Comprehensive Pump Series - Best Practices of Centrifugal Pumps

from

Central Air conditioning and Trading and Services

Presentation -1

MAJOR PUMP COMPONENTS FUNCTIONS OF COMPONENTS DESIGN CALCULATIONS ON SHAFT DEFELCTIONS

Losses in pumps Pump selection Basic Trouble shooting

PART I

Criteria for Selection of Suitable Type of Pump

Design Objectives
Achieve design flow rate and total head. Attain optimum efficiency. Obtain stable head-capacity characteristics. Minimize NPSH required. Ensure wide operating range. Optimize pump size. Attain non-overloading power characteristics. Minimize vibration and noise. Minimize hydraulic axial and radial thrust loads. Design for ease of production. Ensure maximum interchangeability. Minimize cost.

MAJOR COMPONENTS OF A CENTRIFUGAL PUMP

STATIONARY PARTS CASING(TOP & BOTTOM) BEARING HOUSING BEARING BRACKET CASING WEAR RINGS SHAFT SLEEVE BEARING END COVER SHAFT SLEEVE NUTS MECHANICAL SEAL (ROTATING ELEMENT) LUBRICATING / COOLING ARRANGEMENTS

ROTATING ELEMENT
IMPELLER IMPELLER WEAR RING SHAFT SEAL FLUSHING LINE ACCESSORIES STUFFING BOX SEAL

BEARING (INNER RACE)

BEARING LOCK NUT

MAJOR COMPONENTS OF AN END SUCTION PUMP

MAJOR COMPONENTS OF A SPLIT CASE PUMP

CASING

BEARING BRACKET WEAR RING

PACKING

SLEEVE

STUFFING BOX UNIT

IMPELLER

LANTERN RING

FUNCTIONS OF CENTRIFUGAL PUMP COMPONENTS

COMPONENTS
IMPELLER TO DEVELOP DYNAMIC HEAD
SINGLE SUCTION DOUBLE SUCTION

FUNCTIONS

CASING

TO CONVERT KINETIC ENERGY INTO PRESSURE ENERGY WITH MINIMUM HYDRAULIC LOSSES BY MEANS OF VOLUTE, DIFFUSERS OR GUIDE VANES INCORPORATES NOZZLES TO CONNECT SUCTION & DISCHARGE PIPING DIRECTS FLOW INTO & OUT OF THE IMPELLER. PROVIDES SUPPORT TO THE BEARING BRACKET
IN-LINE

SPLIT-CASE

END SUCTION

WEAR RING

TO PROTECT THE ROTATING IMPELLER FROM RUBBING WITH THE STATIONARY CASING. TO PROVIDE A REPLACEABLE WEAR JOINT TO CONTROL THE LEAKAGE LOSSES ACROSS THE ANNULAR PATH BETWEEN IMPELLER AND WEAR RING
WEAR RING

IMPELLER NUT

TO LOCK THE IMPELLER IN ITS PROPER AXIAL POSITION TO PREVENT AXIAL MOVEMENT DUE TO HYDRAULIC THRUST
IMPELLER NUT

FUNCTIONS OF CENTRIFUGAL PUMP COMPONENTS

COMPONENTS FUNCTIONS

SHAFT

TRNSMITS TORQUE TO THE IMPELLER FROM THE DRIVER SUPPORTS IMPELLER AND OTHER ROTATING ELEMENTS
TO ENHANCE THE STIFFNESS OF THE ROTATING ELEMENT TO PROTECT THE SHAFT FROM ABRASION WEAR AT PACKED STUFFING BOX OR AT LEAKAGE JOINTS TO PROTECT THE SHAFT FROM EROSION & CORROSION TO FASTEN THE SLEEVES TO THE SHAFT TO PREVENT MOVEMENT OF THE SLEEVE

SHAFT

SLEEVE

SLEEVE

SLEEVE NUT

SLEEVE NUT

THROTTLE BUSH

CAUSES PRESSURE BREAKDOWN AS THE LIQUID THROTTLES ACROSS IT THUS BOOSTING THE SERVICE LIFE OF PACKING SERVES AS A LANDING FOR THE LOWEST RING OF THE PACKING RESTRICTS SOLID PARTICLE IN THE PUMPED LIQUID FROM GETTING EMBEDDED INTO THE PACKING AREA AND THUS PROTECTING THROTTLE BUSH SHAFT OR SLEEVE FROM WEAR ACTS AS ADDITIONAL HYDRODYNAMIC BEARING SUPPORT FOR THE ROTATING ELEMENT AND REDUCES SHAFT DEFLECTION PREVENTS SOME AMOUNT OF LIQUID LEAKING OUT FROM THE STUFFING BOX TO FLOW BACK

TYPES OF IMPELLERS BASED ON MECHANICAL CONSTRUCTION - USED DEPENDING ON THE NATURE OF THE LIQUID PUMPED

SECTIONAL VIEWS OF IMPELLERS SHOWN BELOW

CLOSED IMPELLER

SEMI-OPEN IMPELLER PARTIAL SHROUDED IMPELLER

OPEN IMPELLER

Type of impellers
Closed Impeller This type of impeller works best with clear water. Semi Open Semi open impellers are used for fibers or potentially clogging materials in the pumping liquid After extensive operation The impeller requires and wear, pump efficiency tight clearance be can normally be restored maintained between the to original levels by open face and its mating replacing the inlet stationary surface wearing ring (originally (clearance between 0.25 clearance) to the adjacent and 0.38 mm casing wearing ring. Open Open impellers are used for high speed pumps of over 10,000 rpm.

TYPES OF IMPELLERS BASED ON NUMBER OF SUCTION EYES

SINGLE SUCTION IMPELLER

DOUBLE SUCTION IMPELLER

MAIN DESIGN PARAMETERS OF AN IMPELLER NUMBER OF VANES IMPELLER DIA. IMPELLER WIDTH VANE OUTLET ANGLE

VANE SPREAD
EYE DIAMETER VANE INLET ANGLE

MAJOR DIMENSIONS OF AN IMPELLER

TYPES OF IMPELLERS BASED ON THE MAJOR DIRECTION OF FLOW WITH RESPECT TO THE AXIS OF ROTATION

RADIAL VANE IMPELLER

MIXED FLOW IMPELLER

PROPELLER

SUITABLE FOR DISCHARGING RELATIVELY SMALL QUANTITY OF FLOW AGAINST HIGH HEAD

SUITABLE FOR DISCHARGING LARGE QUANTITY OF FLOW AGAINST MEDIUM HEAD

SUITABLE FOR DISCHARGING LARGE QUANTITY OF FLOW AGAINST SMALL HEAD

CHANGE OF IMPELLER SHAPE WITH SPECIFIC SPEED

SPECIFIC SPEED & EFFICIENCY

TYPES OF IMPELLERS BASED ON THEIR RELATIVE POSITIONS ON THE SHAFT

OVER-HUNG IMPELLER

IMPELLER BETWEEN BEARINGS

TWO-STAGE PUMP ROTATING ELEMENT ASSEMBLY

Multistage Pumps
Essentially a High Head Pump having two or more Impellers Mounted on a Common Shaft in Series

Multi-stage Pump

Vertical Multistage Can Pumps

VARIOUS TYPES OF COLLECTORS & THEIR ADVANTAGES & DISADVANTAGES

VOLUTE WITH DIFFUSER VANES

SINGLE VOLUTE

VERTICAL PUMP WITH DIFFUSER

DOUBLE VOLUTE

CIRCULAR VOLUTE

FUNCTIONS OF A PUMP VOLUTE

1. TO CONVERT KINETIC ENERGY IMPARTED BY THE IMPELLER INTO PRESSURE ENERGY 2. TO MINIMIZE LOSSES DURING THIS ENERGY CONVERSION PROCESS

