Lab Work: Turbine Technologies, LTD., 410 Phillips Street, Chetek, WI, 54728 USA

Understanding
Centrifugal Pumping
BOOK
Turbine Technologies, Ltd., 410 Phillips Street, Chetek, WI, 54728 USA.
Phone: 715-924-4876, Fax: 715-924-2436, www.turbinetechnologies.com
2
Lab Work
2
UNDERSTANDING CENTRIFUGAL PUMPING
Copyright 2013 by Turbine Technologies, Ltd.
BOOK 2: Understanding Centrifugal Pumping - Lab Work
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UNDERSTANDING CENTRIF UNDERSTANDING CENTRIFUUGAL P GAL PUMPPING
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Copyright 2013 by Turbine Technologies, Ltd. Copyright 2013 by Turbine Technologies, Ltd.
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INTRODUCTION
Upon completion of this book, the student will have solid, hands-on experience running a centrifugal pump-
ing system. Te pump system will be thoroughly introduced, including all components that make up the actual
pumping machinery, its integrated data acquisition system and virtual instrument panel. From there, operating
the pump system will allow the student to experience and study important performance parameters such as; Total
Dynamic Head (TDH), System Curve, Net Positive Suction Head (NPSH), Capacity Curve, Brake Horsepower,
and Efciency. Tis training will provide knowledge and confdence for a student who eventually works in a fuid
processing environment as a part of their career.
Turbine Technologies, Ltd., LabVIEW, National Instruments are trademarks of respective systems and equipment used in equipment
manufactured by Turbine Technologies, Ltd.
All rights reserved. No part of this lesson series may be reproduced, translated or transmitted in any form or by any means without
the permission of Turbine Technologies, Ltd.
Turbine Technologies, Ltd., 410 Phillips Street, Chetek, WI, 54728 USA.
Phone: 715-924-4876, Fax: 715-924-2436, www.turbinetechnologies.com
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UNDERSTANDING CENTRIF UNDERSTANDING CENTRIFUGAL P GAL PUUMMPPING ING
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TABLE OF CONTENTS
Book 2: Understanding Centrifugal Pumping - Lab Work
Lesson 1: PumpLab System Orientation...................................................................................................4
Focus 1: Reservoir
Focus 2: Piping
Focus 3: Sensors
Focus 4: Pump
Focus 5: Other Components
Knowledge Certication Quiz: Lesson 1
Lesson 2: Data Acquisition Orientation......................................................................................................12
Focus 1: Starting up the Data Computer
Focus 2: Tour of Virtual Instrument Panel
Lesson 3: Data Gathering ............................................................................................................................. 20
Focus 1: Total Dynamic Head (TDH) (AKA Pump Curve)
Focus 2: System Curve
Focus 3: Net Positive Suction Head (NPSH)
Lesson 4: Plotting Your Data ....................................................................................................................... 38

Lesson 5: Developing the Pump Performance Curves ........................................................................... 42
Focus 1: Graph Head - Capacity Curve
Focus 2: Graph Break Horsepower (bHp)
Focus 3: Graph Efciency
Focus 4: Graph Net Positive Suction Head
Lesson 6: Applying Pump Performance Curves ....................................................................................... 55
Focus 1: Baseline Calculation
Focus 2: On The Job Scenario
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Lesson 1: PumpLab System Orientation
Te goal of this lesson is to familiarize the operator with all the features of the PumpLab, to start it up and run it to
gain a basic understanding of what to expect when operating the system to run your lab lessons.
Figure 1.1.1: PumpLab System Features
Approximate Lesson
Duration: 25 min.
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Clear View Flow Circuit: Te see-through piping and pump
circuit which allow operators to see what is happening inside a
fow system.
