CHAPTER 10 - PUMPS Chapter 10 PUMPS Section 1.0 General Requirements. 14 12 13 14 15 Scope. This standard deals with the selection and installation of pumps supplying water for domestic, industrials, for private and/or public fire protection. Items include water supplies, suction, discharge and auxiliary equipment, power supplies, electric drive control: internal combustion engine drive and control, acceptance test, operations and maintenance. This chapter does not contain system water supply capacity and pressure requirements. Purpose. The purpose of this standard is to provide a reasonable degree technical know how, and safety, through installation, requirements for pumps based on sound engineering principles, test data and field experience. Guidelines are established for the design, installation and maintenance for pumps, drivers and associated equipment. This standard endeavors to continue the excellent record that has been established by pumps installation and to meet the needs of changing technology. Other Pumps. Pumps other than those specified in this standards and having different design features may be installed when such pumps are listed by a testing laboratory. Pumps shall be selected based on the conditions under which they are to be installed and used. The pump manufacturer shall be given complete information concerning the water, or liquid and power supply characteristics. Unit Performance. The unit consisting of Installation of pumping equipment to supply buildings, from existing water supply should only be allowed if there is always water in the mains ‘to prevent contamination of water system when 194 16 417A air gains entrance due to negative pressure created by pumping. A shut off valve followed by a check valve shall be place between the suction of pump and water mains to prevent any return of water to mains when pump is stopped. Overhead Tank Supply. A water tank may be installed above the roof of the building or by separate tower for the purpose. Water from the water mains is pumped to the tank and the building draws its supply from overhead tank a. Suitable float switch or other devices should be installed with the tank to stop or start operation of pump depending on water level in the tank. b. A check valve should be installed between the pump and tank. c. Water tank should be provided with ar overflow pipe, leading to storm drain and ¢ vent properly protected from insects. d. Water tank should be fully covered to keep out flying debris and to prevent growth of moss, 8. For multi-storey buildings, suitable pressure reducing valves should be supplied to regulate water pressure for each floor. Pneumatic Tank. The tank is an unfirec pressure vessel, initially full of air, into which water from mains is pumped. a. A suitable pressure switch should stop pump when pressure required is attained. b. An air volume control device should be installed to replenish air absorbed by water under pressure to maintain correct air volume in tank.CHAPTER 10 - PUMPS ©. Suitable air valve to take out or replenish air in tank should be installed on top of tank. d. Atank should be designed for maximum total dynamic pressure required multiplied by two to provide for water hammer. Factor of safety should not be less than five. fe. For tanks of 3785 liters or more < ‘separate ait compressor should be installed to replenish air absorbed by the water. f. For figuring equipment, pipes fittings and valves, the right pressure ratings should correspond to total dynamic head multiplied by two to cover water hammer effect, Section 2.0 Definitions One of man’s oldest aids, the pump today ranks second to the electric motor as the most widely used industrial machine. Today the U.S. alone draws more than 200 billion gallons each day from its resources and pumps move almost every drop. Of this total, an impressive 80 billions gallons is said to be industry's share. To meet these demands we find as almost confusingly large variety of available pumps. They range from tiny adjustable displacement units to giants handling well ‘over 100,000 gallons per minute. It is neither possible nor desirable to cover every variation in a concise practical code such as this: So we've made a highly selective choice of widely used industrial pumps of all classes and types — the pumps you're likely to run into your work. 24 Hydraulic. Hydraulics, or hydromechanics, is the mechanics of water or other liquid whether at rest or in motion 2.2 Hydrostatics is the science of water at rest. A good example is a gravity tank filled with water and supplying water to closed valve. Until the valve is opens, the water is at rest, but its weight has potential energy and exerts a definite force, or static pressure against the closed valve. 2.3 Hydrokineties is a science of water in motion. When the valve in the preceding example ‘opens, the potential energy of static pressure becomes kinetic energy. The weight of water 195, 24 25 2.6 27 2.8 2.9 caused it to move up thru the piping and out of the nozzles or opening, Hydrodynamics is a general term, and is generally associated with the science of the force exerted by water in motion, such as driving a turbine connected to an electric generator. Atmospheric Pressure is due to the weight of the atmosphere on the earth. At sea level the atmospheric pressure is 14.7 PSI, or 29.9 inches of Mercury column (Hg), which is commonly designated as one atmosphere. Atmospheric pressure diminishes with elevator above sea level. It is atmospheric pressure on an open body of water that forces the water up in pump suction pipe in those cases when a pump takes suction under lift. (A pump should always take a suction under water pressure at atmospheric pressure). Vacuum. A perfect vacuum is a space entirely devoid of gas, liquids or solids. No one has ever succeeded in exhausting all the air from a closed vessel (such