3. THE PUMP CASING DOES NOT TAKE ANY PART IN DYNAMIC HEAD GENERATION
4. THE BEST VOLUTES ARE OF CONSTANT VELOCITY DESIGN

5. KINETIC ENERGY IS CONVERTED INTO PRESSURE ENERGY ONLY IN THE DIFFUSION NOZZLE IMMEDIATELY AFTER THE VOLUTE THROAT

TYPES OF VOLUTES SINGLE VOLUTE CASINGS

1. SINGLE VOLUTE CASINGS ARE OF CONSTANT VELOCITY DESIGN. 2. THEY ARE EASY TO CAST AND ECONOMICAL TO MANUFACTURE. 3. THEY PRODUCE THE BEST EFFICIENCIES AT DESIGN POINT COMPARED TO OTHER COLLECTOR SHAPES. 4. PRESSURE DISTRIBUTION AROUND THE IMPELLER IS UNIFORM ONLY AT THE DESIGN POINT. 5. RESULTANT RADIAL THRUST DUE TO NON-UNIFORM PRESSURE DISTRIBUTION IS GIVEN BY: P = K x H x D2 x b2 x S.G / 2.31 P = RADIAL THRUST IN POUNDS
K = THRUST FACTOR H = DEVELOPED HEAD/STAGE IN FT D2 = IMPELLER DIA, IN INCHES b2 = IMPELLER WIDTH IN INCHES (INCLUDING SHROUDS)

SINGLE VOLUTE

6.

SINGLE VOLUTE PUMPS ARE USED MAINLY ON LOW CAPACITY, LOW SPECIFIC SPEED PUMPS. 7. THEY ARE ALSO USED FOR SPECIAL APPLICATIONS SUCH AS SLURRIES OR SOLID HANDLING PUMPS.

VOLUTE AS-CAST

VOLUTE SECTIONS FOR SINGLE VOLUTE PUMP

TYPES OF VOLUTES DOUBLE VOLUTE CASINGS

1.

A DOUBLE VOLUTE CASING HAS TWO SINGLE VOLUTES 180 APART.

2.

TOTAL THROAT AREA OF TWO VOLUTE IS SAME AS THE THROAT AREA OF A COMPARABLE SINGLE VOLUTE PUMP.

3.

DOUBLE VOLUTE SIGNIFICANTLY REDUCES THE RADIAL LOAD PROBLEM OF THE SINGLE VOLUTE PUMP.

4.

HYDRAULIC PERFORMANCE OF A DOUBLE VOLUTE PUMP IS NEARLY THE SAME AS THAT OF A SINGLE VOLUTE PUMP.

DOUBLE VOLUTE

5.

DOUBLE VOLUTE PUMP IS AROUND 1 - 1.5 POINT LESS EFFICIENT AT B.E.P BUT ABOUT TWO POINTS MORE EFFICIENT ON EITHER SIDE OF B.E.P .

6.

DOUBLE VOLUTES ARE NOT USED FOR FLOWS BELOW 90 M/HR.(400 US GPM).

VOLUTE AS-CAST

VOLUTE SECTIONS FOR DOUBLE VOLUTE PUMP

VOLUTE 1

VOLUTE 2

SAME THROAT AREA FOR BOTH THE VOLUTES

Volute with Diffuser vanes

An Impeller discharges into multiple divergent passes (normally two or more) with the outer casing functioning as a collector ,directing fluid in to the pump discharge or the next pump stage

Circular (concentric) casing

An Impeller discharges in to a circulator collector with a single discharge port. A circular casing is often used where efficiency is not a concern Casings are commonly fabricated and it may improve the efficiency of very low specific speed. Application : Slurry pumps.

CASING THICKNESS CALCULATION USING ASME STANDARD

Shaft deflection
Shaft deflection is the designed criterion that greatly influences pump performance due to its effect on the mechanical seal, internal clearance and bearings . The radial loads acting on the rotating impellers are transmitted directly to the pump shaft. This forces will deflect the shaft where it is applied ,irrespective of the bearing configuration. The shaft must be designed to accommodated this hydraulic radial load in conjunction with the additional radial load imposed due to the mass of the impellers and other rotating components . Under these condition the rotor must be stiff enough to limit the resulting deflection to within limits .

Standards
Overhung Impeller Pumps as per ASME B73.1 Dynamic shaft deflection at the impeller centerline shall not exceed 0.125 mm in any where within the design region. Maximum shaft deflection at primary seal faces is 0.05 mm.

Overhung Impeller Pumps as per API standard 610 (10 th edition)

Overhung Impeller Pumps as per ISO 5199

0.05 MM at the face of the seal chamber

SHAFT DEFLECTION ACCORDING TO HYDRAULIC INSTITUTE

 Deflection of shaft :Between the bearing Deflection () = P/(6EIc)( C^3+ {(C+B)^3-C^3}/K2 + {(A+B+C)^3-(B+C)^3}/K3)

is in mm.

P= load at the impeller: (P) E( Modulus of elasticity) = 200 GPa =20010^6 Kpa A= length of shaft at section A B= length of shaft at section B C= length of shaft at section C

K2, K3 can be calculated as below, K2= Ib/Ic K3=Ia/Ic Determination of moment of inertia of each section: Ia= moment of inertia = Da^4/64 Ib= moment of inertia = Db^4/64 Ic= moment of inertia = Dc^4/64

Da= Dia of the shaft at section A Db= Dia of the shaft at section B Dc= Dia of the shaft at section C

 Determination of load at the impeller: (P) Wi = Wgt of the impeller Ws = Wgt of the shaft W= static load of rotor = Wi + Ws P (load at the impeller) = W+R

 Calculate Radial Thrust: R= KrHgB2D2

Where,

Kr = thrust factor which varies with rate of flow and specific speed H = Developed head per stage in m = density of the liquid in kg/m3 Gravitational constant = 9.81 m/s2 D2= Impeller dia in m B2= Impeller width at discharge including shrouds in m Note: = H S/ 2.31 in US units

 Calculate specific speed Ns: Ns (US units) = N (Q4.403)^.5 / (H3.28)^.75 where, N in rpm, Q in m3/hr H in m

 Determine Kr:

The variation of Kr with specific speed is given in the table:

Duty 50% Double volute

Ns(Us) 500 1000 1500 2000 3500

Ns(metric) 600 1200 1250 2300 4000

Kr 0.02 0.025 0.035 0.048 0.05

Bearing load calculation Ref- Hydraulic Institute

Overhung Impeller

R1 = Fn X (X +Y) Y

R2 = Fn x X Y

Where, R1 Inboard reaction load , R2 Outboard bearing reaction load Fn = Fr + W ; Where Fn Net force typically applied at the impeller center line , Fr Radial hydraulic thrust applied at impeller center line. W-Impeller weight X- Distance from applied load to the center of the inboard bearing Y= Distance between in board and out board bearing

Bearing load Between the bearing

R1 = Fn x Y X+Y

R2 = Fn x X X+Y

Where, R1 Inboard reaction load , R2 Outboard bearing reaction load Fn = Fr + W ; Where Fn Net force typically applied at the impeller center line , Fr Radial hydraulic thrust applied at impeller center line. W-Impeller weight X- Distance from applied load to the center of the inboard bearing Y= Distance between in board and out board bearing

