually do not.
Some type of seal is provided where the extended 5.33 The pump inlet and discharge ports are oval
shaft passes through the pump end. in shape and extend about three quarters of the way
across the casing width. This less-than-full opening
5.30 Rotors within a particular pump are usually keeps the vanes within the pump casing. The oval
made of the same material. High-carbon steel, steel shape smooths the fluid transfer.
alloy, and stainless steel are commonly used. The
bearings supporting the shaft are usually sleeve bear 5.34 Some vane pumps, called swinging-vane
ings, and are either pressed onto the shaft or inserted pumps, have a series of hinged vanes that swing out
and locked in place in the end or center casing. from the impeller as it rotates. These vanes trap fluid
and force it out the discharge side of the pump. Still
other vane pumps use rolling members. The operation
Vane Pumps
of a rolling-vane pump is similar to that of the sliding-
5 31 The vane pump is another type of rotary pump vane pump. The rolling action of the vanes, however,
distributes wear and reduces sliding friction. Figure 5-
commonly used in industrial plants. Although generally 11 on the next page shows a rolling-vane pump.
used in hydraulic and lubricating oil systems, vane
Fig.5-9. Three-screw pump
Discharge
Center casing Idler rotor
ir
stuffing box
Idler rotor
Power rotor
Suction
other mearts is illegal without permission.

,,S by U.S CopyrigM law. Copying by any optical, electronic, or
uesson FWe
Fig. 5-10. Sliding-vane pump 5.37 In sliding- and rolling-vane pumps, the
vanes are mounted within the impeller with a small
clearance to permit free movement. In some
Discharge pumps, the impeller vanes are spring loaded at the
base. The spring loading ensures complete contact
with the pump housing at all times. In other
pumps, the vanes are manually placed in position
Sliding vanes in the impeller. Centrifugal force and the hydraulic
pressure within the pump keep the vanes in contact
with the pump housing.
5.38 The end casings of the pump require care

ful positioning. Because the impeller shaft extends
through one casing end and part way into the
other, the shaft holes must line up accurately. Any
Suction
misalignment between the two ends can cause the
impeller to bind or jam within the casing.
5.39 Like the end casings in gear pumps, vane

pump end casings are usually bushed with sleeve
5.35 Vane pump housings, like those of other bearings. End casings can be fitted with lubrica
rotary pumps, are usually made of cast iron or cast tion fittings and seals if the application requires.
steel. As in the internal-gear pump, the ends are
machined smooth and the interior is bored in a circu 5.40 A vane pump handling paint is a good
lar shape. example of a pump requiring sealed bearings. The
abrasive pigment in the paint would quickly
5.36 The impeller is circular about its own cen- destroy the pump bearings if it were allowed to
terpoint and is smaller in diameter than the housing. come into contact with them. Seals at the interior
The impeller contains slots, which hold the vanes. edges of the end casing protect the bearings, as
The vanes are often metal, but can be made of mold shown in Fig. 5-12. Lubrication is supplied
ed neoprene or other soft materials. The vane mater through external fittings, because paint is not a
ial selected depends upon the material being lubricant. If the pump were handling a lubricant, a
pumped. ®
shaft seal would be required only at the point
Fig.5-11. Rolling-vane pump
Fig.5-12. Location of seals on rotary pump shaft
End cap
Impeller
Bearing
Casing
Protective seal
This malerial is proteeled bv U S

Û.s Copynghtia. „Copying by any optical, a,« or other.aans.
Ilegal without perirission.
Rotary Pumps 79
where the driving shaft extended through the end charge ports. The angle of the cam plate determines
casing. the length of the piston stroke.
Rotary Piston Pumps 5.45 The cam-and-piston pump contains an eccen

trically mounted cam rotated by a shaft in the center of
5.41 At the mention of piston pumps, many people a cylindrical casing. This cam moves a piston. Each
immediately think of reciprocating piston pumps. rotation of the shaft traps fluid in the casing. As the
There are also several kinds of rotary pumps called rotation continues, the fluid is forced from the casing,
piston pumps. Although they all use some kind of pis through a slot in the piston, to the pump discharge.
ton element, they look and operate very differently
from one another and from reciprocating piston Flexible Member Pumps
pumps. Figure 5-13 shows three types of rotary piston
pumps. 5.46 In flexible-member pumps, the pumping and
sealing action depend upon the flexibility of one of
5.42 In the circumferential-piston pump, arc- the pump's parts. This part might be the impeller, a
shaped pistons travel on rotors in the pump housing. tube, or a liner. The pumping element is usually made
The operation of this pump is similar to that of a lobe of rubber, synthetic rubber, or a plastic compound.
pump, except that the rotors do not mesh or even Figure 5-14 on the next page shows three types of
touch one another. Their only contact is with the walls flexible-member pumps.
of the pump casing.
5.47 The pumping action of di flexible-impeller
5.43 Fluid is carried from the suction to the dis pump is similar to that of a vane pump. Instead of
charge port of the pump in the spaces between the vanes sliding in and out of a rotor, however, blades
pistons. Because the rotors do not contact one anoth bend against the pump casing.
er, timing gears must be used.
5.48 Unlike the vane pump, which has a circular
5.44 In the axial-piston pump, piston elements rec inner configuration, the inner shape of the flexible-
iprocate in cylinders in the pump rotor, parallel to the impeller pump is irregular. This irregular shape
pump shaft. As the rotor rotates, the pumping action increases the impeller's efficiency and gives the pump
comes directly from the motion of the pistons. Unlike its ability to pump both thin and thick fluids.
a reciprocating pump, this pump has no suction or
discharge valves. Valving is accomplished by the 5.49 As shown in Fig. 5-15 on the next page, the
rotation of the rotor relative to the suction and dis pump housing forms one of the end covers and con-
Fig.5-13. Rotary piston pumps
Slot
Cam plate
Discharge
Rotor
Piston
Suction Discharge
Suction Discharge
Eccentric
cam
Piston
Suction Piston
Circumferential piston Axial piston Cam and piston
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Fig.5-14. Flexible-member pumps
Discharge ♦ Impeller 6 Suction
Suction
Discharge
Suction
Eccentnc
Flexible Impeller Flexible tube Flexible liner
tains the shaft support bearings, lubricant, and seals. 5.51 A flexible-tube pump can pump nearly
The end cover has no impeller or shaft support bear any fluid as long as it is compatible with the tub
ings. Because of this construction, impeller replace ing material. Since fluid contacts only the interi
ment is relatively easy. or of the tube, it has no effect on the pump inte-
5.50 The flexible-tube pump operates on a prin

ciple similar to squeezing toothpaste from a tube 5.52 A.flexible-liner pump is operated by f-n
by rolling the tube from the bottom. A flexible eccentric on a driven shaft. As the eccentric in Fig. 5-
hose or tube passes through the pump body where 14 turns, it moves the flexible liner to the left, closing
it is flattened by a cam or rollers. Rotor rotation the suction and opening the discharge. As the eccen
pushes the material in the tube from the suction to tric continues, it squeezes the liner against the pump
the discharge. The tube's recovery from its body, forcing the fluid out the discharge port. Flexi
squeezed position creates a suction at the pump's ble-tube and flexible-liner pumps are also ca[\ed peri
inlet. staltic pumps.
Fig. 5-15. Flexible-impeller pump
This maienal is protectefl by U. S. Copyright law. Copying by any optical, electronic, or other means 15 illegal without permission.
Rotary Pumps 81
Rotary Pump Instal/ations
tained, havtag Senerally self-con-

are "ûallyTore'cTed rtheTriWnr
flexible couDlin<T m fu ^riving motor with a
usualJy installed as a separate pSTof
^'0 a(«i plate or fcttS^LZ^h
ofa ntttnber ofptime movera,incSnttZIZ
or internal
Internal combust.on engines LbulZSeT
are required for poZble the unit. reduces the operating life of
eS^""
^ Pteces^"7""®
of machtnetyIhatnrounted
supplyonhydrauUc fluidssJcZ.
the same to sev- 5.55 Gear and vane pumps are frequently used for
field
field. InIn-plant
nifZ' oonstraction
pumps are usually driven by electricmachinery
motot^ IS the hand-operated pump fitted with a suction pipe
h haôus ataosphenes, the pump can be driven fiom a and placed directly in a 55-gallon drum. Other typL
remote shaft or by special hazardous-duty motors. of manual rotary pumps are used with lubricant-dis-
pensing drums.
82
Programmed Exercises
5_9 higher
An advantage of screw pumps is that
5-9. Ret; 5.23
thev can be operated at —
speeds than most rotary P^mps.
5-10. TIMING; ROTORS

5-10. Two-screw pumps require
IWO-bUiovv pw-.-.r-- - « ..
qears. In three-screw pumps,the dr

1^ A.u«>^^-o/^ro\A/ niimi
Ret; 5.26-5.27
ving force is transmitted by the
5-11. VISCOUS; ABRASIVE

5-11 Vane pumps are often used for
materials and for heavy flu Ref: 5.31
ids containing particles.
force, and 5-12. CENTRIFUGAL; HYDRAULIC

5-12. Spring loading,
pressure all help keep
Ref: 5.37
vanes in contact with the pump hous
ing.
5-13. The operation of a circumferential-pis 5-13. MESH or TOUCH ONE ANOTHER

ton pump is similar to that of a lobe
pump, except that the rotors do not Ref: 5.42
5-14. In an axial-piston pump, the pumping 5-14. PISTONS

action comes directly rom the motion of
the Ref: 5.44
5-15. The flexible member in a flexible-mem 5-15. IMPELLER, TUBE, LINER

ber pump might be afn)
afn) -orafn) Ref: 5.46
5-16. When rotary pumps are motor driven, 5-16. COUPLING

they are usually connected to the
motor with a flexible
Ref: 5.54
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Self-Check Quiz 83

5-1. Rotary pumps can handle 5-6. Screw pumps CANNOT
□ a. only high-viscosity fluids □ a. handle abrasives

□ b. pressures of up to 10,000 psi □ b. handle a wide variety of viscosities
□ c. abrasive fluids □ c. operate at high speeds
□ d. only fluids pumped at low speeds □ d. operate in a close-fitting casing
5-2. If a gear pump handles a lubricating material. 5-7. In the three screw pump, the center screw is
□ a. lubrication seals are needed □ a. the idler rotor

□ b. an external means of lubrication is □ b. the meshing rotor
needed □ c. the driving rotor
□ c. the bearings may be damaged □ d. the timing gear
□ d. no external means of lubrication is
needed 5-8. What type of rotary pump is suitable for
pumping abrasive fluids?
5-3. In the internal-gear pump, which is the driving
gear? □ a. Piston
□ b. Vane
□ a. The external gear □ c. External-gear
□ b. The internal gear □ d. Screw
□ c. The gear with the fewest teeth
□ d. The crescent 5-9. In an axial-piston pump, the pumping action
is a result of the
5-4. The internal gear teeth of an internal-gear
pump mesh smoothly with the external gear □ a. rotation of the eccentric
teeth because □ b. meshing of the rotors
□ c. rotation of the cam plate
□ a. both gears have the same number of □ d. motion of the pistons .
teeth
□ b. the internal gear has more teeth than 5-10. Which of the following is NOT used as a flexi
the external gear ble member in a flexible-member pump?
□ c. the spacing of the teeth is equal
□ d. the pitch diameters are equal □ a. Impeller
□ b. Tube
5-5. In lobe pumps, torque is transmitted by □ c. Piston
□ d. Liner
□ a. pistons
n b. timing gears
□ c. externally driven rotors
□ d. internally driven rotors
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84 Lesson Five
SUMMARY
Rotary pumps move fluid by trapping a portion of similar to external-gear pumps.However,lobe

the fluid between one or more moving elements pumps have rotors,and the rotors are driven by
and a flxed casing. The moving elements can be timing gears.
gears,cams,screws, vanes,or similar devices.
Screw pumps can have one,two,or three screws.
External-gear pumps usually handle hydraulic or Two-screw pumps require timing gears. Three-
oily fluids that lubricate the pump bearings and screw pumps have two idler screws and a driving
eliminate the need for external lubrication and rotor and do not require timing gears. Vane pumps
lubrication seals. Gear pumps usually have spur- are the one kind of rotary pump that can handle
gear impellers,although they may have helical or abrasive materials. Sliding,swinging,or rolling
herringbone gears instead. Internal-gear pumps vanes are the moving elements in vane pumps.
have external (driving) gears and internal (driven) Rotary-piston pumps and flexible-member pumps
gears. The housing of the external-gear pump is are other kinds of rotary pumps.Like most other
elongated, while the housing of the internal-gear rotary pumps,their names are descriptive of the
pump is round and compact. Lobe pumps are ways in which they operate.
5-1. b. Pressures of up to 10,000 psi. 5-6. a.
Ref: 5.01 Ref: 5.23-5.24
5-2. d. No external means of lubrication 5-7. 0.
is needed. Ref: 5.11

5-8. b.
5-3. a. The external gear. Ref: 5.16
5-9. d.
5-4. C. The spacing of the teeth is equal. Ref: 5.44
Ref: 5.18
5-10. C.
5-5. b. Timing gears. Ref: 5.22
Figure 5-2. Viking Pump Division, Houdaille Industries, Inc. Figure 5-9. IMO Pump Division of Transamerica Delaval, Inc.
Figure 5-3. Worthington Division, McGraw-Edison Company Figure 5-10. Blackmer Pump Div./Dover Corp.
Figure 5-5. Viking Pump Division, Houdaille Industries, Inc. Figure 5-11. Hypro, A Division of Lear Siegler, Inc.
Figure 5-7. Roper Pump Company Figure 5-15. ITT Jabsco Products
This material is proteaed by U. S. Copyright law. Copying by any optical, electronic, or other means is illegal without permission.
c• - i
V 3
Ô:

86
Lesson
Reciprocating Pumps
TOPICS
Reciprocating Pump Applications Power Pump Operations

Reciprocating Pump Parts Horizontal Plunger Pumps
Reciprocating Pump Classifications Vertical Plunger Pumps
Steam-Driven Pump Operation Air-Driven Pump Operation
The Fluid End The Fluid End
The Steam End The Air End
OBJECTIVES
• Name the parts that make up the power end of a Explain how the pumped fluid lubricates a recipro
reciprocating pump and describe their operation. cating pump.
• Define the terms single-acting pump and double- Calculate the discharge pressure of an air-driven
acting pump. pump when given the piston ratio and motor air
• Compare simplex and duplex pumps. supply.
KEY TECHNICAL TERMS
Power pump 6.03 a reciprocating pump driven by Cylinder 6.12 a tubular chamber that contains the
an electric motor or internal combustion engine piston or plunger
Direct-acting pump 6.06 a reciprocating pump Cylinder head 6.13 a cap that seals a cylinder
driven by steam or air
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87
Reciprocating pumps have numerous applications in industry. Your plant may

use steam-driven, or power pumps. Reciprocating pumps are classified by the
way in which they are driven, by the pumping action in the fluid end, and by the
number of fluid-end cylinders they have. You should recognize each kind of reci
procating pump according to its classification.
In order to service and maintain reciprocating pumps, you must know the main
parts and the role of each part in the operation of the pump. You should also be
able to explain how the operation of each kind of reciprocating pump differs from
the operation of the other kinds.
After studying this Lesson, you should have a working knowledge of reciprocat
ing pumps and be ready to perform your job as part of the maintenance team.
Reciprocating Pump Applications 6.05 Although all reciprocating pumps are similar
in their pumping action, they vary greatly in construc
6.01 At the mention of the term reciprocating tion. Figure 6-1 on the next page shows an example
pump, mmntenance people with many years of expe of each of the three kinds of reciprocating pumps cov
rience often think of steam-driven, piston-type water ered in this Lesson.
pumps. Although the use of these pumps has
decreased over the years, many refineries and chemi Reciprocating Pump Parts
cal plants still use steam-driven reciprocating pumps.
Since such plants usually have steam available, these 6.06 A reciprocating pump works with a back-and-
pumps are economical to operate. Because they are forth, straight-line motion. A reciprocating pump dri
fireproof and explosion-proof, steam-driven pumps ven by an air- or steam-driven piston is called a
are nearly ideal for pumping volatile or inflammable direct-acting pump. Direct-acting pumps have two
liquids. sections—the/ZwiVf end and the steam or air end. The
fluid end does the pumping. The steam or air end pro
6.02 Many reciprocating pumps used in indus vides the driving force necessary for operating the
try are driven by air pressure. These pumps, which fluid end. Figure 6-2 on the next page shows a direct-
are sometimes called pneumatic pumps, are often acting steam-driven piston pump.
used to transfer fluids from barrels to other con
tainers or to a piping system, which then carries 6.07 In power pumps, the two sections are
the fluid directly to the machine requiring the called the fluid end and the power end. The fluid
material. end does the pumping. The power end provides
the pumping force. The power end consists of a
6.03 Some reciprocating pumps are driven by a crankshaft, a crosshead, and a connecting rod.
rotating crankshaft connected to an electric motor or Figure 6-3 on page 89 shows a typical power
internal combustion engine. These pumps are com pump.
monly called power pumps. Power pumps are well-
suited to high-pressure service. They are often used in 6.08 Many pump parts are called out in Fig. 6-2
hydraulic presses, petroleum processing, boiler feed and 6-3. The following paragraphs describe some of
ing, and pipeline pumping. the most important ones. Refer to the illustrations as
you come to each new term.
6.04 Other kinds of reciprocating pumps use a flexi
ble diaphragm in the fluid end. Diaphragm pumps are 6.09 Piston. Fluid-end pistons convert mechanical
commonly used in low-pressure metering applications, energy into fluid movement. In the steam end of the
where freedom from leakage is important. Diaphragm direct-acting pump,the piston converts the steam into
pumps will be covered in detail in the next Lesson. mechanical energy.
Ths material is protected by U. S. Copyright law. Copying by any optical, electronic, or other means is illegal without permission.
Fig.6-1. Typical reciprocating pumps
6.10 Piston ring. A piston ring acts as a seal 6.13 Cylinder head. The cylinder head is a cap
between a piston and the cylinder in which it is oper that seals the cylinder to allow pressure buildup.
ating. The ring moves with the piston.
6.14 Stuffing box. A stuffing box is filled with
6.11 Plunger. Some pumps, like the one shown in packing to prevent fluid leakage from the cylinder. It
Fig. 6-3, use a plunger rather than a piston in the fluid surrounds the plunger, piston rod, and connecting rod.
end. The plunger slides back and forth in a stationary
packing rather than carrying its own seal. 6.15 Valves. A slide valve controls the flow of
steam into the steam end of the direct-acting pump.
6.12 Cylinder. The cylinder is a tubular chamber On the fluid end of the pump, suction and discharge
that contains the piston or plunger. valves control the flow of fluid into and out of the
Fig.6-2. Direct-acting steam-driven piston pump
Steam chest Valve control arm
Stuffing box Discharge

