Pumps Final

Centrifugal Pumps
Part 2 : Centrifugal Pumps
CNOOC Safety & Technology Services Co., Ltd.

Centrifugal Pump- Definition
• Centrifugal Pump can be defined as a mechanical device used to transfer liquid of

various types.
• As the name suggests, it relies on the principal of Centrifugal force.
• It converts the energy provided by a prime mover, such as an electric motor, steam
turbine, or gasoline engine, to energy within the liquid being pumped.

Types of Pumps
Pumps
Positive Kinetic
Displacement
Rotary
Reciprocating
Vane
Piston Blow Case Centrifugal Regenerative Special Effect
Gear
Screw Turbine

Types of Pumps Continued…..
• Positive Displacement Pump:
– Operate by forcing a fixed volume of fluid from the inlet pressure section of the pump into
the discharge zone of the pump. They add energy directly to a movable boundary, which
imparts the energy to the fluid.
• Kinetic Pumps:
– Add energy directly through a rotating part in the form of velocity, and converts the
velocity to pressure.
• Centrifugal Pumps
• Regenerative Pumps: Unique pump where the impeller is the only moving part. It is
used when high head and low flows are required.
• Special Effects Pumps: Miscellaneous pumps.

Types of Pumps Continued…..
Centrifugal Pump
Impeller between
Overhung Impeller Turbine Type
Bearings
Close Coupled Separately Coupled Separately Coupled Separately

Single and Two Single and Two Single Stage Coupled
Stage Stage Multistage
Axial Split Case Axial Split Case

End Suction Inline
(Horizontal) (Horizontal)
Radial Split Case Radial Split Case

Inline Frame Mounted
(Vertical) (Vertical)

Definitions
• Overhung Impeller Type: The impeller is mounted on the end of a shaft which is
“overhung” from its bearing supports. Example:
– Close Coupled pumps where the impeller is mounted directly on the motor shaft
– Separately coupled or frame mounted where the impeller is mounted on a separate pump
shaft supported by its own bearings.
• Impeller Between Bearings Type: The impeller is mounted on a shaft with the
bearings at both ends. The impeller is mounted “between bearings”. Example:
– Axial Split, Horizontal Split Case
– Axial Split Vertical Split Case

Overhung Impeller- Close Coupled
7
Overhung Impeller, Frame Mounted
8
Impeller Between Bearings: Horizontal Split
9
Impeller Between Bearings: Vertical Split
10
Axial and Radial Flow
• Axial Flow Pump
– The impeller pushes the liquid in a direction parallel to the pump shaft.
– Most of the pressure is developed propelling or lifting the vanes on the liquid.
11

Axial and Radial Flow Continued…..
• Radial Flow Pump:
– Pressure is developed principally by centrifugal force action.
– The liquid enters at the center of the impeller and is directed out along the impeller,
perpendicular to the pump shaft.
12

Operating Principals
• As mentioned earlier, Centrifugal pump relies on the centrifugal force.
When you swing a bucket of water around over your head, you will find
that as you increase the speed, the bucket is pulled harder against
your arm. This pull on your arm is the centrifugal force. It makes no
difference if you swing the bucket horizontal or vertical. If the speed is
fast enough, then the water will remain on the bucket.
13

Operation Principals continued.….
• If you punch a small hole on the bottom of bucket, the
water throws a stream and the distance the water travels
is proportional to the centrifugal force.
• The same force that kept water in the bucket, is
how the simple Centrifugal pump works.
14

Operation Principals continued.….
• Centrifugal Pump consists of a rotating impeller inside a
stationary volute (casing).
• Liquid enters the pump through the suction inlet into the
eye of the impeller.
• The speed of the rotating impeller then forces the liquid
out through the discharge nozzle.
15

Operation Principals continued…..
• The liquid enters the inlet of the centrifugal pump under atmospheric pressure,
and flows into the eye of the impeller.
• The Centrifugal force exerted on the liquid by the rotating impeller,
moves the liquid away from
the impeller eye and out along the impeller vanes to their extreme tip
where the liquid is then forced against the inside walls of the volute
and out through the discharge of the pump.
• Due to the reduction of pressure occurring
at pump inlet and impeller eye, liquid is drawn
into the pump in continuous flow as it moves
through the pump.
16

Operation Principals continued…..
• The shape of the volute casing is such that it is wider at the discharge point than where the liquid is
first forced by the impeller against the volute.
• When the water from the impeller strikes the side of the volute, the
velocity is increased. This accelerated motion is called “Kinetic
Energy”, which is the energy in motion.
• The shape of the volute permits the liquid to expand, which slows
down the motion of the liquid. As soon as the liquid slows down
inside the volute, Kinetic Energy is transformed into pressure. This
pressure
then forces the liquid out of the pump discharge nozzle into the outlet
pipe lines.
17

Nomenclature and Description
18
Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps
HOW Centrifugal Pump work ?