as suction pipe of a pump). The word “vacuum” therefore means “partial vacuum” and is measured by the amount of its pressure below the prevailing atmospheric pressure. Gauge Pressure (PSIG) is just the term implies the pressure on a gauge on open air, the gauge being connected to a closed pipe. Absolute Pressure (PSIA) is the sum of the atmospheric pressure (14.7 PSI or less) and the gauge pressure (PSIG). Pressure Measurements. Unless otherwise stated hereafter in this chapter “pressure” means pressure: pressure in pounds per square inch (PSI); head is in feet of water column (FT); vacuum is in inches of Meroury (Hg), No matter how many square inches are covered by a column of water one foot high, the pressure still 0.433 pounds per square inch or 0.433, PSI, 2.31 is the reciprocal of 0.433. Pressure is force applied to liquids, or force developed by the weight of the liquids. Pressure is also called "head". Pressure is measured in two ways:= a. The number of feet the pressure wil force a column of liquid up to rest. ThisCHAPTER 10 —- PUMPS 2.40 Bourdon Gauge (named for s called head in feet, and designated as nin feet. b. The number of pounds of force exertec on one square inch. This is callec pounds per square inch and designec as p (PSI) and/or kilogram per square meter (kg/m*). Bourdon tube -Zero posiior Mechanism Dial Face Bourdon Gauge-Compound 10-4 The two pressure measurements for water are related in this way: P (in PSI) = 0.433 h (in feet) h (infeet) = 2.31 p (in PSI) its inventor Bourdon) consists essentially of a curved tube, fixed at the open end, with the other (closed) end free and attached to a lever which is geared to the indicator needle. When pressure enters the Bourdon tube, the tube straightens in proportion to the amount of pressure applied and this the needle is moved to the pressure marked on the dial corresponding to the pressure in the tube. By far most of the gauges ipuse are of the bourdon type. (See figure 10- 2.44 Manometer (open type) is a gauge in the form of a glass U-tube one leg of which is open to the atmosphere, or a straight tube one end of which is open to the atmosphere. The height to which a column of water would rise in the open tube is a measure of the feet of head or pressure in the pipe to which the manometer is connected. Tc eliminate unwisely tube heights and freezing at ordinary water freezing temperatures, mercury is generally used, the graduations being in inches 196 212 213 2.14 (or in meters) of mercury (Hg). Differential (closed) manometers, may be used for measuring differences in pressure, such as the difference between two points in a pipe or between the total and normal pressure at the same point in pipe. Pilot Tube. (named for its inventor Pilot) is used to measure the pressure of water discharging from a nozzle or flowing in a pipe by having its open end in the water and the other end connected to a gauge ot manometer. The tube is generally about one-sixteenth inch in diameter, bent at right angles, and mounted with a gauge or manometer connected to the long end. The short end is held by hand in a hose stream, nozzle or flowing water. (See figure 10.2.1; 10.2.2; 10.2.3; and 10.2.4), Piezometer is a device set in a pipe to enable a Bourdon gauge or a manometer attached to the Piezometer to show the net or normal pressure. The Piezometer gives a lower pressure by calming the water entering the gauge or manometer, thus reducing the fluctuations, (See figure 10.2.2 and 10.2.3). Capacity is the rate of flow of liquid measure per unit of time, usually gallons per minute (GPM) or liters per minute (LPM). U-Tube graduated in tenths of PSI arin tenths of inch Plezameters. ——~" P2 Fig. 10.2 Differential Manometer (U-Tube) for Measuring the fiction, 2.15 2.16 ‘Loss between two points on a level pipe Suction Lifts (Hs) exist when the total suction is below atmospheric pressure. Suction lift, as determined on test, is the reading of a liquid manometer at the suction of the pump, converted to the feet of liquid, and referred to datum, minus the velocity head at the point of gage attachment. Suction Head (Hs) exists when the total suction head is above atmospheric pressure. Su head, as determined on test, is a reading of @ gage at the suction flange of the pump converted to feet or meter of liquid and referredCHAPTER 10 — PUMPS to datum, plus the velocity head at the point of gage attachment. 2.17 Velocity Head (Hv) is figured from the average velocity (v) obtained by dividing the discharge in cubic feet per second (cis) or cubic meter second (cms) by the actual area of the pipe ‘cross section in square feet or square meter and determined at the point of the gage connection. Itis expressed by the formula: Velocity Presgure Oo: ig. Differential Manometer (U-Tube) for Measuring velocity pressure by means of the difference between total pressure (from Pitot Tube) normal pressure (from Piezometer) Total Pressure Pilot Tube Total Prossure Normal or Net Pressure = Velocity Pressure Fig. 10-4 Total Pressure Normal or Net Pressure = Velocity Pressure PLAYPIPE FIRE HYDRANT PITOT TUBE ~ HELD BY HAND Fig. 10-5 2.18 2.19 2.20 2.24 2.22 2.23 2.24 2.25 2.26 Where: gis the acceleration due to gravity = 32.17 feet per second square. Vis average velo pipe in feet per second. Total Discharge Head (Hd) is the reading of a pressure gage at the discharge of the pump, converted to feet of liquid and referred to datum, plus velocity head at the point of gage attachment. Total Head is the measure of the energy increase per pound imparted to the liquid by the pump and is therefore the algebraic difference between the total discharge head and the total suction lift exists, is the sum of the total discharge head and total suction lit; and when suction head exists, the total head is the total discharge head minus the total suction head. Net Positive Suction Head (NPSH) is the