Rocker arm
valves
D-type
Suction valves
slide —
valve
•Fluid cylinder
Cylinder -Fluid piston
head [h
Steam end Fluid end
Piston rod
Piston ring | j Piston ring
Steam cylinder Connecting rod Stuffing box
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Reciprocating Pumps 89
fluid cylinder. The valve on the steam end is mechani other side of the piston. When the piston reverses its
cally actuated. The valves on the fluid end are materi travel, the side of the pump that just loaded dis
al actuated. charges its fluid, and the other side of the pump
draws fluid in. Although double-acting pumps are
6.16 Crankshaft. In the power pump, the crank more efficient than single-acting pumps, they still
shaft transmits motion from the prime mover to the have a slight pulsation in the fluid flow as the piston
driving components in the power end of the pump. reaches the end of its stroke.
6.17 Crosshead. The crosshead of the power 6.21 Another means of classifying pumps involves
pump converts the rotary motion of the crankshaft the number of fluid-end cylinders. A simplex pump is
connecting rod into reciprocating motion. a single-cylinder pump. It has only one fluid cylinder.
Reciprocating Pump Classifications 6.22 A duplex pump is a two cylinder pump. It

usually consists of two simplex pumps mounted side
6.18 You have seen so far in this Lesson that recip by side in a common housing. Duplex pumps are usu
rocating pumps can be classified in different ways. ally double acting. The resulting pump capacity is
They can be direct-acting or power pumps, piston or twice that of a simplex double-acting pump.
plunger pumps. They are also classified as horizontal
or vertical. 6.23 In operation, duplex pumps generally have
piston travels that oppose each other. This does not
6.19 Reciprocating pumps can be classified in mean that the pistons work against each other. When
other ways. One involves the pumping action in the the piston in one cylinder is traveling forward, the
fluid end. A single-acting pump (Fig. 6-3 is an exam piston in the other cylinder is traveling in the opposite
ple) discharges fluid only on the forward stroke of the direction. This process is illustrated in Fig. 6-4 on the
plunger. The return stroke is a cylinder-loading stroke next page.
and does not discharge any fluid into the discharge
line. Pumps of this type discharge fluids in pulses. 6.24 Some pumps are made in triplex and multi
plex designs. These pumps, which have three or more
6.20 Double acting pumps, like the one shown in cylinders, are not often used in industrial plants. They
Fig. 6-2, discharge fluid on both strokes of the pis are mentioned at this point so that you will know the
ton. As the piston travels to one end of the pump, meaning of the words. Figure 6-5 on the next page
fluid is discharged from that end of the cylinder. shows a complete classification chart of reciprocating
While this is happening, fluid is drawn in on the pumps.
Fig.6-3. Power plunger pump
Crosshead
Crankshaft
Discharge
Crosshead
extension
Discharge valve
Crankcase Plunger
cover
Cylinder head
■ Suction valve
Suction
Connecting rod Stuffing box
Power end Fluid end
c>
Fig. 6-4. Piston action in a duplex pump
Fig. 6-5. Classification of reciprocating pumps
Simplex Direct acting

Double acting Duplex
Piston
Plunger
Simplex
Single acting Duplex
Double acting Triplex
Reciprocating Multiplex
Diaphragm Simplex Fluid operated

Multiplex Mechanically operated
Fig. 6-6. Steam-driven reciprocating pump
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Fig.6-7. Fluid end of a double-acting steam-driven pump
Discharge valves
Suction valves
Suction
Fig. 6-8. Fluid end valve designs
Suction valve Suction valve
Discharge valves Discharge valve
Suction valves
Side view Front view

Cylinder liner Valve plate Pot va ve
Steam-Drlven Pump Operation Because the cylinder is double acting, there are two
sets of valves and the cylinder is open at both ends. If
6.25 Figure 6-6 shows a steam-driven reciprocat this cylinder were single acting, it would probably be
ing pump. Although steam-driven pumps might vary open on only one end, with the fluid inlet located on
in appearance, their operating characteristics are usu that side of the piston. In some pumps, the fluid is
ally similar. The only differences are in the valves and drawn in at the bottom of the cylinder and discharged
body construction. out of the top of the cylinder. The construction used
depends upon the manufacturer.
6.26 Most steam-driven reciprocating pumps dis
charge fluids at pressures from approximately 125 to 6.28 Notice how the valves are positioned in the
750 psi. Fluid capacities range from 200 to over 1200 fluid end of the pump. In operation, fluid is drawn in
gpm. These pumps are suitable for hot or cold service through one suction valve as the piston travels away
with only slight modifications in their component from that end of the cylinder. When the piston revers
parts. es its travel, the fluid pressure within the cylinder
closes the intake valve and forces the fluid out of the
The Fluid End discharge valve. When the piston again reverses its
travel, the discharge valve is closed by a combination
6.27 Figure 6-7 shows two cross sections of the of discharge line pressure and spring action on the
fluid end of a horizontal, steam-driven pump. valve. The intake valve again opens to admit fluid.
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92 Lesson Six
6.29 The valves on the fluid end of the pump fall allow easy flow of fluid into the cylinder during the
into two categories—valve plate and pot valve. The pump's intake stroke.
general construction and operation of the two types
are similar. Their mounting, however,is different. 6.33 Most manufacturers of these pumps allow the
valves to be used interchangeably. This flexibility
6.30 Pumps with fluid ends of the valve-plate reduces the stock of maintenance parts and simplifies
design, as shown at the left in Fig. 6-8 on the previous maintenance procedures.
page, are frequently referred to as submerged-piston
pumps. This term is used when the discharge valves 6.34 Fluid cylinders in reciprocating pumps often
are positioned above the piston. In this arrangement,a have renewable liners. Generally, the liners are made
quantity of fluid remains in the cylinder at the end of of cast iron or steel, but can be made of abrasion-
the discharge stroke. resistant materials. The material used depends upon
the fluid being pumped. Liners are pressed in place.
6.31 In pumps of the pot-valve design, shown at Occasionally, they require additional holding lugs to
the right in Fig. 6-8, the discharge valves are mounted keep them from moving.
to one side of the cylinder. The fluid being pumped is
still not completely discharged from the cylinder, but 6.35 Fluid-end pistons are usually made of cast
less fluid remains than in the valve-plate pump. iron. They carry piston rings to keep fluid from leak
ing past the piston. The rings are usually made of soft
6.32 In both the valve-plate and pot-valve designs, iron or steel, but their composition varies as required
the intake valves are located above the cylinder to for specific pumping applications.
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6-1. Pumps driven by air pressure are 6-1. PNEUMATIC

sometimes called pumps.
Ref: 6.02
6-2. Pumps driven by an electric motor or an 6-2. POWER

Internal combustion engine are com
monly called pumps. Ref: 6.03
6-3. A reciprocating pump works with a(n) 6-3. BACK-AND-FORTH, STRAIGHT-LINE

motion.
Ref: 6.06
6-4. In direct-acting pumps, the fluid end 6-4. PUMPING: DRIVING FORCE
does the . while the steam or
air end provides the Ref: 6.06
6-5. The power end of a power pump con 6-5. CRANKSHAFT, CROSSHEAD, CON
sists of afnl . afnl NECTING ROD
and afnl
Ref: 6.07
6-6. Pumps that discharge fluid on both 6-6. DOUBLE-ACTING

strokes of the piston are called
pumps. Ref: 6.20
6-7. In pumps with valve-plate fluid ends, 6-7. ABOVE

are the discharge valves positioned
above or below the piston? Ref: 6.30
6-8. Fluid cylinders In reciprocating pumps 6-8. LINERS

are often equipped with renewable
Ref: 6.34
94 Lesson Six
The Steam End Power Pump Operations
6.36 The steam end of the cylinder is made of cast 6.40 Power pumps are usually driven by electric
iron or steel and is not equipped with a liner. Liners motors. They can also be driven by internal combus
are unnecessary in the steam end, because the amount tion engines. The drive can be connected directly to
of wear that takes place between the piston and the the pump crankshaft, or the connection can be made
cylinder is slight. Most of the wear on the fluid end is through a speed reducer. These pumps range in size
caused by the contaminants within the fluids being from relatively small units rated at 20 gpm or less to
pumped or by the abrasive nature of the material. large units with capacities of several thousand gallons
per minute.
6.37 The piston rings on the driving end are made
of cast iron. They are usually self-adjusting and are 6.41 The pressure-range capability of these pumps
supplied in sets of two or more for each piston. is great. It varies from several hundred pounds per
square inch to over 20,000 psi. Because of the high
6.38 The slide valve controlling the steam flow is discharge-pressure capability of these pumps, you
a simple mechanism. Basically, it is a flat plate with must be extremely cautious when servicing them.
several slots or grooves in the face that contacts the Make certain the pressure is relieved before discon
pump body. necting any of the lines. These high-pressure pumps
are usually used for hydraulic cleaning and descaling
6.39 In operation, steam is continuously admitted operations in steel mills and chemical plants. They are
to the center portion of the pump valve. The valve also used to drive hydraulic presses in plastic molding
then directs it to one of the two sides of the piston, and extruding processes.
forcing the piston to move to one side or the other. As
the piston travels, the valve control arm attached to Horizontal Plunger Pumps
the connecting rod moves the slide valve in the oppo
site direction. This action causes the slide valve to 6.42 Power pumps are made in two general
direct the steam to the opposite side of the piston designs. The horizontally mounted plunger pump
when the piston reaches the end of its stroke. uses a plunger to pump the fluid. Compared to a
Fig.6-9. Power plunger pumps
Crosshead Pump
discharge
Suction manifold Connecting

Stuffing
Plunger rod
box
Dischaige
manifold
Crankshaft Crosshead
Crankshaft Plunger suction
Vertical Horizontal
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piston, the plunger is quite long and operates into the pump housing and at the crossheads. The pump is
a relatively open cavity. The end of the plunger lubricated by the splash and pressurized methods.
might even extend into the cavity at the end of its
discharge stroke. The photo at the right in Fig. 6- Alr-Driven Pump Operation
9 shows a horizontal plunger pump.
6.49 Air-driven reciprocating pumps are usually
6.43 The intake and discharge valves are simi vertically mounted and are similar in design, con
lar to those used in other reciprocating pumps struction, and operation. The pumps differ only in the
and, like them, are fluid operated. Depending on control methods of the air and fluid. Two different
the pump design, the valves might be spring types of air-driven pumps are shown in Fig. 6-10 on
loaded to allow for easier closing. the next page.
6.44 The driven end of the plunger is threaded 6.50 The efficiency of air-operated pumps depends
or tapped so that it can be attached to the con upon free, continuous operation. When there is exces
necting rod. The connecting rod, which travels in sive back pressure at the discharge port or the fluid is
a straight line, is connected to a crosshead. The stopped or slowed, the pump will stall until the dis
crosshead stabilizes the movement of the plunger charge line is opened again. This stalling occurs in
and converts the rotary motion of the crankshaft grease guns used for lubrication. When the trigger of
connecting rod to the reciprocating motion of the the gun is pulled, the grease flows and the pump oper
plunger. ates. When the gun trigger is released, the grease flow
ceases and the pump stops.
6.45 The fluid being pumped lubricates the
fluid end of the pump. The power end of the 6.51 The pistons that drive these units vary in size,
pump normally operates in an independent oil which provides a useful ratio between the driving and
bath. pumping ends. For example,if the pistons on the fluid
and air ends are of equal diameter, the ratio is one to
Vertical Plunger Pumps one (1:1). If the area of the air piston is 10 in^ and the
area of the fluid piston is 1 in^, the ratio is ten to one
6.46 The other style of power pump is larger (10:1). The ratio does not affect fluid flow as long as
than the horizontal pump and is mounted in a ver the air pressure remains constant. If the air pressure
tical position, as shown at the left in Fig. 6-9. The drops below that which is required to pump the fluid,
power end of this pump contains a crank-shaft the pump will stall or operate at decreased flow. This
and crosshead and is similar in operation to the ratio does increase the pressure of the fluid being dis
horizontally mounted pump. The fluid end of the charged.
pump uses a plunger to pump the fluid, but it is
unlike the horizontal pump in construction and 6.52 Fluid discharge pressure is simple to calculate.
operation. If the pump has a 10:1 ratio and the motor air supply is
80 psi, the discharge pressure of the fluid is 800 psi. If
6.47 The plunger is connected to a movable one air motor drives two pumps at the same time, the
frame, which controls its movement. The frame is pressure on each pump is one-half the total.
mounted on top of the pump body and is bolted to
the crosshead. The tie rods connecting the frame The Fluid End
and crosshead are stabilized as they pass through
the upper portion of the pump frame. When oper 6.53 Because most air-driven pumps contain only a
ating, the plunger travels vertically in the cylin single cylinder, they are usually of the double-acting
der, drawing in and discharging fluid. type. As shown in Fig. 6-11 on page 97, the fluid end
is constructed very differently from those of the
6.48 Lubrication of vertical plunger pumps is pumps previously discussed. Note that the pump has
similar to that of horizontal units. Additional two separate cylinders. The lower cylinder is larger in
lubrication should be provided at the points where diameter than the upper cylinder. Each cylinder has its
the frame tie rods pass through the upper portion of own piston. The discharge capacity of the pump is
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96 Lesson Six
Fig.6-10. Air-driven reciprocating pumps
based on the area of the upper cylinder rather than on Because of this construction, this type of pump dis
the area of the lower cylinder. charges fluid on both the upstroke and the down-
stroke.
6.54 At the start of operation, the lower piston
draws in fluid on the upstroke through the valve (ball 6.57 Fluid cylinders are usually made of alu
or disk) located in the bottom of the pump. This minum, steel, or stainless steel tubing. In high-pres
motion fills the lower part of the cylinder. As the sure pumps, the pump cylinders are manufactured
pump stroke reverses and travels downward, the pres from heavy-duty steel or stainless steel shafting bored
sure of the fluid in the lower part of the pump closes to the proper inside diameter.
the bottom valve and opens the valve in the piston.
The fluid then flows into the upper chamber of the 6.58 The pistons, connecting rods, and other inter
cylinder. nal components of the pump are normally made of
stainless steel or corrosion-resistant steel alloys.
6.55 As the pump reverses its stroke and again
travels upward, more fluid is drawn into the lower part 6.59 The piston packings are usually made of
of the cylinder through the bottom valve. The valve in leather, neoprene, nylon,or Teflon®. The type of pack
the lower piston closes, and the upward travel of the ing used is determined by the fluid being pumped. In
piston forces some of the fluid in the upper part of the most applications, leather packings give the best ser
cylinder out into the discharge pipe. The rest of the vice. Note that the lower piston packings are positioned
fluid remains in the upper cylinder, below the upper so that one is tumed up and the other is turned down.
piston. They are set this way because fluid is being pumped on
both strokes. In the upper cylinder, all packings are
6.56 When the piston reverses for the down- tumed toward the fluid side of the pump.
stroke, the upper piston forces some of the fluid in
the upper cylinder out of the discharge pipe. At the The Air End
same time, the valve in the lower piston opens from
the force of the fluid captured behind it, and admits 6.60 The air end of an air-driven pump is a simple
more fluid to the upper part of the lower cylinder. piece of equipment. It consists of a brass or steel cylinder
This material is protected by U. S. Copynghi law. Copying by any optical, elearomc, or other r illegal wlthoiit permission.
made from tubing that has sufficient strength to withstand lower air control port then releases the air to the
the air pressure. The piston is a simple plate-type piston. It atmosphere.
carries two piston rings or cups (usually leather) mounted
facing away from each other to seal the piston. 6.64 As mentioned earlier, this pump will stall if
the flow of fluid in the discharge line is restricted.
6.61 The air control valve is probably the most compli When the flow in the discharge line is restricted, the
cated and critical part of the pump's air end. Although air pressure on the fluid end quickly becomes equal to
control valves are made in several styles,they all operate on the pressure of the air coming in on the air end. Since
similar mechanical principles. Figure 6-12 shows the air the piston cannot reverse its direction until it reaches
end of a typical pneumatic pump. the end of its stroke, the pump stalls.
6.62 A small control rod connects the air control 6.65 The cylinder ends are usually bolted to the
valve to the piston. As the piston nears the end of the cylinder by tie rods, although some are threaded. The
downstroke, the air control rod contacts and shifts the cylinder is sealed by "O" rings inserted between the
position of the air control valve on top of the pump.This cylinder wall and the cylinder ends.
shifting either opens or closes the air control valve ports,
depending on their arrangement. Opening the port, in 6.66 Air-driven pumps usually have a stuffing box
this case, admits air to the bottom side of the piston. At located between the air and fluid ends at the point at
the same time, the upper air control port closes and vents which they meet beneath the air cylinder. This stuff
the top side of the piston to the atmosphere. ing box not only seals the air cylinder, but also pre
vents any fluid that gets past the fluid stuffing box
6.63 As the piston travels upward and approach from reaching the air cylinder. Most manufacturers
es the top of the stroke, the control rod again shifts also provide an overflow outlet near the top of the
the valve and closes off the air to the lower portion fluid end of the pump. This outlet allows any fluid
of the cylinder. At the same time it opens the air that gets past the stuffing boxes to discharge back into
inlet valve to the upper portion of the cylinder. The the fluid end.
Fig.6-11. Air-driven pump,fluid end Fig.6-12. Air-driven pump,air end
Upper cylinder
Air valve
Upper piston
Discharge Actuator
pipe
Control rod
Piston valve
Cylinder
Lower
cylinder Piston
packings
Packing
Spring-
Suction valve
This material is protected by U. S. Copynght law. Copying by any ^tical, electronic, or othe illegal without permiasioA
6-9. When servicing high-pressure power 6-9. RELIEVE THE PRESSURE

Dumos. make certain vou
before disconnecting any of the lines. Ref: 6.41
6-10. Power plunger pumps are made in two 6-10. HORIZONTAL, VERTICAL
aeneral desions. and
Ref: 6.42,6.46
6-11. In a horizontal plunger pump, what is 6-11. THE FLUID BEING PUMPED
normally used to lubricate the fluid end
of the pump? Ref: 6.45
6-12. For control of its movement,the 6-12. FRAME

plunger of a vertical plunger pump is
connected to a movable Ref: 6.47
6-13. What happens in an air-driven pump 6-13. THE PUMP STALLS

when excessive back pressure devel
ops at the discharge port? Ref: 6.50
6-14. If an air-driven pump has a 10:1 ratio 6-14. 1000 psi

and the motor air supply is 100 psi,
what is the discharge pressure of the Ref: 6.52
fluid?
6-15. The air end of an air-driven pump carri 6-15. PISTON RINGS OR CUPS
ers two to seal the piston.
Ref: 6.60
6-16. The purpose of the air control valve on 6-16. ADMIT; CLOSE OFF
an air-driven pump is to
and air to the piston. Ref: 6.62, 6.63
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Self-Check Quiz 99
Answer the following questions by marking an