Centrifugal Pumps
Types of impellers of Centrifugal Pump

Centrifugal Pumps
Types of impellers of Centrifugal Pump

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Performance of Centrifugal Pumps
Relationship between Head and Capacity
The curve is used by engineers to determine the suitability of a given pump for a
particular duty.
H
H
HEAD
Q Q Capacity


Also be useful to pump operators to check if pumps are performing correctly to their
design specifications.
H
H
HEAD
Q Q Capacity


The head capacity curve can be used to illustrate two important properties of a
centrifugal pump:
H
1. The discharge from a centrifugal
H pump may be throttled without
causing damage to the pump.
HEAD
Q Q Capacity


centrifugal pump:
shut-off 1. The discharge from a centrifugal
pump may be throttled without
causing damage to the pump.
HEAD
Capacity


centrifugal pump:
2. The total head developed is not
Water
Brain
Oil
affected by the specific gravity of the
liquid being pumped.
HEAD
Capacity

Pump Characteristic Curves

Radial Flow Pump
PERCENT OF BHP AT DESIGN POINT

PERCENT OF HEAD AT DESIGN POINT
HEAD
PERCENT OF BEST EFFICIENCY

BHP
EFF
PERCENT OF DESIGN FLOW


Mixed Flow Pump
HEAD
PERCENT OF BHP AT DESIGN POINT

PERCENT OF HEAD AT DESIGN POINT
PERCENT OF BEST EFFICIENCY

BHP
EFF
PERCENT OF DESIGN FLOW


Axial Flow Pump


System Curve
It is the relationship between flow and hydraulic losses in a system.
The point where the pump operates on its curve is dependent upon the
characteristics of the system In which it is operating.
By plotting the system head curve and pump curve together, it can be determined:
1. Where the pump will operate on its curve.

2. What changes will occur if the system head curve or the pump performance curve changes.

System Curve

System Curve
NO STATIC HEAD - ALL FRICTION

System Curve
POSITIVE STATIC HEAD

System Curve
NEGATIVE (GRAVITY) HEAD

System Curve
MOSTLY LIFT- LITTLE FRICTION HEAD

Specific Speed and Pump Type (NS)

Specific speed (Ns) is a non-dimensional design index used to classify pump impellers as to their type and proportions.
It is defined as the speed in revolutions per minute at which a geometrically similar impeller would operate
if it were of such a size as to deliver one gallon per minute against one foot head.
Where:
N = Pump speed in RPM.
Q = Capacity in gpm at the best efficiency point.
H = Total head per stage at the best efficiency point .


The specific speed determines the general shape or class of the impeller .
Values of Specific Speed, Ns


Pumps of higher specific speeds develop head partly by centrifugal force and partly by axial force.
A higher specific speed indicates a pump design with head generation more by axial forces and less by
centrifugal forces.


An axial flow or propeller pump with a specific speed of 10,000 or greater generates it's head exclusively
through axial forces.
Radial impellers are generally low flow high head designs whereas axial flow impellers are high flow low
head designs.

Net Positive Section Head and Cavitation (NPSH)

it is an analysis of energy conditions on the suction side of a pump to determine if the liquid will vaporize
at the lowest pressure point in the pump.
The Hydraulic Institute defines NPSH as the total suction head in feet absolute, determined at the suction
nozzle and corrected to datum, less the vapor pressure of the liquid in feet absolute.


NPSH Required
The NPSH Required is the positive head in feet absolute required at the pump suction to overcome all
pressure drops in the pump and maintain the majority of the liquid above its vapor pressure.
The NPSH Required varies with speed and capacity within any particular pump. Pump manufacturer's
curves normally provide this information.


NPSH Available
It is a function of the system in which the pump operates.
It is the excess pressure of the liquid in feet absolute over its vapor pressure as it arrives at the pump
suction.


NPSH Available


NPSH Available
Suction supply open to atmosphere with section lift.
NPSHA =PB – (VP +LS +hf)
Where
PB= Barometric pressure in feet absolute.
VP= Vapor pressure of the liquid at maximum
pumping temperature, in feet absolute.
Ls = Maximum static suction lift in feet.
hf = Friction loss in feet in suction pipe at
required capacity.


