Chapter one

Introduction to pump
Pump Definition:
 A pump is a device that is used for lifting the liquid from ground sources to the upper top surface or from
one place to another place.
 Pumps are operated by the mechanism that is rotary, reciprocating and it consumes energy while
performing mechanical work which is moving fluid from one place to another.
 This can be operated by many energy resources which include manual operation, electricity, engine, wind
power and many more, day to day lives to industrial applications.
 Pumps could be used for different kinds of activities.
 The location of the pump station and intake structure, and the anticipated heads and capacities are the
major factors in the selection of pumps.
Types of pump
The selection of type and construction of a pump is very important to meet the process specification and
proper application. Knowledge of the variety of pumps in the market should be reviewed and understood.
A pump can broadly be classified into two categories, and those are:
 Positive Displacement Pump
 Dynamic Pump
Positive Displacement Pumps
 Positive displacement pumps work by allowing a fluid to flow into some enclosed cavity from a low-
pressure source, trapping the fluid, and then forcing it out into a high-pressure receiver by decreasing the
volume of the cavity. This is done intermittently in the case of reciprocating pumps and continuously in
the case of rotary gear and screw pumps. Some examples of PD pumps are: fuel and oil pumps in most
automobiles, the pumps on most hydraulic systems.
Two general types of the positive displacement pumps are as below:
1. Rotary Pump
2. Reciprocating Pump
Rotary Pump
o Rotary pumps function with close clearances such that a fixed volume of liquid is displaced with each
revolution of the internal element. Rotary pumps include:
 Single Rotor Pump (For example, Piston Pump, Vane Pump, Screw Pump)
 Multiple Rotor Pump (For example, Gear pump, Lube pump)
 Rotary vane pumps 
o Rotary-vane pumps are positive displacement machines capable of handling lubricating and other low-
viscosity fluids in low to medium volumes at low pressures and, in some applications, relatively viscous
fluids.
o A rotary vane pump is a positive-displacement pump that consists of vanes mounted to a rotor that rotates
inside a cavity. In some cases these vanes can have variable length and/or be tensioned to maintain
contact with the walls as the pump rotates.
How to Work Vane Pumps
o A slotted rotor is eccentrically supported in a cyclonical cam.  The rotor is located close to the wall of the
cam so a crescent-shaped cavity is formed.  The rotor is sealed into the cam by two side plates. Vanes or
blades fit within the slots of the impeller.  As the rotor rotates and fluid enters the pump, centrifugal force,
hydraulic pressure, and/or pushrods push the vanes to the walls of the housing.  The tight seal among the
vanes, rotor, cam, and side plate is the key to the good suction characteristics common to the vane
pumping principle. The housing and cam force fluid into the pumping chamber through holes in the cam. 
Fluid enters the pockets created by the vanes, rotor, cam, and side plate.
As the rotor continues around, the vanes sweep the fluid to the opposite side of the crescent where it is
squeezed through discharge holes of the cam as the vane approaches the point of the crescent.  Fluid then
exits the discharge port.
Advantage
 Little metal to metal contact
 Ease of maintenance
 Good suction/ vacuum capabilities
 Performance less affected by suction head
 Dry run for short period of time
 Can have one seal or stuffing box
 Develops good vacuum
Disadvantages

 Can have two stuffing boxes

 Complex housing and many parts
 Not suitable for high pressures
 Not suitable for high viscosity
 Not good with abrasives

Applications

o Vane pumps are commonly used as high-pressure hydraulic pumps and in automobiles,

including supercharging, power-steering, air conditioning, and automatic-transmission pumps. Pumps for
mid-range pressures include applications such as carbonators for fountain soft-drink dispensers and
 espresso coffee machines. Furthermore, vane pumps can be used in low-pressure gas applications such
as secondary air injection for auto exhaust emission control, or in low-pressure chemical vapor
deposition systems.
o Rotary vane pumps are a popular and efficient solution for the transfer of clean, low medium viscosity
fluids and fuels at a range of temperatures and relatively low pressures. Rotary vane pumps are a
particularly good choice for the following application.
o Aviation Service Fuel and light oil transfer, Deicing
o Auto Industry - Fuels, Lubes, Refrigeration Coolants
o Gasoline/petroleum
o Bulk Transfer of LPG gas/propane
o Chemical handling
o Alcohol and solvents
o High temperature fluid
o Liquefied gases

Screw Pump
o Screw Pump is a type of Positive displacement rotary Pump. The screws are encased inside of a liner,
usually made of some sort of metal. The fluid fits into the screw cavities within this liner and is forced
through the pump and out of the discharge as the screws rotate and inter-mesh. Screw pumps belong to
the family of dry compressing gas transfer pumps. 
Working Principle of Screw Pump
o Screw pumps operate using two counter-rotating screw rotors which are engineered so that they rotate
“towards each other”. This traps the gas in the space between the “screws” of their rotors. As the screws
rotate, this trapped volume decreases which not only compresses the gas but moves it towards the
exhaust. In the first cases mechanical bearings support the rotors at both ends. The cantilever design
solution supports the rotors at the high pressure end and the rotors can be cooled internally.  A motor
drives the two rotors via a gear. Gear and the bearings are lubricated but separated from the pumping
mechanism ('vacuum generator') via shaft seals, thus the compression is oil-free. The rotors have no
mechanical contact between each other and the pump housing, resulting in zero mechanical wear. To keep
the installed electrical power low, modern pumps are driven by an electronic frequency converter and
rotate slower at pressures ranges near atmospheric pressure. Some versions use so-called blow-off valves
instead to keep the rotating speed constant also at high pressures.  Cooling is normally done by water.
Advantage of Screw Pump
 High robustness.
 High tolerance against water vapor and particles/dust.
 Scales to customer requirements.
 Very high pumping speeds.
 No contamination of the medium being pumped.
 Frictionless rotation - rotor wear is eliminated.
 Highly efficient due to internal compression.
 Operational costs and maintenance requirements are relatively low
 Frequency converter operation – easily optimized for process requirements – leads to high energy
efficiency.
Disadvantages
 A gas ballast needed to pump light gasses.
 Worse ultimate pressure and lower pumping speed for light gasses (Helium and Hydrogen) if without gas
ballast.
 Cannot be scaled down to small pumping speeds below 50 m³/h; below approx. 100 m³/h multistage
roots or scroll pumps are used.
Application
o Screw-type pumps are used for high density stocks such as Paper and pump. They are also used for
Chemical Transfer and metering.
o There are many uses for screw pumps in a variety of different industries, including Manufacturing,
Mining, and Oil & Gas.
o Most of these applications deal with high viscosity fluid, such as oil or asphalt, or multi-phase fluid,
which means there is liquid and vapor mixed together in the fluid stream.

Gear Pump
o A gear pump is basically a positive displacement rotary pump. Gear pumps transfer fluid by gears coming
in and out of mesh to create a non-pulsating pumping action. They are able to pump at high pressures and
excel at pumping high viscosity liquids efficiently. Gear pumps are most commonly used to water
transport. It has more than two internal gears that generate vacuum pressure through the mechanical
movement of the gears, aiming to propel the movement of the fluid in the pump.
How to Gear Pump Works
o Rotary gear pump is a positive displacement principle. Internal and external gear pumps are the two basic
types of gear pumps. The main differences between the two types of gear pumps are the placement of
the gears and where the fluid is trapped. The pump features a casing in which a dual gear (an outer rotor gear
and an internal idler gear) and crescent assembly is housed. As the rotor gear begins to turn, the idler gear rotates
with the teeth beginning to mesh accordingly.
Advantages of Gear Pump
 Easy to use and maintain. The gear pump is compact and consists of only two gears, the pump body and
the front and rear covers.
 Low cost.
 High work efficiency.
 Insensitive to fluid viscosity and density
 Disadvantages of gear pump
 Not easy to repair after wear.
 Large noise.
 Unadjusted displacement.
Application of Gear Pump
o Gear pumps are main stays in the petrochemical industry. They are used for crude oil, diesel oil, lube oil, pitch and
bitumen. They are also used for transporting chemicals such as sodium silicate, mixed chemicals, acids, plastics,
isocyanates and other chemicals that must be handled with care.
o They are also used for adhesives, resins, ink and paint. They are especially popular in the pulp and paper industries,
where they are used for acid, lye, soap, black liquor, latex, kaolin, lime and sludge.
o The food industry uses them for a lot of tasty options, including molasses, vegetable oils, pet food, vegetable fats,
fillers, sugar, chocolate and cacao butter.