6-1 Which of the following is not a reciprocating 6-6. The intake valves are located above the cylin
pump? der in pumps
□ a. Diaphragm pump □ a. of the valve-plate design only

□ b. Pneumatic pump □ b. of the pot valve design only
□ c. Rotary pump □ c. of both the valve-plate and pot-valve
□ d. Power pump designs
□ d. of either the valve-plate or pot-valve
6-2. In a power pump, the end that does the design
pumping is called the
6-7. How is the fluid end of a horizontal plunger
□ a. fluid end pump lubricated?
□ b. power end
□ c. steam end □ a. By the maintenance team
□ d. air end □ b. By lubrication seals
□ c. By the fluid being pumped
6-3. Fluid-end pistons convert mechanical energy □ d. By an independent oil bath
into
6-8. In a vertical plunger pump, the plunger is con
□ a. fluid movement nected to a
□ b. rotary motion
□ c. reciprocating motion □ a. connecting rod
□ d. steam □ b. crankshaft
□ c. crosshead
6-4. In a power pump, the device that converts the □ d. movable frame
rotary motion of the crankshaft connecting
rod into reciprocating motion is the 6-9. If an air-driven pump has a 10:1 ration and
the discharge pressure of the fluid is 800 psi,
□ a. cylinder the motor air supply is
□ b. crosshead
□ c. stuffing box □ a. 8 psi
□ d. plunger □ b. 80 psi
□ c. 800 psi
6-5. Double-acting pumps discharge fluid on □ d. 8000 psi
□ a. the forward stroke of the piston only 6-10. Which way do the piston rings in the air end
□ b. the return stroke of the piston only of an air-driven pump face?
□ c. either the forward stroke or the return
stroke n a. Toward each other
□ d. both the forward stroke and the □ b. Toward the fluid side of the pump
return stroke □ c. Toward the air side of the pump
□ d. Away from each other
100 Lesson Six
SUMMARY
Several kinds of reciprocating pumps are used in Most steam-driven pumps are double-acting. That
industry. Pumps driven by air pressure or steam is they discharge fluid on both strokes of the pis
are calied direct-acting pumps. Pumps driven by ton. The discharge valves on the fluid end may be
an electric motor or by an internal combustion positioned above the piston (valve-plate design)or
engine are called power pumps. Diaphragm mounted to one side of the cylinder(pot-valve
pumps are another kind of reciprocating pump. design). The intake valves are located above the
All reciprocating pumps work with a back-and- cylinder. Air-driven pumps differ from other recip
forth, straight-line motion. rocating pumps only in the control methods of the
air and fluid. The ratio of the air piston area to the
Ail reciprocating pumps have two sections. In fluid piston area does not affect fluid flow as long
power pumps,the two sections are the fluid end as the air pressure remains constant.
and the power end. In direct-acting pumps,the
sections are the fluid end and the air or steam Power pump plungers can operate either horizon
end. In each pump,the fluid end does the pump tally or vertically. The intake and discharge
ing, while the opposite end provides the driving valves are similar to those used in other recipro
force necessary to operate the fluid end. cating pumps.
6-1. c. Rotary pump. Ref: 6.02-6.04 6-6. 0. Of both the valve-plate and pot-valve
designs. Ref: 6.32
6-2. a. Fluid end. Ref; 6.07
6-7. 0. By the fluid being pumped.
6-3. a. Fluid movement. Ref: 6.45
Ref: 6.09
6-8. d. Movable frame. Ref: 6.47
6-4. b. Crosshead. Ref: 6.17
6-9. b. 80 psi. Ref: 6.52
6-5. d. Both the forward stroke and the
return stroke. Ref: 6.20 6-10. d. Away from each other. Ref: 6.60
Figure 6-1. Binks Manufacturing Company and Union Pump Figure 6-8. Worthington Division, McGraw-Edison Company
Company. Figure 6-9. Worthington Division, McGraw-Edison Company
Figure 6-4. Worthington Division, McGraw-Edison Company Figure 6-10. Binks Manufacturing Company; Grover Manufacturing
Figure 6-6. Worthington Division, McGraw-Edison Company Corporation
Figure 6-7. Worthington Division, McGraw-Edison Company
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iriiyilJiiiiiiriiii'a'.i
UNDERSTANDING THE OPERADON OFPUMPS
Metering Pumps
"If O
V

102
Lesson
Metering Pumps
TOPICS
Introduction to Metering Pumps Diaphragm Pumps

Metering Pump Classifications Air-Operated Metering Pumps
Plunger and Piston Metering Pumps Rotary Metering Pumps
OBJECTIVES
• Tell what kinds of pumps are used for metering • Explain the operation of a diaphragm metering
applications. pump.
• Describe metering pump lubrication techniques.
• Name the parts of a diaphragm metering pump
and state the function of each.
KEY TECHNICAL TERMS
Metering pump 7.01 a pump that displaces a Fluid side 7.25 the end of a reciprocating pump
specified volume of fluid in a specified period of that does the pumping
time Disk plate 7.26 a metal backup plate used to pre
Calibrated 7.13 marked with graduations vent excessive diaphragm flexing
Lapped 7.16 ground or polished as a pair
Power side 7.25 the end of a reciprocating pump
that produces the pumping action
Metering pumps are similar in appearance, design, and construction to the
positive-displacement pumps covered in earlier Lessons. Reciprocating
pumps are the type most often used for metering purposes, although rotary
pumps are also sometimes used.
Because of their precision construction, metering pumps are more easily dam
aged by rough handling and changes in temperature than are other positive-dis
placement pumps. Because metering pumps are built with very close internal tol
erances, the pumped fluid is usually filtered before It enters the pump.
This Lesson covers many types of metering pumps—plunger and diaphragm

pumps, air-operated pumps, and rotary pumps—with special emphasis on the
construction and operation of each type.
Introduction to Metering Pumps pumped is usually filtered or strained before it enters

the pump. If the pump is metering paints, slurries, or
7.01 Although metering pumps frequently resem other materials containing solids,larger clearances are
ble other kinds of pumps, they are very special in built into the pump.
their design and construction. A metering pump dis
places a specified volume of fluid in a specified peri- Metering Pump Classifications
od of time. These positive-displacement devices are
also known as controlled-volume, proportioning, or 7.04 Most metering pumps are reciprocating
chemical reagent injection pumps. pumps. They are classified in one of two ways,
according to the design of their fluid ends—as either
7.02 Because of the precision of their construction, plunger (or piston) pumps or diaphragm pumps. An
metering pumps are very sensitive to temperature example of each of these two kinds of pumps is
changes in the fluids they handle. In addition, they are shown in Fig. 7-1.
easily affected by jarring, bumping, and vibration.
You must take special care to protect the adjustable 7.05 The fluid-end assemblies, valves, and stroke-
mechanisms that control the flow rate. adjustment mechanisms of reciprocating metering
pumps are the elements that distinguish them from
7.03 Most metering pumps are designed with a other reciprocating pumps. Such specialized elements
very close fit between the pump casing and the inter give these pumps the capability of zero leakage and
nal parts. To maintain this close fit, the fluid being accurate flow adjustment.
Fig.7-1. Reciprocating metering pumps
Diaphragm Plunger
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104 Lesson Seven
Fig.7-2. Rotary metering pumps
Flexible liner
7.06 Although reciprocating pumps are the type cal industrial plunger pump. Changes, if any, are usu
most often chosen for metering purposes, rotary ally in the driving end of the pump, although some
pumps are sometimes used. Three types of rotary modifications can be made to the fluid end for pump
metering pumps—vane, gear, and flexible liner—are ing specific fluids.
shown in Fig. 7-2.
7.11 The pump housing is mounted independently
7.07 Metering pumps are usually driven by an exter of the drive mechanism. An externally mounted con
nal power source, which can be at constant or variable necting rod connects the pump plunger to the gear
speed. If a variable-speed drive is used, the flow rate of reducer or motor. On this type of pump, the connect
the pump changes with the pump speed.In other pumps, ing rod is usually adjustable at the crankshaft. Adjust
flow rate is adjusted mechanically within the pump. ment of the connecting rod varies the amount of fluid
pumped.
7.08 Some reciprocating metering pumps are air-
driven. The fluid ends of these pumps are similar to 7.12 On some pump models, connecting rods are
the fluid ends of other reciprocating metering pumps. threaded at the point at which the rod is attached to
The power ends, however, are different. Instead of the plunger. This additional fine adjustment gives the
being driven by a rotating crank, these pumps are dri metering plunger the ability to regulate the fluid being
ven by compressed air. pumped more precisely.
7.09 The terms used to describe the various parts of 7.13 The adjustable connecting rod is usually cali
metering pumps are the same as those used with the brated (marked with graduations) to indicate the
general-purpose, positive-displacement pumps length of the plunger stroke. Marking can also indi
described in earlier Lessons. Definitions are given in cate the amount of fluid that will be pumped with
this Lesson only when the parts are unique to metering each stroke of the plunger.
pumps or different from those previously discussed.
7.14 When operating, a metering pump can dis
Plunger and Piston Metering Pumps charge fluids in amounts ranging from 0 to over 20
gpm. The amount of fluid that can be pumped varies
7.10 The basic design and construction of a with the size and type of pump. Systems that require
plunger metering pump are similar to those of a typi larger capacities often use more than one pump.
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Metering Pumps 105
7.15 A detailed view of the fluid end of a plunger 7.19 Like other piston and plunger pumps, the
metering pump is shown in Fig. 7-3. You can see the intake and discharge valves of reciprocating metering
construction of the body, plunger, plunger packing, pumps are moved by the material being pumped. The
and the check valves. Because this is a reciprocating particular model shown in Fig. 7-3 uses two check
pump, a crosshead or plunger support is located at the valves on both the intake and discharge side of the
rear of the fluid end. This crosshead stabilizes the pump. This double check valve system ensures fluid
motion of the plunger and eliminates unusual loading control at all times and minimizes the possibility of
or wear between the plunger and the body. both check valves being held open by material
jammed around the seat area. The check valves shown
7.16 Most pump bodies and plungers are made of are ball valves. Some pumps use disc valves.
stainless steel or other corrosion-resistant alloys. Usu
ally, the clearance between the plunger and the pump 7.20 Most check valves are made of stainless steel,
body is very small. In many cases, the plunger and the but they can be made of chrome-plated alloy steel. No
pump body are lapped (ground or polished as a set or matter what material is used, the valves are polished
pair) to ensure a close fit. This close fit eliminates to a smooth finish to ensure positive seating when the
leakage within the pump and helps to meter the fluid valve closes. In many piston and plunger pumps, the
discharge accurately. valves are closed by springs as well as the pressure of
the fluid acting on them.
7.17 The plunger in this pump is packed with
chevron packing. Chevron packing has a V-shaped 7.21 Most metering pumps are lubricated by the
cross section. The packing material might be rubber, fluid they pump. Some pumps have additional lubri
neoprene, nylon. Teflon®, or some other material, cation points in the packing area. These points pro
depending upon the fluid being pumped. An vide lubricant to areas of the pump that normally do
adjustable packing gland is usually placed at the rear not contact the pumped fluid. Use care in lubricating
of the fluid end to maintain pressure on the packing, these parts to avoid overlubrication.
thereby preventing leakage. For more details on pack
ing and seals,see Lesson Nine. 7.22 Some pumps cannot be lubricated by the fluid
they are pumping. If a pump is switched from one instal
7.18 Figure 7-3 shows the plunger recessed within lation to another, you must determine if the lubricant in
a cylinder that has a remote check valve area. Some the pump body and the seal or stuffing box is compatible
pump designs allow the plunger to extend into the with the new fluid before any new fluid is added to the
check valve area. The particular design depends upon pump. If the lubricant is not compatible, it must be
the manufacturer and on the fluid being pumped. removed and the seals or packing must be changed.
Fig. 7-3. Plunger pump fluid end
Fluid discharge Chevron packing

I \ For grease or internal flush
Spring-loaded
stainless steel balls
Purge port Plunger
ii
Lantern ring Crosshead

Fluid inlet
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Fig 7-4. Vertically mounted piston metering pump
I Sight well
' External
adjusting screw
Discharge check valve
Cylinder—
Downstroke
Upstroke
Reservoir
123 Figure 7-4 shows a vertically mounted piston stroke, lubricant is drawn into the cylinder from the
metering pump. This particular pump is the heart of a sight well. This creates a vacuum in the airtight
force feed lubricator which pumps small amounts of oil to sight well which causes lubricant from the reservoir
machineiy injection points. The lubricator consists of a to be drawn into the well until the pressure is equal
steel reservoir which contains the oil to be pumped. A ized. On the piston upstroke, the oil in the cylinder
camshaft inside the reservoir operates the single-piston is ejected through the discharge check valve to the
pump.All working parts are enclosed,so they remain free machine injection point. The number of drops seen
from dirt, water, and other impurities. The pump parts are falling into the sight well is the amount of oil dis
lubricated at all times by the fluid in the reservoir. charged by the pump. The pump can be adjusted by
an external screw. This adjustment changes the
7.24 Rotation of the lubricator's cam operates length of the piston stroke, which changes the pump
the piston in the reservoir. On the piston's down- discharge volume.
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7-1. A metering pump displaces a specified

volume of fluid in afn) 7-1. SPECIFIED AMOUNT OF TIME
Ref: 7.01
7-2. Metering pumps are sensitive to temper 7-2. TRUE

ature changes in the fluids they handle.
True or False? Ref: 7.02
7-3. To maintain the close fit within a meter 7-3. STRAINED or FILTERED
ing pump, the pumped fluid is usually
before it enters the Dump. REF: 7.03
7-4 Most metering pumps are 7-4. RECIPROCATING

pumps.
REF: 7.04
7-5. The connecting rod of a plunger meter 7-5. CALIBRATED

ing pump is usually to indi
cate plunger stroke length. Ref: 7.13
7-6. Most metering pumps are lubricated by 7-6. THE FLUID THEY PUMP
Ref: 7.21
7-7. If a pump's the lubricant is not compat

7-7. SEALS or PACKING
ible with a new installation, remove the
lubricant and chance the
Ref: 7.22
7-8. On the piston's downstroke, lubricant is 7-8. SIGHT WELL

drawn into the cylinder from the
. in a vertical mount oiston Ref: 7.24
pump.
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108 Lesson Seven
Diaphragm Pumps adjustable eccentric point between the crankshaft and

the connecting rod of the plunger, in a manner similar
7.25 Most diaphragm metering pumps use hydraulic to the adjustable-stroke plunger pump. By changing
iaphragm. the stroke of the plunger in the power end, the amount
Under these conditions, the pump diaphragm has fluid of fluid forced against the diaphragm changes, this
on both sides,as illustrated in Fig. 7-5.The side that pro adjustment changes the amount of diaphragm move
duces the pumping action is called the power side, while ment and the amount of fluid pumped. Figure 7-6
the side doing the pumping is called fluid side. shows an adjustable-stroke diaphragm pump.
7.26 Because the diaphragm is flexible, it reacts to 7.30 Some manufacturers use a variable-speed
any pressure exerted on it by outside forces. drive connected to the pump plunger to control pump
Diaphragms are designed to withstand maximum flow. The variable-speed drive changes the number of
flexing and to prevent penetration by the fluids being plunger strokes per minute instead of the length of the
pumped. Some diaphragms have metal backup plates stroke,
called disk plates to prevent excessive flexing.
7.31 Another manufacturer places the plunger
7.27 As hydraulic fluid is forced against the power directly within the crankshaft of the pump. The con
side, the diaphragm flexes away. This motion discharges stant rotation of the crankshaft and plunger is convert
the fluid on the fluid side of the diaphragm. This pressure ed to reciprocating motion by changing the position of
closes the suction check valve.As the pump piston retracts, the reaction ring, as shown in Fig. 7-7. Shifting the
the hydraulic fluid is withdrawn from the power side. The reaction ring to one side or the other varies the amount
diaphragm flexes away from the fluid side. The vacuum of fluid that the plunger pumps as it rotates. The pulsat
produced in the cavity causes the discharge valve to close. ing fluid is directed against the diaphragm, which flex
The suction valve is forced open by the incoming fluid, es and pumps the fluid on the fluid side. This pump is
and the pumped material is drawn into the open space. designed to be adjustable while it is operating. Most
mechanically adjustable pumps can be adjusted only
7.28 The method of fluid control on the power when they are stopped,
side of the diaphragm varies with each manufacturer.
However,the basic operation remains the same for all 7.32 A further variation of the basic diaphragm
diaphragm pumps. pump is shown in Fig. 7-8 on page 110. As in other
models, the piston on the power end of the
7.29 The power end of a diaphragm pump can be diaphragm is driven by a crankshaft. The piston
adjusted in one of several ways. One design uses an stroke is not usually adjustable. The amount of fluid
Fig.7-5. Diaphragm pump operation
Diaphragm
Piston
Suction stroke Discharge stroke
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Fig. 7-6. Adjustable-stroke diaphragm pump
pumped is regulated within the pump by means of a 7.34 The cylindrical diaphragm is expanded by the
hydraulic fluid capacity adjusting knob. This knob hydraulic fluid pumped into the diaphragm interior.
varies the amount of fluid admitted to the power side The amount of hydraulic fluid admitted to the
of the diaphragm by changing the position of the diaphragm is regulated by a capacity-control port. As
fluid-closing port. the plunger travels downward,control fluid is bypassed
back to a reservoir until the control port is closed. The
7.33 Another type of diaphragm pump, which acts trapped fluid is then forced into the chamber,extending
on the same principle, is shown in Fig. 7-9 on the the diaphragm and pumping the fluid on the fluid side.
next page. In this particular pump, the diaphragm is
cylindrical. Pumping takes place when the entire 7.35 Stainless steel or another corrosion-resistant
diaphragm cylinder flexes. alloy usually forms the pump body. The diaphragm is
Fig. 7-7. Diaphragm pump with rotating plunger
Automatic air escape mechanism-