NPSH Available
Suction supply open to atmosphere with section head.
NPSHA =PB + LH - (VP +hf)
Where
LH = Minimum static suction head in feet.
required capacity.


NPSH Available
Closed suction supply with suction head.
NPSHA =P + LH - (VP +hf)
Where
P = Pressure on surface of liquid in closed
suction tank, in feet absolute.

LH = Minimum static suction head in feet.
required capacity.


NPSH Available
Closed suction supply with suction lift.
NPSHA = P - (VP - LS +hf)
Where
P = Pressure on surface of liquid in closed
suction tank, in feet absolute.

Ls = Maximum static suction lift in feet.
required capacity.


NPSH Available
In an existing system, the NPSH Available can be determined by a gauge on the pump suction. The following formula
applies:
NPSHA = PB - VP - (Gr +hv) 
Where
VP= Vapor pressure of the liquid at maximum pumping temperature, in feet absolute.
Gr = Gauge reading at the pump suction expressed in feet (plus if above atmospheric, minus if below atmospheric)
corrected to the pump centerline.
hf = Friction loss in feet in suction pipe at required capacity.

Cavitation
Cavitation means different things to different people. It has been described as:
• A reduction in pump capacity.

• A reduction in the head of the pump.
• The formation of bubbles in a low pressure area of the pump volute.
• A noise that can be heard when the pump is running.
• Damaged that can be seen on the pump impeller and volute.
Just what then is this thing called cavitation?
Actually it is all of the above.

Cavitation
It takes place as the following:
1. The pressure of the liquid is reduced to a value equal to or below its vapor pressure.
2. The liquid begins to boil and small vapor bubbles or pockets begin to form.
3. As these vapor bubbles move along the impeller vanes to a higher pressure area above the
vapor pressure, they rapidly collapse.
4. As these vapor bubbles move along the impeller vanes to a higher pressure area above the
vapor pressure, they rapidly collapse.
5. In high suction energy pumps, the collapses are generally high enough to cause minute
pockets of fatigue failure on the impeller vane surfaces.

Cavitation
Now we will go back to clear up some of the confusion:
The capacity of the pump is reduced:
This happens because bubbles take up space and you cannot have bubbles and liquid in the same place at the
same time.
If the bubble gets big enough at the eye of the impeller, the pump will lose its suction and will require priming.

Cavitation
The discharge head is often reduced

Bubbles, unlike liquid, are compressible. It is this compression that can change the head.
The bubbles form in a lower pressure area because they cannot form in a high pressure area.
You should keep in mind that as the velocity of a fluid increases, the pressure of the fluid decreases. This means
that high velocity liquid is by definition a lower pressure area. This can be a problem any time a liquid flows
through a restriction in the piping, volute, or changes direction suddenly. The fluid will accelerate as it changes
direction. The same acceleration takes place as the fluid flows in the small area between the tip of the impeller
and the volute cut water.

Cavitation
A noise is heard
Any time a fluid moves faster than the speed of sound in the medium you are pumping, a sonic boom will be
heard. The speed of sound in water is 4800 feet per second (1480 meters/sec) or 3,273 miles per hour (5,267
kilometers per hour).

Cavitation
Pump parts show damage

The bubble tries to collapse on its self. This is called imploding, the opposite of exploding. The
bubble is trying to collapse from all sides.
If the bubble is laying against a piece of metal such as the impeller or volute it cannot collapse
from that side, so the fluid comes in from the opposite side at this high velocity proceeded by a
shock wave that can cause all kinds of damage. There is a very characteristic round shape to
the liquid as it bangs against the metal creating the impression that the metal was hit with a
"ball peen hammer".

Cavitation
Pump parts show damage

This damage would normally occur at right angles to the metal, but experience shows that the
high velocity liquid seems to come at the metal from a variety of angles.
This can be explained by the fact that dirt particles get stuck on the surface of the bubble and
are held there by the surface tension of the fluid. Since the dirt particle has weakened the
surface tension of the bubble, it becomes the weakest part, and the section where the collapse
will probably take place.

Cavitation
The higher the capacity of the pump the more likely cavitation will occur.
High specific speed pumps have a different impeller shape that allows them to run at high capacity with
less power and less chance of cavitating.
This impeller is normally found in a pipe shaped casing rather than the volute type of casing that you
commonly see.