Lobe Pump
o Lobe pumps offer superb sanitary qualities, high efficiency, reliability, corrosion resistance, and good
clean-in-place and sterilize-in-place (CIP/SIP) characteristics. Thus they are very popular in F&B and
pharmaceutical industries. Rotary lobe pumps are non-contacting and have large pumping chambers,
allowing them to handle solids such as cherries or olives without damage. They are also used to handle
slurries, pastes, and a wide variety of other liquids. If wetted, they offer self-priming performance.
Working Principle of Lobe Pump

o Lobe pumps are similar to external gear pumps in operation in that fluid flows around the interior of the
casing. As the lobes come out of mesh, they create expanding volume on the inlet side of the pump.
Liquid flows into the cavity and is trapped by the lobes as they rotate.
Advantages
 Pass medium solids
 No metal-to-metal contact
 Superior clean-in-place and sterilize-in-place capabilities
 Long term dry run (with lubrication to seals)
 Non-pulsating discharge
Disadvantages
 Requires timing gears
 Requires two seals
 Reduced lift with thin liquids
 Applications
Common rotary lobe pump applications include, but are not limited to:
o Polymers
o Paper coatings
o Soaps and surfactants
o Paints and dyes
o Rubber and adhesives
o Pharmaceuticals
o Food applications

Piston Pump
o A piston pump is a type of positive displacement pump where the high-pressure seal reciprocates with the
piston. Piston pumps can be used in multiple applications and can be used to transfer paint, chocolate,
pastry, etc.
How Piston Pump Works

o They work by creating pressure by distributing energy into the pumped fluid. This action results in a
pressurized fluid cylinder. Piston pumps are ideal when an application requires higher flow rates of fluid
and low pressure, which can discharge fluid at a high rate with little effort.
Advantage
 Piston pumps have a wide pressure range, can reach high pressures and the pressure can be controlled
without an impact on the rate of flow.
 Piston pumps have a continuous rate of discharge. Pressure changes and discharge rate have minimal
effect on performance.
 Piston pumps can maneuver viscous fluids, high gas volumes and solids, only if the valves are correctly
designed.
Disadvantage
 Piston pumps cost more per unit to run compared to centrifugal and roller pumps. T
 The mechanical parts are prone to wear, so the maintenance costs can be high.
 The valves must be resistant to abrasives for large solids to pass through.
 Piston pumps are heavy due to their large size and the weight of the crankshaft that drives the pump.

Application
o Piston pumps are used for water and oil hydraulics, industrial processing equipment, high pressure
cleaning and the pumping of liquids.
o All those pumps above have the similar working principles: pumping the liquid with the help of
rotating elements. The difference lies on the rotating elements; they could be gear, lobe, vane, or
screw.

Main Components of Rotary Pump

The Main Components of any type of rotary pump are:

1. Pumping chamber - Pumping chamber of the rotary pump is the area which contains the pumped fluid
when the pump is pumping. Fluid may enter the pump through one or more ports and can leaves through
one or more outlet ports.

2. Casing - It is that part of the pump which surrounds the pumping chamber. It is also referred to as the
housing, body or stator of the pump.

3. End plates - They serve to close off the ends of the body so as to form integral part of the pumping
chamber. These plates can also be referred as the end covers.

4. Rotating assembly - It refers to all the moving parts inside the pump. The moving parts generally
comprises of a driver and driving shaft. The driver shaft is turned by the motor and the driver is turned by
the driving shaft.

5. Seal chamber - The cavity through which the driving shaft comes out or protrudes is called seal
chamber and the leakage through this chamber is controlled either by a mechanical seal or by a normal
packing material.

6. Seal -The seal can either be a mechanical seal or a normal packing material. The seals used should be
leak proof when the pump is pumping any toxic substances. Cooling and lubrication of these seals is done
by the same liquid which the pump is pumping

6. Relief valves - They are given so as to control the outlet pressure of the pump. As soon as the pressure
increases above the pre-determined value, the relief valve lifts and releases the excess pressure to the inlet
port, thus controlling the pressure. The relief valve is generally set 5-10% above the normal working
condition.

Reciprocating Pump
o Reciprocating pump is a positive displacement pump; it’s a hydraulic machine which converts the
mechanical energy into hydraulic energy. Here a certain volume of liquid is collected in the enclosed
volume and is discharged using pressure to the required application. Reciprocating pumps are more
suitable for low volumes of flow at high pressures.

o Reciprocating pump is a small amount of liquid is transported into a chamber and physically displaced or
forced with pressure by moving mechanical elements, and reciprocating pumps are used to raise the
energy level of the water.

o It does not require any kind of priming for their functioning.

o The reciprocating pump delivers high discharge pressure but discharges at a relatively small volume.
o It has a moving part which reciprocated in a to and fro manner.
o Liquid discharge pressure is limited only by strength of structural parts. A pressure relief valve and a
discharge check valve are normally required for reciprocating pumps.
o
Reciprocating pumps can be further classified into three types of pump as below
 Diaphragm Pump (For example, Fluid Operated Pump, Mechanically Operated Pump)
 Piston and Plunger Type Pump
Diaphragm Pump
o A diaphragm pump is a PD or positive displacement pump. It is also called as a membrane pump. This
pump works with using a blend of the reciprocating action of a rubber, Teflon diaphragm otherwise
thermoplastic & appropriate valves on any face of the diaphragm to push a liquid.
o These pumps are widely used to handle a wide range of fluids in many industries. These pumps can push
fluids with high, low, or medium viscosities. These can also be used to handle numerous violent
chemicals like acids as they are assembled with an extensive range of diaphragms and body materials.

How Diaphragm Pump Works

o A diaphragm or membrane pump is a positive displacement reciprocate pump that uses two flexible

diaphragms that move forward and backward to form a temporary Vacuum. This Vacuum can either draw
or drain the liquid from the diaphragm pump. The membrane acts as a partition wall between liquid and
air.
o A double diaphragm pump uses two bendable diaphragms that respond back & forward to make a
temporary hall, where both receives and ejects liquid through this pump. The working principle of the
pump is on an air displacement principle which is like a separation partition among the air as well as the
fluid.
Advantages of Diaphragm Pumps

 Seal-less and oil-free

 These pumps are not expensive due to the proper maintenance
 Self-priming
 Explosion proof
 Changeable flow rate and expulsion pressure
 Portable
 Easy installation
 They can operate in the long term
 These are energy-efficient as they apply extra force while the forward hit of the pump.
 These are well suited for pumping chemicals otherwise other harming fluids
Disadvantage of Diaphragm Pumps
 Most of the diaphragm pumps need approximately 20 typical cubic-feet for each minute & 100 PSI of air
intake for operating powerfully (Low maximum speed)
 These pumps are inclined not to push extremely accurate at their base end (Not very energy efficient)
 This diaphragm pump pulsates, so a dampener has to be fixed on top of the pump to decrease pulsing
(Pulsed flow - requires dampener for reduction)
Application

o The applications of diaphragm pump commonly applicable in many industries. These pumps are used

to push liquids like corrosive chemical, volatile solvents, viscous, shear-sensitive foodstuffs, pharmacy
product, sticky fluids, dirty water, smaller solids, creams, abrasive slurry, oils, and gels.

Piston and plunger Pump

Piston pump

o Piston pump is a positive displacement reciprocating pump. Piston pumps have displacement bodies
which are disc-shaped with a piston sliding to and fro within a hollow cylinder sealing at the periphery. 

o In which the high-pressure seal rotates with the piston.

o The two piston pumps are lift and force pumps operated by hand or by the engine.
o The seal within the pump slides back and forth meaning a piston pump is better suited for lower pressures
than plunger pumps. Its Output pressure is 100-1200psi.

o High-pressure seal reciprocates with the piston in the cylinder and Inlet Design Pressure of 8.5psi to 40psi.

o Best suited to short duty cycles unless larger pump running slowly and Inlet valves mechanically actuated.

o There are two main types of piston pump types—valve and valve less. Valved piston pump—as the name suggests
— rely on a number of check valves to operate. Ball valves sit at the inlet and outlet to control the flow

Plunger pump 
o A plunger pump is a type of positive displacement pump where the high-pressure seal is stationary and a
smooth cylindrical plunger slides through the seal. This makes them different from piston pumps and
allows them to be used at higher pressures. This type of pump is often used to transfer municipal and
industrial sewage.

o Plunger pumps are more suited for higher pressures. Its Output pressure is 100 to 10,000psi.

o High-pressure seal is stationary. Plunger slides through seal allowing pump to be used at higher pressures.

o Inlet design pressure of 60-70psi, OK for continuous operation when running slowly.

o Requires flooded suction or higher inlet pressure supplied by a booster pump.