total suction head in feet or in meter of liquid absolute determined at the suction flange and referred to datum, less the vapor pressure of the liquid in feet or meter absolute. Centrifugal Pump. A pump in which the pressure is developed principally by the action of centrifugal force. End Suction Pump. A single suction pump having its suction nozzle on the opposite side of the casing from the stuffing box and having the face of the suction nozzle perpendicular to the longitudinal axis of the shaft. In Line Pump. A centrifugal pump whose drive Unit is supported by the pump having its suction and discharge flanges on approximately the same center. Horizontal Pump. A pump with the shaft normally in a horizontal position Horizontal Split-Case Pump. A centrifugal ump characterized by @ housing which is split parallel to the shaft. Vertical Shaft Turbine Pump. A centrifugal pump with one or more impellers discharging into one or more bowls and a vertical eductor orCHAPTER 10 —- PUMPS 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 2.35 column pipe used to connect the bowls to the discharge head on which the pump driver is mounted. A Booster Pump is a pump that takes suction from a public service main or private-use water system for the purpose of increasing the effective water pressure. Submersible Pump. A vertical turbine pump with the pump and motor closed coupled and designed to be installed underground, as in the ‘case of the deepwell pump, Aquifer. An underground formation thal contains sufficient saturated permeable material to yield significant quantities of water. Aquifer Performance Analysis. A test designed to determine the amount of underground water available in a given field and proper well spacing to avoid interference in that field. Basically, test results provide information concerning transmissibility and storage coefficient (available volume of water) of the aquifer. Wet Pit. A timber, concrete, or masonry enclosure having a screened inlet kept partially filled with water by an open body of water such as pond, lake, or streams. Ground Water. That water which is available from a well, driven into water-bearing subsurface strata (aquifer). Static Water Level. The level with respect tc the pump, of the body of water from which i! takes suction when the pump is not in operation. Pumping Water Level. The level, with respect to the pump, of the body of water from which if takes suction, when the pump is in operation. Draw-Down. The vertical difference between the pumping water level and the static water level Section 3.0 Pumps THESE QUICK GUIDES TO THE WORLD OF PUMPS SHOW THE MAJOR CLASSES AND TYPES IN USE TODAY: The majority of centrifugal pumps Volute bul today are the volute. type 198 Diffuser Turbine or Regenerative Gear Vane & # Mixed-Flow ‘am and Piston Direct-Acting Power Crank- ‘lywhee! They are available as horizontal ¢ vertical pumps, single or multi-stage for wide flow ranges. Diffuser-type centritugals find many uses as multi-stage high-pressure units. Originally more efficient than volute-type pumps, today efficiency of both types is about equal. Mixed-flow centrifugals pumps are ideal for low head large-capacity applications. Usually vertical, they have a single-inlet impeller. Some horizontal units are bul. Axial-low units, often called propeller pumps, develop most of their head by lifting action of vanes, are usually vertical, and best suited for low heads, large capacities. For clear liquids, turbine pumps, either horizontal or vertical, fil @ need between other centrifugal anc usual rotary designs. ‘They are low- tormedium-capacity high head Gear pumps consist of two or more gears (spur, single-or double-helical teeth) while vane pumps have a series of vanes, blades or buckets turned by a single rotor. This rotary class also includes lobe or shuttle- block designs. Cam and piston rotaries, like most types in this class, are positive- displacement units, giving steady discharge flow along with screw- type pumps, and related designs, they handle'a wide range of non- abrasive viscous liquids. Old standbys for years, direct- acting pumps now are available in many designs for handling cold or hot water, oll, and a wide range of industrial liquids of many types. Power pumps are driven from outside through a crankshaft or other device, Capacities range from very low to medium flows, at pressure up to 15,000 psi, (1033.5 bars), or higher. Crank-and-flywheel pumps are one form of reciprocating power pump, 50 designated to distinguish. them from power pumps using, for example, an eccentric as. drive mechanism,CHAPTER 10 —- PUMPS A CENTRIFUGAL r—|_Single-stage Close Impelier Fixed Pitch 1 pnatsiow ~ H, Lome eee pees ‘Single Suction amy — aa Radial Flow ‘Double Sucion ‘Single stage (| _ Sinaie-stage ‘Seleprinting — = ‘Hydraulic Ram —[_Eecvomennete | ‘simplex oem aT Les 1] Double etna Lf ia sown ie 7 (Crank and Flywheel) aa sony - Sea 199CHAPTER 10 - PUMPS 34 3.2 Pump Classification Centrifugal Pumps. A centrifugal is a machine which the pumping action is accomplished by imparting kinetic. energy to the fluid by a high speed revolving impeller with vanes and subsequently converting this kinetic energy inte pressure energy either by passing the fluid thru a volute casing or thru diffuser vanes. After the conversion is accomplished, the fluid is discharged from the machine. When the kinetic energy is converted to pressure energy by means of the volute shape of the casing, the pumps are called volute centrifugal pumps. When the conversion of kinetic energy to pressure energy occurs in the passage of the fluid thru stationary diffusers vanes, the pumps are called diffuser centrifugal pumps. The radial type of impeller is characterized by rather long narrow passages for the water. The ratio of outside impeller diameter D2 to impeller eye diameter D1 is approximately 2. The Francis