Pumps and Pumping

Systems

INTRODUCTION, TYPES AND

ASSESSMENTS
Pumps


Hydraulic Machinery
A Machinery Solely responsible for
• Pumps, Introduction of Life in Working fluid….
Turbines... …
 Fluid Machinery
Positive Displacement
 Working fluid is confined within a
boundary.
 Energy transfer is by volume
changes due to the movement of the
boundary.
Dynamic
 Working fluid is not confined within
a boundary.
 Energy transfer is by dynamic effects
of the rotor on the fluid stream.
Turbomachines-Categories

 Pump: adds energy to a

fluid, resulting in an
increase in pressure
across the pump.
 Turbine: extracts energy
from the fluid, resulting
in a decrease in pressure
across the turbine.
 Training Agenda: Pumps

Introduction
Type of pumps
Assessment of pumps
Energy efficiency opportunities

6
Pump
• Pump (mechanics), device
used to raise, transfer, or
compress liquids and gases
• A pump is a device used
to move fluids,
such , gases or slurries.
• A pump displaces a
volume by physical or
mechanical action

7
 Introduction
What are Pumping Systems

 20% of world’s electrical energy

demand
 25-50% of energy usage in some
industries
 Used for
 Domestic, commercial, industrial and
agricultural services
 Municipal water and wastewater services
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Energy Used for Heat & Power
Pump systems use about 6% of total
U.S. industrial energy

Handling
Fans
Fired Heaters 14%
12%
31%
Motor Compressed Processing
Steam Systems Air 14% 25%
26% 23%

Process Cooling Pumps

Facilities Other 25% Other
2%
10% 4% Electrochemical 10%
4%
A General Pump
11
 External Considerations

Hydraulic
Installation
Operating Drive Train
Conditions Practices

Flow Rate Piping Base Coupling Driver

Size and Size and

Pressure Configuration Size
Style Style

Turbulent
Alignment Grouting Alignment Speed
Flow

Support
12
Simultaneous loads on pump shaft
Impeller Radial Thrust

Impeller Axial
Thrust

Hydraulic
Induced
Forces due to
Recirculation &
Seal or Cavitation
Packing
Impeller Axial
Thrust
Radial Thrust
due to Hydraulic Imbalance Hydraulic
Imbalance
 Introduction
Pumping System Characteristics

 Head
destination
 Resistance of the system Static
head
 Two types: static and
friction
source

 Static head
 Difference in height between Static
head
source and destination
 Independent of flow
14
Flow
 Introduction
What are Pumping Systems

Objective of pumping system

 Transfer liquid
from source to
destination
 Circulate liquid
around a system
(US DOE, 2001)
15
 Introduction
What are Pumping Systems

 Main pump components

 Pumps
 Prime movers: electric motors, diesel
engines, air system
 Piping to carry fluid
 Valves to control flow in system
 Other fittings, control, instrumentation
 End-use equipment
 Heat exchangers, tanks, hydraulic 16
machines
 Introduction
Pumping System Characteristics

• Static head consists of

• Static suction head (hS): lifting liquid relative to
pump center line
• Static discharge head (hD) vertical distance
between centerline and liquid surface in
destination tank
• Static head at certain pressure
Head (in feet) = Pressure (psi) X 2.31
Specific gravity
17
 Introduction
Pumping System Characteristics

• Friction head
• Resistance to flow in pipe and fittings
• Depends on size, pipes, pipe fittings, flow
rate, nature of liquid
• Proportional to square of flow rate
• Closed loop system
only has friction head Friction
head
(no static head)

Flow 18
 Introduction
Pumping System Characteristics

In most cases:
Total head = Static head + friction head

System
System
curve
Friction curve
head
System System
head head Friction
Static head head

Static head

Flow Flow
19
 Introduction
Pumping System Characteristics

Pump performance curve

• Relationship between Head

head and flow

• Flow increase
• System resistance increases Flow

• Head increases
Performance curve for
• Flow decreases to zero centrifugal pump

• Zero flow rate: risk of

pump burnout 20
 Introduction

Pumping System Characteristics

Pump suction performance (NPSH)
• Cavitation or vaporization: bubbles inside pump
• If vapor bubbles collapse
• Erosion of vane surfaces
• Increased noise and vibration
• Choking of impeller passages
• Net Positive Suction Head
• NPSH Available: how much pump suction exceeds
liquid vapor pressure
• NPSH Required: pump suction needed to avoid
cavitation 21
 Introduction
Pumping System Characteristics

Pump operating point

• Duty point: rate of flow Pump performance

curve
at certain head
Pump
• Pump operating point: operating
Head System point
intersection of pump curve
curve and system
curve Static
head

Flow
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23
24
25
Training Agenda: Pumps