Cavitation
The cavities form for five basic reasons and it is common practice to lump all of them into the general classification
of cavitation.
This is an error because to correct each of these conditions, you must understand why they occur, and how to fix
them.
In no particular order they are :
• Vaporization cavitation
• Air ingestion cavitation.
• Internal recirculation cavitation.
• Flow turbulence cavitation.
• Vane Passing Syndrome cavitation.

Cavitation
The way to prevent the undesirable effects of Vaporization cavitation in standard low suction energy
pumps is to insure that:
NPSHA > NPSHR

High suction energy pumps require an additional NPSH margin, above the NPSH Required. Hydraulic Institute
Standard (ANSI/HI 9.6.1) suggests NPSH margin ratios of from 1.2 to 2.5 times the NPSH Required, for high and
very high suction energy pumps, when operating in the allowable operating range.

NPSH and Suction Specific Speed

In designing a pumping system, it is essential to provide adequate NPSH available for proper pump operation.
Insufficient NPSH available may seriously restrict pump selection, or even force an expensive system redesign.
On the other hand, providing excessive NPSH available may needlessly increase system cost.
Suction specific speed may provide help in this situation.
Suction specific speed (S) is defined as:


Suction specific speed (S) is defined as:
Where:
N = Pump speed RPM.
GPM = Pump flow at best efficiency point at impeller inlet (for double suction
impellers divide total pump flow by two).
NPSHR = Pump NPSH required at best efficiency point.
For a given pump, the suction specific speed is generally a constant - it does not change when the
pump speed is changed.


Experience has shown that 9000 is a reasonable value of suction specific speed.
Example:
Flow 2,000 GPM; head 600 ft. What NPSHA will be required?
Assume: at 600 ft., 3500 RPM operation will be required.
3550  (2000 )1 2
= 9000 =
(NPSH R )3 4
3 4
NPSH R = 17.7
NPSH R = 46ft(Pump)
NPSHA =(NPSHR) (NPSH Margin Ratio) = 46 x 1.5 = 69 ft


According to the Hydraulic Institute, NPSH margin is required above the NPSHR of the pump to suppress incipient
cavitation. The amount of margin is a function of Suction Energy and the critical nature of the application as follows:
Section Energy NPSHMargin Ratio (NPSHA/NPSHR)

Low 1.1 - 1.3
High 1.2 - 1.7
Very High 1.7 - 2.5

How to stop vaporization Cavitation

By increasing the suction head
• Raise the liquid level in the tank
• Elevate the supply tank.
• Put the pump in a pit.
• Reduce the piping losses.
• Retrofit the pump with a higher specific speed impeller.
• Install a booster pump or inducer.
• Pressurize the tank.
• Be sure the tank vent is open and not obstructed. Some vents can freeze in cold weather.


By lowering the fluid inlet temperature
• Injecting a small amount of cooler fluid at the suction is often practical.
• Insulate the suction piping from the sun's rays.
• Be careful of discharge re-circulation and vent lines re-circulated to the pump suction; they can heat up
the suction fluid.


By decrease the fluid velocity
• Remove obstructions in the suction piping.
• Do not run the impeller too close to the pump cutwater.
• Reduce the speed of the pump.
• Reduce the capacity of the pump.
• Do not install an elbow too close to the pump suction.


By reducing the net positive suction head required (NPSHR)
• Use a double suction pump. Double suction designs can reduce the net positive suction head required
(NPSHR) by as much as 27%, or in some cases it will allow you to raise the pump speed by 41%.
• Use a lower speed pump.
• Use a pump with a larger impeller eye opening. If possible install an inducer. These inducers can cut net
positive suction head required (NPSHR) by almost 50%.
• Use several smaller pumps. Three half-capacity pumps can be cheaper than one large pump plus a spare.
This will also conserve energy at lighter loads.

Affinity Laws
The affinity laws express the mathematical relationship between the several variables involved in pump
performance.
They apply to all types of centrifugal and axial flow pumps.

Affinity Laws
They are as follows:
With impeller diameter D held constant:

Affinity Laws
With speed N held constant:
When the performance (Q1, H1, & BHP1) is known at some particular speed (N1) or diameter (D1), the formulas
can be used to estimate the performance (Q2, H2, & BHP2) at some other speed (N2) or diameter (D2).
The efficiency remains nearly constant for speed changes and for small changes in impeller diameter.