How to work piston and plunger pump

o Piston or plunger pumps are a reciprocating positive displacement pump type. This means that they
operate through the displacement of fluid through a reciprocal pumping action. A set volume of fluid is
drawn into an enclosed chamber where it is held until being discharged at a pressure determined by the
application. Also known as plunger pumps, piston pumps are typical in industrial applications and
laboratory environments where accurate and repeatable performances are essential. The pump
design supports the delivery of these performances even at high pressures.

Advantage

o This pump is Self priming pump-not require filling the cylinder by starting
o This pump Can work wide pressure range
o Priming is not necessary in pump
o They are use for air also
o The reciprocating pump gives a high suction lift. (Provide elevated suction lift)
o Also has high efficiency.
o It can deliver water at high pressure. (Provide high pressure at outlet )
o It has a constant rate of discharge.
Disadvantage
o High wear and tear, so need lot maintenance
o Low discharging capacity
o The flow is not uniform (consistent), so we have to fit a bottle at equally both ends.
o The flow is extremely very low and cannot be used for high flow operation or process
o They are more additional heavy and bulky in shape.
o The initial cost is very high in this pump.
o More parts mean higher initial costs.
o It has high maintenance cost.
o No uniform torque and Hard to pump viscous liquids.
Applications

o Typical applications for Piston and plunger pumps are often where a low flow rate of a liquid is required at high
pressure across a number of industries.

 Some the most common applications include:

o Used to move liquids or compressed gases.

o Chemical injection
o Misting
o Adour Control
o Drill cutting injection
o Water cutting
o Gas Dehydrations
o Jetting / cleaning / Wash down
o Oil and gas industry.
o Petrochemical and Refinery.
o Sugar industry.
o Soap and Detergent Industries
COMPONENTS OF RECIPROCATING PUMPS:
 Piston or piston rod: A piston and a piston rod that rotates in a closely fitted cylinder.
A piston is a solid type cylinder part which moves backward and forwards inside the hollow cylinder,
to perform suction and delivery of liquid.
Piston rod helps the piston to its linear motion.
 Crank and connecting rod: Crank and connecting rod mechanism operated by a power source.
The power source gives the rotary motion to the crank with the help of a connecting rod; it translates
the motion by rotating it to the piston in the cylinder.
  Strainer: A strainer is provided at the end of the suction pipe to prevent the entrance of solids from a
water source into the cylinder.
 Air Vessel: Air vessels are connected to both suction and delivery pipes to eliminate the frictional head and
to give a uniform discharge rate.
 Suction pipe: One end of the suction pipe is liquid in the inlet of the cylinder and dips in the other
end.
It is used to suck the water from the water reservoir to the cylinder.
It connects the inlet of the pump with the water tank.
 Delivery pipe: One end of the supply pipe is linked with the delivery part and the opposite end on the
discharge level.
It is a pipe that is used to deliver the water from the cylinder to the desired location.
It connects the outlet of the pump to the tank where the water is to be delivered.
 Suction valve: The suction valve is a non-return valve which means the only one-directional flow is
possible in this type of valve.
This is placed between the suction pipe inlet and the cylinder.
During suction of liquid, it is opened and during discharge, it is closed.
 Delivery valve: Delivery valve also non-return valve placed between the cylinder and delivery pipe
outlet.
It is in a closed position during suction and opened position during the discharging of liquid.
 Cylinder: A hollow cylinder made of steel alloy or cast iron. 
An arrangement of piston and piston rod is inside this cylinder.

Dynamic Pumps

o Dynamic types of pumps use centrifugal force to create velocity in the liquid being handled. This velocity
is then converted to pressure. Kinetic energy is decreased and the pressure will be increased. This
difference in pressure drives the fluid through the system or plant.
o A dynamic pump contains a rotating impeller that creates a vacuum that helps in moving fluids. This
impeller is enclosed in housing as it reduces pressure at the inlet. The motion created is what drives fluid
to the outside of the pump’s housing. The pressure increases at this stage so that it can send it out the
discharge.
o Dynamic pumps, in which energy is continuously added to increase the fluid velocities within the
machines to values greater than those occurring at the discharge so subsequent velocity reduction within
 or beyond the pump produces a pressure increase. Major kinds which often used in many industries are
centrifugal pumps
There are two types of Dynamic pump, and those are:
 Centrifugal pumps and vertical pumps
Centrifugal pumps
o Centrifugal pumps are a dynamic pump it’s the most common type of pump that can transfer fluid of low
viscosity at a high flow rate.
o Centrifugal pump is a hydraulic machine which converts mechanical energy into hydraulic energy (i.e.
pressure energy) by the use of centrifugal force acting on the fluid. The flow of liquid takes place in radial
outward direction which is reverse of the inward radial flow reaction turbine. It is used in different areas
where fluid is needed to raise from low level to high level.
Centrifugal pumps classified into three types of pump as below
 Based on direction of flow (For eg. Radial flow pump, axial flow and mixed flow pump)
 Based on suction type (For eg. Single suction pump and double suction pump)
 Based on mechanical construction (For eg. Closed, open and Semi open or vortex type pump)

Working Principle of Centrifugal Pump:

o The Centrifugal pump acts as a reversed of an inward radial flow reaction turbine. This means that flow in
a centrifugal pump is in the radial outward directions.
o The centrifugal pump works on the principle of forced vortex flow which means that when a certain mass
of liquid is rotated by an external torque, the rise in pressure head of the rotating liquid takes place.
o The rise in pressure head at any point of the rotating liquid is proportional to the square of the tangential
velocity of the liquid at that point.
o Therefore the rise in pressure head is more at the outlet of the impeller and the liquid will discharge with
a high-pressure head at the outlet. Due to this, the high-pressure head of the liquid can be lifted to a high
level. This pump is suitable for low head discharge. It develops normally at the head of 50m.

Advantage

 The advantages of centrifugal pumps include simplicity, compactness, weight saving, and adaptability to
high-speed prime movers.

 The biggest advantage of centrifugal pumps is their simplicity.

 They are suitable for large discharge and smaller heads.
 They don’t require any valves or many moving parts.
 This pump allows them to run at high speeds with minimal maintenance.
 Their output is very steady and consistent.
 Centrifugal pumps provide a lot of flexibility, are easy to move, and don’t take up a lot of space.

 Small in size, space saving & less capital costs

 Easy for maintenance

 No danger creates if discharge v/v is closed while starting

 Deal with large volume

 Able to work medium to low head

 Able to work medium to low viscous fluid

Disadvantage of Centrifugal Pump

 Disadvantage of centrifugal pumps is their relatively poor suction power. When the pump end is dry, the
rotation of the impeller, even at high speeds, is simply not sufficient to lift liquid into the pump; therefore,
the pump must be primed before pumping can begin.

 Extra priming pump requires.

 Cannot be able to work high head.
 Cannot deal with high viscous fluid.

Applications of Centrifugal Pumps are:

o Centrifugal pumps are used in buildings for pumping the general water supply, as a booster and for
domestic water supplies.
o The design of a centrifugal pump makes them useful for pumping sewage and slurries.
o They are also used in fire protection systems and for heating and cooling applications.
o Beverage industry: Used to transfer juice, bottled water, etc.
o Waste Management, Agriculture & Manufacturing – Wastewater processing plants, municipal industry,
drainage, gas processing, irrigation, and flood protection
o Pharmaceutical, Chemical & Food Industries – paints, hydrocarbons, petrochemical, cellulose, sugar
refining, food and beverage production
o Dairy industry: Used to transfer dairy products such as milk, buttermilk, flavored milk, etc.
o Various industries (Manufacturing, Industrial, Chemicals, Pharmaceutical, Food Production, Aerospace,
etc.) for the purposes of cryogenics and refrigerants.
o Oil Energy: pumping crude oil, slurry, mud; used by refineries, power generation plants

Main components of centrifugal pump

The various main parts of a centrifugal pump are:

1. Impeller
Impeller is a rotor used to increase the kinetic energy of the flow. It is the rotating part of the pump. The
impeller is mounted on a shaft and the shaft of impeller is again connected with the shaft of an electric
motor. It is rotated by the motor and consists of series of backward curved blades.

2. Casing
It is an air tight passage which surrounds the impeller. The design of the casing is done in such a way that
it is capable of converting the kinetic energy of the water discharging from the outlet of the impeller into
pressure energy before it leaves the casing and enters into the delivery pipe.

Commonly three types of casing are used in centrifugal pump and these are

(i). Volute Casing: It is a spiral type of casing in which the area of flow increases gradually. The increase
in area of flow decreases the velocity and increases the pressure of the liquid that flows through the
casing. The volute casing is shown in figure above:

(ii). Vortex Casing: In vortex casing, a circular chamber is introduced in between the impeller and
casing. This is done in order to prevent the loss of energy due to formation of eddies. The efficiency of
the vortex casing is more than that of the volute casing.