type of impeller is characterized by wider passages for the water and the ratio of D2 to D1 is about 1.5. The mixed flow type of impeller is characterized by a mixed flow velocity vector, which naturally has a horizontal component along the shaft as well as a vertical component perpendicular to the shaft. The ratio of D2 to D1 is slightly over unity. The axial or propeller type of impeller has a ratio of D2 to D1 equal to unity. The pumping action is accomplished by lifting of the water by the pitch of the blades of propeller as it revolves. As this type of impeller has no guidance for the flow of water, it cannot operate with suction lift, The impeller or propeller is generally immersed in the liquid. a. Classification of Centrifugal Pumps Centrifugal pumps can be classified, as follows; + By Geometry - the common form of classification of turbo machines, and centrifugal pumps in particular, from the shape of the casing. 200 By Inlet Geometry — Commonly applied to turbo machines and rotary pumps , to a lesser extent; which describes the basic ‘geometry of the section entry of the pump. By Layout - Refers to the design (or possible) position of the pump, shaft access, such as horizontal, vertical or inclined . This indicates the mounting requirements (most likely floor space). A further classification is appiicable for turbo machines, particularly where the casing halves ‘divide for disassembly. By Mounting - Generally describes the design method of mounting the pump and applies but not necessarily always specified for all pump types. By Operation - Basically is the description of the design duty of the stand by pump , like for the example, air pump, source pump, stand by pump, auxiliary pump, etc. But this does not necessarily follow that the use of such a pump is restricted to the specified ‘operation. By Liquid Handled - This specific description indicates that the pump can handle a particular type or types of fluid or product like chemicals and other corrosive liquids. By Material — This indicate the type of the pump whose material of construction particularly the wetted parts is suitable for handling chemically active or corrosive fluids, By Drive — This specifies the method of drive intended or applicable for the pump as spiced in the design mounting area limitations or other requirements to use, for example, electric motor, engine (gas or diesel), integral (electric) motor, magnet drive, manual drive, turbo driven, shaft- driven, etc, Submersible Pumps - Pumps of this type are of sufficient importance to warrant 2 classification of their own, representing the type of pump with integral electric motor, which can be immersed in the product being handled. They can be subdivided into various categories according to intendec duty, for example deepwell, borehole, etc. and by the form of canned motor. Basic Parts of a Centrifugal Pump. Impeller - Imparts velocity to the liquid, resulting from centrifugal force as the impeller is rotated.CHAPTER 10 - PUMPS Casing - Gives direction to the flow from the impeller and converts this velocity ‘energy into pressure energy which is usually measured in feet of head. Shaft - Transmit power from the driver to the impeller. Stuffing Box - This is a means of throttling the leakage which would otherwise occur at the point of entry of the shaft into the casing, Usually not a separate part, but rather made Up of a group of small details. 1. Packing — This is the most common means of throttiing the leakage between the inside and outside of the casing 2. Gland - To position and adjust the Packing pressure. 3. Seal Gage (also called water-seal of lantern ring) ~ Provides passage to distribute the sealing medium uniformly around the portion of the shaft that passes through the stuffing box. This is very essential when suction lift conditions. prevail to seal against in leakage of air. 4, Mechanical Seal. Provides. a mechanical sealing arrangement that takes the place of the packing, Basically, it has one surface rotating with the shaft and one stationary face. The minute close clearance between these two faces prevents leakage of liquid out or air in. Shaft Sleeve — Protects the shaft where it passes through the stuffing box. Usually used in pumps with packing but often eliminated if mechanical seals are employed. Wearing Rings - Keeps internal recirculation down to @ minimum. Having these rings as replaceable wearing surfaces permits renewal of clearances to keep pump efficiencies high. On small types only one ring is used in the casing and on larger sizes, companion rings are used in the casing and on the impeller. Specific Speed. Specific speed is a type characteristic of centrifugal pumps and is 201 defined as the speed in rpm at which a given impeller would operate if reduced proportionately in size, as to deliver a rated capacity of 1 GPM against a total dynamic head of one foot. The visualization of this definition, however has no practical value for specific speed if used to classify impellers as to theit type or proportions and as a means of predicting other important pump characteristics, such as the suction limitation of the pump. The effect of suction lift on a centrifugal pump is related to its head, capacity and speed. Impoliors for high head usually have low specific speeds. Impellers for low heads usually have high specific speeds. The specific speed is found to be very valuable criterion in determining the permissible maximum suction lift, or minimum suction head. Abnormally high suction lifts beyond the suction rating of the pump, usually causes serious reductions in capacity and efficiency, which often leads to serious trouble from vibration and cavitation, For @ head and capacity, a pump of low specific speed will operate safely with greater suction lift than one of the higher specific speed. Pumps at the higher speeds without proper suction conditions