Series Operation of Centrifugal Pumps

Parallel Operation of Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

Centrifugal Pumps

 Introduction
 Types of cavitation?
 Effects of cavitation
 Cavitation in Centrifugal Pumps
 What is the cause of cavitation &how to avoid it?
 Effects on Performance
 Model
 Conclusions
 References
What is cavitation?
 Cavitation is the formation of vapour bubbles of a flowing liquid in a region where the
pressure of the liquid falls below its vapour pressure.
 In general a liquid is set to cavitate when vapour bubbles are observed to form
and grow because of pressure reduction.

Cavitation Inception
✓ It is the phenomenon of rupture of a volume of liquid when it is
subjected to sufficiently low pressure.
✓ Liquid may forms a cavity close to the fixed surface.
✓ It may occur
➢behind the blade of a rapidly rotating propeller.
➢on any surface vibrating under water.

Travelling cavitation:
❖ Develops after inceptions.

❖ This involves detachment of liquid flow from the rigid boundary
of an immersed body to form a cavity attached to the boundary.
❖ Cavities may have highly turbulence boiling surface or it may also have smooth
surface.

Vortex Cavitation:
❖
❖ Cavities are found in the cores of vortices, which form in zones of high shear.
❖ It often occurs on the blade tips of ships propellers.
❖ also referred as Tip cavitation.
Vibratory Cavitation:
❖ the forces causing cavities to form and collapse are due to continuous series of
high amplitude, high frequency pressure pulsation in the liquid, generated by a
submerged surface, which vibrates, normal to it’s face.

Harmful Effects:
Loss in efficiency of the performance of hydraulic machines like turbines, pumps &
Propellers.
Production of the noise, which is undesirable in the case of
submarines.
Increase in the drag force of cavitating parts
Undesirable vibrations due to collapse of the bubbles are due to shock waves set up.
Material damage due to erosion.

The beneficial effects of Cavitation:
Cavitation can be used for agitation and mixing.
Acavitation noise boomer can be used as sound source for an echo ranging survey of
ocean bottom conditions
Jet cavitations can be used very effectively for tunneling through rock.

❑ Cavitation poses problem in operation, of all three types of centrifugal pumps, viz. radial, mixed and
axial flow pumps, whenever high discharge, high rotational speed, or low head is encountered .
❑
All The three factors lead to the higher pressure differences between two sides of the impeller blade,
pressure becoming lower on the suction side & higher on the pressure side. If the pressure at any point in
the impeller reaches a critical temperature, cavitation will result.
Sign of Cavitation:
➢ knocking noises and vibrations can be heard when it isoperating.
➢ erratic power consumption and fluctuations or reductions.
When water enters a pump, its velocity increases causing a reduction in pressure within
the pumping unit. If this pressure falls too low, some of the water will vaporize, forming
bubbles entrained in the liquid. These bubbles collapse violently as they move to areas of
higher pressure creating the noise and vibration from the pump. The pressure required to
operate a pump without causing cavitation is called net positive suction head (NPSH).
Therefore the pressure head available at the pump inlet should exceed the NPSH required.
This is specified by the pump manufacturer, and is a function of the pump design.
:

:

water level should not experience cavitation.
The following guidelines should be applied to avoid the problem:

 Minimize the number of valves and bends in the suction line Use eccentric
 reducers, not concentric
 Ensure the straight side of the eccentric reducer is installed along the
top of the suction line
 Suction length should be as short as possible
 Suction pipe should be at least the same diameter as the pump inlet
connection
 Use long radius bends
 Increase the size of valves and pipe work
 Do not allow air into the suction line
 Ensure adequate submergence over the foot valve.
 The submergence should be at least 5.3 times the suction diameter.

❖ The most important effect of cavitation as far as pumps are concerned is the drop in the head
and efficiency.
❖ In the case of turbines it causes damage to the turbine runner.
❖ Cavitation cannot be allowed to develop in the pump to such a stage as to cause damage. This is
because the cavities rapidly choke the narrow passages, restricting the discharge. This is one
reason why damage observations in pumps are far less numerous thanin turbines.
❖ The performance of a pump at a given speed is described in terms of discharge, head, power and
efficiency. If a graph of head, BHP or efficiency of the pump at constant discharge and speed is
drawn against Hsv (Net Positive Suction Head) pumps of different specific speed will show
different behavior.
BEHAVIOUR OF PUMPS WITH VARIATION IN Hsv ATCONSTANT DISCHARGE
M
L
1. Cavitation is transient unsteady phenomenon characterized by a
growth of holes or Cavities.
2. Along with harmful effects like loss in efficiency of performance of hydraulic machines like
turbines, pumps, production of noise it has got beneficial effects also such as in control
devices, for agitation and mixing in special processes.
3. Cavitation creates problem in operation of all three types of centrifugal pumps viz. radial,
mixed and axial flow pumps, whenever high discharge, high rotational speed or low head is
encountered.
4. The most important effect of cavitation on pumps is drop in head and efficiency. Cavitation
can’t be allowed to develop in pump to such a stage as to cause damage as in turbine
runners.
5. For the pumps with Ns<25 the curves BHP, head and efficiency Vs Hs drops abruptly as
compared to gradual drop of pump having Ns>60.So pumps with low specific speed are
more susceptible to cavitation as compared to high specific speed pumps.
6. The impeller outlet conditions have no influence on cavitations.