(iii). Casing with Guide Blades: In this casing, the impeller is surrounded by series of guide blades. The
guide blades are mounted on a ring which is called as diffuser. The design of the guide vanes are kept as
such that the water which is leaving the impeller enters the guides without shock. The area of the guide
vanes increases; this helps to decrease the velocity of the liquid and increases its pressure. After guide
vanes, water passes through the surrounding casing. In most of the cases, the casing remains concentric
with the impeller.

3. Shaft (Rotor)
The impeller is mounted on a shaft. Shaft is a mechanical component for transmitting torque from the
motor to the impeller.

4. Shaft Sealing
Centrifugal pumps are provided with packing rings or mechanical seal which helps prevent the leakage
of the pumped liquid.

5. Bearings
Bearings constrain relative motion of the shaft (rotor) and reduce friction between the rotating shaft
and the stator.
6. Suction Pipe with Foot Valve and Strainer
A pipe whose one end is connected with the inlet of the impeller and the other end is dipped into the sump
of water is called suction pipe. The suction pipe consists of a foot valve and strainer at its lower end. The
foot valve is a one way valve that opens in the upward direction. The strainer is used to filter the
unwanted particle present in the water to prevent the centrifugal pump from blockage.

7. Delivery Pipe
It is a pipe whose one end is connected to the outlet of the pump and other end is connected to the
required height where water is to be delivered.

 Vertical centrifugal pumps

 Vertical turbine pump [deep well turbine pump] is vertical axis centrifugal or mixed flow type pump
comprising of stages which accommodate rotating impellers and stationary bowls possessing guide
vanes.
 These pumps are used where the pumping water level is below the limits of Volute centrifugal pump.
They have higher initial cost and are more difficult to install and repair. The pressure head developed
depends on the diameter of impeller and the speed at which it is rotated. The pressure head developed
by single impeller is not great. Additional head is obtained by adding more bowl assemblies or stage.

o Vertical centrifugal pumps are also referred to as cantilever pumps. They utilize a unique shaft
and bearing support configuration that allows the volute to hang in the sump while the bearings
are outside the sump. This style of pump uses no stuffing box to seal the shaft but instead utilizes
a "throttle bushing"
o The vertical turbine pump is also known as a deep well turbine pump. These are mixed flow, or a
vertical axis centrifugal pump which includes stages of rotating impellers & stationary bowls to
process the guide vanes. Vertical pumps are utilized wherever the level of water pumping is under
the volute centrifugal pump limits.
o These pumps are expensive and are more complicated to fit and refurbish. The designing of
pressure head mainly depends on the length of the impeller as well as the speed of its rotation. The
pressure head which is designed with single impeller cannot be great. Because an extra l head can
be attained by inserting extra stage otherwise bowl assemblies.
 Vertical Centrifugal pumps can be further classified into different types of pumps mainly include
 Horizontal self-priming pump
 Submersible pump
 In Line shaft pump
 Barrel pumps
 Deep well pumps
Working Principle of vertical pump

 The vertical pump working principle is, they usually work with a diesel engine or an AC
electric induction motor throughout an exact angle drive. The last part of this pump can be
designed with minimum one spinning impeller. This can be connected toward a shaft through the
well water into a bowl or a diffuser casing.
 The several impellers can be used by different configurations over the similar shaft to make high
pressure. This will be required for deep wells at earth level.
 These pumps work whenever water flows through the pump at the base throughout a suction bell
and the shape of this is like a bell part. After that, it moves into the primary stage impeller to raise
the velocity of the water. Then the water flows into the diffuser bowl immediately over the
impeller, wherever this high-velocity energy can be changed into high-pressure.
 The fluid from the bowl also supplies into the secondary impeller which can be situated instantly
on top of the bowl. So this method continues throughout the phases of the pump. Once the water
supplies away from the previous diffuser bowl, then it flows during a lengthy vertical column pipe
when it flows up from the well-bore in the direction of outside.
 The rotating shaft within the column can be supported at 3 or 5-foot intervals through sleeve
bushings. These are placed within the column & greased by the water flowing past them. The
discharge head of the pump will be located at the surface of this pump that allows the water flow
to modify direction, in the direction of the discharge pipe. A vertical high push AC motor is
placed on the top of the discharge head.

Advantages of Vertical Pump

 Suitable for space with limited ground area.

 NPSH can be increased by using vertical turbine pump
 The flow rate of the vertical type centrifugal pump even, stable, and easy to adjust.
 Pumps wearing parts are less.
 Takes less floor space to install.
 Suitable for fluids with high temperature and high pressure.
 Vertical turbine pumps have a small footprint, and there are no priming issues (as long as minimum
submergence requirements are met) due to the impellers being submerged in fluid.
 They are easily customized, and are highly efficient on high head, low flow applications
Disadvantages of vertical design:

 The performance of the pump is sensitive to change in the viscosity of a fluid.

 Requires large amount of headroom for installation because of hydraulic thrust is difficult to
balance on vertical turbine pumps due to their overhang design, especially in high suction, high
pressure applications.
 For a large multistage pump, requires a pit and barrel which is costly to construct.
 The overhung design creates a challenge to balance axial thrust at high suction pressure.
 Liquids with high dissolved gases are difficult to handle. This can damage the mechanical seal of
the pump.
 They require a lot of installation and maintenance space, especially when it comes to multistage
units or vertical turbine pump
 The pump can only be used when it is directly connected to the motor. Vertical turbine pump will
not be the best choice for your industry to use engines or turbines and other types of drivers.
Application

o Vertical turbine pumps can be found in a wide range of agricultural, municipal, and industrial
applications.
o They are generally meant for clean water applications that require high pressure and high head.
o They are most commonly used to pump out of deep pits or wells to supply the water to
agricultural otherwise grass irrigation
o They also used to offer fire water to industrial plants. .
o These pumps can also be used to pump the water from a river, a bored well, and reservoir.
o boiler feed water piping system
 Figure: positive displacement pump diagram

 Dynamic Pumps
 Figure: Dynamic pump diagram

 Every pumps have two main parts

1. Driving part – motor
2. Driven part - pump assembly
 Pumps could be driven by electrical motor or internal combustion engine.
 IC engine is a machine which converts heat energies in to mechanical energies by using compressed
air and fuel combustion.
 IC engines are constructed form three main parts
 Cylinder head
 Engine block
 Oil sump
 IC engines further categorized by input type
 Diesel engine
 Gasoil engine
 Main IC engine parts
 Injection pump
 Fuel tank
 Fuel filter
 Oil filter
 Rope rounding pulley/ starting pulley
 Throttle valve
 Other accessories
Safety guidelines and precaution

Pump Safety Guidelines

Read the Installation of the pump manual

 Always read your owner’s manual before installing, operating or performing maintenance on the pump
or its related equipment. No matter what brand pump you decide to purchase, every company knows
how to operate their own pumps with the highest degree of safety. While safety fundamentals are
always the same, specifics often differ, depending on what brand and what type of pump you are
installing. Even if you’ve used a water
 pump before, you can’t assume that you know how to use every pump that’s available. Always read
the instructions!

Switch off a Pump if it becomes overheated

 Never run an overheated pump. Pumps Overheated can cause severe burns and injury. If your pump
overheats, turn it off immediately, and allow it to return to cool air temperature. Then, vent the pump
at the drain plug if applicable (Slowly and cautiously). Consult the owner’s manual before restarting
the Installation, Operation and Maintenance. Operating pump with suction and/or discharge closed is
one cause of severe overheating. This simple precaution can drastically reduce the risk of a pump
becoming a fire hazard.

Do not operate the pump without all guards and shields in place.

 Always make sure all safety guards and shields are in place while operating your water pump.
 Be sure that only experienced personnel operate machinery.

Don’t pump substances that your pump isn’t designed to cope with

 Pumps can break and become hazardous if you try to use them to pump substances they weren’t
designed to handle. Pump only liquids for which the pump was designed. The most dangerous cases
are Acids, corrosive substances and flammable substances should never be pumped using an ordinary
water pump. You should also make sure that you don’t try to pump any substance that is more viscous
than your pump can handle. If in doubt, refrain from pumping.

Wherever possible, keep your pump away from walls and obstructions

 It is highly inadvisable to leave any pump in a confined space where heat can build up. You should
also avoid leaving it against walls or other obstructions that may prevent it from expelling heat
effectively. This is because powerful pump engines can generate a lot of heat. Always keep your pump
at least 3 feet away from walls and other equipment during operation. This allows the pump’s motor or
engine to ventilate properly, and avoids turning the pump into a fire hazard if it overheat
 This heat needs to be allowed to dissipate safely. If it isn’t, the pump can become a fire hazard. Simply
ensuring that your pump is kept out of confined spaces and other areas where it might overheat can
prevent this problem however. So Never use a pump in a flammable or explosive environment. The
heat from the pump could cause a fire or an explosion.