HYDRAULIC THURSTS GENERATED IN A CENTRIFUGAL PUMP

RADIAL THRUST AXIAL THRUST RADIAL THRUST
SUMMATION OF UNBALANCED HYDRAULIC FORCES ACTING RADIALLY. DUE TO UNEQUAL VELOCITY OF THE FLUID FLOWING THROUGH THE CASING AT PART FLOW, A NON-UNIFORM PRESSURE DISTRIBUTION EXISTS OVER THE CIRCUMFERENCE OF THE IMPELLER. RADIAL THRUST IS AN IMPORTANT PARAMETER WHEN DESIGNING PUMPS MECHANICAL ELEMENTS LIKE SHAFT AND BEARINGS. SINGLE VOLUTE CASING DOUBLE VOLUTE CASING

SECOND VOLUTE

STATIC PRESSURE DISTRIBUTION OVER THE IMPELLER OUTLET FOR DIFFERENT CASING GEOMETRIES AT PART FLOW REGIME CONCENTRIC CASING

VANED DIFFUSER

RADIAL THRUST IS A FUNCTION OF TOTAL HEAD OF THE PUMP & WIDTH & DIAMETER OF THE IMPELLER P = K x H x D2 x b2 x S.G / 2.31
P = RADIAL THRUST IN POUNDS K = THRUST FACTOR H = DEVELOPED HEAD/STAGE IN FT D2 = IMPELLER DIA, IN INCHES b2 = IMPELLER WIDTH IN INCHES(INCLUDING SHROUDS)

RADIAL REACTION VECTOR REPRESENTED BY THE ARROWS AT DIFFERENT FLOW CONDITIONS FOR A SINGLE VOLUTE CASING

RADIAL FORCE PERCENT OF FORCE AT SHUT-OFF FOR VOLUTE CASING

RADIAL FORCE FOR VARIOUS TYPES OF VOLUTES

AXIAL THRUST
SUMMATION OF UNBALANCED HYDRAULIC FORCES ACTING AXIALLY ON THE IMPELLER. SEVERITY OF AXIAL THURST DEPENDS ON THE TOTAL HEAD, SUCTION PRESSURE & MECHANICAL CONFIGURATION OF IMPELLER.

AXIAL PRESSURE ACTING ON THE IMPELLER SHROUDS TO PRODUCE AXIAL THRUST

SPECIFIC SPEED OF A CENTRIFUGAL PUMP ITS A DESIGN INDEX THAT DETERMINES THE IMPELLER TYPE AND GEOMETRIC SIMILARITY OF PUMPS.

Ns =

N x Q / (H)0.75

Ns =

N x Q / (H)0.75

WHERE , Ns = SPECIFIC SPEED IN METRIC UNITS. Q = FLOW IN M3/HR. AT B.E.P. N = ROTATIVE SPEED IN R.P.M . H = HEAD DEVELOPED IN M. AT B.E.P.

WHERE , Ns = SPECIFIC SPEED IN US CUSTOMARY UNITS. Q = FLOW IN US GPM AT B.E.P. N = ROTATIVE SPEED IN R.P.M . H = HEAD DEVELOPED IN FT. AT B.E.P.

EFFECT OF SPECIFIC SPEED ON ACCECTABLE OPERATING ZONE OF A PUMP LOW SPECIFIC SPEED PUMPS
HEAD
B.E.P

EFFICIENCY

BKW

COMPARATIVELY WIDER ACCEPTABLE OPERATING ZONE

ACCEPTABLE OPERATING ZONE HIGH SPECIFIC SPEED PUMPS

FLOW-RATE HEAD
B.E.P

EFFICIENCY

COMPARATIVELY NARROWER ACCEPTABLE OPERATING ZONE

BKW

ACCEPTABLE OPERATING ZONE

FLOW-RATE

SPECIFIC SPEED & ITS EFFECT ON PUMP PERFORMANCE CHARACTERISTICS

COMPARATIVELY FLAT H-Q CURVE

COMPARATIVELY LOW NPSH REQUIREMENT

HIGH LOWSPECIFIC SPECIFICSPEED SPEEDPUMP PUMP

RISING POWER CURVE

SPECIFIC SPEED & ITS EFFECT ON PUMP PERFORMANCE CHARACTERISTICS

COMPARATIVELY STEEP H-Q CURVE

COMPARATIVELY HIGH NPSH REQUIREMENT

HIGH SPECIFIC SPEED PUMP

NON-OVERLOADING POWER CURVE

Allowable Operating Region & Preferred Operating Region

Reference Source ANSI HI 9.6.3-1997

Preferred Operating Region - POR

The flow remains well controlled within a range of rates of flow designated as the Preferred Operating Region ( POR). Within this region the service life of the pump will not be significantly affected by hydraulic loads, vibration or flow separation.

Specific Speed Metric < 5200 > 5200 US Units < 4500 > 4500

POR Between 70% & 120% of BEP Between 80% & 115% of BEP

SUCTION SPECIFIC SPEED

Suction specific speed is an indicator of the net positive suction head require for 3% drop in head at a given flow rate and rotation speed.

Nss =

N x Q / (NPSHr)0.75

Nss =

N x Q / (NPSHr)0.75

WHERE , Nss = Suction specific speed in metric units

where, Nss = Suction specific speed in us customary units.

Q = Flow in m3/hr at b.e.p (use half of the total flow for double suction pumps)
N = rotative speed in r.p.m NPSHr = Net +ve suction head required in m (established by 3% head drop test)

Q = Flow in us gpm at b.e.p (use half of the total flow for double suction pumps)
N = Rotative speed in r.p.m NPSHr = Net +ve suction head required in ft (established by 3% head drop test)

SPEED LIMITATION AND SUCTION SPECIFIC SPEED Increased pump speed without proper suction conditions Abnormal pump wear Failure due to excessive vibration Noise Cavitations damage

can lead to

Suction specific speed has been found to be a valuable criterion in determining the maximum speed

Hydraulic institute uses a value of 10,000 metric units (8500 us units) as a practical value for determining the maximum operating speed.

In metric units, n = 10,000 x npsha0.75 / q 0.5 where , n = max. speed(r.p.m). npsha = npsh available in m. q = flow in m3/hr. (take half of the flow for double suction pump).

In us customary units, n = 8,500 x npsha0.75 / q 0.5

where , n = max. speed(r.p.m). npsha = npsh available in ft. q = flow in us g.p.m. (take half of the flow for double suction pump).

SAFE OPERATING WINDOW Vs SUCTION SPECIFIC SPEED

Ttest of a 4 inch pump with different Nss impellers. bep & impeller profiles are identical,only eye geometry is different for each Nss

NPSHr & NPSHa

NPSHr IS A CHARACTERISTIC OF YOUR PUMP. THIS IS A FUNCTION OF PUMP SUCTION DESIGN. IT VARIES WITH THE SPEED & CAPACITY FOR A PARTICULAR PUMP. THIS IS THE +VE HEAD IN M ABSOLUTE REQUIRED AT PUMP SUCTION TO OVERCOME PUMP INTERNAL LOSSES LOSSES DUE TO TURBULANCE (GENERATED AS THE LIQUID STRIKES THE IMPELLER AT IMPELLER INLET), LOSSES IN THE SUCTION PASSAGE & VANE INLET PASSAGES TO MAITAIN THE PUMPING FLUID IN LIQUID STATE. NPSHa IS A CHARACTERISTIC OF YOUR SYSTEM. THIS IS A FUNCTION OF SYSTEM CONFIGURATION ON THE SUCTION SIDE OF THE PUMP.