Introduction
Type of pumps
Assessment of pumps
Energy efficiency opportunities

26
 Type of Pumps
Pump Classification

Classified by operating principle

Pumps

Others (e.g. Positive

Dynamic Impulse, Buoyancy) Displacement

Centrifugal Special effect Rotary Reciprocating

Internal External Slide

Lobe
gear gear vane
28
Type of Pumps

Positive Displacement Pumps

• For each pump revolution

• Fixed amount of liquid taken from one end
• Positively discharged at other end

• If pipe blocked
• Pressure rises
• Can damage pump

• Used for pumping fluids other than

water 33
 Type of Pumps
Positive Displacement Pumps

 Reciprocating pump
 Displacement by reciprocation of piston
plunger
 Used only for viscous fluids and oil wells

 Rotary pump
 Displacement by rotary action of gear, cam
or vanes
 Several sub-types
 Used for special services in industry 34
 Type of Pumps
Dynamic pumps

 Mode of operation
 Rotating impeller converts kinetic energy
into pressure or velocity to pump the fluid

 Two types
 Centrifugal pumps: pumping water in
industry – 75% of pumps installed
 Special effect pumps: specialized
conditions

35
 Type of Pumps

Centrifugal Pumps

How do they work?

• Liquid forced into

impeller
• Vanes pass kinetic
energy to liquid: liquid
rotates and leaves
impeller
• Volute casing converts
kinetic energy into
pressure energy

36
 Type of Pumps
Centrifugal Pumps

Rotating and stationary components

37
 Type of Pumps

Centrifugal Pumps

Impeller
• Main rotating part that provides centrifugal
acceleration to the fluid
• Number of impellers = number of pump stages
• Impeller classification: direction of flow, suction type
and shape/mechanical construction

Shaft
• Transfers torque from motor to impeller during pump
start up and operation
38
 Type of Pumps
Centrifugal Pumps

Casings
• Functions
Volute Casing
• Enclose impeller as “pressure vessel”
• Support and bearing for shaft and impeller

• Volute case
• Impellers inside casings
• Balances hydraulic pressure on pump shaft

• Circular casing
• Vanes surrounds impeller
• Used for multi-stage pumps
39
Pumps in Parallel – Add Discharge
Pumps in Series – Add Head
 Cavitation
A phenomenon which occurs within a moving liquid when
the static pressure at some location falls to or below the vapor
pressure of the liquid.
To prevent cavitation:
NPSHA > NPSHR
 Cavitation – Impeller

Cavitation can occur at the inlet of the impeller if the suction pressure
falls below the liquid vapor pressure.
 Large vapor volumes can
cause reduction in head • Bubbles collapsing create
generation, or loss of prime. intense pressures and
(10,000 psi) shock waves.

• Intense pressures near metal

surfaces exceed material
strength and fatigue metals.

Large vapor volumes can cause • Creates pitted surfaces.

surging and unstable flows.

Cavitation – Impeller
 Cavitation

 Cavitation is caused by liquid changing into a

vapor and then back into a liquid.
 Formation of partial vacuums in a flowing liquid
as a result of the separation its parts.
 When These collapse, pitting or other damage is
Caused on metal surface in contact.

Cavitation is NOT AIR in the PUMP!

There are two forms of cavitation:
• Suction Cavitation, which occurs at the eye of the impeller, (also referred to as
“true cavitation”.

• Discharge Cavitation, which occurs at the tip of the impeller, (also referred to as
recirculation cavitation).
What Damage Does Discharge Cavitation Cause?

 Break Shafts

 Shortens Bearing Life

 Destroys Impellers and

Volutes

 Ruins Mechanical Seals

Total Dynamic Head Too “HIGH”

 What Damage Does Suction Cavitation Cause?

 Shortens Bearing Life

 (Increased radial & thrust loads)
 Destroys Impellers
 Destroys Wear Plates
 Ruins Mechanical Seals
 (Vibration & thrust loads)

Total Dynamic Suction Lift Too “HIGH”

Discharge Head Too “LOW”
Chemical Attack Abrasive Wear

Discharge Cavitation Suction Cavitation

 Shaft Breakage Problems

 Radial Fatigue Break

• Total Dynamic Head Too “High”

• Air (Hydraulic Imbalance)

• Mechanical Imbalance  Torsional Break (Twisting Break)

 Pump Lock-UP

 Reverse Rotation (Open Check Valve)

 Short Cycling
 Training Agenda: Pumps

Introduction
Type of pumps
Assessment of pumps
Energy efficiency opportunities

50
 Assessment of pumps
How to Calculate Pump Performance

• Pump shaft power (Ps) is actual horsepower

delivered to the pump shaft
Pump shaft power (Ps):
Ps = Hydraulic power Hp / pump efficiency ηPump
Pump Efficiency (ηPump):
ηPump = Hydraulic Power / Pump Shaft Power