Don’t use the wrong direction of rotation –

 The operating pump in the wrong direction may cause impeller to unscrew and damage pump casing or
other pump parts. Locate the pump in an accessible location, as close as safely possible to the liquid to
be pumped.

When overhauling the pumps don’t remove

  Do not remove the cover plate, fill port cap, gauge port plug, or drain plug from any overheated pump.
Allow pump to cool to air temperature. Check pump temperature before opening cover plate, fill port,
gauge port plug or drain plug.

Never operate a self-priming pump unless the pump casing is filled with liquid

 Don’t operate a self-priming pump unless the pump casing is filled with liquid. Doing so may damage
the pump. The pump will not prime unless the pump casing is filled with liquid.

Before working on pumps with electric motors and panels

 LOCK control panel in the OFF position:

 If control panel cannot be locked, pull main fuse or circuit breaker.

 Remove all V-belts.
 Disengage drive coupling.

Personal (operator) safety precaution

Procure and wear proper safety equipment such as:

 Hard hat
 Safety glasses
 Gloves
 Safety shoes
 Personal habit
 Personal practice
 Never wear loose clothing around machinery.
Pump safety precaution
Before the machine start:
 Determine that the service of the pump is no longer needed.
 Notify those involved that the pump is going to be shut down.
 Push the local "Off" switch or "Off" on the motor starter if remote.
 Determine that the pump motor is actually off and that the discharge check valve has closed.
 Recheck the condition of the system with the pump off.
 Reset any automatic restart controls as may be needed.
 Close any discharge and suction valves
When start up the pump:
 Make sure the discharge valve is closed.
  Open the vent valve if necessary
 Make sure that the pump is filling with liquid.
 Open the cooling water valves and make sure that the proper amount of water is flowing.
 Open the flushing oil valves.
 Turn the rotor by hand to make sure of smooth rotation.
 Fully open the suction valve.
 Start the motor & check leakage from seals or packing.
 After confirming gradual increase of discharge pressure, open the discharge valve slowly and
completely.
 If leakage is found, stop the pump and repair.
During pump is running:
 Check Lubricating oil level in the reservoir (or tank)
 Check Flow of cooling water
 Check Suction and discharge pressure.
 Check noise and vibration of machine.
 Leakage from seals or other connections
Pump shut off the procedure:
 Close the discharge valve.
 Stop the motor.
 Stop the cooling water and the flushing oil.
 Drain out the pump as required.
Machine safety precaution
 Environment and pump placement
 Fuel quality
 Pipe condition
Pump operation procedure
 Pipe connection
 Pump preparation to start
 Machine/pump starting
 Machine/Pump running
 Machine/Pump stopping
Other pump safeties
 If the pump is a gas pump, remember that it emits carbon monoxide as it runs. Don’t run the engine
indoors. If you must place the engine indoors, ventilate the area to the outside and seal it off from the
rest of the building.
 Check all lubricants before installation and operation and in accordance with maintenance
programs.
 On driven pumps always be careful not to overfill the fuel tank.  When you have filled the tank to the
proper level, be sure to close the cap tightly.  Also, do not spill fuel during fuelling or refueling.
 Drain pump completely of water before freezing weather.
 When lifting pumps, use only is lifting equipment in good repair with adequate capacity.
 Do not operate pump against a closed valve.
 Keep your pump out of the reach of children, or keep your children away from the pump
 Check the suction strainer regularly to be sure that it is not clogged.
 Secure the pump so that it cannot move after it is in its operating position.
 Check the pump thoroughly upon delivery for any shipping damage.
 Never operate pumps in explosive or volatile atmospheres unless they are designed to
be operated in these environments.
 Do not work in underground pump systems alone or without adequate ventilation.
 Always rest the pumps
 Check the water quality before filling in the motor.
 Always suspend the pump set at least 3 meters above the bottom of the bore.
 The pumps must be installed 1meters below the water level surface.
 Always check the cable joints and vertical play after coupling the pump set.
 Run the pump set until pure water comes out.
 Always use a good quality control panel.
 Bending of cable must be avoided
 Don't run the pumps if any of the following defects are observed.
 Water is sandy or acidic.
 If there is no water.
 If discharge valve is closed for more than 4 minutes.
 Don't pull the motor with the help of cable
Pump maintenance and troubleshooting
Maintenance and trouble shouting

Controls/check(when in use) activity Frequency

Engine visual inspection (Every day)

Check engine oil level (Every day)

Air filter (especially in dusty environment)

Fuel amount (Every day)

Fuel hoses/ pipe connection/ (Every day)

Change engine oil First change after 50 hour operation

change engine oil filter First change after 50 hour operation

change fuel filter First change after 50 hour operation

change air filter Every 1200 hours

Change oil filling & engine oil Every 600hours

Change fuel fileter Every 600 hours

 Change fan belt Every 1200hours

Clean foot valve/strainer When in necessary

 Troubleshooting
 Unable to engine start
 Insufficient engine power
 Engine stop
 Pump delivery very low flow rate
 Although engine operate pump absolutely fail to delivery water
 Pump is noisy and vibrates
Pump Troubleshooting Guide
Centrifugal Pump Troubleshooting Guide
This “TROUBLESHOOTING” information is intended to guide in the general determination of pump
problems and their solutions.

Common Pump Problems and Troubleshooting Guide

 No job is perfect. All industrial equipment has the potential for failure and things going wrong. Here’s
how to troubleshoot the most common issues that happen with pumps and pump equipment.
Sometimes pumps will wear out, often for a variety of factors. A lot of the wear and tear can be
minimized through routine maintenance of critical components and replacing them when a problem is
spotted.
 This pump troubleshooting guide can help with your common pumping concerns. Understanding the
cause and remedy of your pump issue, along with some simple preventative steps, you can get back on
track with smooth pump operation.
  Many pump issues are due to the set-up or other factors in the system as a whole, as most
manufacturers, test every pump before shipment to ensure proper function. However, many of the
problems mentioned here are easy to correct.
What follows are a few of the more common problems pump users face
Little or no liquid discharge

Possible cause Possible solution/remedy

Casing not initially filled with
water
Total head too high
Static discharge head is too high
Suction lift too high, or too long
Foot valve or suction line not
submerged deep enough in water
Impeller damaged
Suction piping too small
Fill pump casing
Shorten suction and/or head
Check pipe friction losses, use larger discharge pipes.
Lower suction lift, install foot valve and prime, or shorten length
of suction line
Submerge lower in water‐‐at least 3 feet
Replace impeller
Increase to pump inlet size or one size larger)

Casing gasket or "O" ring Replacing

leaking
Motor wired incorrectly
Lack of prime Fill pump and suction pipe completely with liquid.
Ensure the pump and volute are completely full of liquid before
Pump is not primed operating the pump. If any air is trapped in the pump, it will not operate
correctly.
Loss of prime Check for leaks in suction pipe joints and fittings; vent casing to
remove accumulated air.
Check for leaks in the pump, pipeline, and couplings which could cause
Pump loses prime air to enter the pump. If you suspect air in the pump, make sure to vent
volute/casing to remove trapped air before resuming pumping.
Suction lift too high If no obstruction at inlet, check for pipe friction losses.  However,
static lift may be too great. Measure with mercury column or
vacuum gauge while pump operates. If static lift is too high, liquid
to be pumped must be raised or pump lowered.
Check the pipeline for friction losses and ensure the static lift is not too
Suction lift is too high high. If the static lift is too high, you’ll need to lower the pump closer to
the source material or raise the material closer to the pump.
Discharge system head too high Check pipe friction losses. Larger discharge piping may correct
condition. Check that valves are wide open.
Speed too low
Rotor speed to low
Wrong direction of rotation
Impeller completely plugged
Air leaks in suction piping
Air leaks in stuffing box
Cavitation insufficient NPSH
(depending on installation)
Defective impeller
Defective packing
Foot valve too small or partially
obstructed
Suction inlet not immersed deep
enough
Wrong direction of rotation
Rotor spinning the wrong direction
Impeller diameter too small
Check whether motor is directly across-the-line and receiving full
voltage. Alternatively, frequency may be too low; motor may have
an open phase.
Ensure the motor is receiving the required voltage and correct
frequency if using a variable frequency drive.
Check motor rotation with directional arrow on pump casing.
Wrong rotation will cause pump damage.
Dismantle pump or use piping hand hole to clean impeller.
If liquid pumped is water or other non-explosive, and explosive
gas or dust is not present, test flanges for leakage with flame or
match. For such liquids as gasoline, suction line can be tested by
shutting off or plugging inlet and putting line under pressure.  A
gauge will indicate a leak with a drop of pressure.
Increase seal lubricant pressure to above atmosphere.
a. Increase positive suction head on pump by lowering pump or
increasing suction pipe size or raising fluid level.
b. Sub-cool suction piping at inlet to lower entering liquid
temperature.
c. Pressurize suction vessel.
Inspect impeller.  Replace if damaged or vane sections badly
eroded.
Replace packing and sleeves if badly worn.
Area through ports of valve should be at least as large as area of
suction pipe- preferably 1½ times.  If strainer is used, net clear area
should be3 to 4 times area of suction pipe.
If inlet cannot be lowered, or if eddies through which air is sucked
persist when it is lowered, chain a board to suction pipe. It will be
drawn into eddies, smothering the vortex.
Compare rotation of motor with directional arrow on pump casing.
Wrong rotation will cause pump damage.
Check the motor rotation direction as indicated by arrows on the pump
casing. Make sure the rotor is spinning in the correct direction when the
pump is in operation.
Check with factory to see if a larger impeller can be used;
 (probable cause if none of above) otherwise, cut pipe losses or increase speed, or both, as needed. 
But be careful not to seriously overload drive.