IT IS THE AVAILABLE TOTAL SUCTION HEAD IN METRES ABSOLUTE DETERMINED AT THE INLET NOZZLE OF THE PUMP & CORRECTED TO THE PUMP DATUM LESS THE VAPOUR PRESSURE HEAD OF THE LIQUID IN METRES ABSOLUTE AT THE PUMPING TEMPERATURE.

FOR CAVITATION-FREE SAFE OPERATION, YOUVE TO KEEP, NPSHa > NPSHr

CALCULATION OF AVAILABLE NPSH (NPSHa)

CHARACTERISTIC OF THE PROCESS SUCTION SYSTEM.

AN ANALYSIS OF TOTAL ENERGY ON THE SUCTION SIDE OF A PUMP TO DETERMINE WHETHER THE LIQUID WILL VAPOURIZE AT A LOW PRESSURE POINT IN THE PUMP.

CALCULATION OF NPSHA FOR SYSTEMS WITH SUCTION HEAD & SUCTION LIFT

NPSHa (M) = ATMOSPHERIC PRESSURE(M) NPSHa (M) = ATMOSPHERIC PRESSURE(M) +

SUCTION LIFT(M) FRICTIONAL HEAD LOSS(M) - V.P (M)

SUCTION HEAD(M) FRICTIONAL HEAD LOSS(M) - V. P (M)

REASONS FORSAFETY MARGIN FOR MOTOR SELECTION

IF A MOTOR IS CONSTANTLY OVERLOADED PRODUCING A POWER MORE THAN THE RATED, IT WILL DRAW MORE CURRENT AND THIS WILL INCREASE THE POWER LOSS (I2R). HIGHER THE LOSS, HIGHER WOULD BE THE HEAT GENERATED LEADING TO RAPID DAMAGE TO THE MOTOR INSULATION.

BKW (for pump) = (Capacity in cum/hr X Head in meters X sp. Gravity) 367 x eff. of the pump at duty
A GUIDE FOR SELECTING SAFETY MARGIN ISO 5199
MOTOR RATING
1 kW TO 100 kW ABOVE 100 kW

MARGIN OF SAFETY (% OF MOTOR RATING)

135% TO 110% 110%

TYPICAL SPEED TOQUE CURVE WITH TVA DATA

CLASSIFICATION OF LOSSES
LOSSES IN A CENTRIFUGAL PUMP ARE CLASSIFIED INTO FIVE TYPES:

MECHANICAL LOSSES
IMPELLER LOSSES DISK FRICTION LOSSES

LEAKAGE LOSSES
There are number of mechanical ,hydraulics losses in impeller and pump casing, this will affect the pump performance is lower than predicted by the Euler pump equation. CASING HYDRAULIC LOSSES

MECHANICAL LOSSES

EXCLUSIVELY POWER LOSS TAKES PLACE PRIMARILY IN BEARINGS, MECHANICAL SEALS OR GLAND PACKING CONTD..

LOSSES IN CENTRIFUGAL PUMP

Pump Losses

LOCATIONS OF VARIOUS LOSSES IN A CENTRIFUGAL PUMP

Casing Hydraulic loss

Leakage loss Mechanical losses

Entrance shock loss

Disk friction loss

LOCATIONS OF VARIOUS LOSSES IN A CENTRIFUGAL PUMP

Casing Hydraulic loss Leakage loss

Entranc e shock loss

Mechanical losses

Disk friction loss

Mechanical losses

The pump shaft consists of bearings, shaft seals ,gear depending on pump type. These components all causes mechanical friction losses.

P losses, mechanical = P losses ,bearing + P loss, shaft seal

P losses ,bearing - Power loss in bearing (W) P loss, shaft seal - Power loss in shaft (W)

Hydraulic Losses

Hydraulic losses arise on the fluid path through the pump. The losses occur because of friction or because the fluid must change direction and velocity on its path through the pump IMPELLER HYDRAULIC LOSSES

I) ii)

Shock losses at inlet to the impeller Shock losses leaving the impeller

iii) Losses during conversion of mechanical energy to kinetic energy

CASING HYDRAULIC LOSSES I) RECIRCULATION LOSSES II) LOSSES DURING CONVERSION OF K.E TO P.E III) LOSSES DUE TO SKIN FRICTION IN CASING

GENERAL EXPRESSION FOR DEFINING FRICTIONAL LOSSES:

Hf = f x v2/2g x L/DH
WHERE, Hf = FRICTIONAL HEAD LOSS f = FRICTION CO-EFFICIENT v = FLUID VELOCITY L = PASSAGE LENGTH DH = HYDRAULIC DIA. OF THE PASSAGE

DISK FRICTION LOSSES

FRICTIONAL LOSSES AT THE IMPELLER SHROUDS General expression for disk friction power consumption:

PD = k x n3 x D25

D2

n
WHERE, PD = POWER ABSORBED BY DISK FRICTION k = CONSTANT n = SPEED (R.P.M) D2 = IMPELLER OUTER DIA.

The disk friction is the increased power consumption which occurs on the shroud and hub of the impeller because it rotates in a fluid filled pump casing. The size of the disc friction depends primarily on the speed the impeller diameter as well as the dimensions of the pump housing in particular the distance between impeller and pump casing.

LOSSES IN CENTRIFUGAL PUMP

M= exponent equals 1/6 for smooth surface , 1/7 to 1/9 for rough surface, v- kinematic viscosity m/sec , U2 = Peripheral velocity [m/s], D2 = Impeller diameter [m]

LEAKAGE LOSSES
Caused by liquid flowing past wear rings, inter-stage bushes, mechanical seals, glands & balancing devices, Leakage losses results in a loss in efficiency because the flow in a impeller is increased compared to the flow through the entire pump.
CASING WEAR RING IMPELLER WEAR RING

The general expression for determining the amount of leakage across an annular clearance is

MAIN FLOW PATH

QL = x Acl x (2.g.Hcl)
HERE, QL = LEAKAGE FLOW = LEAKAGE GAP LOSS CO-EFFICIENT g = GRAVITATIONAL ACCELERATION Hcl = HEAD LOSS ACROSS ANNULAR PATH

LEAKAGE FLOW PATH

FLOW PATH

Acl = AREA AT CLEARANCE ZONE

Pump selection method

Pump selection method Available data's, Type - double suction split casing pump Application - Water Capacity - 750 cum/hr Head - 35 Meters Suction lift - 3 Meters ( Can be estimated NPSH A,NPASHR Pump speed, motor rating Calculate Available NPSH A in the system

NPSH for open system = ATM head - (suction head + friction losses + vapor losses) Assumed , Friction losses = 0.5 M Vapour losses = 0.6 M NPSH A = 10.3 - (3 +0.5+0.6) = 6.2 Meters

Maximum permissible speed and actual speed of the motor

NSS = Ns X Q^0.5 NPSHr ^ 0.75

Speed (NS) = Nss x NPSH A ^0.75 Q^0.5

Ns= 8500 x( 20)^0.75 (1651)^0.5

NSS = 7500 TO 10000

Assumed - 8500 in US units

2004 Speed = RPM The recommended motor speed is - 1450 RPM /4 Pole 3. Motor Power BKW = Capacity in cum/hr X Head M X sp.gravity 367 X Eff.at duty BKW = 750 X 35 X 1 367 X 0.86 85.54 KW ADD 15% Margin = 85.54 x 1.15 = 98 KW ,So recommendable is 110 KW/1450 RPM/50 Hz (Efficiency is taken from the HI chart)

4. NPSH Required for the pump NSS = NS X Q^0.5 NPSHr ^ 0.75 NPSH^0.75 = Ns x Q ^0.5 Nss NPSH R = 1500 X (1651)^0.5 8500 NPSH R = 7.17 FT NPSH R = 2.1 Meters NPSH A is greater than NPSH R 5. Minimum shaft diameter at coupling area. Shear stress formula = HP = S N(D)^3 / 321000 S- Permissible shear stress in shaft- PSI = 8500 ( SS410) D ^3 = 150 X 321000 8500 X 1500 D = 1.577 Inches = 39.55 mm at coupling area

6.Suction and delivery nozzle size :

Velocity at inlet (assume) - 4 m/sec.