Action: Trace the see-through fow circuit, starting from the
intake pipe located inside the tank, going through the lower
piping section above the cabinet into the volute (center of the
impeller), then out of the volute exit, across the top piping section
of the unit all the way back to the tank. Notice the square block
section on the lower level; this provides better optics to see what
is going on in that part of the fow circuit. Its primary purpose is
to show the phenomenon of cavitation clearly (cavitation is a
major topic which will be covered). Also note that the intake pipe in the tank can be likened to a straw when drinking liquid
from a glass. Tis intake pipe features a check valve at the bottom of the pipe that allows fuid to be pulled up through it (just
like sucking on a straw), but will not allow the fuid to fow backwards once the sucking action ceases. Tis allows the inlet
piping to remain primed (which will be discussed in the Prime Pump section).
Focus 1: Reservoir
Fluid Tank: Fluid reservoir for system-holds 15 gallons of water. System is recirculating,
so water leaves tank, fows through system and returns to tank.
Action: Locate tank and note water level. Now, compare water level to center of pump
inlet. Notice water level is approximately 12 inches (300mm) lower than the pump inlet.
Tis is referred to as a negative head pressure (the water weight isnt above pump where it
can use gravity to help it fall into the pump), so it needs to be sucked into the pump, just
like sucking a drink (positioned below our mouth) through a straw. Its a similar scenario
to our PumpLab; the liquid level in the tank (drinking glass) is lower than the pump
entrance (our mouth).
System Item Descriptions
Locate each item on the PumpLab and perform the action that is indicated. Be sure you understand how each
individual function works before you move on to the next.
Focus 2: Piping
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Inlet Valve: Allows control of the amount of water that can fow into the pump.
Action: Locate inlet valve (blue body on lower pipe section). Turn handle on top of valve
clock-wise. Notice body of valve lowers across the cross-section of the pipe, essentially
closing it of. Reversing this action slowly opens it up.
Outlet Valve: Allows control of the amount of water that fows out of the pump.
Action: Locate outlet valve (black handled valve on upper pipe section). Just like inlet
valve, turning valve handle clock-wise closes valve body, counter clock-wise opens it.
Focus 3: Sensors
Inlet Pressure Sensor: Senses the inlet pressure of the water fowing into the pump.
Action: Locate inlet pressure sensor in the inlet piping circuit in the square view section
of the inlet tubing. Note its position and follow its signal wire back into where it enters the
cabinet.
Outlet Pressure Sensor: Senses the outlet pressure of the water fowing out of the pump.
Action: Locate outlet pressure sensor in the outlet piping circuit above the pump volute.
Note its position and follow its signal wire back into where it enters the cabinet.
Flow Rotometer: A highly visual fow sensor that allows operator to actually see Flowrate,
while the sensor sends a fow signal to the data acquisition system.
Action: Locate the fow rotometer on the top section of piping. Notice the impeller inside.
Tis impeller is forced to spin as water starts fowing against it. Little magnets on the tips of
these impeller blades go past an embedded sensor called a hall-efect sensor (located at the
bottom of the housing). Te hall-efect sensor is energized by the magnet in the impeller
blade tip and reads that magnet passing by as a pulse. Tere are three evenly spaced
magnets in the impeller. Te system is calibrated against time to indicate how much fow
we have by how many pulses we record over a given period of time.
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Focus 4: Pump
Pump Casing (Volute): Tis is the see-through body of the pump which houses the
impeller. Te volute is internally shaped to provide proper pump fow capability.
Action: Locate Volute. Notice black C-shaped clamps around the volute. Tese can be
removed to allow impeller to be exchanged. Notice Vent screw on top of volute. Tis is
opened to allow air to escape out of volute when priming the system (see changing pump
impeller instructions in operators manual). Notice piping inlet which enters volute at the
center of impeller location. Notice piping outlet which is at the top of volute.
Pump Impeller: Tis is the heart of the pump. Te impeller spins, imparting energy to the
water and finging it out of the system. Te ridges on the face of each impeller are called
vanes and they are what grab the water and fing it. Vanes can be confgured for diferent
operation.