often cause Serious trouble from vibration, noise and pitting. The equation for specific speed of a centrifugal pump is expressed as follows: Specific Speed, Ns = wVaQ ay" where: Ns = specific speed of pump in RPM Ns = ated speed of pump, RPM Q = pump capacity in GPM (Note: 1 gallon = 3.785 liters) = pump head per stage, feet Stage (Note: 3.28 ft = 1 meter) For double suction pumps the Q value is determined by dividing the given capacity by 2, which is then substituted in the formula. For multi-stage pumps the H value is determined vy dividing the total head by the number ofCHAPTER 10 - PUMPS stages available from the pump. This is so because each impeller contributes a definite value of head of the total developed by the pump. Affinity Laws for Centrifugal Pumps: The mathematical relationship between these several variables, that is; capacity, head power at constant impeller diameter and speed. These relationships are expressed as follows a. _ at constant impeller diameter Law at Bae eres Nj ot Q No = Nh Ne No At constant impeller speec Law bt a Q Law b2 eeu See He 7 Law b3 Hi = Di KW D2 Where: Q1 = Capacity H1 = head at N1 RPM or with impeller Diameter o1 Q2 = Capacity H2 = head at N2 RPM or with impeller Diameter p2 Law at applies to the Centrifugal, Angle Flow, Propeller, Peripheral, Rotary and Reciprocating pumps. Law a2 and a3 apply to Centrifugal, Angle Flow, Mixec Flow, Propeller and Peripheral pumps. Law b1, b2 and b3 apply to Centrifugal Pumps only. 5922F 1770 RPM 1500 GPM 150-228 Psi 202CHAPTER 10 - PUMPS Parallel and Series Operation of Centrifugal Pumps Pumps are installed in parallel to satisfy variable Pumping requirements to maintain pump operation at peak efficiency and optimum power consumption. With this installation program plant shutdown are easily ‘scheduled without disrupting critical operations. Similarly, multiple pumps in series may be used when liquid must be delivered at high heads. 3.3 Rotary Pumps. A rotary pump is a positive displacement pump consisting of a fixed casing containing gears, cams, screws, vanes, plungers or similar elements actuated by rotation of the drive shaft, a. Types 1, Cam and Piston Pumps. This type consists of an eccentrically bored cam, rotated by a shaft concentric in a cylindrically bored casing, with an abutment or follower so arranged that with each rotation of the drive shaft a positive quantity of liquid is displaced from the space between the cam and follow and the pump casing, 2. Gear Pumps. This type consists of two or more gears, operating in closely fitted casing so arranged that when the gear teeth unmeet on ‘one side liquids fills the space between the gear teeth and is carried around in the tooth space to the opposite side and displaced as the teeth mesh again. There are two types of gear pumps: (a) Extemal gear pumps have all the gear rotors cut externally. The gears maybe spur, single helical or double helical. {b) Internal gear pumps have one rotor with internally cut gear teeth meshing with an externally cut gear idler. Pumps of this type are made with or without a crescent shaped partition, (c) Screw Pumps. This type consists of one, two or three screw rotors so arranged that as the rotors tum liquid fills the 203 3.4 shape between the screw threads and is displaced axially as the rotor threads mesh. () Vane Pumps. This type consists of one rotor in a casing machined eccentrically to the drive shaft. The rotor is fitted with a series of vanes, blades or buckets which follow the bore of the casing thereby displacing liquid with each revolution of the drive shaft. Vane pumps may have swinging vanes or sliding vanes. The rotary pump combines the constant discharge characteristic of the centrifugal type with the positive discharge characteristic of the reciprocating pump. The flow from a reciprocating pump is pulsating whereas the flow from many rotary types of pump is constant. The positive discharge characteristic including reciprocating pump prevents the operation of these pumps against a closed discharge unless an automatic unloader is provided to bypass the discharge with the suction well. Rotary pumps are capable of handling only a clean solution essentially free of solids and particularly adopted to handling liquids of high viscosities, such as heavy fuel oil, paint, et. Reciprocating Pumps. A reciprocating pump is a positive displacement unit wherein the pumping action is accomplished by the forward and backward movement of a piston or plunger inside a cylinder usually provided with valves. Piston types are used for low pressure light duty or intermittent service. Less expensive than the plunger design, but cannot handle gritty liquids. Plunger types are used for high pressure heavy duty or continuous service. Suitable for gritty and foreign material service, and more expensive than the piston design. a. Types of Reciprocating Pumps 1. Direct Acting Steam Pumps. This type has a steam cylinder with no lap on valves, a water cylinder and a common piston rod. As there is no lap, the steam is admitted throughout the length of the stroke, hence the pressure volume diagram of the steam end is rectangle. Consequently, the water end flow diagram will also be a rectangle withCHAPTER 10 - PUMPS ing effect of speed change on centrifugal pump performance. the discharge flow constant throughout the length of the stroke and going down to zero value at the instant or reversal of the piston at the end of each stroke. 2. Crank and Flywheel Reciprocating Pump. This type is driven by compound, _cross- compound, or _triple-expansion steam engines. In large sizes such units are known as pumping engines. 