Check valve
Needle bearings —
Rotating plunger-
Hollow drive shaft-
Reaction ring
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Fig. 7-8. Diaphragm pump with fluid capacity control
Capacity
adjustment knob
Refill hole
Diaphragm
Eccentric
made of a chemically resistant, flexible material. 7.37 Most metering pumps that are mechanically
Most manufacturers make several diaphragms for adjustable by cams or varying speed arrangements
each pump, each of a different material. Although can be controlled by electric or pneumatic actuating
these diaphragms are interchangeable, you must make devices. These electric or pneumatic controls are con
sure that a particular diaphragm material is suitable nected to the adjustable metering control devices and
for your particular application. can be remotely controlled.
7.36 Both the suction and discharge valves are 7.38 Frequently, a sensing mechanism is inserted in
fluid-actuated and are either of the ball or disc type. the fluid-flow line to the main fluid system. In these
They may or may not be spring-loaded. applications, a pickup device will detect any variation in
Fig.7-9. Cylindrical-diaphragm pump
Capacity —
control port
Discharge
Suction
Suction stroke Discharge stroke
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Metering Pumps 111
Fig. 7-10. Air-operated metering pump short, metered strokes instead of long, complete
strokes.
7.42 As the piston reaches the end of its stroke,

the air on the power side is vented, while air is
admitted to the opposite side of the piston. This air
movement reverses the air piston and returns it to its
original position in one smooth movement. The
power end of the diaphragm pump uses a spring-
loaded diaphragm. In this case, the diaphragm is
returned by spring action while the inlet air is vented
to the atmosphere.
7.43 In air cylinders that use a limit switch as

the control mechanism, the actuating air is
stopped and started somewhat differently. As the
trip mechanisms attached to the connecting rod
pass a limit switch, the air inlet valve opens or
closes as required. When the cylinder reaches the
end of its stroke, the air is vented. Air is admitted
the makeup of the fluid. When it senses variation, it to the opposite side, and the piston returns to its
sends a signal to the controlling unit, which automatical starting position. During its return stroke, a limit-
ly makes a correction. For example, it might increase or switch override is used to prevent the limit
decrease the amount of chemical being pumped. switches from stopping the smooth return move
ment of the cylinder.
Air-Operated Metering Pumps
7.44 The return of the piston to its original posi
7.39 An air-operated, reciprocating metering pump tion draws fluid into the pump chamber. This is true
is shown in Fig. 7-10. The fluid end of the pump is of all metering pumps that use pistons or plungers. As
similar in design, construction, and operation to those in other pump models, fluid intake and discharge are
previously covered. The power end, however, is quite controlled and directed by a set of check valves.
a bit different. Instead of using the rotary motion of a
crankshaft or eccentric to create the reciprocating Rotary Metering Pumps
motion of the pump, an air cylinder is connected
directly to the pump. 7.45 Rotary metering pumps are most often vane
pumps. Their construction is similar to that of the
7.40 During operation, the air cylinder piston fixed-capacity vane pump covered in Lesson Five. In
travel is controlled by limiting the amount of air order for the pump to have a variable flow, however,
admitted to the cylinder or by using a limit switch the body housing is made movable about a central
mounted on the connecting rod. Inlet air is usually point.
controlled by an electrically timed metering device.
This device automatically admits air to the cylinder 7.46 This arrangement is shown in Fig. 7-11 on the
at the required pressure and for a specific amount of next page. The outer body of the pump can be rotated
clockwise or counterclockwise to vary the amount of
fluid pumped. Changing the position of the body
7.41 As the timer closes the inlet valve,the air that changes its position with respect to the impeller
advances the piston in the air cylinder is shut off. vanes. With this arrangement, fluid delivery can be
Because the piston is in a sealed unit, however,the air varied to suit the conditions at hand.
that has been admitted remains there until the piston
completes its stroke. In this way, the air holds the 7.47 The position of the pump body is changed
cylinder in position and allows the pump to make by turning a handwheel mounted on the outside of
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Fig.7-11. Vane metering pump operation
Gear segment
Handwheel
Partial forward flow

Full forward flow
Neutral flow Reverse flow
the pump. This handwheel rotates the worm on the 7.48 Another rotary pump design sometimes
other end of the shaft. The worm changes the posi used for metering is the gear pump. It becomes a
tion of the gear segment, which is connected to the metering pump when driven by a variable-speed
pump body. motor. On some internal gear models, the crescent
segment is movable. Moving the crescent changes
the position of the idler gear with respect to the
Fig.7-12. External gear metering pump inlet opening in the pump body. This adjustment
reverses the fluid direction. No changes are neces
sary in the piping or valves. External-gear pumps,
like the one shown in Fig. 7-12, are also used for
metering.
7.49 Peristaltic pumps (flexible tube or liner

pumps) are also sometimes used for metering pur
poses. Variable-speed motors allow precise con
trol.
7.50 The materials used in the construction of

rotary metering pumps depends upon the application
for which the pump is used. Like most other metering
pumps, the pump body, impeller, and internal pump
housing are made of materials that are corrosion-
resistant. The materials are selected for long service
life with little maintenance.
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Metering Pumps 113
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7-9. A variable-speed drive can control a 7-9. NUMBER OF STROKES PER MINUTE
diaphragm pump flow by changing the
Ref: 7.30
7-10. Most mechanically adjustable pumps 7-10. FALSE

can be adjusted during operation.
True or False? Ref: 7.31
7-11. In a cylindrical-diaphragm pump, both 7-11. FLUID

the suction and discharge valves are
-activated. Ref: 7.36
7-12. Most mechanically adjustable metering 7-12. ELECTRIC, PNEUMATIC

Dumos can be controlled bv
or actuating devices. Ref: 7.37
7-13. The power end of an air-operated 7-13. SPRING

meterina pump uses afn) to
return the diaphragm. Ref: 7.42
7-14. In all air-operated metering pumps that 7-14. CHECK

use pistons or plungers, fluid intake and
discharge are controlled by a set of Ref: 7.44
valves.
7-15. Rotary metering pumps are most often 7-15. VANE

pumps.
Ref: 7.45
7-16. Flexible tube or liner pumps, also 7-16. PERISTALTIC

known as pumps, are some
times used for metering purposes. Ref: 7.49
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Self-Check Quiz 115

7-1 All of the following describe positive displace 7-6. Most diaphragm metering pumps are actuat
ment metering pumps EXCEPT ed by
□ a. controlled-volume pumps □ a. a flywheel

□ b. centrifugal pumps □ b. an electric motor
□ c. proportioning pumps □ c. hydraulic pressure
n d. chemical reagent injection pumps □ d. pneumatic pressure
7-2. Most metering pumps are classified as 7-7. Unlike most mechanically adjustable
pumps or pumps. diaphragm pumps, one design can be adjust
ed while in operation because of its
□ a. plunger, diaphragm
□ b. diaphragm, peristaltic □ a. adjustable eccentric
□ c. peristaltic, centrifugal □ b. variable-speed drive connected to the
□ d. centrifugal, plunger plunger
n c. plunger within the pump's crankshaft
7-3. What two capabilities distinguish reciprocat □ d. threaded connecting rod
ing metering pumps from other reciprocating
pumps? 7-8. In an air-operated reciprocating metering
pump, the inlet air is usually controlled by
□ a. Zero leakage, high speed
□ b. High speed, increased volume □ a. an electrically timed metering device
capacity □ b. a limit switch mounted on the con
□ c. Accurate flow adjustment, zero leak necting rod
age □ c. a pressure sensor linked to the intake
□ d. High pressure capacity, accurate flow valve
adjustment □ d. a programmable controller
7-4. To ensure a close fit between the plunger and 7-9. Rotary metering pumps are most often
the pump body, they are often
□ a. gear pumps
□ a. lapped □ b. vane pumps
□ b. napped □ c. flexible liner pumps
□ c. coated □ d. centrifugal pumps
□ d. tinned
7-10. In a rotary metering pump, the position of the
7-5. What moves the check valves used in recip pump body is changed by adjusting a{n)
rocating metering pumps?
□ a. crescent segment
□ a. A handwheel □ b. control arm
□ b. An electric timer □ c. eccentric
□ c. The hydraulic fluid □ d. handwheel
□ d. The material being pumped
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116 Lesson Seven
SUMMARY
Metering pumps frequently resemble other types discharge. Most pump bodies and plungers are
of positive displacement pumps in appearance made of stainless steel or other corrosion-resis
and operation. Metering pumps, however, are tant alloys. Diaphragms are made of several
designed with a close fit between internal parts to types of chemically resistant flexible material.
discharge precise amounts of liquid.
Several types of rotary metering pumps can be
Most metering pumps are of the reciprocating adapted for metering purposes, including vane,
type, either plunger or diaphragm. They might be gear, and peristaltic pumps. Some rotary pumps
mechanically driven or air-operated. On recipro are adjusted internally to vary fluid delivery, while
cating pumps,the connecting rod is usually others are driven by variable-speed motors.
adjustable to give more precise control of fluid
7-1. b. Centrifugal pumps. Ret; 7.01 7-6. c. Hydraulic pressure. Ref: 7.25
7-2. a. Plunger, diaphragm. Ref: 7.04 7-7. c. Plunger within the pump's crankshaft.
Ref: 7.31
7-3. 0. Accurate flow adjustment, zero
leakage. Ref: 7.05 7-8. a. An electrically timed metering device.
Ref: 7.40
7-4. a. Lapped. Ref: 7.16
7-9. b. Vane pumps. Ref: 7.45
7-5. d. The material being pumped.
Ref: 7.19 7-10. d. Handwheel. Ref: 7.47
Contributions from the foiiowing sources are appreciated:
Figure 7-1. Jaeco Pump Company

Figure 7-2. Vanton Pump & Equipment Company., Blackmer Figure 7-8. Jaeco Pump Company
Pump Division./Dover Corporation, Viking Pump Divi Figure 7-10. Teledyne Meria
sion, Houdaille Industries, Incorporated. Figure 7-11. Viking Pump Division, Houdaille Industries, Incorpo
Figure 7-6. The Madden Corporation rated
Figure 7-7. BIF, A Unit of General Signal Figure 7-12. Viking Pump Division, Houdaille Industries, Incorpo
rated
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Lesson Eight
Special-Purpose
Pumps
V J
Ô: /
WPCTi-aining Systems
118
Lesson
Special-Purpose Pumps
TOPICS
Handling Difficult Materials Pulp-Handling Pumps

Chemical Pumps Trash and Sewage Pumps
Special Chemical Pumps Diaphragm Pumps
Magnetic-Drive Pumps Reciprocating Slurry Pumps
Canned-Motor Pumps Vortex Pumps
Centrifugal Slurry Pumps
OBJECTIVES
• Describe the operation of a flexible-tube pump. Explain how to prepare a new centrifugal pump
• Give an application for a progressing-cavity for operation.
pump. Tell which parts of a reciprocating slurry pump
• Name one disadvantage of a seal-less magnetic- require the most maintenance.
drive pump.
KEY TECHNICAL TERMS
Difficult material 8.01-8.03 any material requiring Catalyst 8.06 a chemical agent that causes a
handling by a special pump because of corrosive, resin to harden
abrasive, or solid properties
Resin 8.05 liquid chemical used to make plastic
products
119
Many plants handle materials described as difficult to pump. Some applications

in your piant might require the use of special-purpose pumps to handle difficult
materials. Most of these special-purpose pumps are modifications of the pumps
covered in eariier Lessons. Some, however, have not yet been covered in this
Unit.
Different special-purpose pumps are used in different applications. After study

ing this Lesson, you shouid be abie to explain the operating characteristics of
peristaitic pumps, sealless magnetic-drive pumps, sewage pumps, and other
kinds of special-purpose pumps. You should also know which parts of these vari
ous pumps are iikely to require the most maintenance.
As you study this Lesson, try to remember the applications iisted for the
various special-purpose pumps. The style of the impeller is often a guide
to the kinds of materials a particular pump can handle.
Handling Difficult Materials chemical plant before they are ready for conversion to
the final product. During final processing, the resins
8.01 Lesson One discussed several systems used to might be converted to dry pellets or powder, or they
pump difficult materials. This Lesson provides more might remain in liquid form.
examples, plus detailed information about the design,
construction, and operation of the pumps used. 8.06 Often the resins are combined with another
chemical agent, called a catalyst, during final mixing.
8.02 The term difficult material can have different The catalyst causes a chemical reaction in the resin
meanings for different people. In one plant, a difficult that causes it to harden. Fiberglass pro-ducts use resin
material might be an extremely corrosive chemical. In as a base during the manufacturing process.
another plant, it might be a semi-solid or abrasive
material. Your plant probably has its own kinds of dif 8.07 Pumps used to handle resins are usually air-
ficult materials. operated reciprocating pumps. Reciprocating pumps
are used because the resins have a high viscosity,
8.03 Some materials are problems under certain requiring a positive-displacement pump to move
conditions but not under others. Oil, for example, is them. The stalling characteristic of the air-operated
difficult to pump in the crude stages. After it is pump maintains constant pressure throughout the sys
refined, however, it becomes an easy material to tem, even when the fluid is not being pumped. In
pump. The remainder of this Lesson will cover some addition, the straight-line motion of the piston reduces
common difficult-material applications and special- heat buildup and foaming, problems frequently
purpose pumps. caused by rotary pumps.
Chemical Pumps 8.08 Less viscous chemicals are usually handled

by centrifugal pumps like the ones shown in Fig. 8-1
8.04 Because of the increase in the use of chemical on the next page. The first consideration when select
products in recent years, chemical pumps are more ing a chemical pump is to make sure the materials
commonly used in all industries. The chemicals used for both the pump casing and the impeller can
pumped might be hot, corrosive, viscous, or difficult resist attack by the chemical being pumped. The prop
in other ways. Commonly pumped chemical materials er corrosion-resistant seals must also be selected.
also include liquid fertilizer, acid, solvent, and plastic
resin. 8.09 Many pump casings are made of corrosion-
resistant alloys. Others are made of Teflon®,
8.05 Most plastic products start out as liquid polypropolyene, chlorinated polyvinyl chloride
chemicals. These liquids are sometimes called resins. (CPVC), and similar materials. Most materials can be
These resins often must be piped throughout the used with more than one chemical. However, you
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Fig.8-1. Chemical pumps
must take care to ensure that the materials selected for carbide treated parts for use with abrasive and corro
a chemical pumping system are compatible with the sive fluids.
fluid and will not corrode or erode because of the
chemical action within the system. Special Chemical Pumps
8.10 A special centrifugal chemical pump is shown 8.11 Some unusual kinds of pumps are somedmes
in Fig. 8-2. Although the pump resembles a common used in chemical pumping applications. These pumps
end-suction centrifugal pump, it dilfers in construc are also good to use when pumping viscous fluids or
tion. The entire casing, impeller, and shaft sleeve are thick slurries.
made of impervious graphite. Use of the graphite
material results in a pump that is strong, lightweight, 8.12 The pump shown in Fig. 8-3 is called a flexi
and highly resistant to acids and salt solutions. In ble tube pump or peristaltic pump. This type of pump
addition, the pump shown is available with silicon- was covered briefly in Lesson Five. As the pump
rollers come into contact with the flexible tube, they
press the pumping tube against a curved track. As the
Fig. 8-2. Graphite pump roller travels through its circle, the tube is com
pressed, forcing any fluid ahead of the roller out the
discharge port. After the roller passes,the tube returns
to its original shape and draws in fluid from the intake
side.
8.13 Peristaldc pumps are available with different

numbers of rollers to change their capacity. The tubes
are usually made of natural or synthetic rubbers. The
compression tubes must be not only flexible but also
elastic, in order to resume their shape after they have
been compressed. Tubing comes in many diameters
and wall thicknesses. The larger the tube diameter, the
greater the capacity of the pump. Peristaltic pump
capacities range from 5 to 2000 gph.
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Special-Purpose Pumps 121
8.14 Figure 8-4 shows d, flexible-liner pump. This Fig. 8-3. Flexible-tube pump
pump was covered briefly in Lesson Five. Because it
is sealless and has few moving parts, it can handle
corrosives, volatile fluids, and abrasives safely and
efficiently.
8.15 As shown in Fig. 8-4, a rotor mounted on an

eccentric shaft oscillates within the liner, thus creat
ing a progressive squeegee action on the fluid trapped
between the liner and the body block. The pumped
fluid contacts only the outer surface of the liner and
the inner surface of the body block. These surfaces
may be made of various plastics, natural or synthetic
rubbers, stainless steel, or other materials.
8.16 A progressing-cavity pump is shown in Fig.