Action: Locate impeller in the volute. Also, locate the replacement impellers that are in the
storage area in the cabinet. Notice that the red impeller has straight vanes, black has forward
swept and gold has rearward swept vanes. Also notice the gold impeller has some mini-
vanes called splitter vanes. When the impeller is mounted in the volute, notice the spacing
around impeller gradually gets larger as fow gets closer to the outlet of the volute.
Pump Impeller Spinner Tool: Located in the PumpLab Cabinet Accessory Section, the
tool is used to help remove the impeller spinner which holds the impeller into the drive
shaf.
Action: Locate Pump Impeller Spinner Tool in accessory section. Refer to Changing Pump
Impeller section of Operators Manual on how to use it.
Drive Motor: Electric Motor which drives the pump impeller. It is a 3 phase industrial
rated electric motor that is powered by a single phase 208V controller.
Action: Locate the electric drive motor which is located behind the pump volute.
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Focus 5: Other Components
Lockable Casters: Tis allows unit to be rolled around and then locked in place so it doesnt
roll away during operation.
Action: Unlock all casters and roll unit to get a feel for its movement. Make sure power to
unit is unplugged before moving and be sure unit is clear of other close proximity equipment
to avoid bumping into it. Lock the casters to get the feel for how to do it.
MASTER Power Switch: Tis keyed switch activates the electric power to run the system.
Te key is turned clock-wise for ON, counter-clockwise for OFF. Te key can be
removed to prevent unauthorized system operation. PRIME Switch: Tis two position
switch operates the Prime Pump. A green indicator light will glow when the switch is
fipped up into its ON position.
Action: Locate the keyed switch and PRIME Switch in the control panel section of the
cabinet right below the pump volute. Do not activate it at this time.
PRIME Pump and PRIME/DRAIN Valve: Because the reservoir tank (and its water level)
is lower than the pump location, the system must be primed (flled with water) with the
on-board primer pump. Te PRIME/DRAIN Valve is a 2 position valve (located in the
cabinet accessory section) that can be positioned to either allow the primer pump to fll the
inlet fow circuit with water or to pump the water out of the tank before the unit is placed
into long-term storage. A PRIME/DRAIN Valve Wrench (located in the cabinet accessory
section) is used to position this valve for either function.
Action: If volute and inlet piping are flled with water, drain the circuit by opening Volute
Vent (threaded shaf with knurled knob; unscrew counter-clockwise) on top of volute to
allow pressure to equalize in the system with atmospheric pressure, which allows the inlet
piping circuit water to fow back into the tank. Allow all the water in the inlet circuit to drain
back into the tank. Check PRIME/DRAIN Valve position by inserting PRIME/DRAIN
Valve Wrench into PRIME/DRAIN Valve and turning counter-clock-wise to be sure it is in
the priming position. Turn PumpLab MASTER Power Switch ON. Turn PRIME Pump
On/Of Switch ON. Observe the piping coming from the tank. Water should start to rise
from the tank through the inlet tube. As the water level in the volute starts to approach the
top of it, start screwing in the vent screw on top of the volute to seal the system and then
shut of the PRIME Power Switch. Be prepared to get this done quickly, otherwise you will
start pumping water out of the vent hole.
DRAIN FITTING: Provides a hose connection to allow system to be drained for water
change-out or for long-term storage. It is located in the cabinet accessories section.
Action: Connect the system drain hose to the DRAIN FITTING by inserting hose into
ftting. Find a bucket that you can put the drain hose into for water capture. Insert the
PRIME/DRAIN Valve Wrench onto PRIME/DRAIN Valve and turn clock-wise. Tis
positions the valve to allow water to fow out the DRAIN FITTING when the PRIME PUMP
is turned ON. Turn on MASTER Power Switch. Ten turn on PRIME Power Switch. Water
should start fowing through hose into bucket. Once it does, turn of PRIME Power Switch,
remove hose by pushing the button on top of the ftting and close PRIME/DRAIN Valve by
turning PRIME/DRAIN Valve Wrench counter-clockwise.