Capacity = Area X velocity Area (3.147/d^2)) = capacity / velocity 4 d^2 = (750 x 4)/4 x3600 d= 0.456 meters = 456 mm ,So =450 mm.(wetted area) For discharge this can be one size lower - 400 mm say 16 inches.
7. Selecting Impeller Diameter:

U2 = KU (2 X g X H ) ^0.5
KU = Co efficient related to specific speed -refer to the chart for 2004 specific speed the KU value is 1.1

U2 = 1.1 ( 2x 9.81 x 35) ^0.5 U2 = 28.82 m/sec

Impeller diameter can be calculated by using the below formula, U2 = 3.147 X D2 X N /60 D2 =( 28.82 X 60)/ 3.147 X 1500 D2= 0.366 MTRS = 366 MM.

Efficiency Chart - II Optimum Efficiency as a Function of Specific Speed & Flow-rate Fraser-Sabini Chart

Specific Speed & Efficiency

Specific Speed Ku 400 0.965

Km2 0.040

D1/D2 0.380

K3 0.555

800
1200 1600 2000 2400 2800 3200 3600

1.000
1.035 1.065 1.100 1.135 1.165 1.200 1.235

0.073
0.100 0.120 0.140 0.160 0.175 0.193 0.205

0.430
0.470 0.510 0.550 0.590 0.620 0.640 0.650

0.490
0.425 0.375 0.335 0.300 0.275 0.260 0.265

DIFFERENT HEAD TERMS IN A PUMPING SYSTEM

TOTAL HEAD IN A +VE SUCTION SYSTEM

TOTAL HEAD IN A -VE SUCTION SYSTEM

UNDERSTANDING PRESSURE & HEAD IN A PUMPING UNIT

ALL PRESSURES CAN BE VISUALIZED AS BEING CAUSED BY THE WEIGHT OF A COLUMN OF LIQUID AT ITS BASE.

P1

P2

P3

THREE IDENTICAL PUMPS DESIGNED TO DEVELOP SAME HEAD PRODUCES DIFFERENT PRESSURES WHICH VARY IN PROPORTION TO THEIR SPECIFIC GRAVITY.

H1 P

H2 P

H3 P

PUMPS SHOULD BE SPECIFIED IN TERMS OF HEAD AND NOT IN TERMS OF PRESSURE TO AVOID AMBIGUITY.

THREE PUMPS PRODUCE SAME DISCHARGE PRESSURE BUT DEVELOP HEADS INVERSELY
PROPORTIONAL TO THEIR SPECIFIC GRAVITY.

UNDERSTANDING PRESSURE & HEAD IN A PUMPING UNIT

ALL PRESSURES CAN BE VISUALIZED AS BEING CAUSED BY THE WEIGHT OF A COLUMN OF LIQUID AT ITS BASE.

P1

P2

P3

THREE IDENTICAL PUMPS DESIGNED TO DEVELOP SAME HEAD PRODUCES DIFFERENT PRESSURES WHICH VARY IN PROPORTION TO THEIR SPECIFIC GRAVITY.

H1 P

H2 P

H3 P

PUMPS SHOULD BE SPECIFIED IN TERMS OF HEAD AND NOT IN TERMS OF PRESSURE TO AVOID AMBIGUITY.

THREE PUMPS PRODUCE SAME DISCHARGE PRESSURE BUT DEVELOP HEADS INVERSELY
PROPORTIONAL TO THEIR SPECIFIC GRAVITY.

VARIOUS TYPES OF H-Q CURVE SHAPES

FLAT CURVES SHOWS LITTLE VARIATION OF HEAD AT ALL FLOWS BETWEEN DESIGN POINT & SHUT-OFF

HEAD

FLOW DROOPING CURVE

HEAD DEVELOPED AT SHUT-OFF IS LESS THAN HEAD DEVELOPED AT SOME FLOW BETWEEN B.E.P & SHUT-OFF
HEAD

FLOW STEADILY RISING CURVE HEAD RISES CONTINUOUSLY FROM DESIGN POINT TO SHUT-OFF HEAD

FLOW

VARIOUS TYPES OF H-Q CURVE SHAPES

STEEP CURVE HEAD LARGE INCREASE IN HEAD DEVELOPED AT SHUT-OFF FROM B.E.P.

FLOW

STABLE CURVE HEAD ONLY ONE FLOW RATE AT ANY ONE HEAD

FLOW

UNSTABLE CURVE HEAD

THE SAME HEAD IS DEVELOPED AT MORE THAN ONE FLOW RATES

FLOW

System Curve
A system curve describes the relationship between the flow in a pipeline and the head loss produced.
The essential elements of a system curve include: A) The static head of the system, B) The friction or head loss in the piping system. C) Pressure head

Calculation method
System curve 944@28M
30

L/s
25

RL/S

20

15

10

944 944 944 944 944 944 944 944 944 944

28 28 28 28 28 28 28 28 28 28

0 188 283 377 472 566 660 755 849 944

0 1.110529 2.516442 4.465774 7 10.06577 13.6868 17.91051 22.64798 28

0% 10% 20% 30% 50% 60% 70% 80% 90% 100%

10

Designed flow 944 L/s Designed Head 28 Meters Head at 50 % flow (472 l/s) -???? H2 =( Q2 ^2)x HI Q1^2 H2= (472)^2 x 28 = 7 Meters = (944) ^2

SYSTEM HEAD CURVE

ITS YOUR SYSTEM THAT CONTROLS YOUR PUMP.

ALL PUMPS MUST BE DESIGNED TO COMPLY WITH OR MEET THE NEEDS OF THE SYSTEM & THE NEED OF THE SYSTEM IS RECOGNIZED USING THE TERM TDH

TDH = Hs + Hp + Hf + Hv
DUTY POINT
HEAD

HERE, TDH = TOTAL DYNAMIC HEAD Hs = STATIC HEAD (DIFFERENCE IN THE LIQUID SURFACE LEVELS AT SUCTION SOURCE & DISCHARGE TANK Hp = PRESSURE HEAD (CHANGE IN PRESSURE AT SUCTION & DELIVERY TANK) Hv = VELOCITY HEAD Hf = FRICTION HEAD (HEAD LOSS DUE TO FRICTION ACROSS PIPES, VALVES, CONNECTIONS & SUCTION & DELIVERY ACESSORIES).

FRICTION HEAD + VELOCITY HEAD

PRESSURE HEAD STATIC HEAD

THE SYSTEM HEAD CURVE Hs & Hp BEGINS AT ZERO FLOW AT THE SUM OF Hs & Hp & RISES EXPONENTIALLY WITH THE SQUARE OF THE FLOW Hs & Hp EXISTS WHETHER THE PUMP IS RUNNING OR NOT WHEREAS Hf & Hv EXISTS ONLY AT THE RUN-TIME.
FLOW

NATURE OF SYSTEM CURVES

PUMP CURVE

TDH (M)

ALL FRICTION INTERMEDIATE STATIC DOMINANT

FLOW RATE(M3/HR.)