• Pump output/Hydraulic/Water horsepower (Hp) is

the liquid horsepower delivered by the pump
Hydraulic power (Hp):
Hp = Q (m3/s) x Total head, hd - hs (m) x ρ (kg/m3) x g (m/s2) / 1000

hd - discharge head hs – suction head, 51

ρ - density of the fluid g – acceleration due to gravity
Pumps

Introduction
Type of pumps
Assessment of pumps
Energy efficiency opportunities

52
 Assessment of pumps
Difficulties in Pump Assessment

 Absence of pump specification data

to assess pump performance
 Difficulties in flow measurement and
flows are often estimated
 Improper calibration of pressure
gauges & measuring instruments
 Calibration not always carried out
 Correction factors used 53
Cavitation is Evil

• Cavitation can occur whenever the absolute

pressure locally gets below the vapor pressure
of the water
• Frequent issue when pump is higher than water
reservoir but can occur with any pump 
• Common site of cavitation is near tips of impellor
vanes where velocity is high
 Energy Efficiency Opportunities

1. Selecting the right pump

2. Controlling the flow rate by speed variation
3. Pumps in parallel to meet varying demand
4. Eliminating flow control valve
5. Eliminating by-pass control
6. Start/stop control of pump
7. Impeller trimming

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 Energy Efficiency Opportunities

1. Selecting the Right Pump

Pump performance curve for centrifugal pump

BEE India,
2004
56
Pump Selection
How to size a pump

 To find operating point:

 obtain pump curve from manufacturer, pumps
pump less water at higher heads
 calculate the system curve, the system curve is an
equation that tells how much water flows through a
pipe system as a function of the head (energy per
unit weight) added by the pump.
 Energy efficiency is maximized when the operation
point (intersection of pump and system curves) is
at the point of maximum pump efficiency
 Energy Efficiency Opportunities
1. Selecting the Right Pump

 Oversized pump
• Requires flow control (throttle valve or by-
pass line)
• Provides additional head
• System curve shifts to left
• Pump efficiency is reduced

 Solutions if pump already purchased

• VSDs or two-speed drives
• Lower RPM
• Smaller or trimmed impeller 59
 Energy Efficiency Opportunities

2. Controlling Flow: speed

variation
Explaining the effect of speed
 Affinity laws: relation speed N and
• Flow rate Q  N
• Head H  N2
• Power P  N3

 Small speed reduction (e.g. ½) = large

power reduction (e.g. 1/8)
60
 Energy Efficiency Opportunities
2. Controlling Flow: speed
variation
Variable Speed Drives (VSD)
• Speed adjustment over continuous
range
• Power consumption also reduced!
• Two types
• Mechanical: hydraulic clutches, fluid couplings,
adjustable belts and pulleys
• Electrical: eddy current clutches, wound-rotor
motor controllers, Variable Frequency Drives
61
(VFDs)
 Energy Efficiency Opportunities
2. Controlling Flow: speed
variation
Benefits of VSDs
• Energy savings (not just reduced flow!)
• Improved process control
• Improved system reliability
• Reduced capital and maintenance
costs
• Soft starter capability
62
 Energy Efficiency Opportunities
4. Eliminating Flow Control Valve

• Closing/opening discharge valve

(“throttling”) to reduce flow

• Head increases:
does not reduce
power use
• Vibration and
corrosion: high
maintenance costs
and reduced pump
lifetime
63
(BPMA)
 Energy Efficiency Opportunities

3. Parallel Pumps for Varying Demand

 Multiple pumps: some

turned off during low
demand
 Used when static head
is >50% of total head
 System curve
does not change
 Flow rate lower
than sum of
individual
flow rates (BPMA)
64
 Energy Efficiency Opportunities
5. Eliminating By-pass Control

 Pump discharge divided into two

flows
 One pipeline delivers fluid to destination
 Second pipeline returns fluid to the source

 Energy wastage because part of fluid

pumped around for no reason

65
 Energy Efficiency Opportunities
6. Start / Stop Control of Pump

 Stop the pump when not needed

 Example:
 Filling of storage tank
 Controllers in tank to start/stop

 Suitable if not done too frequently

 Method to lower the maximum demand
(pumping at non-peak hours)

66
 Energy Efficiency Opportunities

7. Impeller Trimming

 Changing diameter: change in velocity

 Considerations
 Cannot be used with varying flows
 No trimming >25% of impeller size
 Impeller trimming same on all sides
 Changing impeller is better option but more
expensive and not always possible

67
 Energy Efficiency Opportunities
7. Impeller Trimming
Impeller trimming and centrifugal pump performance

(BEE India,
2004)
68
 Energy Efficiency Opportunities
Comparing Energy Efficiency
Options

Parameter Change Trim impeller VFD

control valve
Impeller 430 mm 375 mm 430 mm
diameter
Pump head 71.7 m 42 m 34.5 m
Pump efficiency 75.1% 72.1% 77%
Rate of flow 80 m3/hr 80 m3/hr 80 m3/hr
Power 23.1 kW 14 kW 11.6 kW
consumed

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Pumps & Pumping
Systems 
THANK YOU
FOR YOUR ATTENTION

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