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Pump Control Key Pad: Provides primary speed and programming controls for the Pump
Drive Motor.
Action: Verify that the system is primed by checking to see that the inlet piping and volute
are full of water. Verify Inlet and Outlet valves are open. Ten turn MASTER Power Switch
to the ON position. Te Pump Control Key Pad will also light up. Tere is plenty to study
regarding all the functionality of the key pad. However, the primary purpose of this keypad
is to control an on-board variable frequency drive which controls the speed of the pump
through a range of 0-1800 RPM. Press the LOCAL/REMOTE button to clear pad for local
operation. Press the FWD button (forward) on the pad and then press the up indicator
arrow. Te motor will start to ramp up in speed the longer this button is held in. Te unit
will accelerate all the way to approximately 1800 RPM if the button is continuously held in.
Te variable frequency drive will allow you to run the motor speed at any point desired in
the speed range. Pressing the up and down arrows demonstrate the ability of speed to be
manually increased or decreased. Press the down arrow to reduce speed until it comes to a
stop. Ten press the Stop button to initiate the stop.
Strobe Light: Allows operator to view boundary layer of impeller during operation,
especially during cavitation.
Action: Plug in strobe light into power plug outlet located on side of PumpLab cabinet.
Turn MASTER Power Switch ON. Press FWD on Pump Control Key Pad. Push up arrow
indicator and bring unit speed up to its maximum level (approximately 1780 RPM). Start
closing Inlet Valve by turning handle on top of valve in a counter-clockwise direction. As
valve slowly starts closing of the inlet piping, vapor bubbles will start to form at the bottom
of the valve, which will get stronger and more intense as the valve closes. Aim the strobe
light at the pump impeller and adjust the strobe speed so that the impeller vanes can be
seen standing still. Observe the air vapor bubbles around the vanes. Continue to close
the inlet valve and observe the conditions change in the impeller. Now, start opening Inlet
Valve and observe the conditions around the impeller vanes change. Continue opening
the Inlet Valve until fully opened. Press downward arrow on Pump Control Key Pad until
RPM is stopped. Press Stop button.
Data Display/Record Computer: Computer with a virtual
instrument panel which displays all the major data points of the
PumpLab, records all operational data and enables computer
control of the PumpLab System.
Action: Go to System Orientation Part 2: Overview of PumpLab
Virtual Instrument Panel afer taking section quiz.
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Without referring to your notes, place the description number near component in the picture for the following:
1. Volute Vent
2. Pump Impeller (and alternates)
3. Pump Impeller Spinner Tool
4. Drive Motor
5. Fluid Tank
6. Clear View Flow Circuit
7. Inlet Valve
8. Outlet Valve
9. Inlet Pressure Sensor
10. Outlet Pressure Sensor
11. Flow Rotometer
12. Lockable Casters
13. MASTER Power Switch
14. PRIME Pump Switch
15. PRIME/DRAIN Valve
16. DRAIN FITTING
17. Drain Hose
18. Pump Control Key Pad
19. Strobe Light
20. Lockable Casters
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Briefy defne each element:
Pump Casing (Volute)_____________________________________________________________
Volute Vent _____________________________________________________________________
Pump Impeller (and alternates)______________________________________________________
Pump Impeller Spinner Tool ________________________________________________________
Drive Motor _____________________________________________________________________
Fluid Tank ______________________________________________________________________
Clear View Flow Circuit ____________________________________________________________
Inlet Valve _______________________________________________________________________
Outlet Valve _____________________________________________________________________
Inlet Pressure Sensor ______________________________________________________________
Outlet Pressure Sensor _____________________________________________________________
Flow Rotometer __________________________________________________________________
MASTER Power Switch ____________________________________________________________
PRIME Pump Switch ______________________________________________________________
PRIME/DRAIN Valve _____________________________________________________________
DRAIN FITTING ________________________________________________________________
Drain Hose ______________________________________________________________________
Pump Control Key Pad _____________________________________________________________
I certify that I have answered all certifcation quiz questions correctly and am ready for the next section.