THREE DIFFERENT TYPES OF SYSTEM CURVES WITH A SINGLE COMMON FLOW RATE/HEAD POINT

SYSTEM HEAD CURVE SUPERIMPOSED ON H-Q CURVE OF THE PUMP

H-Q CURVE

OPERATING POINT

SYSTEM RESISTANCE CURVE FRICTION HEAD TOTAL DYNAMIC HEAD (TDH)

HEAD

STATIC HEAD FLOW

SYSTEM HEAD CURVE SUPERIMPOSED ON H-Q CURVE OF THE PUMP

H-Q CURVE

OPERATING POINT

SYSTEM RESISTANCE CURVE FRICTION HEAD TOTAL DYNAMIC HEAD (TDH)

HEAD

STATIC HEAD FLOW

PARALLEL OPERATION
DISCHARGE HEADER

SUCTION HEADER

WHEN THE SYSTEM FLOW DEMAND VARIES OVER A WIDE RANGE, PARALLEL OPERATON OF SEVERAL SMALL PUMPS INSTEAD OF A SINGLE LARGE ONE MAY BE EMPLOYED. COMBINED H-Q CURVE IS OBTAINED BY ADDING THE DISCHARGES GENERATED BY INDIVIDUAL PUMPS AT THE SAME HEADS.

SERIES OPERATION OF PUMPS

SERIES OPERATION FOR SYSTEMS WITH HIGH HEAD REQUIREMENT

COMBINED CURVE OBTAINED BY ADDING THE HEADS DEVELOPED BY INDIVIDUAL PUMPS AT THE SAME FLOW RATES.

Parallel operation two pumps systems (constant speed)

(P1 +P2)

Dynamic losses dominated system curve .

1450 RPM

160

Power-hp

140 120 100 80

D3 D1

Operating at low head then designed.

D2
P1 +P2

Head-FT

P1
60 40 20 0 0 25 th floor Primary 500 1000 1500 2000 2500

Flow-GPM

OPERATION FAR TO THE LEFT OF B.E.P POSSIBLE PROBLEMS

OPERATION AT LOW FLOW MAY RESULT IN

CASES OF HEAVY LEAKAGE FROM THE CASING, SEAL OR STUFFING BOX. DEFLECTION & SHEARING OF SHAFT. SEIZURE OF PUMP INTERNALS. CLOSE CLEARENCE EROSION. SEPERATION / LOW-FLOW CAVITATION. PRODUCT QUALITY DEGRADATION. EXCESSIVE HYDRAULIC THRUST. PREMATURE BEARING FAILURE. VIBRATION & NOISE HEATING OF LIQUID PUMPED.

IDEAL OPERATING ZONE

ONSET OF ADVERSE EFFECTS WHEN OPERATING AWAY FROM B.E.P

IDEAL OPERATING ZONE

OPERATIONTO TO THE RIGHT OF B.E.P PROBABLE PROBLEMS

SHAFT STRESS TORSION & BENDING COMBINED TORSIONAL & BENDING STRESSES OR SHAFT DEFLECTION IN SINGLE VOLUTE PUMPS MAY EXCEED PERMISSIBLE LIMITS. SHAFT DEFLECTION DUE TO HIGH THRUST VALUES SHAFT DEFLECTION IN SINGLE VOLUTE PUMPS MAY EXCEED PERMISSIBLE LIMITS.

NPSHr > NPSHa NPSH REQUIRED MAY BE IN EXCESS OF NPSH AVAILABLE FOR THE SYSTEM. EROSION, NOISE & VIBRATION EROSION DAMAGE, NOISE & VIBRATION MAY OCCUR DUE TO HIGH LIQUID VELOCITIES.

CONTROL POSSIBILITIES FOR CENTRIFUGAL PUMPS

THROTTLING

PUMP OUTPUT CAN BE CONTROLLED BY THE FOLLOWING METHODS

CONNECTION OR DISCONNECTION OF PUMPS - RUNNING IN PARALLEL - RUNNING IN SERIES BYPASS REGULATION AFFINITY LAW IMPELLER TRIM,SPEED REGULATION IMPELLER VANE & WIDTH ADJUSTMENTS PREROTATION CONTROL CAVITATION CONTROL

FIVE VANE IMPELLER

SIX VANE IMPELLER

AFFINITY LAWS
FOR A PARTICULAR PUMP THE HEAD DEVELOPED & THE DISCHARGE CAN BE CONTROLLED, WITHIN CERTAIN LIMITS, ACCORDING TO THE AFFINITY LAWS: WHEN ONLY IMPELLER DIA. CHANGES & SPEED REMAINS THE SAME WHEN ONLY SPEED CHANGES & IMPELLER DIA. REMAINS THE SAME WHEN BOTH DIA & SPEED CHANGE

Q2 = Q1 x (D2/D1)

Q2 = Q1 x (N2/N1)

Q2 = Q1 x (D2/D1) x (N2/N1)

H2 = H1 x (D2/D1)2

H2 = H1 x (N2/N1)2

H2 = H1 x { (D2/D1) x (N2/N1) }2

BKW2 = BKW1 x (D2/D1)3

BKW2 = BKW1 x (N2/N1)3

BKW2 = BKW1 x { (D2/D1) x(N2/N1)}3

Q1, H1, BKW1, D1 & N1 ARE CAPACITY, HEAD, INPUT POWER IN KW, IMPELLER DIA. & SPEED AT INITIAL CONDITION. Q2, H2, BKW2, D2 & N2 ARE CAPACITY, HEAD, INPUT POWER IN KW, IMPELLER DIA. & SPEED AT CHANGED CONDITION.

APPLICATION OF AFFINITY LAWS

ONE PUMP IS USED TO SERVICE DIFFERENT DUTIES REDUCING THE DIAMETER OF THE IMPELLER MAKES AN EXISTING PUMP RUN MORE EFFICIENTLY AT LOWER FLOWS WITHOUT THE NEED FOR THROTTLING.

SAME PUMP WITH A RANGE OF IMPELLER DIAMETERS TO MEET DIFFERENT DUTY H & Q.

SAME PUMP WITH DIFFERENT MOTOR SPEEDS THROUGH VSD TO ALLOW ONE PUMP TO BE USED OVER A MUCH WIDER RANGE OF DUTIES.

VIBRATION IN A CENTRIFUGAL PUMP

TYPICAL PUMP OR PUMP ELEMENT VIBRATIONS

PROBLEM RELATED TO SYSTEM

MISALIGNMENT BETWEEN PUMP & DRIVE

TYPES OF VIBRATION LATERAL SHAFT VIBRATION VIBRATION IN THE SYSTEM PUMP BASE PLATE

EXCITATION FROM THE DRIVE EXCITATION FROM COUPLING EXCITATION FROM THE COMPONENTS OF PIPING SYSTEM EXCESSIVE PIPING LOAD ON THE CASING (DISCHARGE PIPE-STRESS) INADEQUATE LEVELLING OF THE PUMP FOUDATION BOARD & PUMP-BASEPLATE LOOSE FOUNDATION POOR FLOW QUALITY IN THE SUMP/ UNFAVOURABLE PUMP INLET CONDITIONS (NPSH, INLET VORTICES, ETC.) WATER HAMMER