8-5. This pump, which is sometimes referred to as a
single-screw pump, was also covered briefly in Les
son Five. This pump is actually a positive-displace
ment rotary screw pump. Because of its construction,
this type of pump is particularly suitable for pumping
viscous solutions and thick slurries. the fluid is forced along the open area in the stator.
Continued rotation of the rotor forces the fluiid toward
8.17 It is composed of five main parts—the hous the discharge port.
ing, the stator, the rotor, the connecting rod, and the
drive shaft. The rotor is usually made of either 8.19 Figure 8-5 on the next page shows the stuff
chrome-plated tool steel or stainless steel. The stator ing box on the drive shaft. The connecting rod is
is made from natural rubber, Buna-N, butyl rubber, or located within the drive shaft. Because the connect
other materials. The material selected for the rotor ing rod dead-ends within the drive shaft, it will not
and stator is determined by the application. allow any fluid leakage. The only place leakage can
occur is through the stuffing box. Because the fluid
8.18 In operation, the fluid enters at the suction flows away from the stuffing box, the packing is in a
end of the pump and flows into the open cavity negative pressure area, except when the pump is
between the rotor and the stator. As the pump rotates. stopped.
Fig. 8-4. Flexible-liner pump
Body block
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Fig.8-5. Progressing-cavity pumps
Discharge
Inlet hopper
Drive shaft
Suction
stuffing box
8.20 The progressing-cavity pump can be oper 8.22 Progressing-cavity pumps are frequently used
ated in reverse. When operating in reverse, the in food processing plants and refineries, as well as in
reversed fluid flow and rotor action can remove chemical plants. These pumps are also used to handle
any plugging in the suction or discharge line or in sewage and industrial waste. The temperature of the
the pump itself. After the obstruction is removed, pumped fluid should be kept below 200®F to keep the
reversing the pump again restores it to its original stator from drying out and becoming brittle.
rotation, which allows regular pumping to
resume. 8.23 Progressing-cavity pumps can even be used
for pumping mineral gypsum, perlite, and other roof
8.21 The pump housing is usually made of cast materials. In these applications, the inlet pipe is
iron, but cast steel or cast stainless steel are also replaced by an inlet hopper with a rectangular open
used. The housing can be either of one or two- ing or throat. The rectangular opening prevents the
piece construction, depending upon the size of the material from bridging. A small screw conveyor or
pump. feeder at the bottom of the hopper ensures full materi-
Fig.8-6. Magnetic-drive pump
Driving magnet
II
This material is protected by U. S. Copyright law. Copying by any optical, electronic, or othe illegal wUhoiit permission
al flow to the pump rotor. This design is also shown Fig,8-7. Canned-motor pump
in Fig. 8-5.
Magnetic-Drive Pumps
8.24 Although many improvements have made

pumps increasingly resistant to chemical attack, one
problem remains. That problem is leakage. Although
many types of sealing devices have been used with
good results, better sealing methods are always being
sought. As a result, the sealless magnetic-drive pump
was perfected. This pump is shown in Fig. 8-6.
8.25 From the outside, the magnetic-drive pump

looks like many other chemical pumps. Its construc
tion, however, is very different from that of other cen
trifugal pumps.
8.26 The impeller of the magnetic-drive pump Canned-Motor Pumps

has an extension hub on its driving side that
extends into the pump housing, as shown in Fig. 8- 8.29 Canned-motor pumps are sealless, close-cou
6. The impeller hub is made of a magnetic material. pled, centrifugal pumps, with the motor and pump
When the pump is operating, the motor drives a contained in a common sealed steel enclosure or can.
small circular magnet located at the rear of the Motor bearings run in the pumped fluid, thus elimi
pump housing. The magnet is positioned around the nating the need for shaft seals. Since the pumped fluid
impeller hub and controls both the impeller's speed is also the lubricant, it is important that no solid parti
and position. As the motor turns the driving mag cles or grit enter the pump. A typical canned-motor
net, magnetic flux passes through the pump hous pump is pictured in Fig. 8-7.
ing and couples the rotation of the motor and
impeller. 8.30 Single-stage canned-motor piimps are avail
able for deliveries up to 700 gpm at heads up to 250
8.27 There are two things to remember when ft. Two-stage pumps will deliver heads up to 600 ft.
using pumps of this type. First, the pump is not Canned-motor pumps are commonly used to pump
designed to operate under suction lift conditions. It liquid refrigerants, solvents, heat-transfer fluids, and
must have a positive suction head and must be light oils. They are also well suited for applications
primed (filled with fluid) before it is started. Second, involving toxic or hazardous liquids, where no leak
because the impeller hub is magnetic, it can wander age can be tolerated.
during operation. The positioning and balancing of
the impeller hub are aided by the fluid passing
through the pump.
8.28 Because of their characteristics, magnetic-

drive pumps are usually made for fixed-capacity
applications. Most of these pumps operate with small
motors and handle flows from about 0.5 to 25 gpm.
This material is proteaed by U. S. Copyright law. Copying by any opiical, electronic, or other means is iiiegai without permission.
R-1 Difficult materials include 8-1. CORROSIVE; ABRASIVE

. and semi-solid materials.
Ref: 8.02
8-2. Pumps used to handle resins are usual 8-2. RECIPROCATING

ly air-operated pumps.
Ref: 8.07
8-3. In the peristaltic pump, fluid moves 8-3. TUBE; ROLLERS

throuoh a flexible com
pressed by Ref: 8.12
8-4. In the progressing-cavity pump, fluid is 8-4. ROTOR

forced toward the discharge port by the
rotation of the Ref: 8.18
8-5. The sealless magnetic-drive pump 8-5. POSITIVE; PRIMED

must have suction head and
must be before it is started. Ref: 8.27
8-6. The maximum flow for most sealless 8-6. 25

magnetic-drive pumps is about
gpm. Ref: 8.28
8-7. No seals are needed in canned-motor 8-7. BEARINGS

pumps because the run in
the pumped fluid. Ref: 8.29
8-8. Single-stage canned-motor pumps are 8-8. 700; 250

available for deliveries uo to
gpm at heads up to ft. Ref: 8.30
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Centrifugal Slurry Pumps

Pulp-Handling Pumps
8.31 The slurry pumps used in industry can handle 8.36 Centrifugal pulp-handling pumps are com
a wide variety of materials. Because many of the monly used in paper mills. Impellers are usually open,
materials are abrasive in nature, the pump is expected as shown in Fig. 8-10 on the next page, although
to wear. For this reason, pumps are often modular in
design and have renewable segments for easier main closed impellers are sometimes used.
tenance and accessibility. An example of a modular
slurry pump is shown in Fig. 8-8. When using this 8.37 As in other slurry pumps, the impellers of
type of pump, you can remove and replace parts easi these pumps are fairly large in diameter and have only
ly and quickly.
a few vanes. Some pumps used for pulp are connected
to a screw conveyor or other feeding mechanism. The
grabbing action of the screw conveyor or feeder
8.32 Most slurry pumps are centrifugal pumps. breaks up the pulp and draws it into the pump.
Some are diaphragm pumps, which will be discussed
later in this Lesson.
Trash and Sewage Pumps
8.33 Many slurry pumps are lined with rubber, 8.38 Trash and sewage pumps, like slurry pumps,
ceramic, or other abrasion-resistant materials. An must move a certain amount of debris. Usually, they are
example of a lined pump is shown in Fig. 8-9. of the wet-sump design and are placed directly in the
fluid being pumped. Sometimes these pumps are used to
8.34 Some slurry pumps use semi-open pump out excavations or flooded areas. These pumps
impellers, while others use closed impellers. Slur must be able to handle trash, twigs,rags, and stone.
ry-pump impellers are usually relatively large and
have only a few widely spaced vanes. This allows 8.39 The centrifugal pumps shown in Fig. 8-11 on
the slurry to pass through without clogging the the next page are examples of those used for wet-
impeller. sump applications. The impeller and the pump casing
are fairly large, which allows the bulky materials to
8.35 Because the materials handled by slurry pass without clogging the pump.These pumps usually
pumps are very bulky and viscous, large-horsepower have their suction intake on the underside.
motors are required. Many of these pumps are mount
ed on bedplates that support not only the motors, but 8.40 Note that on the dry-type sump pump shown in
also speed-reducing devices. Fig. 8-12 on page 127,the suction intake is near the top.
Fig. 8-8. Modular slurry pump Fig. 8-9. Lined slurry pump
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Fig.8-10. Pulp-handling pump
By having the suction intake above the impeller, a small ed to allow you to clean out debris that collects on the suc
amount of fluid is retained within the pump casing when tion side. Although not all pumps are exactly the same,
the pump stops. This feature makes the pump self-prim most sump pumps are made with easy access for cleaning.
ing. If the pump has never been used, pour a small
amount of water into the top of the pump to prime it. 8.42 Some pumps have guide vanes attached to the
Once die pump has been used, it will normally retain its cover to direct the flow of material into the impeller.
prime unless the water is drained out completely. To increase pump life, a wearplate or liner can be
bolted to the cover. The impellers are usually of the
8.41 On portable sump pumps, the section of the semi-open type.
pump just ahead of the impeller is usually removable.
Also, a small cover plate in front of the impeller is provid- Diaphragm Pumps
8.43 Although diaphragm pumps are often thought

Fig. 8-11. Sump pump of as metering pumps,they can also be used for trans
ferring fluids, slurries, or sewage. The pumping
action of diaphragm pumps is similar to the pumping
action of other types of reciprocating pumps.
8.44 Diaphragm pumps operate with a flexing

action. The diaphragm can be deflected mechanically
Discharge
or by hydraulic or air pressure. The mechanically dis
placed design requires a pressure-relief valve. The air
and hydraulic designs, because of their stalling char
acteristic, do not require relief valves.
8.45 Diaphragms can be made of metal or inert

plastic. The diaphragm's only function is to isolate the
pumped fluid from the motivating force. When used to
pump chemicals or other corrosive fluids, diaphragm
pumps should either be lined or manufactured of stain
less steel or other corrosion-resistant materials.
8.46 Mechanically actuated pumps are commonly

used for low-pressure service. An unsupported
Thi$ maiBrial is protwed by U S. CopyngW law. Copying by any optical, eleetrore, or other means is illegal without permissior
diaphragm is moved in the discharge direction by an 8.49 The other type of reciprocating slurry pump
eccentric cam and is returned by a compression shown is motor or engine driven. In this type of
spring. pump, the fluid end is similar to the one in the air- or
steam-operated slurry pump. The power end, howev
8.47 Air-operated double-diaphragm pumps, like er, is driven by a crankshaft through a connecting rod.
the ones shown in Fig. 8-13 on the next page, have A separate cylinder rod guide or crosshead provides
two flexible diaphragms connected by a common the flexible point needed to connect the piston rod to
shaft. As compressed air is admitted behind one the connecting rod.
diaphragm, the air behind the other is exhausted. At
the end of a stroke, air flow is automatically reversed 8.50 The check valves of these slurry pumps can be
by an air distribution valve. One pumping chamber is rubber lined or can be made entirely of molded mbber.
always filling while the other is discharging. This The use of rubber in the valves reduces valve wear
simultaneous intake/discharge pumping action is when abrasive materials are pumped. Note that these
illustrated in Fig. 8-14 on the next page. pumps are of the double-acting type, which means they
will maintain a constant flow of fluid with only a slight
Reciprocating Slurry Pumps pulsation as the piston reaches the end of the stroke.
8.48 In addition to diaphragm slurry pumps, two Vortex Pumps

other types of reciprocating slurry pumps are avail
able. Both are shown in Fig. 8-15 on page 129. The 8.51 Vortex pumps are often used to pump sewage,
air- or steam-operated pump is a close relative of slurries, and other fluids with a high solids content.
other direct-acting reciprocating pumps of the side- They are also useful for pumping fluids containing
pot design. The air- or steam-driven reciprocating large amounts of air and gas. These pumps have capac
slurry pump usually has renewable cylinder sleeves ities to about 1200 gpm and produce discharge heads to
and valve seats. These are the parts that receive the 180 ft. Figure 8-16 on page 129 shows a vortex pump.
most wear and, therefore, require the most mainte
nance. To ensure long operating life, the pump must 8.52 The impeller of the vortex pump is placed in
be equipped with renewable parts. such a way that no more than half its depth extends
Fig. 8-12. Dry-type sump pump
ma
This material is protected biy U. S. Copyright law. Copying Oy any optical, electronic, or other
Fig. 8-13. Air-operated double-diaphragm pumps
into the pump case. In some cases, the impeller is the suction piping will pass through the pump and
completely behind the case. This placement allows an out the discharge. The food industry pumps beans,
unobstructed flow of fluid with almost no interference cherries, peas, and even live fish with this type of
by the impeller. pump.
8.53 Because of the impeller location, pumped 8.54 As in a typical end-suction centrifugal pump,
particles need not pass through the blades of the the impeller transfers mechanical energy to the
impeller. The vortex is formed in front of the pumped fluid. The fluid is not thrown against the
blades. Nearly any material that will pass through inside of the pump case, however, because the
Fig.8-14. Fluid action in a diaphragm pump
Top intake-
Air
Stainless steel distribution
valve seats valve
Diaphragm
connecting shaft
Flap-type J
check valves I •Diaphragm
Bottom discharge
Left side discharge, right side intake Right side discharge, left side intake
This rratenal is prolected By U. S. Copyright law. Copying by any optical, electrohic. or other means is illegal without permission.
Fig. 8-15. Reciprocating slurry pumps
impeller is not within the case. The water tends to the discharge. Typical fluid flow is also illustrated in
twist and move out of the discharge, causing a partial Fig. 8-16.
vacuum at the center of the impeller.
8.56 Vortex pumps can be frame mounted vertically
8.55 The partial vacuum, along with the vortex or horizontally or can be obtained as submersible pumps.
action of the fluid, pulls fluid up the suction line. As Unlike the volute case of an end-suction pump,the case of
fluid enters the vortex within the pump housing, it is the vortex pump is nearly round. This feature allows the
thrown, by centrifugal force, to the outer edge of the vortex pump to hold its prime more readily, since there is
pump case. It then twirls around until it exits through no area in the case in which air can become trapped.
Fig,8-16. Vortex pump
Vortex forming Complete vortex
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8-9. Pulp-handling pumps with screw con 8-9. GRABBING

veyors or feeding mechanisms have
afn) action that breaks up Ref: 8.37
and pulls in the pulp.
8-10. Centrifugal pumps with the suction 8-10. SELF-PRIMING

intake above the impeller are
Ref: 8.40
8-11. Diaphragm pumps operate with a(n) 8-11. FLEXING

action.
Ref: 8.44
8-12. The function of a diaphragm is to 8-12. ISOLATE

the fluid from the motivatino
force. Ref: 8.45
8-13. In an air- or steam-driven reciprocating 8-13. CYLINDER SLEEVES, VALVE SEATS

slurrv pump, the and
receive the most wear. Ref: 8.48
8-14. Slurry pump check valves are usually 8-14. RUBBER, RUBBER
lined or made of molded
Ref: 8.50
8-15. In the vortex pump, the is 8-15. IMPELLER

placed no more than halfway into the
pump case. Ref: 8.52
8-16. The case of the vortex pump is 8-16. ROUND

in shaoe.
Ref: 8.56
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Self-Check Quiz 131

8-1. Which of the following is not a difficult materi 8-6. Centrifugal pumps with suction intakes locat
al to pump? ed above the impeller are primed by
□ a. Crude oil □ a. fluid retained within the pump casing

□ b. Liquid plastic □ b. adding water before each use
□ c. Refined oil □ c. running the pump continuously
□ d. Perlite □ d. oil moving through the casing
8-2. Pumps used to handle resins are usually 8-7. Which type of diaphragm pump requires a
pressure-relief valve?
□ a. reciprocating pumps
centrifugal pumps □ a. Air-operated pump
□ b.
peristaltic pumps □ b. Hydraulic pump
□ c.
diaphragm pumps □ c. Mechanically operated pump
□ d.
□ d. Double-diaphragm pump
8-3. The capacity of a peristaltic pump is deter
mined by the 8-8. One of the parts most likely to wear in a slurry
pump is the
□ a. impeller design
□ b. number of vanes □ a. check valve
□ b. valve seat
□ c. size of the discharge port
□ c. shaft
□ d. tube diameter
□ d. diaphragm
8-4. Which of the following is NOT a characteristic
of the sealless magnetic-drive pump? 8-9. Where is a vortex pump impeller usually posi
tioned?
□ a. It must be primed
□ b. It must have a positive suction head □ a. Completely within the case
□ c. It is used for fixed-capacity applica □ b. Halfway into the case
tions
□ c. On top of the case
□ d. It usually has a large motor □ d. Below the case
8-5. Slurry-pump impellers have 8-10. The case of the vortex pump is
many vanes □ a. triangular

□ a.
widely spaced vanes □ b. oval
□ b.
small vanes □ c. square
□ c.
□ d. round
□ d. no vanes
132 Lesson Eight
SUMMARY
The term "difficult material" applies to numerous large impellers with few,widely spaced vanes that
materials and may differ from plan to plant with allow the slurry to pass through the pump without
the material being pumped.A variety of special- clogging the impeller.Pulp-handling,trash-han
purpose pumps is used to pump difficult materials. dling,and sewage-handling pumps are all similar
in design. Sewage-handling pumps are usually of
Reciprocating pumps are used to pump high-viscosi wet-sump design and are placed directly in the
ty chemicals, while low-viscosity chemicals are often fluid being pumped.
handled by centrifugal pumps.Peristaltic pumps
and progressing-capacity pumps are used to pump Diaphragm pumps are used for transferring flu
viscous fluids or thick slurries. Magnetic-drive ids,slurries, and sewage. They operate with a
pumps and canned-motor pumps are also chemical flexing action. Vortex pumps differ from other
pumps.Unlike other pumps,these have no seals. pumps in several ways. The pump impeller is
positioned so that is does not interfere with the
Most slurry pumps are centrifugal pumps,but fluid being pumped Also,the case of the pump is
some are diaphragm pumps.Slurry pumps have round.
8-1. c. Refined oil. Ret. 8.03 8-6. a.
Ret: 8.40
8-2. a. Reciprocating pumps. Ref: 8.07
8-7. c.
8-3. d. Tube diameter. Ref: 8.13
8-8. b. Valve seat. Ret: 8.48
8-4. d. It usually has a large motor.
Ref: 8.27-8.28 8-9. b.
8-5. b. Widely spaced vanes. Ref:8.34 8-10. d.
Contributions from the foiiowing sources are appreciated:

Figure 8-1. Crane Co., Chempump division; Puisafeeder Div.,
Figure 8-8. Gould Pumps
Clevepak Corp.
Figure 8-2. Union Carbide Corporation, Carbon Products Division Figure 8-9. Gould Pumps
Figure 8-3. Waukesha Foundry Div., Abex Corp. Figure 8-10. Gould Pumps
Figure 8-4. Vanton Pump & Equipment Co. Figure 8-11. PACO Pump Company
Figure 8-5. Moyno Products; Fiuids Handling Division; Robbins & Figure 8-12. The Gorman-Rupp Co.
Figure 8-13. The Warren Rupp company
Meyers, Inc.
Figure 8-6. SERFILCO, Ltd, Glenview, IL Figure 8-14. The Warren Rupp Company
Figure 8-7. Pacific Pumps Division, Dresser Industries, Inc. Figure 8-15. Wagener Pump Division/Detroit Stoker Company
Figure 8-16. The Gorman-Rupp Company
aidfhi'
Lesson Nine
^'I'o
co
7PC Training Systems