Obstruction in liquid passages or Dismantle pump and inspect passages of impeller and casing. 
Suction line is clogged Remove obstruction.

Air or gases in liquid (Test in May be possible to over rate pump to point where it will provide
laboratory, reducing pressure on adequate pressure despite condition.  Better to provide gas
liquid to pressure in suction line.  separation chamber on suction line near pump, and periodically
Watch for bubble formation.) exhaust accumulated gas. See item 14.

Excessive impeller clearance Adjust impeller clearance.

Rotor is clogged or jammed Disassemble the pump and volute to clear the rotor jam or clog.

Loss or low suction pump (Malfunction of pump suction)

Possible cause
Air leak in suction line
Suction lift too high
Clogged foot valve, check valve or strainer
Defective, worn out or dirty foot valve or check
valve
Not enough hydraulic oil
The relief valve is leaking (internally or
externally)
Not enough suction pressure
The liquid is nearing the boiling point
Liquid has a viscosity that’s too high
Clogged suction strainer or inlet
Insufficient hydraulic fluid
Leak in the suction pipeline or hose
Insufficient suction pressure
Worn check valves
Possible solution/remedy
Repair & replace
Lower suction lift, install foot valve and prime
Unclog or Clean suction strainer
Evaluate check valves and clean or replace as
necessary
Add hydraulic oil until filled to the proper level
Reset leaking relief valve
Increase the level in the liquid tank
Either cool the liquid or increase the suction head
Reduce the liquid’s viscosity and change the ball
material and/or size
Clean out the strainer and ensure it is free from
obstructions which could clog the suction inlet.
Ensure the pump motor is filled to proper hydraulic
fluid levels. Consult the manual for your hydraulic
equipment for proper fluid levels.
Inspect and repair pipeline or hose for leaks.
Raise the liquid tank level closer to the pump.
Clean or replace broken or worn-out valves to ensure
proper operation.

Motor Overheats and Shuts Off (Overload)

Possible cause Possible solution/remedy
Motor voltage does not match power supply Check motor connection against wiring diagram
voltage on the motor nameplate and against the power supply

Impeller is rubbing against pump case or not
turning freely
Low voltage at the motor
The pump operated over its discharge
pressure rating and the motor was overloaded
Vicous hydraulic oil
Ambient temperature is too high
Operating motor in excess of rating
Improper wiring or voltage too low
Hydraulic oil too viscous
High ambient temperatures
Pump leaks at shaft
Possible cause
Worn mechanical seal
Mounting plate or foundation not rigid
enough
Foreign material in pump
Worn motor bearings
Pump will not deliver water or develop pressure
Possible cause
No priming water in casing
Mechanical seal leaking
Leak in suction line
Discharge line is closed and priming air has
nowhere to go
Pump is down
Foot valve or check valve is leaking
voltage
Dismantle pump, unclog or replace the
impeller
Make sure electrical connections are tight
Keep discharge pressure within the range specified
Drain current oil and refill with the correct, less
viscous oil
Evaluate pump location and take measures to
ventilate, protect it from the sun, or relocate
Limit discharge pressure to max specified by the motor
manufacturer.
Check power supply vs motor nameplate details for
correct specs.
Drain and refill with the correct type of oil.
Increase ventilation or relocate pump to a cooler area.
Possible solution/remedy
Replace mechanical seal
Reinforce
Dismantle pump and clean
Replace bearings
Possible solution/remedy
Fill pump casing
Replace mechanical seal
Repair or replace the line
Open the discharge line
Replace worn parts
Replace valve
Pump will not prime
Possible cause Possible solution/remedy
No priming water in casing Fill pump casing
Mechanical seal leaking Replace mechanical seal
Leak in suction line Repair or replace
Suction line or valve is closed Open the line suction valve
Foot valve or check valve is leaking Replace the valve
Suction screen clogged Clean or replace

Pump will not start or run

Possible cause Possible solution/remedy
Improperly wired Check wiring against diagram on motor
Stone or foreign object lodged in impeller Dismantle pump and remove foreign object
Motor shorted out Replace motor
Thermal overload has opened circuit Allow unit to cool, restart after reason for overload has
been determined
Determine and fix the cause of the overload and replace
Fuse is blown or breaker is tripped
the fuse/reset the breaker
Determine and fix the cause of the thermal overload, then
The motor starter has an open thermal
reset the thermal overload. If the motor still won’t start,
overload
evaluate the heater size.
Line current is too low Fix the cause of the low line current
A control device in the pump motor starter
Reset any open circuits in the pump motor starter
circuit has an open circuit
Evaluate the motor for any damage that may prevent
Damage to the motor
proper operation
Clean out the strainer and ensure it is free from
Blown fuse or breaker
obstructions which could clog the suction inlet.
Starter overheating Correct cause of thermal overload and reset the motor.
Low line current Inspect lines and fix the problem.
Check for physical damage to motor, repair, or replace as
Motor damaged
needed.

Pump operates for short time, then stops

Possible cause Possible solution/remedy

Incomplete priming Free pump, piping and valves of all air.  If high points in
suction line prevent this, they need correcting.
 Suction lift too high
Air leaks in suction piping
Air leaks in stuffing box
Air or gases in liquid
Pump takes too much power
Possible cause
Head lower than rating; thereby
pumping too much liquid
Cavitation
Mechanical defects
Suction inlet not immersed enough
Liquid heavier (in either viscosity or
specific gravity) than allowed for
Lower suction lift, install foot valve and prime
If liquid pumped is water or other non-explosive, and
explosive gas or dust is not present, test flanges for
leakage with flame or match. For such liquids as gasoline,
suction line can be tested by shutting off or plugging inlet
and putting line under pressure.  A gauge will indicate a
leak with a drop of pressure.
Increase seal lubricant pressure to above atmosphere.
May be possible to over rate pump to point where it will
provide adequate pressure despite condition.  Better to
provide gas separation chamber on suction line near
pump, and periodically exhaust accumulated gas.
Possible solution/remedy
Machine impeller's OD to size advised by factory.
a. Increase positive suction head on pump by lowering pump or
increasing suction pipe size or raising fluid level.
b. Sub-cool suction piping at inlet to lower entering liquid
temperature.
c. Pressurize suction vessel.
Inspect impeller.  Replace if damaged or vane sections badly
eroded. Replace packing and sleeves if badly worn. Area
through ports of valve should be at least as large as area of
suction pipe- preferably 1½ times.  If strainer is used, net clear
area should be3 to 4 times area of suction pipe.
If inlet cannot be lowered, or if eddies through which air is
sucked persist when it is lowered, chain a board to suction
pipe. It will be drawn into eddies, smothering the vortex.
Use larger driver. Consult factory for recommended size. Test
liquid for viscosity and specific gravity.
 Wrong direction of rotation
Stuffing box too tight (Packing)
Casing distorted by excessive strains
from suction or discharge piping
Shaft bent due to damage - through
shipment, operation, or overhaul
Mechanical failure of critical pump
parts
Misalignment
Speed may be too high (brake hp of
pump varies as the cube of the
speed; therefore, any increase in
speed means considerable increase
in power demand)
Electrical defects
Mechanical defects in turbine,
engine, or other type of drive
exclusive of motor
Zero Flow after Startup (Pump Doesn’t Deliver When Running)
Possible cause
Air in Pump or Suction Pipe work
Suction Lift Too High
Insufficient Manometric Head
Check motor rotation with directional arrow on pump casing.
Wrong rotation will cause pump damage.
Release gland pressure. Tighten reasonably. If sealing liquid
does not flow while pump operates, replace packing.  If
packing is wearing too quickly, replace scored shaft sleeves
and keep liquid seeping for lubrication.
Check alignment.  Examine pump for friction between impeller
and casing. Replace damaged parts.  Check for pipe strain.
Dismantle pump and inspect shaft.
Check bearings and impeller for damage.  Any irregularity in
these parts will cause a drag on shaft.
Realign pump and driver.
Check voltage on motor.
The voltage and frequency of the electrical current may be
lower than that for which motor was built or there may be
defects in motor.  The motor may not be ventilated properly
due to a poor location.
If trouble cannot be located, consult factory.
Possible solution/remedy
Ensure Pump and Pipe work are Completely Filled with Liquid.
Pump cannot prime with air in suction line.
Check Inlet for obstruction. If there is not an obstruction
calculate friction losses. If static lift is too high the liquid in the
suction tank must be raised or pump lowered
Actual head with friction losses is higher than pump design.
Calculate head and friction   losses in discharge. Check all
valves are open. To correct increase pipe diameter, or increase