____________________________________ _____________________________
Your Signature Date
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Lesson 2: Data Acquisition Orientation
Te goal of this lesson is to familiarize the operator with all the details of the PumpLab Virtual Instrument Panel
(VI), locate and understand basic components of the sofware and to gain a better understanding of this system.
Focus 1: Starting Up the Data Computer
Verify that data computer is connected via USB cable to the USB outlet on the PumpLab.
With the PumpLab OFF, turn the computer ON and let it fully boot up.
Turn ON PumpLab MASTER Power Switch. Give it a few seconds to get itself set.
Double Click PumpLab Icon on computer home screen to load the PumpLab Virtual Instrument Panel.
Te system is now ready to use.
IF THIS PROCEDURE WAS NOT FOLLOWED, power down computer and PumpLab, and retry.
Focus 2: Tour of Virtual Instrument Panel
Lets tour the VI so that you become familiar with its operation for the PumpLab portion of the system. Please keep in mind
that PumpLab also has another major capability called Process Control. Tis will be covered in a future educational module.
With the VI up and running, click Connect which connects the data computer to the PumpLab. Ten click Pump Lab button
to put the unit into Pump Lab Mode. Te Process Control button will be used in another educational module and will not
be used for this training session. Te Exit Application button is used when the work with the system is completed and the
connection for that session is to be ended.
Figure 2.1.1: PumpLab Virtual Instrument Panel (VI)
Approximate Lesson
Duration: 30 min.
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In the upper lef of the screen, a pump system schematic shows real time values for the following:
Inlet Pressure (Pin)
Outlet Pressure (Pout)
Flow
Speed: RPM of the Pump
Torque: Torque value of motor needed to drive the pump at that specifc setting.
Power: Power required to drive the motor/pump at that specifc setting.
In the upper middle portion of the screen, the following appears:
Start DAQ: Pressing this button will start displaying PumpLab operational data on the screen and start recording it so that
you can save it when youre done recording. Te primary data display elements listed above are displayed in real time as well as
graphical representations (discussed below).
Log Data: Tis button is used when you want to see your Logged Data graph accumulate the data for the full run (so you can see
it) verses the data streaming by and of the screen.
Map Point: Tis is used to save specifc data points during the run as a means a real time controlled data plotting. Tis will tie
to the Map View discussed below.
Units: Tis allows operator to change the units on the values from English to SI.
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On the center right of the panel, the Pump Lab remote motor control resides. Tis allows you to control pump motor speed
right from the computer screen rather from the control key pad that resides on the unit.
Te Pump Lab tab should be clicked to be in the right mode. (Process Control should not be used).
Te Motor Speed Command can adjust the motor speed 2 diferent ways;
1. Press the curser on the graphical slider and drag it to the desired speed, or
2. Arrow up or down the digital speed window shown below the slider.
Te Run Motor button can then be pressed to start the motor running. Note: It is best if a low (or no) speed is selected on the
slider/speed window before turning motor on to avoid a quick ramp up of the motor.
Te Stop Motor button is pressed to stop the motor.
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1. Logged Data Tab
In this view, a running line graph of data
flls in as time advances. Te elements
graphed are:
Inlet Pressure (Pin)
Outlet Pressure (Pout)
Flow
Speed (RPM)
Torque
Te line color representation is shown
for each element around the border
of the graph. Te Write Data to File
button enables data accumulated
during the run to be saved for later
analysis. Te Clear Plot button clears
the screen of the accumulated data so
that a new plot can be initiated.
Te bottom lef of the screen houses the live graphical section of the PumpLab. Te primary elements of the system are
graphed in real time to give the operator a good idea of how each element works with and afects the other. Tere are three
diferent views that can be used.