134
Lesson
Packings and Seals
TOPICS
Pump Sealing Requirements installing Packing

Stuffing Boxes Mechanical Seals
Types of Stuffing Boxes Special Seals
Packing Materials
OBJECTIVES
• Tell why slight leakage through shaft seals is nec Describe the procedure involved in replacing pump
essary. packing.
• Name the type of stuffing box required for pumps Describe a packingless seal.
operating under suction lift conditions.
• Give a typical application each for cotton,
Teflon®^, and aluminum packing.
KEY TECHNICAL TERMS
Stuffing box 9.04 a sealing area that is manually Externally sealed pump 9.12 a pump that gets
packed and adjusted its sealing fluid from an outside source
Mechanical seal 9.04 a molded seal held in place Lantern ring 9.13 a device used to distribute
by springs or other constant-pressure devices sealing fluid within a stuffing box
internally sealed pump 9.12 a pump that sup
plies its own sealing fluid
This material is protected by U. S. Copyrigtit law. Copying by any optical, electronic, or other means is illegal without permission.
All pumps require some means of fluid leakage control. The stuffing box is one
commonly used sealing device. Many kinds of packing materials are used in
stuffing boxes. After studying this Lesson, you should be able to describe a
stuffing box. If you follow the packing procedure given in the text, you should
be able to install packing in a stuffing box.
The choice of packing material depends upon the requirements of the applica
tion. This Lesson describes the recommended packing materials for many com
mon applications.
Mechanical seals are another kind of sealing device. Seals have advantages
over stuffing boxes in some applications. You must be able to determine when
to use a mechanical seal and when to use a stuffing box. Because seals are
classified in several ways, you must also be able to select the correct kind of
seal.
Pump Sealing Requirements however, use a through shaft supported by externally

mounted bearings. Small pumps have two stuffing
9.01 In pumps, the impellers and pistons that impart boxes,one on either side of the casing.
motion to the fluid being pumped are always driven by a
shaft. To prevent fluid leakage along the driving shaft, 9.06 When installing a new pump, always check
sealing devices are used. Shaft sealing deviceslnust con the stuffing box for packing. Some pumps are
trol fluid leakage without causing wear to the pump shipped with the stuffing boxes packed, and some
shaft. If shaft wear occurs, an expensive and time-con are not. If the boxes are packed, the packing is usu
suming shaft replacementjob must be performed. ally loose and must be adjusted or tightened both
before the pump is filled with fluid and again after
9.02 Although shaft seals are designed to control start-up.
fluid leakage from the pump, a slight amount of leak
age through the seals on most pumps is required. This 9.07 Before starting the pump, it is a good idea to
leakage lubricates the shaft and the seal and cools the make sure that the stuffing boxes allow a slight
contacting surfaces. amount of leakage. Once the pump is running, reduce
the amount of leakage to a minimum to prevent fluid
9.03 Some pumps have a supply line connected to damage to surrounding equipment.
the seal area. This supply line directs fluid to the
packing to cool and lubricate it. The cooling fluid
might be the fluid being pumped. If the pumped fluid
is hot, corrosive, or abrasive, the fluid is supplied Fig.9-1 Solid-packed stuffing box
from an outside source. Retaining lip
9.04 The first half of this Lesson covers stuffing

boxes. The second half covers mechanical seals. Stuff
ing boxes are sealing areas that are manually packed
and adjusted. They contain braided cotton. Teflon®,
carbon, graphite, or synthetic sealing materials.
Mechanical seals are molded seals held in place by
springs or other constant-pressure devices.
Stuffing Boxes
9.05 Small pumps with a single shaft entrance

Packing
generally use only one stuffing box. Many pumps.
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136 Lesson Nine
Fig.9-2. Injection-type stufUng boxes
Fluid from
pump discharge
Fluid from
outside source
Lantern ring Lantern ring
Internally sealed Externally sealed
Types of Stuffing Boxes 9.10 A packing gland is placed on the outer end of
the packing rings. As the packing rings wear and leak
9.08 Several kinds of stuffing boxes are used in age increases, you can adjust the gland to reduce the
industrial pumps. The kind used in a particular pump amount of leakage. Because a solid-packed stuffing
depends upon the application, the design of the pump, box has no built-in means of lubrication, you must not
and the pump manufacturer. draw the packing down too tightly. A small amount of
leakage is necessary to cool and lubricate the shaft
9.09 The most common stuffing box arrangement and packing.
used in pumps is the solid-packed stuffing box, as shown
in Fig. 9-1 on the previous page.In this arrangement,the 9.11 Pumps that are supplied with this simple
pump casing has a retaining ridge or lip at the interior stuffing box should not be used under suction lift con
edge of the pump.(The interior edge is the one closest to ditions. When used under such conditions, air can be
the fluid being pumped.) Many pump manufacturers drawn in through the packing. This causes the pump
equip the pump shaft with a replacement sleeve. This to become airbound or to lose fluid suction.
sleeve protects the shaft from wear by the packing,
thereby reducing maintenance repair costs and lost time. 9.12 Pumps designed to operate under suction lift
conditions use a sealing or injection-type stuffing box.
This arrangement uses fluid to help seal the packing
Fig. 9-3. Lantern ring and keep air from being drawn in. The fluid can come
from the discharge side of the pump or from another
source, as shown in Fig. 9-2. If the sealing fluid is
supplied by the pump,the pump is said to be internal
ly sealed. If the sealing fluid is supplied from a source
outside the pump,it is externally sealed. Some pumps
have provisions for both internal and external sealing,
and either can be used as needed.
9.13 When a pump uses an injection-type stuffing

box, some means must be provided to distribute the
sealing fluid within the box. Usually this is done with
a lantern ring. Lantern rings are commonly made of
brass or plastic and separate the packing into two sec
tions. Rings must be correctly positioned in the pump
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Packings and Seals 137
Fig. 9-4. Circulating stuffing box system Fig. 9-5. Bleed-off stuffing box system
Sealing fluid Bleed-off point
Throat bushing
to distribute the sealing liquid properly along the the bleed-off point. It is usually connected to the suc
shaft. Figure 9-3 shows a lantern ring. tion side of the system, so the fluid is not discharged
as waste material.
9.14 If a pump is to handle gritty or corrosive
fluids, the sealing fluid must be obtained from an 9.18 In the bleed-off system, sealing fluid can be
outside source. In addition, the sealing fluid should injected into the portion of the pump casing just
be at a higher pressure than the pump suction pres ahead of the stuffing box, as shown in Fig. 9-6. In this
sure. If the pump is to handle gasoline, kerosene, injection/bleed-off system, the bled-off fluid is han
oil, or similar materials, it is especially important dled as waste.
that the sealing fluid be compatible with the fluid
being pumped. 9.19 Pumps handling fluids that can form flamma
ble gases or noxious fumes use a smothering or
9.15 A variation of the injection-type stuffing box quench system. The smothering system is similar to
is shown in Fig. 9-4. This arrangement is called a cir the injection bleed-off system just described, but is
culating stuffing box system. In this system, the seal positioned at the exterior end of the stuffing box. By
ing fluid enters on one side of the stuffing box (usual
ly the top). It passes through the sealing area and is
discharged through an opening on the opposite side of
Fig. 9-6. Combination injection/bleed-off system
the pump casing.
9.16 The sealing fluid performs two functions as it

flows along the stuffing box. First, it seals the injection
pumped fluid within the pump. Second, the circulat

ing fluid cools the packing and the shaft or sleeve.
This arrangement is especially useful if the pumped
fluid is hot. Supplying cooling water to the packing
keeps it cool,thus extending its life.
9.17 Another kind of stuffing box arrangement is

the bleed-offsystem, as shown in Fig. 9-5. In this sys Bleed off
tem, a small amount of the fluid being pumped is
internally discharged by the pump into the throat
bushing of the stuffing box. The fluid drain is called
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138 Lesson Nine
Fig,9-7. Packing styles
Overbraid
Interlocking
Twisted
Laminated
Wrapped
Square
Table 9-1. Packing recommendations

Fluid Packing Fluid Packing
Clear water (hot or cold), Flax or cotton, plaited Solvents, alcohols, chlorinated Teflon, TFE, and
sewage slurries, calcium brine, construction with general hydrocarbons, fuel oils, kerosene. impregnated synthetics.
neutral liquids. Maximum service lubricant. Graphited. Maximum temperature—250°F(120°C).
temperature—212°F(lOCC).
Where metallic packing is preferred for Crinkled lead foil sheets
Clear water (hot or cold), Synthetics or Teflon, plaited cold or hot water, mild alkalies, mild with resilient core.
neutral liquids. Maximum construction with a high-tem acids, brine, boiler feed service.
temperature—400°F (205''C). perature lubricant. Graphited. Maximum temperature—450°F(230°C).
Where suction pressure exceeds 50 psi.
Acids (sutfuric, nitric, and Teflon, carbon, graphite, or
others). Maximum temperature— synthetics, plaited construction Alkalies and other liquids with pH Teflon, synthetics,
250"'F (120"'C). with an acid-resisting lubricant. factors above 7. For temperatures of carbon, or graphite.
90 to 450°F(32 to 230''C).
Alkalies (caustic soda, silicate Same as alxive.
of soda, sulphates, Kraft liquors, Acids, weak or concentrated, Same as atxive.
salt brine, and others). Maximum specifically those with a pH factor of
temperature—250°F (120°C). 4 or less. For temperature of 90 to
450''F(32 to 230''C).
Food products, beverages, and Teflon and Teflon-impregnated
other applications where non- synthetics
contamination is the governing
factor. Maximum temperature—
180°F (80°C).
locating the sealing fluid entrance at this point, nox coating acts as a lubricant and also as a bonding agent
ious gases or vapors that escape past the packing to help the packing retain its shape. Several styles of
rings are trapped by the cooling water and reduced to packing are shown in Fig. 9-7.
a nonhazardous state. The discharge from a smother
ing system is usually treated as waste. 9.21 Packing can be purchased in long strands on
spools, or it can be purchased precut to a specified
Packing Materials size. If the packing is purchased as a long strand, it
must be cut to size in the plant as required. When the
9.20 The materials commonly used to make pack packing rings are precut, they are often packaged in
ing include cotton, flax. Teflon®, carbon, graphite, quantities sufficient to repack an entire stuffing box.
and, most recently, various synthetic materials. Usual They might even be in the form of preformed rings.
ly these materials are woven or braided to form a con
tinuous strand. The strands are sometimes wire rein 9.22 Flax and cotton packing materials are most
forced and usually have some type of coating. The commonly used on pumps that handle cool liquids.
This material is protected by U. S. Copyright law. Copying by any optJcaJ, electronic, or other means is illegal without permissbn.
Installing Packing 9.31 After the last ring has been installed, replace
the packing gland and adjust it evenly. Do not jam the
9.24 It is extremely important that you use the packing into place by over-tightening the gland. Start
proper methods when you repack a pump. Incorrect the pump and allow it to leak freely for 15 min. Then
packing installation causes many packing failures and tighten the gland gradually until leakage is decreased
much pump damage. As a general rule, you should to a tolerable minimum. Make sure to take up gland
replace packing when leakage cannot be controlled by bolts evenly. Do not stop leakage entirely at this
tightening the packing gland. The following para point, or the packing will bum up.
graphs outline the correct way to install pump pack
ing.
9.32 If the stuffing box has^ lantem ring, make
sure that it is installed slightly behind the sealing fluid
9.25 First, make sure you shut off and lock out inlet so that it will move under tpe inlet when the
power to the pump. Remove all the old packing gland is tightened.
from the stuffing box. Clean the box and the shaft
and examine the shaft or sleeve for wear or scor Mechanical Seals
ing. If wear is excessive, replace the shaft or
sleeve. 9.33 Mechanical seals are used in many pumps to
prevent fluid leakage. Mechanical seals might be cho
9.26 To find the correct packing size, measure the sen over packing on a given application for two rea
diameter of the shaft, then the diameter of the stuffing sons. First, mechanical seals provide a better fluid
box. If the shaft is worn, be sure to make the shaft seal than packing. Second, mechanical seals usually
measurement within the stuffing box area. Subtract require less maintenance than packing. This fact is
the shaft measurement from the stuffing box measure especially advantageous if the pump is in an out-of-
ment, then divide by two. The answer will give you the-way place. Third, mechanical seals can withstand
the correct packing size. higher pressures than stuffing boxes.
9.27 If you are working with a continuous strand 9.34 Many different types of mechanical seals are
of packing, cut the packing into rings. Never wind the available, and pump manufacturers have preferences
strand into the stuffing box. Hold the packing tightly for mounting seals in their pumps. All seals have simi
on the shaft, but do not stretch it excessively. You can lar components and operate in a similar manner. For
cut rings with butt, bias, or diagonal joints. special applications, some pump manufacturers design
their own seals. Even though they are custom-made,
9.28 You can cut each ring by winding the packing these seals function in the same manner as other
around the shaft, or you can use the first ring as a mechanical seals.
master from which to cut the rest of the rings. If the
rings are not cut to the correct size, packing life will 9.35 Nearly all mechanical seals consist of two
be greatly reduced. main parts—a rotating member and a stationary mem
ber—as shown in Fig. 9-8 on the next page. The illus
9.29 Precut rings can be a great advantage because tration shows the relationship between the parts of the
they give you the exact ring size for the diameters of seal and the pump. More details on the seals them
the shaft and stuffing box. There is no waste and no selves are given later in this Lesson.
worry about incorrect fit.
936 The contacting or wearing surfaces of the two
9.30 Before installing a ring, make sure that it has parts are highly polished. This fine finish is important if
not picked up any dirt. Install one ring at a time, mak the seal surfaces are to match and seal properly. To ensure
ing certain that it fits properly. Then seat each ring proper contact between the parts, the shaft or pump hous
firmly (unless the packing manufacturer suggests oth ing on which they are mounted must be free of butts and
erwise). Stagger the joints of the rings so that they are other surface irregularities.The seal and shaft must also be
about 90° apart. Seat each ring with a tamping tool as of compatible materials to prevent corrosion of the shaft
it is installed. and seal parts. Corrosion at this point can prevent the seal
142 Lesson Nine
from moving or flexing with the shaft, thus breaking the

Fig.9-8. Typical mechanical seal
seal between the two members.
stationary member
9.37 Mechanical seals can be classified as car
Rotating member tridge seals and separate seals. They are similar in
operation but differ in construction. Cartridge and
separate seals are shown in Fig. 9-9.
9.38 The cartridge seal has a metal housing that

encloses all of the component parts except the station
ary member. The stationary member is held by the
pump housing. A spring holds the rotating member in
contact with the stationary member. The spring can be
Wearing surface one large coil that fits over the shaft or several small
coils spaced around the circumference of the shaft.
Pump housing
Fig. 9-9. Cartridge and separate mechanical seals
Fig.9-10. Internal and external seals
stationary member Stationary member
member
Internal External
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Fig. 9-11. Double mechanical seal Fig.9-12. Unbalanced seal
Stationary members Spring force Fluid force
Rotating members
9.39 Mechanical seals are also classified according the stuffing box, near the fluid. The other member is
to the way they are installed and operated. They are located at the outer edge of the box.
classified in this way as internal seals and external
seals. As shown in Fig. 9-10, an internal seal's rotat 9.41 Many industrial pumps use variations of these
ing member is mounted within the seal housing near basic seal arrangements. These variations include
the fluid end of the pump. The stationary member is gland cooling, lubrication, flushing, and venting.
located outside. On the external seal, the stationary These variations have little effect on the configuration
member is located toward the fluid side of the pump, of the seal itself. Most of the changes are made in the
and the rotating member is mounted outside the pump seal housing.
housing. Both of these seals are single seals, which
means that only one sealing element is used. Most 9.42 Mechanical seals are also classified as bal
mechanically sealed pumps use single seals. anced or unbalanced. This classification does not
refer to the static or dynamic balance of the seal itself,
9.40 Occasionally, pumps use double seals, similar but to the method by which internal pressure is
to the one shown in Fig. 9-11. In this application, the applied to the seal face.
seals are mounted back-to-back with the stationary
members at the outer extremities of the packing area. 9.43 An unbalanced seal is shown in Fig. 9-12.
One stationary member is located at the inner edge of The pressure of the fluid within the pump housing
Fig.9-13. Balanced seals
With stepped shaft Without stepped shaft
This maleria) is protecjed by U. S. Copyright law. Copying tjy any optical, electronic, or other
Fig. 9-14. Bellows shaft-sealing arrangement
Bellows element Sealing faces
Vibration ring
Fluid
pressure
Stationary
element
Rotatiiog element
and the mechanical pressure applied by the seal to the other forces, it is less than the applied end
spring act on the rear portion of the seal's rotating force.
member. This pressure forces it against the stationary
member. A slight amount of force from the fluid being 9.44 In a balanced seal design, the mechanical
pumped tries to push the rotating and stationary mem seal also has fluid forces and mechanical forces
bers apart. But because this force acts perpendicularly acting on it from within the pump housing, as
Stuffing box
Sllnger
0-rings
Shaft I sleeve bushing

Hex Seal ring
Lantern ring
■
O-rings
shown in Fig. 9-13 on page 143. Note, however, of the boiler feed pumps would cause other seals to
that the seal's rotating member has a step design on fail in a relatively short time. These special sealing
its front edge. This step allows a certain amount of arrangements are shown in Fig. 9-15.
pumped fluid to counteract the force on the back of
the seal element. This force relieves some of the 9.48 One of the sealing arrangements shown in Fig.
pressure on the seal, thus producing lighter contact 9-15 is called a packingless seal This arrangement does
pressure between the rotating and stationary ele not use a mechanical device to seal the fluid in the
ments. This lighter contact pressure increases seal pump. Instead, the small clearance between the shaft
life and ensures adequate lubrication of the contact sleeve and the stuffing box bushing, which is supplied
ing surfaces. with boiler condensate under pressure, forms the seal.
The condensate is injected into the seal area at a pressure
9.45 On mechanical seals, a secondary seal is approximately 5 to 50 psi above the suction pressure of
needed between the shaft and the rotating seal the pump. A small amount of condensate is drawn into
member. Usually, wedge or 0-ring seals are used. the pump,and the rest is bled off to a drain system.
Internal fluid pressure or spring pressure provide
the necessary force to maintain contact between 9.49 The other type of boiler feed pump sealing
the seal component and the shaft. device in Fig. 9-15 is called the floating-ring seal.
The floating-ring seal is a mechanical seal. Instead of
9.46 Sometimes a synthetic rubber bellows is having a single sealing element, however, several seal
used to seal against leakage between the rotating rings are placed on the shaft sleeve. Each of these
element and the shaft. This arrangement is shown rings is supplied with an 0-ring. An outer seal-ring
in Fig. 9-14. Axial movement of the rotating seal container completes the seal. This outer seal-ring con
ing element caused by wear does not affect the tainer is the stationary part of the seal mechanism. As
position of the shaft-sealing element. Axial move in the packingless seal application, condensate is
ment is compensated for in the bellows portion of injected into the seal at a pressure about 5 to 50 psi
the seal. above the pump suction pressure.
Special Seals 9.50 Although these two kinds of sealing

devices are somewhat unusual in many industries,
9.47 Two types of special seals are frequently used you should know about them and their operation.
on high-pressure boiler feed pumps. Special seals are You may encounter these or similar seals in high-
required because the high rpm and head requirements pressure pump maintenance.
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9-9. Packing should be replaced when leak 9-9. PACKING GLAND

age cannot be controlled by tightening
the Ref: 9.24
9-10. SUBTRACT THE SHAFT DIAMETER