3. Power Driven Pumps. This type receives its forward and backward motion of the piston and plunger from the rotary motion of a revolving crankshaft by means of a crank and connecting rod. Reciprocating pumps can be single acting or double acting. They can be simplex, duplex, triplex, etc., depending on the number of water cylinders on the machine. Due to the manner of operation of direct- acting steam pumps, practically almost all directa steam pumps are built double acting, b. Accessories of Reciprocating Pumps. The reciprocating pumps need some accessories for better and safe operation 204 35 besides the piston and cylinder and various forms of valves used. 1. Air Chamber. Its function is to smoothen the flow due to the nature of flow of the liquid from such type ‘of pump. The size of air chamber required depends on the type of pump, and generally on the pressure and length of pipe line. Air chamber can be placed either on the suction side or discharge side of the piping installation. 2. Pressure Relief Valve. This shoule be installed on the discharge side between pump and any other valve. 3. Foot Valve and Strainer. These should also be installed at the end of the suction pipe. The footwalve should be of a size at least equal to the size of the suction pipe. The clear area of the strainer should be at least three times the area of the suction pipe in order to minimize head loss at this point. c, Head, Capacity, Efficiency. The total head as defined for centrifugal pumps also applies to reciprocating pumps. It is general practice of manufacturers of reciprocating pumps to state capacities in terms of piston ‘or plunger displacement without deduction for the piston rod area or slippage. Volumetric efficiency is defined as: Where: Q = actual volume of liquid discharged Q+ = true piston or plunger displacement Q includes all losses of capacity due to leakage past piston packing, stuffing boxes, and valves and also that loss due to delayed closing of valves. All losses of capacity given in percentage of the displacement are referred to as slip (1- e, ). In new pumps the slip is of the order of 2%, Deep Well Pumps a. Deep well may be divided into plunger or reciprocating, turbine, _ejector-centrifugal types and air lifts.CHAPTER 10 - PUMPS Plunger Pumps. Modern plunger Pumps are refinement of the old hand pumps that have played such an important role in country-home and small town water supply from wells. A ball valve, plunger, and check valves are used in this pump. In operation, only the plunger moves. When the plunger is raised a vacuum is created below it, and water flows in through the check valve to fill the void. When the plunger is lowered, the check valve ‘close and traps the fluid in the pump, and it is forced up through the valve in the plunger, to be lifted ‘on the next upward stroke of the plunger. Turbine Pumps. These pumps represent the application of vertical centrifugal pumps to deep well service and are built for heads up to 305 meters and for capacities up to 26 495 liters per minute. The turbine pump includes two principal parts; the head, comprising a vertical driving motor, discharge connection, and step bearing, and the pumping unit. The pump unit is that part installed under the pump head below the surface of the ground. It comprises the pump column, shafting, and pump stages, the latter consisting of the bowis and impellers. A type of turbine pump wherein the motor is below the turbine bowls is called the submersible motor pumps. In this set-up the propelling shaft is very short and the usually long, smali- diameter motor —_ operates submergod at all times in tho well water. However, the liquid pumped does not come in contact with the electrical parts on motor bearings, as these are enclosed in an oil-filled case with a mercury seal where the shaft passes through at the top. The turbine and the submersible motor form a compact unit that is attached to an supported by the discharge pipe. Ejector-Centrifugal Pump. A type ‘of deep well pump that has come into wide use for small capacities 205 b. Water Horsepower. combines a single-stage centrifugal pump at the top of the well and an ejector or jet located down in the water. This is best suited where the lift is 7.6 meters or over the capacities up to 190 liters per minute net discharge. The amount of water required to flow down the pressure pipe for jet operation increases as the lift from well-water level to the pump increases. Air Lifts. Another method of pumping wells is by air lifts with compressed air being admitted to the well to lift water to the surface. For successful operation of the system, the discharge pipe must have its lower end submerged in the well water. The amount of submergence before air is admitted will vary from 70 per cent for 6.1 meter lifts to 40 per cent for a 214 meter lift, When air is admitted to a well, the water recedes from the level of static head to the bottom of the discharge pipes. This displaced column of liquid rises up the discharge pipe and as the air flow continues, it enters the pipe, aerating the water and lowering the specific gravity of the mixture. Pressure in the well is momentarily decreased and then increased as the bottom end of the pipe is uncovered and covered. The cycle repeats rapidly, producing a nearly constant flow from the top of the discharge pipe. Horsepower and —_ Brake The theoretical amount of energy necessary to raise a given volume of is: fiuid (Q) from a lower to a higher elevation foot - pounds volume of fluid in gallons weight of fluid in Ib. per gallor vertical distance between elevations in feetCHAPTER 10 - PUMPS The water horsepower is: WHP = _QWH When Q is expressed in 33 000 gprr or WHP = _QH_ for water at standard 3960 temperature i.e., one gallon of water weighs 8.334 lbs For liquids other than water or for water at other temperatures than the standard: WHP = _QxHxSp. Gr 3.960 Where specific gravity of the liquid considered at the corresponding temperature. When pressure, expressed in psi, is considered instead of head, H, in feet, for water H = 2.31 P for standard conditions. WHP = _Qx231P = _OF 3.960 1774 When pumping any liquid having a specific gravity against a pressure (P) in psi, the WHP equation becomes: 231P Qx Sp. gr. x_Sp. Gr. 3.960 WHP = = Qx231P = 3 960 QP 1714 Due to the various losses in the flow of water thru pump, the friction in piping both suction and discharge, and due to turbulence of the water and the energy, to create the velocity of flow, the brake horsepower required by the pump is much greater than the water horsepower. The relation is: BHP = __WHP efficiency Section 4.0 Fluid Power Metrication 44 If the hydraulic or pneumatic circuitry designed within metric parameters, equipment and other components such as valves, cylinders or gages must have mounting that are compatible with metric fasteners, such as bolts and clevis pins. 206 There are several metric methods of specifying pressure. The most basic is the newton per square meter (Nim*). However, it is convenient to use the term pascal (Pa) which represent one Newton per square meter, by doing this pascal is associated with pressure and not with stress. Segments of the fluid power industry prefer the term bar, which is equal to 100 000 pascals, The following relationship can be used for converting to metric: 100 000 Pa 100.000 Nim* 14.5 psi 1 inch mercury (at 60°F) = 0.034 bars 1 bar Other manufacturers of fluids power equipment prefer to express gauge pressure in units of kglcm2. For basis of comparison 4 psi = 0.07045 kgem* Customarily, fluid flow has been expressed as gallons per minute for liquids and cubic feet per minute for gases. For liquid in metric units, cubic meter per minute or liters per minute are usable quantities. The following relationships represent relative magnitudes. gpm = 3.785liters/min. = 0.003785 m°/min. Section 5.0 Metric Pump Formula 5A Theoretical Power in Kilowatts Power, KW. = _QxWxH 6 130.25 where = pump capacity in liters/min. weight of fluid in kgsfiter = total head in meters £50 For cold water, W = 1 kg per liter hence eq (1) becomes KW, = _QxH 6 130.28 and for other fluids, the equation has to be multiplied bv their corresponding specific gravities.CHAPTER 10 thus, KW, = QxHx sp. gravity 6 130.25 5.2 Actual Power Required, KW, efficiency Water from a reservoir is pumped over a hill through a pipe 3 ft. in diameter, and a pressure of 30 psi is maintained at the summit, where the pipe is 300 ft above the reservoir. The quantity pumped is 49.5 cfs, and by reason of friction in the pump pipe there is 10 ft of head loss between the reservoir and the summit. What amount of energy must be fumished the water each second by the pump? Solution’ By the energy equation (English) Q = 49.efs = vxarea V = 49.5 = (0.7854 x 9) = 7 fps *Vel.Head= ye 2g = 49 64.4 = o7ft Pressurehead = 30 psix 2.31 = 69.3 ft Elevation = 3008 Head Loss = 10f ‘Total head of the pump = pressure head + velocity nead + elevation + head loss (if any) 69.3 +0.7 + 300+ 1¢ 380 fl 380 fx 49.5 cfs x 62.4 Ibs/cu.ft 550 fps Energy of pump = 2.130 hp (2 134 hp) b. Bythe English Unit pump formula ~ Whp = _QxHt Q 3.960 9.5 cfs x 448.83 = 22217.14 gpm 207 — PUMPS 380 fi = 2132 hp ¢. Bythe metric pump formula - Power = _QxH 6 130.26 Q 22 217.14 gpm x 3.785 84 091.9 liters/min H 380 ft + 3.28 fmeter = 115.9 meter KWt = 84.091.9% 115.9 6 130.25 = 1589.86 KW Check: 1589.89 KW-+ 0.746 = 21312hp When pressure, expressed in kg/om, is considered instead of Head in meters H = P in kgiom x 10 mikg/om for water at normal (standard) condition. Hence, Power (theoretical) = __Qx(Px10)_ kw 6 130.25 When pumping any liquid having a specific gravity, (sp. gr.) against a pressure in kg/cm, eq. (5) will remain the same since Px10 Power = Gr. x_$p. Gi 6 130.25 = QxPx10 6 130.25 Example 2: If the pump in example 1 is working against a pressure of 11.6 kg/cm indicated by a gage installed at the discharge side approximately 1 meter from the pump, how much power is reauired? Solution: Power 8 130.25 = 84.091.90 x (11.6 x 10} 6 130.25 = 1591.2kwCHAPTER 10 —- PUMPS 5.3 Summary of Pump Data. The following table 10.5.3(a) indicates the minimum recommended pipe sizes for the following pump with rated capacities: Table 10.5.3(a) Summary of Pump Date mn Pipe Sts (Nona Rati? — water Pam? sucton Discharge Ret Vae Vawter apmiinin in (mm) in* (mm) in (mm) Discharge. Device ag 9) 1025) 105) OMI) te) A 50189) 117208) 1 14(82) 1142) 1172098) 20 100378) 260) 260) + 12088) 2050) 22 150 (668) 2v2ce8) 21205) 2160 21268) Se 200757) 375) 3075) 2060) 2172068). 3078! coe) 1260.90 200) 21m BP stot) 409) 4900) ava) awe HIP 400(1514) 4(400) 4,900) 375) star) 400) 40 (1709 St1z) Sta) 375) Siz) 4100) soo een) Stay Stan 3) Sua Sura) 750 (2830) 6 (150) 64180) 4 (100) 6160) 5(127) 1000 (786) 6(%60) 8At80) (100) BIE) 5 U127) {20 4731) 8(200) 8200) BtIS0) 81200) 880) 1600877) 8(200) 8 (200) (180) 8,200) 200) 2000 (7570) 10,250) 101280) 8(180) 101280) 8200) 2500 (462) 10 250) 10,250) 81180) 10480) 8 00) 3000 (11388) 12 200) 12(300) 81200) 12 (800) 8 200) 3500 (13247) 121300) 121800) 81200) 2200) 10250) 2000 (18140) 1486) 12(800) 8200) 14,458) 10,280) 4500 17002) 16400) 14(368) 8,00) 14,088) 10,280) 5000 (18025) 16 (400) 14 (355) 6200) 14 355) 10 260) “ Actual pump flange may be less than pump size 5.4 Pump Foundation and Alignment. Pumps should be installed properly. It is very important that the pump and driver be provided with rigid and the pump and driver are foundation, aligned. 