2. Map View Tab
In this view, the operator has the ability
to capture Power and Pressure verses
Flow data points as time moves along.
Floating target points, which represent
the specifc data point at that specifc
time, allow the operator to Map these
specifc data points at whatever point
of time is desired. Tis enables the
operator to build trend graphs with the
plotted data points. Tese trend graphs
give a good view of how conditions are
changing without requiring a constant
barrage of data, which makes things
much cleaner. Te data is also being
recorded and can be saved using the
Write Data to File button for later
analysis.
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3. Graph View Tab
In this view, a running line graph
progresses across the screen displaying
Speed, Torque, Pressure and Flow
while the time function moves along
with it. Tis allows the real time
progress of each data element to be
seen (which gives another point of
reference to the Logged Data Tab
which accumulates the data and
compresses the time axis when in Log
Data mode).
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Action: Start the PumpLab System, plot and capture some data.
1. Use Connect button to establish connection to PumpLab.
2. Verify Units are being displayed and saved in English units.
3. Click Run Motor button.
4. Click the Start DAQ button to start logging data. Green indicator bar should be lit.
5. Use Motor Speed Command to bring motor speed to 1500 RPM.
6. Click on the Logged Data Screen tab. Notice values of each data measurement item. Click on Log Data if
you want to see data accumulate on this screen.
7. Click on the Map View Screen tab. Notice the target points. Click the Map Point button. Notice the
original target points are mapped, while new foating target points are tracking the current conditions.
8. Click on the Graph View screen tab. Notice data is tracking past on a timeline that fows rather than
bunches up like the Logged Data screen when in Log Data (button) mode.
9. Use Motor Speed Command to increase motor speed to 1600 RPM.
10. Repeat steps 6, 7 and 8. Note the changes.
11. Use Motor Speed Command to increase motor speed to 1700 RPM.
12. Repeat steps 6, 7 and 8. Again, note the changes.
13. Click Write Data to File. Tis saves your logged data as a fle that can be looked at later. Follow on screen
directions for saving the data fle and save it to a known fle folder.
14. Click Clear Plot. Notice all data screens are now cleared and data gathering and display starts over
(check each screen to verify). It will not clear Graph View.
15. Click Start DAQ button to shut of data gathering. Green indicator bar should be unlit.
16. Use Motor Speed Command to lower motor speed to 0 RPM.
17. Click Stop Motor.
18. Click Exit Application to end the use of the VI.
19. Turn MASTER power switch of on the PumpLab.
20. Find and open the data fle that was saved during the run. Export it to a spreadsheet program such as
MS-Excel and graph the data for use later. Data conversion and graphing instructions are included in
a following section.
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Only referring to the picture on page 19, please answer the following questions about the VI;
1. When starting the VI, do you turn the computer on before you turn on the PumpLab?
Why?
2. Which button gives permission for the VI to talk with PumpLab?
3. Which mode should the unit be in; Pump Lab or Process Control?
4. Which data items are displayed as numerical readouts?
5. Which data items are displayed as graphical readouts?
6. List 2 ways to control motor speed from the VI.
7. Is it the right process to set a high motor RPM and then hit the Run Motor button?
Why?
8. What units besides English can PumpLab display data as?
10. What does the Start DAQ button do?
11. What does the Log Data button do?
12. Describe what mapping a point with Map Point accomplishes.
13. Describe what is happening in the Logged Data graph.
14. Describe what is happening in the Map View graph.
15. What does Graph View accomplish for us?
16. If we want to save our data that we just gathered to a fle we can retrieve later, what do we do?
17. Describe the best way to stop the motor afer data gathering is through.
18. When youre done using the VI, which button do you press to indicate this?
19. When you save a data fle, what is one good way to get the data in a useful format for analysis?
I certify that I have answered all certifcation quiz questions correctly and am ready for the next section.
____________________________________ _____________________________
Your Signature Date
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