9-10. How do you determine the correct pack FROM THE STUFFING BOX DIAME
ing size to use in a given stuffing box?
TER, THEN DIVIDE BY 2
Ref: 9.26
9-11. Which provides a better fluid seal, a 9-11. MECHANICAL SEAL

mechanical seal or packing?
Ref: 9.33
9-12. Most mechanical seals have two main 9-12. ROTATING, STATIONARY
oarts-afn) member and afnl
member. Ref: 9.35
9-13. The contacting surfaces of the mem 9-13. POLISHED

bers of a mechanical seal are highly
to ensure proper sealing. Ref: 9.36
9-14. In the mechanical seal, the 9-14. BALANCED

front edge of the rotating member has
a step design that relieves some of the Ref: 9.44
pressure on the seal.
9-15. In a packingless seal, pressurized boil 9-15. CONDENSATE

er fills a small clearance
between the shaft sleeve and the stuff Ref: 9.48
ing box bushing.
9-16. On a floating-ring seal, the outer seal- 9-16. STATIONARY

rino container is the part of
the seal mechanism. Ref: 9.49
Self-Check Quiz 147
Answer the following questions by marking an "X"

9.1 Sealing devices prevent fluid leakage along 9-6. Packing should be replaced when leakage
the can no longer be controlled by
□ a. impeller □ a. adding more packing

□ b. pistons □ b. reconditioning the shaft
□ c. lantern ring □ c. cleaning the rings
□ d. driving shaft □ d. tightening the packing gland
9-2. In a solid packed stuffing box, a small amount 9-7. To find the correct packing size for a specific
of leakage stuffing box, measure the diameters of the
shaft and the stuffing box, then
□ a. is the first indication of worn packing and divide by 2.
□ b. is necessary for cooling and lubrica-
tion □ a. add the two measurements
□ c. means the gland needs tightening □ b. subtract the smaller diameter from
□ d. can damage the pump the larger
□ c. multiply the two measurements
9-3. Which arrangement uses fluid to seal the □ d. divide the larger diameter by the
packing and keep air from entering the smaller
pump?
9-8. On a cartridge seal, all of the components are
□ a. Packingless seal located inside a metal housing except the
□ b. Solid packed stuffing box
□ c. Injection-type stuffing box □ a. bellows
□ d. Mechanical seal □ b. spring
□ c. stationary member
9-4 In a bleed-off system, the bleed-off point is □ d. rotating member
usually connected to the
9-9. On mechanical seals, a secondary seal is
□ a. suction side of the pump needed between the shaft and the
□ b. pump casing ahead of the stuffing
box □ a. stationary member
□ c. exterior end of the stuffing box □ b. rotating member
□ d. sealing area □ c. spring
□ d. rubber bellows
9-5. Which of the following packing materials is
used on pumps handling temperatures over 9-10. Pressurized boiler condensate is used to form
450°F (230°C)? the seal in the
□ a. Aluminum □ a. cartridge seal

□ b. Babbitt □ b. internal seal
□ c. Carbon □ c. balanced mechanical seal
□ d. Cotton □ d. packingless seal
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148 Lesson Nine
SUMMARY
Stuffing boxes are sealing areas that are manually Mechanical seals are molded seals held In place
packed and adjusted. The most common Is the by springs or other constant-pressure devices.
solid-packed stuffing box. A packing gland can be Mechanical seals provide a better fluid seal than
adjusted to reduce the amount of leakage. An does packing. They usually require less mainte
Injection-type stuffing box should be used under nance than packing. Most mechanical seals
suction lift conditions. The circulating stuffing have a rotating member and a stationary mem
box system uses sealing fluid within the pump ber.
and to cool the packing and the shaft.
Mechanical seals are classified as cartridge and
Cotton,flax, Teflon®, carbon, graphite, and vari separate seals, according to their construction.
ous synthetic materials are used to make packing. They are also classified by the way they are
You should replace packing when leakage can no Installed and operated, as Internal seals or exter
longer be controlled by tightening the packing nal seals. Finally, mechanical seals are classified
gland. It Is Important to follow the Installation as balanced or unbalanced according to the
procedure exactly to prevent packing failure and method used to apply Internal pressure to the
pump damage. seal face.
9-1. d. Driving shaft. Ref: 9.01 9-6. d. Tightening the packing gland.
Ref: 9.24
9-2. b. Is necessary for cooling and lubrica
tion. Ref: 9.10 9-7. b. Subtract the smaller diameter from
the larger. Ref: 9.26
9-3. 0. Injection-type stuffing box.
Ref: 9.12 9-8. c. Stationary member. Ref: 9.38
9-4. a. Suction side of the pump. 9-9. b. Rotating member. Ref: 9.45
Ref: 9.17
9-10. d. Packingless seal. Ref: 9.48
9-5. a. Aluminum. Ref: 9.23
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m■
■
150
Lesson
Pump Maintenance
TOPICS
Pump Bearings Pump Maintenance

Sleeve Bearings End-Suction Centrifugal Pumps
Antifriction Bearings Vertical Turbine Pumps
Special Bearings Rotary Pumps
Bearing Lubrication Reciprocating Pumps
Bearing Seals Difficult-Material Pumps
Pump Installation Other Maintenance Problems
OBJECTIVES
• Name three types of antifriction bearings. Tell the two major maintenance problems
• Name three factors to consider when preparing encountered in rotary pumps.
pump lubrication schedules. Explain how to identify worn piston rings in a reci
• Describe a typical application for each of the fol procating pump.
lowing bearing seals: felt, leather, synthetic.
KEY TECHNICAL TERMS
Axial load 10.07 a load parallel to the shaft Contact seal 10.25 a bearing seal that maintains
Radial load 10.07 a load perpendicular to the a constant sealing contact between the seal lip
shaft and the rotating shaft
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1S1
Bearings are a primary part of a pump. After studying this Lesson, you will be
able to explain the importance of pump bearings. You will also be able to name
the various kinds of pump bearings and applications of each kind.
In order to operate correctly, bearings must be lubricated with the proper kind
of lubricating material in the correct amount. This Lesson explains the bearing
lubrication in detail. You should pay special attention to the section on lubrica
tion, because the wrong kind or too much lubrication can be harmful to pump
bearings as no lubrication at all.
Pump installation is sometimes part of the maintenance worker's job. After

studying the section on pump instailation, you will have all the basic informa
tion necessary to do the job. you wiil also be familiar with maintenance prob
lems that are common to each kind.
Pump Bearings extend the full length of the bearing surface. If it did,
the lubricant could escape.
10.01 Many pumps use rotary motion to impart
force to the fluid being pumped. The pump impellers Antifriction Bearings
are driven by shafts connected to motors or other
power sources. The shafts require some means of sup 10.05 When the surfaces of two objects slide along
port and lubrication. To provide support for the shaft, each other, friction, and thus heat, develop. Antifriction
and at the same time reduce the amount of friction bearings are designed to reduce the friction and heat that
between the shaft and pump frame, pumps require develop between the two surfaces. The two types of
bearings and some type of lubrication. antifriction bearings are ball bearings and roller bearings.
10.02 Nearly all types of bearings have been used 10.06 All antifriction bearings consist of four main
on pumps. Bearings in general fall into two major cat parts;
egories—j/iWmg contact bearings and rolling contact • the inner ring
bearings. Although sliding contact bearings, also
called plain or sleeve bearings, were once very popu • the outer ring
lar, they now have been almost entirely replaced by • the rolling elements (either balls or rollers)
rolling contact bearings for use on pumps.
Sleeve Bearings Fig. 10-1. Typical sleeve bearing

10.03 Because sleeve bearings are seldom used on
pumps today, they will be covered only briefly. Continuous groove
Sleeve bearings are made of babbitt, bronze, or other
soft alloys, depending upon the application and the
pump manufacturer. The upper half of a typical sleeve
bearing is shown in Fig. 10-1.
10.04 Sleeve bearings have lubrication grooves on

their inside surfaces. The grooves store a small
amount of lubricant, thus eliminating the need for fre
quent lubrication. Figure 10-2 on the next page shows
an example of grooving in a split bearing. Only the
top half is grooved. Oil is supplied as needed through
the oil hole. Notice that the groove—like the continu
ous groove in the bearing in Fig. 10-1—does not
152 Lesson Ten
Fig. 10-2. Grooving in a split bearing 10.08 The four kinds of antifriction bearings used
most often to support pump shafts are:
Oil groove (beveled)
• single-row, deep-groove ball bearing
Upper half
• angular-contact ball bearing
Chamfers ■■ • spherical roller bearing
• single-row tapered roller bearing.
The four kinds and their operating characteristics are

shown in Fig. 10-3.
10.09 Of the four kinds, single-row, deep-groove ball

Lower half bearings are the most commonly used. They have good
radial load capacity and will accept light thrust loading.
If the thrust loading becomes heavy, angular-contact
• a cage that keeps the rolling elements evenly bearings can be used. These bearings can be used singly,
spaced. doubly,or in any combination to support pump shafts.
10.07 Different kinds of bearings are capable of car 10.10 Most close-coupled pumps do not have shaft-
rying different kinds of loads. Loads parallel to the supporting bearings in the pump housing. Instead, the
shaft are called axial or thrust loads. Loads perpen pump impellers are mounted directly on the motor shaft.
dicular to the shaft are called radial loads. Some In these instances, the motor shaft bearings must absorb
bearings are designed to carry axial loads, some to the radial and thrust loads from the pump impeller, as
carry radial loads, and some a combination of axial well as their own loads. Close-coupled pumps are nor
and radial loads. mally operated by fractional or low-horsepower motors.
Fig. 10-3. Common antifriction bearings
CHARACTERISTICS
A Single-row, deep- Good radial load and reasonable

groove ball bearing amount of thrust in either direction.
Requires good alignment. High speed.
B Angular-contact ball Heavy thmst one direction. Moderate
bearing radial load. With sides flush ground,
can t>e used in multiple numbers.
C Spherical roller High load capacity, both radial and
bearing thrust. Thoist either direction. Self-
aligning.
D Single-row tapered Good for heavy one-way thrust or

roller bearing combined load. Predominantly thrust
load. Requires adjustment of internal
clearance.
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Pump Maintenance 153
10.11 Antifriction bearings used on the majority of Fig. 10-4. Rubber-lined strut bearing
pumps must accept at least a small amount of thrust load
ing. It is important to keep this fact in mind when select
ing antifriction bearings. If you anticipate exceptionally Rubber lining
high thrust loading, check pump conditions to determine

whether or not you need to install thrust bearings.
10.12 The amount of thrust loading present varies with

the type of pump. In single-stage, double-suction pumps,
the amount of thmst loading is negligible, and a set of dou
ble-row ball bearings is sufficient to carry the shaft loads.
In multi-stage pumps,spherical roller bearings or a single-
Steel housing
row,tapered roller bearing is used on one end of the shaft.
A bearing of the same design (facing in the opposite direc
tion) is placed on the other end.The bearings face towards
or away from each other depending on the pump manufac
turer. If the bearings face in the same direction, they can better than grease, because its lubricating qualities are
handle thrust loading in only one direction. not affected by changing temperatures.
Special Bearings 10.16 Oil lubrication is commonly used for light-to-

moderate duty in high-speed pumps. When oil is used,
10.13 Many vertical turbine pumps use a special rub check the pump manufacturer's lubrication instmctions
ber-lined strut bearing as an intermediate shaft support. As for the type and viscosity of oil to use. If no lubrication
shown in Fig. 10-4, the bearing outer case is made of instmctions are available, usually a good filtered, non-
metal and the inner bearing surface is made of mbber.The detergent mineral oil of grade SAE 10 or 20 can be
area of contact with the shaft is small, but is sufficient to used. Change the oil at regular scheduled intervals, or
withstand the load. The bearings are lubricated by the sooner if it becomes dirty or contaminated. Before
fluid being pumped. Because of their design, these bear changing oil, it is a good practice to flush the bearing
ings offer excellent resistance to abrasion. and the bearing housing or sump with a solvent to
make sure that all contaminants and dirt have been
Bearing Lubrication removed.This keeps the new oil clean longer.
10.14 Proper lubrication of pump bearings is extremely

10.17 There are many ways to ensure proper lubrica
important. Without proper lubrication, bearings will over
tion of the bearings in a pump. Two methods are shown
heat, mst,corrode, and eventually cause the shaft to seize
in Fig. 10-5 on the next page. Whatever method is used,
and stop. If a pump has been shut down for a long period
give it regular attention to make certain that the proper
of time without proper lubrication, the bearings can
amount of lubricant is reaching the bearings.
become so rusted that the motor will be unable to turn the
pump shaft. Proper lubrication means not only regular
10.18 If an oil reservoir or sump is used, overfilling the
lubrication, but use of the proper lubricant in the proper
reservoir can be as serious as not providing enough oil.
amount. For instance, if a water pump is lubricated with a
Overfilling the reservoir wiU cause the bearings to over
grease that does not repel water, the water wiU soon attack
heat, as will insufficient lubrication. Some pumping sys
the bearings and ruin them.
tems for hot fluids have water-cooled lubricating oil
sumps or sumps that circulate the oil through a cooler.
10.15 In most applications, pump bearings are lubri
cated with oil or grease. Some special applications use
10.19 The constant-level oiler shown in Fig. 10-5 is
synthetic lubricants. The type of lubricant used
a combination drip-feed and ring-type oiler. The ring
depends upon the pump application and the manufac
used to distribute the oil is the same as in any other
turer's instmctions. For example,if the pump is operat
ring oiler. The constant level controlling device, how
ing outdoors in changing temperatures, oil will work
ever, does not supply ft-esh oil all of the time. Its pur-
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Fig. 10-5. Two oil lubricating devices
Scraper
Lucite
or glass
Reservoir Oil level ■

Ring oiler Constant-level-oiler
pose is to maintain a constant oil level in the sump by 10.21 Like excessive oiling, excessive greasing of a
replacing oil that leaks out. bearing can cause much damage. In addition to gener
ating heat, an excessive amount of grease can rupture
10.20 Grease is generally used as a lubricant for lubricant seals. Ruptured seals can allow contaminants
heavy loads at low to moderate shaft speeds. When to enter the bearing, thus causing bearing failure.
grease is used in a pump application, check its grade
and consistency to make sure that it is the type speci 10.22 Industrial plants normally maintain lubrication
fied by the pump manufacturer. Usually, a soda-soap schedules for the various pieces of equipment they have
grease with a mineral oil base is acceptable. Bearing installed. This schedule should include pumps. The
grease should be free of clay, mica, talc, and other schedule is based on operating time and load, as well as
fillers. These mineral fillers are highly abrasive, even on pump age and condition. The pump manufacturer
when finely ground and mixed with oil or grease. might also have recommended lubrication schedules
that can be used as guidelines. As a general rule, grease
pumps at intervals of approximately three months. If the
Fig. 10-6. Grease cup lubricator pump is not often run, greasing intervals can be extend
ed. When the pump is running, inspect the bearings
daily for noise,cleanliness, and operating temperature.
1023 Stand-by and other infrequently used pumps also

need attention. Take care to keep moisture out of the bear
ings. You can do this by wrapping plastic around the bear
ing and shaft when not in use. Turn the shaft frequently,
by hand,to keep the shaft and bearings lubricated. If pos
sible, alternate the operation of stand-by pumps.
10.24 Because a pump has simpler greasing require

ments than a large machine tool, for example, pumps
do not always have automatic lubrication systems.
Some pumps are lubricated with a hand-operated
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grease gun or by a portable lubrication cart. These they are made depend upon the degree of sealing
carts are usually equipped with an air or electrically required. Seals are commonly made from leather, felt,
operated pump placed in the drum of lubricant. The and synthetic compounds.
grease gun is attached to the pump by a long,flexible
hose. Many pumps have grease cups, like the one in 10.28 Felt seals are used for slow shaft speed appli
Fig. 10-6. Turning the cup handle one or two turns at cations in which only small amounts of lubricant are
regular intervals supplies the needed lubrication. Be present. Leather seals are also used for slow-speed
sure to keep the cup filled with the proper lubricant. applications, but they are usually used to retain large
amounts of lubricant. They can tolerate a slightly
Bearing Seals rough or irregular shaft surface without wearing out
quickly. Synthetic seals are used for high-speed appli
10.25 Bearing seals come in an almost endless vari cations and large lubricant quantities. These seals
ety. This Chapter describes some of the more common require ground or polished shaft surfaces.
contact-type seals used with pump bearings. Contact
seals retain lubricant and exclude dirt and other conta 10.29 Synthetic seals are usually made from rubber
minants by maintaining a constant sealing contact compounds, nitriles, polyacrylates, and silicones. Fre
between the seal lip and the rotating shaft or sleeve. quently, bearings on similar pumps will have different
seals. If you have to change seals, be sure that the
10.26 The bearing seal shown on the left in Fig. 10- replacement seal is either the same as the existing
7 is positioned so that its sealing lip faces the fluid it seal, or a recommended substitute. In many cases,
retains. The seal on the right in Fig. 10-7 is a felt seal you can use seals of different manufacturers inter
with an oil slinger placed on the fluid side to keep the changeably if the seal material is the same. In an
oil away from the seal. These seals are quite different emergency, you can usually use seals of different
from the sealing devices (stuffing boxes and mechani materials, although seal life might be shortened.
cal seals) used to seal fluids within the pump. Design
variations are determined by the amount of lubricant 10.30 If bearing seal failure is a recurring problem
each seal must retain. on a particular pump, inspect the shaft. If the shaft is
rough or corroded, you will need to recondition it or
10.27 Although the seals shown in Fig. 10-7 have install a new shaft or shaft sleeve before installing
only one sealing lip, some seals have two or more. new seals. In some cases, the shaft might have to be
The number of seal lips and the material from which built up before it can be reconditioned.
Fig. 10-7. Bearing lubricant seals
Bearing Bearing
Slinger
Lip seal
Fe t sea
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10-1. Pump bearinas support the 10-1. SHAFT; FRICTION

and reduce the amount of
between the shaft and pump frame. Ref: 10.01
10-2. The two work kinds of antifriction bear 10-2. BALL, ROLLER
inas are and bear
ings. Ref: 10.05
10-3. Loads to the shaft are called 10-3. PARALLEL; PERPENDICULAR

thrust loads. Loads to the
shaft are called radial loads. Ref: 10.07
10-4. Single-row, deep-groove ball bearings 10-4. RADIAL

have Good load capacity.
Ref: 10.09
10-5. Proper lubrication means 10-5. REGULAR; AMOUNT

lubrication with the proper lubricant in
the proper Ref: 10.14
10-6. What kind of lubricant is commonly 10-6. OIL

used for light to moderate duty in high
speed pumps? Ref: 10.16
10-7. Grease is used as a lubricant for 10-7. HEAVY

loads at low to moderate
shaft speeds. Ref: 10.20
10-8. As a general rule, pumps should be 10-8. THREE

oreased about every
months. Ref: 10.22
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Fig. 10-8. Methods of checking shaft alignment
Thickness gauge
Dial indicator
Concrete pad
Pump Installation 10.34 After the concrete has cured, remove the
form and place the pump base in position on the pad.
10.31 There are three separate steps in pump instal Using a mechanic's level, level the base in both
lation: directions. Place shims or wedges wherever needed
to keep the base level. Then tighten the anchor bolt
• base installation
nuts to secure the base. Fill in any irregular areas
• pump alignment beneath the edges of the base with grout and allow it
to cure.
• piping connection.
All of these steps are essential to proper pump oper 10.35 After the base is firmly in place and the
ation and should not be done hastily or poorly. In grout has cured, place the pump and motor on the
some instances, pumps are installed by outside con base. If they are separate pieces, make sure they are
tractors during plant construction. In many cases, properly aligned. Use thickness gauges or a dial
however, a plant's maintenance department is indicator, as shown in Fig. 10-8, to check for prop
responsible for installing new pumps. Most manu er alignment at the coupling. If necessary, add
facturers recommend that certain procedures be fol shims beneath the pump or motor to correct mis
lowed. This Chapter outlines some of the common alignment.
procedures.
10.36 After the pump and motor are aligned and
10.32 Large pumps are usually installed on concrete bolted down, connect the piping. Correct piping
pads, as shown in Fig. 10-8. Anchor bolts in the pad installation is most important on the suction side
keep the pump base rigid and dampen vibration, of the pump. If piping is improperly installed on
which helps reduce piping leaks. The first step in the suction side, air pockets can form. These air
installing a large pump is to excavate the floor to pockets have a detrimental effect on the pump's
accommodate the pad, as specified by the plant engi operation and can cause maintenance problems.
neer or pump manufacturer. Also, make sure the piping is not being supported
by the pump housing. Stress on the pump housing
10.33 Next, build a wooden form that will allow the should be avoided. Correct and incorrect installa
pad to extend 8 to 12 in. above the floor. Then, build a tion techniques for the pump suction piping are
wooden frame and drill it to match the bolt-hole pattem of shown in Fig. 10-9 on the next page.
the pump base. Place the frame over the form to hold the
anchor bolts in position. The bolt threads must extend far Pump Maintenance
enough above the concrete pad to pass through the pump
base and still leave room for nuts and washers. Fasten the
10.37 Although many pump maintenance proce
bolts to the frame with nuts and pour the concrete. dures vary with the kind of pump, many other proce
dures are the same on all pumps. For example, pump
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158 Lesson Ten
Fig. 10-9. Suction pipe installation
Check valve
Gate valve
Increaser
Gradual rise to the pump