BEARING HOUSING VIBRATION

TYPICAL VIBRATION CHART FOR SPLIT-CASE PUMP

BETWEEN BEARING SINGLE OR MULTI-STAGE

VIBRATION - MM/SEC. RMS, UNFILTERED

INPUT POWER AT TEST CONDITIONS - KW

TYPICAL VIBRATION CHART FOR SPLIT-CASE PUMP

END-SUCTION FOOT-MOUNTED
INPUT POWER AT TEST CONDITIONS - KW

VIBRATION - MM/SEC. RMS, UNFILTERED

PROBABLE FAULT Air vapour lock in suction line

REMEDY Stop pump and re-prime

Inlet of suction pipe insufficiently submerged

Pump not up to rated speed

Ensure adequate supply of liquid

Increase speed

Air leaks in suction line or gland arrangement

Make good any leaks or repack gland

Clean foot valve or strainer

PUMP DOES NOT DELIVER RATED QUANTITY

Foot valve or suction strainer choked

Restriction in delivery pipe-work or pipe-work incorrect

Head underestimated

Clear obstruction or rectify error in pipe-work

Check head losses in delivery pipes, bends and valves, reduce losses as required

Unobserved leak in delivery

Blockage in impeller casing Excessive wear at neck rings or wearing plates Impeller damaged Pump gaskets leaking

Examine pipe-work and repair leak

Remove half casing and clear obstruction Dismantle pump and restore clearances to original dimensions Dismantle pump and renew impeller Renew defective gasket

PROBABLE FAULT Impeller rotating in wrong direction Reverse direction of rotation Stop pump and re prime Ensure adequate supply of liquid Make good any leaks or repack gland Increase speed

PUMP DOES NOT DELIVER LIQUID

Pump not properly primed air or vapour lock in suction line Inlet of suction pipe insufficiently submerged Air leaks in suction line or gland arrangement Pump not up to rated speed PROBABLE FAULT Impeller rotating in wrong direction

Reverse direction of rotation Increase speed Dismantle pump and restore clearances to original dimensions Dismantle pump and renew impeller or clear blockage Renew defective gaskets

PUMP DOES NOT GENERATE ITS RATED DELIVERY PRESSURE

Pump not up to rated speed Impeller neck rings worn excessively Impeller damaged or chocked Pump gaskets leaking

PROBABLE FAULT Suction line not fully primed air or vapour lock in suction line Stop pump and reprime Ensure adequate supply of liquid at suction pipe inlet Make good any leaks or renew gland packing Clean out liquid seal supply Unpack gland and locate logging ring under supply orifice

PUMP LOSES LIQUID AFTER STARTING

Inlet of suction pipe insufficiently submerged Air leaks in suction line or gland arrangement Liquid seal to gland arrangement logging ring (if fitted ) chocked Logging ring not properly located PROBABLE FAULT Air or vapour lock in suction Fault in driving unit

Stop pump and reprime Examine driving unit and make good any defects Make good any leaks or repack gland Ensure adequate supply of liquid at suction pipe inlet

IRREGULAR DELIVERY

Air leaks in suction line or gland arrangement Inlet of suction pipe insufficiently immersed in liquid

PROBABLE FAULT Air or vapour lock in suction line Inlet of suction pipe insufficiently submerged

REMEDY Stop pump and reprime Ensure adequate supply of liquid at suction pipe inlet Make good any leaks or repack gland Disconnect coupling and realign pump and driving unit

EXCESSIVE NOISE LEVEL

Air leaks in suction line or gland arrangement Worn or loose bearings

Rotating element shaft bent

Foundation not rigid

Dismantle pump, straighten or renew shaft

Dismantle pump and driving unit, strengthen foundation

PROBABLE FAULT Pump gaskets leaking Renew defective gasket Repair leak

PUMP OVERLOADS DRIVING UNIT

Serious leak in delivery line, pump delivering more than its rated quantity

Speed too high

Impeller neck rings worn excessively Gland packing too tight

Reduce Speed
Dismantle pump and restore clearances to original dimensions Stop pump, close delivery valve to relieve internal pressure on packing, slacken back the gland nuts and retighten to finger tightness Dismantle pump and renew impeller Dismantle pump, check internal clearances and adjust as necessary Disconnect pipe work and realign to pump

Impeller damaged Mechanical tightness of pump internal components Pipe work exerting strain on pump

PROBABLE FAULT

Pump and driving unit out of alignment

Oil level too low or too high

REMEDY Disconnect coupling and realign pump and driving unit Replenish with correct grade of oil or drain down to correct level

Wrong grade of oil

BEARING OVERHEATING
Dirt in bearing

Drain out bearing, flush through bearings; refill with correct grade of oil
Dismantle, clean out and flush through bearings; refill with correct grade of oil Drain out bearing, flush through and refill with correct grade of oil. Determine cause of contamination and rectify Ensure that bearings are correctly bedded to their journals with the correct amount of oil clearance. Renew bearings if necessary Clean out old grease and repack with correct grade and qty of grease Disconnect pipe work and realign to pump

Moisture in oil

Bearings too tight

Too much grease in bearing Pipe work exerting strain on pump

PROBABLE FAULT Air or vapour lock in suction Inlet of suction pipe insufficiently submerged Pump and driving unit incorrectly aligned Stop pump and reprime Ensure adequate supply of liquid at suction pipe inlet Decouple pump and driver, realign & check alignment after coupling. Dismantle pump and renew bearings Dismantle pump and clear or renew impeller Dismantle pump, straighten or renew shaft Remove pump, strengthen the foundation and reinstall pump Renew coupling Disconnect pipe work and realign to pump

EXCESSIVE VIBRATION

Worn or loose bearings Impeller chocked or damaged Rotating element shaft bent Foundation not rigid Coupling damaged Pipe work exerting strain on pump

PROBABLE FAULT Pump and driving unit out of alignment Rotating element shaft bent Disconnect coupling and realign pump and driving unit. Renew bearings if necessary Dismantle pump, straighten or renew shaft. Renew bearings if necessary Ensure that only clean oil is used to lubricate bearings. Renew bearings if necessary. Refill with clean oil

BEARING WEAR

Dirt in bearings

Lack of lubrication

Ensure that oil is maintained at its correct level or that oil system is functioning correctly. Renew bearings if necessary
Ensure that bearings are correctly bedded to their journals with the correct amount of oil clearance. Renew bearings if necessary Ensure that pipe work is correctly aligned to pump. Renew bearings if necessary Refer excessive vibration

Bearing badly installed

Pipe work exerting strain on pump Excessive vibration

Symptom CV As per pump curve Open valve Q1 <Q, H1> H Q1, H1 on pump curve

Diagnosis Changed system condition blockage pipe friction, filters, strainers, etc

Symptom CV As per pump curve Open valve Q1 <Q, H1> H

Diagnosis Pump fault Blockage in impeller, increased leakage loss

Symptom

Diagnosis

CV As per pump curve Open valve Head lower in vicinity of the system curve. Sudden break down of H-Q

Insufficient NPSH leading to cavitation breakdown

Symptom

Diagnosis

CV Lower than pump Incorrect speed curve Incorrect diameter Lower Q, Lower H of impeller Wrong direction of rotation

TROUBLE SHOOTING SYMTOMPS COMMON CAUSES

PUMP NOT PRIMED

REMEDY
FILL THE PUMP & SUCTION LINE COMPLETELY WITH LIQUID REMOVE AIR/GAS ELIMINATE HIGH POINTS IN SUCTION PIPING CHECK FOR FAULY FOOT VALVE, CHECK VALVE INSTALLATION

AIR-POCKET IN SUCTION LINE

NO DELIVERY OR DELIVERY NOT UPTO THE EXPECTATION

CHECK FOR GAS, AIR IN SYSTEM/SUCTION LINE INSTALL GAS SEPERATION CHAMBER CHECK FOR AIR-LEAKAGE OPEN AIR-VENT VALVE IF ANY LOWER SUCTION PIPE OR RAISE SUMP WATER LEVEL CORRECT SPPED, CHECK RECORDS FOR PROPER SPEED CHECK ROTATION WITH ARROW ON CASING REVERSE POLARITY ON MOTOR CHECK IMPELLER