Operation is Reversed
Speed Incorrect
Impeller, strainer or check valve
clogged
Not enough hydraulic oil
Solids lodging open check valves
lodged
Check valves are worn out or dirty
Blockage in suction or discharge
line
Closed isolation valve
Unprimed pump
Improperly installed check valves
Flow Decreases or None at All
Possible cause
Air ingress through   shaft seal, suction
piping, suction port. Pump lifts liquid with air. and fittings. Check shaft seal and if necessary,
Air pocket in suction pipe
Increase of Manometric Head
Impeller, strainer or   check valve clogged
Air leaks in the suction hose
Air leaks in the stuffing box
Cavitation
Defective rotor
impeller diameter, motor power or pump.
Check motor direction of rotation is in the direction of arrow on
pump casing
Check supply voltage and frequency. Motor may also have open
phase
Clean impeller, valve and strainer
Add more hydraulic oil until filled to an adequate level
Evaluate check valves and clean or replace as necessary
Evaluate check valves and clean or replace as necessary
Remove blockage by cleaning the line
Open the isolation valve
Before pumping against pressure, fill suction line and pump
head with liquid
Evaluate the installation of check valves. Remove and reinstall
relevant valves properly.
Possible solution/remedy
Check suction pipe work for leaks, including all joints
increase pressure of sealing liquid. Check depth of
suction pipe work or valve in liquid and deepen if
required. Check inlet tank for vortex.
Check angle of suction line and ensure there is no
possibility for an air pocket and if so ensure air
eliminator valves are fitted
Check valves are fully open and there are no
obstructions in discharge pipe
Clean impeller, valve   and strainer
If liquid pumped is water, test flanges for leakage with
flame or match. For such liquids as gasoline, the suction
line can be tested by shutting off or plugging inlet and
putting the line under pressure. A gauge will indicate a
leak with a drop of pressure.
Increase the lubricant pressure to exceed atmospheric
pressure, effectively locking air out of the stuffing box.
Check NPSHr and NPSHa, you may not have enough
positive suction head for what is required.
Open up the pump and volute casing to inspect the rotor
for damages. If the rotor has been damaged, ensure it is

Defective packing
Rotor spinning the wrong direction
repaired or replaced prior to powering on the pump.
Inspect and replace packing if sufficiently worn.
Ensure the rotor is spinning in the correct direction by
comparing it with the indicator on volute. A rotor or
impeller spinning in the wrong direction could damage
the pump.

Driver Overloaded

Possible cause Possible solution/remedy

Pump operating at lower manometric head
Speed too high
Mechanical Friction inside pump
Packing wound too tight
Coupling Alignment
Density or viscosity of the liquid pumped is
higher than originally advised
Motor Defects
The actual head is lower than originally specified.
Reduce impeller size to diameter advised by supplier or
utilize an inverter to reduce pump speed
Decrease pump rotational speed or trim impeller to
required size
Check pump rotor for any obstruction or deflection
Loosen nuts on packing gland
Check coupling rubber and realign pump and coupling
Increase motor size
Check for motor defects. May not be ventilated
correctly and be in a poor location

Bearings   Overheating

Possible cause Possible solution/remedy

Poor Coupling Alignment
Bearing Covers too tight
Pumped flow is less than minimum safe
continuous flow
Too much grease
Insufficient lubrication or lubricating oil /
grease dirty or contaminated
Check coupling rubber and realign pump and coupling
Check and loosen if necessary, bearing cover
Increase flow. If necessary, use by-pass recirculation
valve or line
Remove excess grease
Check the amount of oil/grease. Clean the bearings,
bearing housing and lubricate

Vibration

Possible cause Possible solution/remedy

Partially clogged impeller Clean Impeller
Worn or defective impeller Replace impeller
Poor Coupling Alignment Check coupling rubber and realign pump and coupling
Oblique Shaft Check shaft and replace if required
Unbalanced parts Check and rebalance parts if required
Noise level high (Check Valves are Noisy When Operating)

Possible cause Possible solution/remedy

Air in liquid
Pump working in cavitations area
Pump operating outside of duty range
Excessive wear on gears
End play in motor shaft
Wrong lubrication
Bearings are worn out
Suction pipe needs to be submerged to ensure vortexes are
not created on the surface of the liquid.
Check liquid level in suction pipe or increase depth of
suction pipe.
NPSH is too low. Check liquid level in suction tank, check
suction losses. Check valve in suction line and ensure fully
open. Increase suction head by lowering pump.
Check duty point
Repair gear set
Reshim shaft
Lookup correct oil and replace
Replace bearings with new ones

Oil Leaking From Pump

Possible Cause Possible solution/remedy

Loose oil plug Tighten oil plug

Too much oil in the pump Drain out the excess oil until it’s at the proper level

The breather cap is either too loose or missing Tighten or replace breather cap

The diaphragm head bolts are not tightened Tighten diaphragm head bolts to specifications

Erratic Pump Operation

 Don’t use pipe smaller than the manufacturer-supplied suction connection
 Properly support piping to not strain pump connections
 Install a properly-sized screen in the suction line to prevent debris from entering the pump
 Always flush the suction piping before connecting the pump

Possible Cause Possible solution/remedy

Suction connections are too small Replace connections with larger components

Debris in the supply tank, piping, or check Disconnect and flush the piping, pump, and
 valves check valves and install a properly sized strainer

Location Suggestions
When choosing the location for your pump, always read the manufacturer’s instructions and
recommendations. Pump location can cause many issues, especially if it’s exposed to extreme temperatures or
too far from the supply vessel.
Choose a firm, level surface accessible for routine maintenance. If possible, place suction connection below
the supply liquid level to create full flooded suction
Pump Periodic Maintenance Routine

Check temperatures.

Daily Check cavitation & bearing noise.

Check motor current and voltage.

Weekly Check suction & discharge pressures.

Check vibration & noise.

Visual check for seal leakage.

Remove the safety guards and inspect the pump

shaft.
Monthly
Check for coupling alignment.

Fill lubrication oil.

If the pump is a spare, run the pump and check

for any maintenance issues.

Check for any axial movement of the motor

shaft.
Annually
Remove and clean all auxiliary components
including valves, manometers, pipes, and hoses.

Remove couplings and inspect for wear on

rubber parts.

Every 2 Years or 10000 Hours Dismantle pump and inspect: impeller, wear
 rings/plates, O-rings, pump shaft.

Apply coating to un-machined surfaces.

 Improperly wired (Check wiring against diagram on motor)

 Stone or foreign object lodged in impeller (Dismantle pump and remove foreign object)
 Motor shorted out (Replace motor
 Thermal overload has opened circuit (Allow unit to cool, restart after reason for overload has been
determined
Issue: Pump isn’t delivering rated capacity
Cause Remedy
Wrong capacity setting Change capacity setting
Not enough hydraulic oil Add hydraulic oil until filled to an adequate leve
Suction is starved Increase the size of the suction piping or suction
Relief valve (internal or external) keeps relieving because it’s set too
Check the pump rating and adjust relief valves to
low for the system
Suction piping is leaking Determine and repair the cause of the leak
Suction lift is too much Decrease suction lift
The liquid is nearing the boiling point Either cool the liquid or increase the suction hea
Liquid has a viscosity that’s too high Change ball material or size and reduce the liqui
Check valves are worn out or dirty Evaluate check valves and clean or replace as ne

Pump Troubleshooting – Preventative Steps

With some simple preventative steps, your pump can run smoothly without needing a pump troubleshooting
guide. Start by reading your manufacturer’s manual and any installation and operation instructions. A pump
properly set up, in the beginning, will be free from several issues.
Establish some preventative maintenance practices, like checking oil levels and seal integrity semi-regularly.
Keep some spare parts, like check valves, on hand for easier fixes in the future.
Only use your pump for the application for which it was designed. If you need to change the application,
contact your manufacturer to check if the new chemicals are compatible with pump materials and design.
When choosing your pump, ask questions and provide lots of information to your manufacturer. That’s how
they can help you choose the best pump for your application. Properly matched components, materials, and
installation are the key to smooth pump operation.
 1. PUMP RUNNING DRY

In a perfect world, pumps would not run dry. The reality of many applications, however, often creates a dry-
running situation. Tanks need to be emptied, light products vaporize, and sometimes debris (or a closed valve)
blocks the pump suction. In these situations, metal wear components can seize and cause severe damage.