55 5.6 A substantial maintaining alignment. preferably be made of reinforced concrete, foundation important ir The foundation shoule If pumps and drivers were shipped from the factory with both machines mounted on a ‘common base plate, they were accurately aligned before shipment. All base plates are flexible to some extent and, therefore, must not be relied upon to maintain the factory alignment. Realignment is necessary after the complete unit has been leveled on the foundation and again after the grout has set and foundation bolts have been tightened. The alignment should be checked after the unit is piped and 208 rechecked periodically. To facilitate accurate field alignment, most manufacturers either do not dowel the pumps or drivers on the base plate before shipment, or at most dowel the pump only. After the pump and driver unit has been placed (on the foundation the coupling halves should be disconnected. The coupling should not be reconnected until the alignment operations have been completed. A flexible coupling should not be used te compensate for misalignment of the pump and driver shafts. The purpose of the coupling is to compensate for temperature changes and to permit end movement of the shafts without interference with each other while transmitting power from the driver to the pump. There are two forms of misalignment between the pump shaft and the driver shaff, as follows: a, Angular misalignment - shafts with axes concentric but not parallel. b. Parallel misalignment — shafts with axes parallel but not concentric. The faces of the coupling halves should be spaced far enough apart so that they cannot strike each other when the driver rotor is moved hard over toward the pump. Due allowance should be made for wear of the thrust bearings. The necessary tools for an approximate check of the alignment of a flexible coupling are a straight edge and a taper gage or a set of feeler gases. A check for angular alignment is made by inserting the taper gage or feelers at four points between the coupling faces and comparing the distance between the faces at four points spaced at 90-degree intervals around the coupling. The unit will be in angular alignment when the measurements show that the coupling faces are the same distance apart at all points. A check for parallel alignment is made by placing a straight edge across both coupling rims at the top, bottom, and at both sides. The unit will be in parallel alignment when the straight edge rests evenly on the coupling rim al all positions. Allowance may be necessary for temperature changes and for coupling halves that are not of the same outside diameter. CareCHAPTER 10 - PUMPS must be taken to have the straight edge parallel to the axis of the shafts Angular and parallel misalignment are corrected by means of shims under the motor mounting feet. After each change, it is necessary tc recheck the alignment of the coupling halves Adjustment in one direction may disturk adjustments already made in another direction It should not be necessary to adjust the shims under the pump. The permissible amount of misalignment will vary with the type of pump and driver. The best method for putting the coupling halves in final accurate alignment is by the use of a dial indicator. Checking Angular Alignment When the alignment is correct, the foundatior bolts should be tightened evenly but not toc firmly. The unit can then be grouted to the foundation. The base plate should be completely filled with grout, and it is desirable to grout the leveling pieces, shims, or wedges in place. Foundation bolts should not be fully tightened until the grout is hardened, usually about 48 hours after pouring. After the grout has set and the foundation bolts have been properly tightened, the unit should be checked for parallel and angular alignment and, if necessary, corrective measures taken. After 209 the piping of the unit has been connected, the alignment should be checked again The direction of driver rotation should be checked to make certain that it matches that of the pump. The corresponding direction of rotation of the pump is indicated by a direction arrow on the pump casing. The coupling halves can then be reconnected, With the pump properly primed, the unit then should be operated under normal operating conditions until temperatures have stabilized. It then should be shut down and immediately checked again for alignment of the coupling. All alignment checks must be made with coupling halves disconnected and again after they are reconnected. ‘After the units have been in operation for about 10 hours or three months, the coupling halves should be given a final check for misalignment ‘caused by pipe or temperature strains. If the alignment is correct, both pump and driver should be dowelled to the base plate. Dowel location is very important and the manufacturer's instructions should be obtained, especially if the unit is subjected to temperature.CHAPTER 10 - PUMPS 87 58 Fig, 10.4.7(b) Right and Wrong Pump Suctions The unit should be checked periodically for alignment. If the unit does not stay in line after being properly installed the following are possible causes: (a) Setting, seasoning, or springing of the foundation, Pipe strains distorting or shifting the machine. (b) Wear of the bearings. (c) Springing of the base plate by heat from an adjacent steam pipe or from a steam turbine. (d) Shifting of the building structure due to variable loading or other causes. It may be necessary to slightly readjust alignment, from time to time, while the unit foundation are new. Supervision of Installation. Satisfactory operation of vertical turbine-type pumps is dependent to a large extent upon careful and correct installation of the unit; therefore, it is recommended that this work be done under the direction of a representative of the pump manufacturer. Pump Maintenance and Servicing. like any other machines requires regular preventive main-tenance and servicing. The following tables are the list of the possible causes of the troubles, may be experienced during and after the installation of the pumping system. Pumps the ane Fig. 10.4.7(a) llustration of Water-Lubricated and Oil-Lubricated Shaft Pumps. Water Lubricated Oil Lubricatec Open Line shaft pump Enclosed line shaft pump Surface discharge Underground discharge Threaded column and Flanged columns and bow! bow!