Level
Flow
Correct
Pipe centerline
Incorrect
Air pocket
n
incorrect I r
Air pocket
Eccentric elbow
Flow Flow
Distance plus eccentric

elbow straightens flow
Gradual rise to the pump (no air pocket)
Correct
Air pocket
Flow Flow
Incorrect
bearings and sealing devices operate in a similar man 10.38 Pumps have a tendency to overheat if used
ner, regardless of the pump on which they are in an environment that is too hot, and freeze if the
installed. Bearing maintenance usually involves only environment gets too cold. If the pump is located
periodic lubrication. Stuffing boxes require only outdoors or in an unusual place (near a furnace or
minor adjustments from time to time, and mechanical chilling compartment, for example), consider pro
seals require only a visual inspection for leakage. The viding protection for the pump. Specially designed
only seals that require special attention are those used casings and insulation are available for this pur
on chemical or difficult-material pumps. pose.
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10.39 The following maintenance tips cover some 10.44 If the pumped fluid has a high chemical
of the most common pump problems. Problems are content, the chemical can attack the wearing rings
grouped according to pump type. Table 10-1 on the and corrode them quickly. This condition can be
next page describes several common pump prob improved by selecting the proper wearing ring
lems, identifies their symptoms and causes, and lists material. In some cases, short wearing-ring life is
likely steps toward their solutions. acceptable because corrosion of the wearing rings
protects the pump casing and impeller from chemi
End-Suction Centrifugal Pumps cal attack.
10.40 End-suction centrifugal pump maintenance Vertical Turbine Pumps

problems are generally confined to only a few compo
nents. These components are the casings, wearing 10.45 Vertical turbine pump maintenance problems
rings, and impellers. Pump casings cause problems are similar to those of other centrifugal pumps. Bowl
when the fluid handled by the pump is corrosive or and impeller corrosion, impeller clogging, obstruc
incompatible with the pump. Pump casings used with tions, and blinding of the suction bell will prevent the
corrosive fluids are usually designed to resist the cor pump from pumping its required capacity. Although
rosive action of the fluid. If only a small amount of the pump suction may be below the fluid it is pump
corrosive fluid is suspended in the fluid being ing, the suction bell call still become clogged with
pumped, however, the effect on the pump is small. debris.
Most pump casings are of such size and strength that
slight corrosion of the interior will not affect pumping 10.46 Vertical turbine pumps differ from end-suc
capacity. In some cases, casings that corrode through tion centrifugal pumps in the way in which the
completely can be patched without any decrease in impeller clearances are adjusted. Most vertical turbine
pump capacity. pumps do not have wearing rings. Impeller clearance
is changed by adjusting the drive shaft at the motor,
10.41 The impeller is the heart of an end-suction as shown in Fig. 10-10 on page 161. If the pump is
centrifugal pump. If an impeller is seriously dam multistage, all impellers are adjusted at the same time
aged by corrosion or abrasion, the pump's overall and by the same amount.
capacity will be reduced. Capacity is also reduced
when the impeller becomes clogged or has excessive Rotary Pumps
material buildup. Selection of the proper impeller
shape and the proper impeller material for the fluid 10.47 Unlike the impellers of end-suction centrifu
being pumped is essential to good impeller perfor gal or turbine pumps, the impellers of most rotary
mance. pumps are subject to very little wear by abrasive
materials. The major maintenance problems in these
10.42 The wearing rings in an end-suction centrifu pumps occur in the bearings and seals. This statement
gal pump are the components that most often require is especially true when the bearing is lubricated by
maintenance. Although many small centrifugal pumps the fluid being pumped. To extend bearing life, main
have no wearing rings, most larger pumps do. Wear tain proper alignment between the end caps and the
ing rings maintain a minimum clearance between the pump casing during pump assembly.
impeller and the casing. They can be installed on both
the housing and the impeller. Minimum impeller 10.48 Impeller wear by abrasive materials is greatest
clearance improves pump capacity. in screw and vane pumps where there is only a small
amount of clearance between the rotors or impellers
10.43 In order to extend their operating life and and the pump casing. Internal gear pump impellers are
reduce replacement costs, many impeller wearing also subject to wear by abrasives because of the close
rings are adjustable. Once adjusted, locknuts hold clearances between the mating teeth. Most tooth wear
them in place. The type and amount of impurities sus is caused by the abrasive nature of the material, not by
pended in the fluid being pumped determines the rate tooth contact. Keeping pumps as clean as possible
at which wearing rings wear. helps eliminate this type of wear.
160 Lesson Ten
Table 10-1. Pump problems

Symtom and cause Solution
NO LIQUID DELIVERED
Lack of prime. Fill pump and suction pipe completely with liquid.
Suction lift too fiigh. If no obstruction at inlet, check for pipe friction losses. If static lift is too high, liquid to be
Discharge head too high. pumped must be raised or pump lowered.
Impeller plugged. Check pipe friction losses. Check that valves are wide open.
Dismantle pump and clean impeller.
NOT ENOUGH LIQUID DELIVERED

Air leaks in suction piping. Test flanges for leakage. Suction line can be tested by plugging inlet and putting line
under pressure.
Air leaks in stuffing box. Increase seal liquid pressure to above atmosphere.
Impeller partially plugged. Dismantle pump and clean impeller.
Defective impeller. Inspect impeller and shaft. Replace if damaged or vane sections badly eroded.
Defective packing or seal. Replace packing or mechanical seal.
Suction not immersed enough. Lower inlet.
NOT ENOUGH PRESSURE

Speed too low. Check whether motor is receiving full voltage.
under pressure.
Mechanical defects. Inspect impeller and shaft. Replace if damaged or vane sections badly eroded. Replace
packing or mechanical seal.
Obstruction in liquid passages. Dismantle pump, inspect passages, and remove obstruction.
Air or gas bubbles in liquid. Possibility of overrated pump. Periodically exhaust accumulated air.
PUMP OPERATES FOR SHORT TIME

THEN STOPS
Incomplete priming. Free pump, piping, and valves of all air. Correct any high points in suction line.
under pressure.
Air leaks in stuffing box. Increase seal liquid pressure to above atmosphere.
PUMP TAKES TOO MUCH POWER

Mechanical defects. Inspect impeller and shaft. Replace if damaged or vane sections badly eroded. Replace
packing or mechanical seal.
Suction not immersed enough. Lower inlet.
Stuffing box too tight. Release gland pressure.
Shaft bent or damaged. Check deflection of rotor by turning on bearing journals.
Failure of pump parts Check bearings and impeller for damage.
Reciprocating Pumps addition, a leaking stuffing box at the end of the

connecting rod might cause the pump to act as if it
10.49 Maintenance problems in reciprocating had worn piston rings.
pumps usually involve the stuffing boxes or seals at
the connecting rod and the piston rings. Because of 10.51 In high-pressure pumps, the condition of the
the constant reversing motion and fluctuating pres connecting rod stuffing boxes is critical. They must
sures within the pump, the piston rings in the fluid be kept in good condition at all times. Loss of pres
section generally wear out sooner than any other com sure through the stuffing box of a high-pressure pump
ponent in the pump. can cause serious damage or personal injury, if
neglected.
10.50 Lack of fluid pressure while the pump is
running often indicates worn piston rings. Pump Difficult-Material Pumps
pressure might also be low if any of the internal
check valves are stuck open. Always check the 10.52 Difficult-material pumps are usually made in
pump valves before you replace piston rings. In the standard pump types already discussed. Because
they resemble standard pumps, always check for the Fig. 10-10. Shaft adjustment in a vertical
typical maintenance problems of the specific pump turbine pump
type first.
10.53 Many maintenance problems in difficult- Top shaft adjusting nut Adjusting nut screw
material pumps are caused by the material itself.

Abrasive fluids, slurries, trash, high-viscosity
materials, and chemicals all cause their own
unique problems. Check with the pump manufac Hollow
turer for maintenance information related to spe Gib key motor
cific applications.
Other Maintenance Problems
10.54 Not all pumping system problems are

caused by the pump. Frequently, obstructions in
the suction or discharge piping reduce the pump
capacity and cause the pump to act as though it screens for blinding. In addition, improper valve
were operating improperly. If the pump does not installation (such as reversed check valves) can
produce its required capacity, first check suction cause serious operation problems for the pump.
10-9. Large pumps are usually installed on 10-9. CONCRETE PADS
Ref: 10.32
10-10. Correct piping installation is most 10-10. SUCTION SIDE

important on the of the
pump. Ref: 10.36
10-11. Problem components in end-suction 10-11. CASINGS, WEARING RINGS,

centrifugal pumps are the , IMPELLER
, and .
Ref: 10.40
10-12. If the impeller of an end-suction cen 10-12. CAPACITY

trifugal pump is damaged, the pump's
overall is reduced. Ref: 10.41
10-13. In vertical turbine pumps, impeller 10-13. DRIVE SHAFT

clearance is changed by adjusting the
at the motor. Ref: 10.46
10-14. The major maintenance problems in 10-14. BEARINGS, SEALS

rotary pumps occur in the
and . Ref: 10.47
10-15. Lack of fluid pressure in a running reci 10-15. PISTON RINGS

procating pump often indicated worn
Ref: 10.50
10-16. When a pump is not producing its full 10-16. SUCTION SCREENS
capacity, the first thing to check is its
Ref: 10.54
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Self-Check Quiz 163
Answer the following questions by marking an "X"

10-1. Loads perpendicular to the shaft are called 10-6. Which type of seal is used for slow shaft
speed application with small amount of lubri
□ a. axial loads cant?
□ b. combination loads
□ c. radial loads □ a. Leather seal
□ d. thrust loads □ b. Felt seal
□ c. Paper seal
1G-.2 The most important part of bearing mainte □ d. Rubber seal
nance is
10-7. Which seal requires ground or polished shaft
□ a. good seals surfaces?
□ b. proper lubrication
□ c. even loads □ a. Felt seal
□ d. periodic cleaning □ b. Leather seal
□ c. Paper seal
10-3. Before changing oil, it is a good practice to □ d. Synthetic material seal
□ a. flush the bearing area with solvent 10-8. The first step in installing a large pump is to
□ b. filter the old oil for reuse
□ c. clean the screens □ a. pour a concrete pad
□ d. make sure the old oil is really dirty □ b. build a wooden pad form
□ c. excavate the floor
10-4. The constant-level oiler □ d. align the pump and motor
□ a. replaces oil that leaks out 10-9. In an end-suction centrifugal pump, damage
□ b. supplies fresh oil continuously or corrosion of the will reduce the
□ c. is a visual oil level indicator overall capacity of the pump.
□ d. sounds an alarm when the oil level
drops □ a. case
□ b. impeller
10-5. As a general rule, pumps should be greased □ c. shaft
about every □ d. gib key
□ a. two weeks 10-10. Which part generally wears out the fastest in
□ b. month a reciprocating pump?
□ c. two months
□ d. three months □ a. Piston rings
□ b. Valves
□ c. Stuffing box
□ d. Lubricant
164 Lesson Ten
SUMMARY
Bearings are used in pumps to support the shaft Seals are made from leather,felt, and synthetic
and to reduce the amount of friction between the materials.
shaft and pump frame.Antifriction bearings-ball
bearings and roller bearings-are commonly used. Pump installation consist of building a base,
Some bearings are designed to carry axial loads, aligning the pump and the motor,and connect
some to carry radial loads,and some to carry a ing the piping. A good installation can mean
combination of the two kinds. fewer problems when the pump is put into oper
ation.
Lubrication is necessary to prevent overheating,
rust,corrosion,and other bearing problems.The All pumps have parts that cause problems.In end-
lubricant can be oil, grease,or a synthetic materi suction centrifugal pumps,be aware of problems
al. Proper lubrication consists of regular applica with casings, wearing rings,and impellers. Rotary
tions of the proper lubricant in the proper amount. pumps often develop bearing and seal disorders.
In reciprocating pumps,maintenance problems
Bearing seals are used to retain lubricant and keep include stuffing boxes or seals at the connecting
dirt and other contaminants out of the pump. rod and the piston rings
10-1. 0. Radial loads. Ref: 10.07 10-6. b. Felt seal. Ref: 10.28
10-2. b. Proper lubrication. Ref: 10.14 10-7. d. Synthetic material seal.

Ref: 10.28
10-3. a. Flush the bearing area with solvent.
Ref: 10.16 10-8. c. Excavate the floor. Ref: 10.32
10-4. a. Replaces oil that leaks out. Ref: 10.19 10-9. b. Impeller. Ref: 10.41
10-5. d. Three months. Ref: 10.22 10-10. a. Piston rings. Ref: 10.49
Contributions from ttie foiiowing sources are appreciated:
Figure 10-3. The Timken Company

Figure 10-9. Allis-Chalmers/Fluid Products Company
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Understanding the

Lesson One Pump Development and Application.

Lesson Two Basic Pump Hydraulics 19

Lesson Three End-Suction Centrifugal Pumps 35

Lesson Four Propeller and Turbine F^imps 53

Lesson Five Rotary Pumps 69

Lesson Six Reciprocating Pumps 85

Lesson Seven Metering Pumps 101

Lesson Eight Special-Purpose Pumps 117

Lesson Nine Packings and Seals 133

Lesson Ten Pump Maintenance 149

© Copyright 1998, 1986 by TPC Training Systems, a division of Telemedia, inc.

All rights reserved, including those of translation.

>rlJL:b ;on fj'i,

The Development of Pumps Waste Pumping Systems

After studying this Lesson, you should be able to...

KEY TECHNICAL TERMS

Chemical pumping systems have special design and construction requirements

High viscosity material pumping systems have special requirements, as do

Fig. 1-1. Archimedean screws

1.11 A typical direct water supply system is

1.13 Industrial plants use many types of chemical

Fig. 1-5. Typical water supply system

Dead-end system Recirculating system

Fig. 1-7. Chemical pumping system

1 -1. Fluids can be moved through pipes 1-1 PUMPS

1-2. Maintenance problems in pumping sys 1-2. PIPING

1 -3. What is the most common type of 1-3. WATER SYSTEM

1 -4. If a large amount of hot water is 1-4. DEAD-END

1-5. In a(n) system, unused hot 1-5. RECIRCULATING

1-6. Applications in which chemicals must 1 -6. POSITIVE-DISPLACEMENT

1-7. Chemical handling arrangements are 1 -7. LAYOUT; APPLICATION

Waste Pumping Systems

trifugal pumps are used to pump wastewater in a Float _ Sump

1.23 If the pump is handling corrosive waste, the

Fig. 1-9. Separate waste systems

Waste storage tank

Plant waste -Chemical waste

1.27 Because spray booths require large quantities

High-Viscosity Materiai Pumping Systems

1.28 Viscosity is the property of a material that

Fig. 1-11. Paint spray systems

Paint recirculating lines Paint heater

Spray gun Spray gun

Air compressor Air compressor

Fig. 1-13. Grease or mastic pumping systems

Recirculating system Dead-end system

Fig. 1-14. Use of a follower plate

1-9. When sump pumps are used. 1-9. INTAKE SCREENS

1 -10. Because spray booths require large 1-10. RECIRCULATING

1-11. High-viscosity materials are materials 1-11. FLOW-PRODUCING

1 -12. What type of pump is usually used for 1 -12. POSITIVE-DISPLACEMENT

1-13. In some cases, a fluid is to 1-13. HEATED

1 -14. Two problems encountered in paint 1-14. PIGMENTS; ABRASIVENESS

1 -15. Systems handling greases, heavy mas 1-15. SOLIDS

1 -16. Repair of solids pumping systems is 1-16. REPLACEABLE

Answer the following questions by marking an "X'

□ a. under high pressure □ a. kept in motion

1-4. Insulated piping systems are NOT necessary

□ a. hot water □ a. makes them flow more easily

1 -5. When sump pumps are used in a waste

Answers to Self-Check Quiz

1-1. 0. Chemicals. Ref:1.13 1-6. a. Thick. Ref:1.28