2. PUMP SEIZURE

Pumps running dry is only one cause of pump seizure. A wide range of off-design conditions can also lead to
high-energy pump seizures. Foreign objects can enter the pump, low flow operation can cause excessive shaft
deflection, or fatigue stresses can cause a shaft to break. Again, a pump with metal wear components runs the
risk of seizure and excessive damage. The remedy is replacing the wear. For example, in the photos a piece of
metal is lodged in the impeller of the pump, causing extreme vibration. Operators immediately shut down the
pump and switched to the installed spare. Fortunately, the pump had been rebuilt with composite case rings,
which did not seize. The rotor spun down, the seals did not leak, and the plant continued to operate at full
capacity. Even after being exposed to such extreme loads, the composite rings were intact with minimal wear.

3. PUMP CAVITATION

In classic pump cavitation, the net positive suction head available (NPSHA) is less than the net positive
suction head required (NPSHR). Sometimes, the problem can be easily solved by raising the level in the
suction tank or making other small modifications to the suction system. Unfortunately, the easy fixes are
rarely available. More commonly, the choices are a complete redesign of the suction system, a hydraulic rerate
of the pump, or a complete replacement of the pump. In this evaluation, the wear rings are often overlooked,
but they shouldn’t be. The NPSHR for a pump is directly related to the wear ring clearance. Reduce the wear
ring clearance and the NPSHR is reduced. Increase the clearance and the NPSHR increases. Worn out pumps
that have been in service for many years begin to cavitate because their wear rings are worn out. By upgrading
the wear rings, you can dramatically reduce the wear ring clearance to 50 percent of the API610 minimum
values and reduce the NPSHR of the pump. The magnitude of the change is a function of the pump specific
speed and the percentage by which the clearance can be reduced. In many situations, the extra margin from
tighter wear ring clearance is all that is needed to avoid pump cavitation.

4. GALLING DURING ALIGNMENT

Although less dangerous than a full pump seizure, pumps that gall during alignment can be a major
annoyance. The most common type of pump to experience this problem is a horizontal multi-stage pump.
These pumps rely upon the wear rings to create hydraulic forces that “lift” the rotor once the pump is running
at full speed. While the rotor is being turned during alignment, the rotor experiences shaft sag, which often
causes the center-stage bushing and middle-stage wear rings to contact. During this contact, some metals will
gall, cause the rotor to stick, and require a return trip to the maintenance shop for disassembly, cleaning, and
rebuild. Alternatively, small particles can enter the tight clearance between the wear rings, pick up a piece of
metal and roll it like a snowball until it causes the rotor to gall during alignment. Using Vespel CR-6100
stationary wear components essentially eliminates this risk by eliminating the metal-to-metal contact points in
the pump.
5. SUCTION PROBLEMS AT START-UP

Directly related to cavitation is the ability of a pump to achieve suction at start up. There are many services
such as hot water condensate, LPG, LNG, and other flashing hydrocarbons where pumps can fail to achieve
suction at start up because the process fluid vaporizes. This can cause the pump to run dry (see problem #1),
cause premature wear of the wear components (see problem #9), or cause repeated efforts to start and stop the
pump until it runs. Reducing the wear ring clearance significantly improves the ability of a pump to achieve
suction at start-up due to the reduction in NPSHR.

6. MECHANICAL SEAL FAILURES FROM EXCESSIVE SHAFT DEFLECTION

Many older pump designs, and some new pump designs, incorporate a long, slender shaft. During operation,
the thin shaft can deflect, putting undue stress on the mechanical seal, leading to premature seal failures.
The wear rings have a powerful impact on shaft stiffness through hydraulic forces called the “Lomakin
Effect.” In short, when you reduce the clearance of wear rings by 50 percent, the stiffness and damping forces
from the Lomakin Effect double. This leads to lower shaft deflection, and more reliable mechanical seals. In a
long-term study of pumps at a refinery using Vespel CR- 6100, seal leaks in volatile organic compound
(VOC) service were reduced by 60 percent. The twelve pumps in VOC service required monthly emissions
testing to comply with local environmental regulations. Before the composite wear rings were installed, the
testing detected an average of six leaks per year. After the installation with reduced clearance, testing detected
an average of two leaks per year.

7. HIGH VIBRATION

The Lomakin Effect described above also reduces overall pump vibration levels. In the same long-term study,
the overall vibration readings from twenty-five horizontal pumps were tracked for one year before the
conversion to the Vespel CR- 6100 composite and for 4.5 years afterwards. The average reduction in vibration
resulting from the upgrade was 25 percent, and this improvement persisted for the full 4.5 years. Some of the
pumps experienced vibration reductions by as much as 50 percent.

8. POOR EFFICIENCY

Pump wear rings also act as the “seal” between high pressure and low pressure areas in the pump. Reducing
the wear ring clearance reduces internal recirculation within the pump and improves pump efficiency. For a
typical process pump, the efficiency gain from a 50 percent clearance at the wear rings will be in the range of
2 to 5 percent. Where the internal clearances can be reduced by more than 50 percent, efficiency gains can be
substantially higher. For a pump running near its limit, this added efficiency can help achieve full production
rates. For example, a fertilizer plant in Alberta upgraded their wear rings, inter-stage rings, and throttle
bushings of a nine-stage boiler feed water pump to Vespel CR-6100 and reduced the clearance to 50 percent
of the API610 standard for metal wear rings. This change allowed the plant not only to run at full load with
one pump but to do so with a 5 percent reduction in power usage.

9. EXCESSIVE CLEARANCE AT PUMP WEAR RINGS AND SHAFT BUSHINGS

Pumps are often supplied with materials like bronze or cast iron for wear rings or shaft bushings. These
materials are often chosen because they are cheaper and resist seizing somewhat better than stainless steels.
The cost, though, is a high wear rate. High friction from metal-to-metal contact at the wear parts opens the
clearance and within a short time, the pump is running with low efficiency, high vibration, and lower
reliability. Vespel CR-6100 exhibits a very low wear rate running against a rotating metal component. The
wear rate is reduced because it has a very low coefficient of friction, high load carrying capability, and
exceptional dimensional stability. When contact occurs between the rotating and stationary parts, there is
lower friction and less wear. The pump runs longer, with higher efficiency and a lower life cycle cost.

10. LIMITED MATERIAL SELECTION DUE TO CHEMICAL COMPATIBILITY PROBLEMS

Some pump services significantly restrict the materials which can be used for the wear components. It is not
uncommon for strong acids or other chemicals to restrict the metal parts to a single alloy. For example, in
hydrofluoric acid, wear parts are almost universally made from Monel. This situation creates a unique
challenge because when the rotating and stationary wear components in a pump are made from the same
material, pump seizure is a significant risk. This is often avoided with increased clearance, which as you
understand by now, significantly reduces the reliability and efficiency of the pump. Vespel CR-6100 is made
from Teflon® PFA resin and carbon fibers. With this composition, it is chemically compatible with nearly all
process fluids used in industry. Furthermore, because of DuPont’s patented manufacturing process, the
material possesses exceptional dimensional stability. This unique combination of properties replaces metal
alloys, carbon or graphite components, filled PTFE components, or polyetheretherketone components in
nearly any kind of rotating machine.

CONCLUSION

While no single change can eliminate all causes of pump failure, some changes offer significant upside across
a broad range of services. Changing the stationary wear components in a pump and reducing the clearance
addresses many causes of pump failure, while increasing the pump efficiency and safety. Conjunctions with
reduced clearance, maintenance personnel will want to review pump rebuild practices to ensure adequate rotor
concentricity so that the rotor retains freedom of movement within the pump case. The standard check is to
turn the rotor once the repair is complete. If the pump in question is a long-shaft vertical pump, the rotor
should also be free to move after the pump has been coupled in the field. With proper rebuild practices, tight
clearance, and Boulden B-Series stationary wear parts, plants all over the world have experienced significant
reliability gains.

Find new slurry pumps.