INSUFFICIENT IMMERSION OF SUCTION PIPE, VORTEXING SPEED OF PUMP TOO LOW OR WRONG DIRECTION OF ROTATION

SYSTEM HEAD HIGHER THAN PUMP DESIGN HEAD

DECREASE SYSTEM RESISTANCE CHECK DESIGN PARAMETERS INCREASE PUMP SPEED INSTALL PROPER SIZE PUMP

TROUBLE SHOOTING SYMTOMPS COMMON CAUSES

WRONG IMPELLER SELECTION WRONG IMPELLER INSTALLATION

REMEDY
VERIFY PROPER IMPELLER SIZE CHECK IF THE IMPELLER IS INSTALLED BACKWARD(DOUBLE SUCTION PUMP) CHECK FOR GAS, AIR IN SYSTEM/SUCTION LINE INSTALL GAS SEPERATION CHAMBER CHECK FOR AIR-LEAKAGE OPEN AIR-VENT VALVE IF ANY CORRECT SPPED, CHECK RECORDS FOR PROPER SPEED CHECK ROTATION WITH ARROW ON CASING - REVERSE POLARITY ON MOTOR CHECK IMPELLER CHECK FOR DAMAGE & CLEAN

AIR-GAS ENTRAINMENT IN LIQUID

INSUFFICIENT DISCHARGE PRESSURE

SPEED OF PUMP TOO LOW OR WRONG DIRECTION OF ROTATION

IMPELLER CLOGGED

IMPROPER PUMP SELECTION

DECREASE SYSTEM RESISTANCE CHECK DESIGN PARAMETERS INCREASE PUMP SPEED INSTALL PROPER SIZE PUMP

TROUBLE SHOOTING SYMTOMPS COMMON CAUSES

MISALIGNMENT

REMEDY
CHECK ANGULAR & PRALLEL ALIGNMENT BETWEEN PUMP & DRIVER ELIMINATE STILT-MOUNTED BASE-PLATE CHECK FOR LOOSE MOUNTING CHECK FOR UNUNIFORM THERMAL EXPANSION OF PUMP PARTS

BENT SHAFT

CHECK TIR AT IMPELLER END (SHOULD NOT EXCEED 0.002) REPLACE SHAFT OR BEARING IF NECESSARY CHECK ORIENTATION OF BEARING ADAPTER CHECK FOR PIPE ALIGNMENT & ANALYZE PIPE LOADS & SUPPORTS CHECK FOR NPSHa/NPSHr MARGIN & TAKE NECESSARY STEPS CHECK FOR FLASH POINT MARGIN CHECK FOR GAS ENTRAINMENT INSTALL PROPER SEAL THAT SUITS PUMP OPERATING CONDITIONS RUN DRIVER DISCONNECTED FROM PUMP UNIT - PERFORM VIBRATION ANALYSIS

SHORT SEAL LIFE

CASING DISTORSION DUE TO PIPE STRAIN

PUMP CAVITATING

IMPROPER OPERATING CONDITION

UNBALANCE DRIVER

TROUBLE SHOOTING SYMTOMPS COMMON CAUSES

BEARING FAILURES

REMEDY
CHECK FOR PROPER LUBRICATION & CONTAMINATION OF LUBRICANT CHECK FOR PROPER BEARING INSTALLATION CHECK FOR THE SUITABILITY OF BEARING SELECTED CHECK ANGULAR & PRALLEL ALIGNMENT BETWEEN PUMP & DRIVER ELIMINATE STILT-MOUNTED BASE-PLATE CHECK FOR LOOSE MOUNTING CHECK FOR UNUNIFORM THERMAL EXPANSION OF PUMP PARTS CHECK TIR AT IMPELLER END (SHOULD NOT EXCEED 0.002) REPLACE SHAFT OR BEARING IF NECESSARY CHECK ORIENTATION OF BEARING ADAPTER CHECK FOR PIPE ALIGNMENT & ANALYZE PIPE LOADS & SUPPORTS CHECK FOR NPSHa/NPSHr MARGIN & TAKE NECESSARY STEPS CHECK FOR FLASH POINT MARGIN CHECK FOR GAS ENTRAINMENT RUN DRIVER DISCONNECTED FROM PUMP UNIT - PERFORM VIBRATION ANALYSIS

MISALIGNMENT

SHORT BEARING LIFE

BENT SHAFT

CASING DISTORSION DUE TO PIPE STRAIN

PUMP CAVITATING

UNBALANCE DRIVER

TROUBLE SHOOTING SYMTOMPS COMMON CAUSES

MOTOR TRIPPING-OFF

REMEDY
CHECK STARTER CHECK RELAY SETTING CHECK FOR THE SUITABILITY OF MOTOR SELECTED FOR CURRENT OPERAING CONDITION CHECK FOR SPEED OR PREVIOUS RECORDS FOR PROPER SPEED ELIMINATE STILT-MOUNTED BASE-PLATE CHECK FOR LOOSE MOUNTING CHECK FOR UNUNIFORM THERMAL EXPANSION OF PUMP PARTS LOOSE IMPELLER FIT WRONG ROTATION REPLCE IF SHAFT IS BENT HIGH NOZZLE LOADS VERY SMALL INTERNAL RUNNING CLEARANCES CHECK FOR NECK RING DIMENSIONS CHECK DESIGN SP. GRAVITY CHECK MOTOR SIZE USE LARGER DRIVER OR CHANGE PUMP TYPE HEAT UP THE LIQUID TO REDUCE VISCOSITY CHECK FOR PROPER LUBRICATION & CONTAMINATION OF LUBRICANT CHECK FOR PROPER BEARING INSTALLATION CHECK FOR THE SUITABILITY OF BEARING SELECTED CHECK COUPLING SIZE

SPEED TOO HIGH

EXCESSIVE POWER DEMAND

ROTOR IMPELLER RUBBING ON CASING

PUMP NOT DESIGNED FOR LIQUID DENSITY & VISCOSITY BEING PUMPED

BEARING FAILURES

IMPROPER COUPLING SELECTION

TROUBLE SHOOTING SYMTOMPS COMMON CAUSES

PUMP IS CAVITATING

REMEDY
CHECK FOR NPSHa/NPSHr MARGIN & TAKE NECESSARY STEPS CHECK FOR FLASH POINT MARGIN CHECK FOR GAS ENTRAINMENT CHECK FOR VALVE CONDITION OPEN THE VALVES

SUCTION OR DISCHARGE VALVE CLOSED OR PARTIALLY CLOSED

MISALIGNMENT

NOISE & VIBRATION

INADEQUATE GROUTING OF BASE PLATE

CHECK ANGULAR & PRALLEL ALIGNMENT BETWEEN PUMP & DRIVER ELIMINATE STILT-MOUNTED BASE-PLATE CHECK FOR LOOSE MOUNTING CHECK FOR UNUNIFORM THERMAL EXPANSION OF PUMP PARTS CHECK GROUTING, CONSULT PROCESS INDUSTRY PRACTICE RE-IE-686 IF STILT MOUNTED, GROUT BASEPLATE

BEARING FAILURES

CHECK FOR PROPER LUBRICATION & CONTAMINATION OF LUBRICANT CHECK FOR PROPER BEARING INSTALLATION CHECK FOR THE SUITABILITY OF BEARING SELECTED

IMPROPER COUPLING SELECTION

CHECK COUPLING SIZE, GRAESING , ALIGNMENT