IMPROVING PUMP RELIABILITY

Maintenance vs. Capital
• What does a pump actually cost ?
Most plants regard the pump as a commodity... purchased
from the lowest bidder with little consideration for:
• The operation and maintenance cost of the pump over its life cycle... which
could be 20 - 30 years
• Costs to be considered:
• Spare parts (inventory costs)
• Operation downtime (lost production)
• Labor to repair (maintenance costs)
• Power consumption based on pump efficiency
• Environmental, disposal, and recycle costs

• Repair costs can easily exceed the price of a new pump (several
times) over its life of 20 -30 years
• Documented Pump failures cost $4000 or more per incident (
parts and labor)
• If MTBF was improved from 1 to 2 years for a pump in a tough
application
• Results in savings of $2000 /year over the life of the pump

WHY PUMPS AND SEALS FAIL?
MECHANICAL
Affects Bearings, Seals and Shafts
-EXTERNAL ENVIRONMENTAL
1. Operation off the BEP
Affects Wet End Components,
2. Coupling Misalignment
3. Insufficient NPSH Bearings and seals
4. Poor Suction and Discharge
Piping Design 1. High Temperature
5. Pipe Strain / Thermal Expansion 2. Poor Lubrication
6 Impeller Clearance / Oil Contamination
7. Foundation and Baseplate 3. Corrosion
4. Erosion
-INTERNAL 5. Abrasion
1. Pump Design and Manufacturing
Tolerances
2. Impeller Balance (Mechanical and Hydraulic)
3. Mechanical Seal Design

HOW ARE FAILURES INITIATED?
Installation
Piping system & Pipe Strain
Alignment
Mechanical Seal installation
Foundation
Operational
System: cavitation, dry running, shutoff
Product changes: viscosity, S.G., temp.
Seal controls: flush, cooling
Misapplication
Pump, seal, metallurgy selection

RADIAL LOAD
Operation of a pump away from the BEP results in higher radial loads ...
creating vibration and shaft deflection
H
B.E.P
E
A
D
FLOW

Radial Forces
• By design, uniform pressures exist around the volute at the design
capacity (BEP)
• Resulting in low radial thrusts and minimal deflection.
• Operation at capacities higher or lower than the BEP
• Pressure distribution is not uniform resulting in radial thrust on the impeller
• Magnitude and direction of radial thrust changes with capacity (and pump specific
gravity)

Shaft Deflection
• Most pumps do not operate at BEP:

• Due to improper pump selection (oversized)
• Changing process requirements (throttling)
• Piping changes
• Addition of more pipe, elbows and valves
• System head variations
• Change in suction pressure, discharge head req’d
• Buildup in pipes
• Filter plugged
• Automatic control valve shuts off pump flow
• Change in viscosity of fluid
• Parallel operation problems (starving one pump)

• CLASSIFIES IMPELLERS ON THE BASIS OF PERFORMANCE AND PROPORTIONS
REGARDLESS OF SIZE OR SPEED
• FUNCTION OF IMPELLER PROPORTIONS
• SPEED IN RPM AT WHICH AN IMPELLER WOULD OPERATE IF REDUCED
PROPORTIONALLY IN SIZE TO DELIVER 1 GPM AND TOTAL HEAD OF 1 FOOT
• DESIGNATED BY SYMBOL Ns
Ns = RPM(GPM)1/2
H3/4
RPM = SPEED IN REVOLUTIONS / MINUTE
GPM = GALLONS /MINUTE AT BEST EFF. POINT
H = HEAD IN FEET AT BEST EFF. POINT

• CLASSIFIES IMPELLERS ON THE BASIS OF PERFORMANCE AND PROPORTIONS
REGARDLESS OF SIZE OR SPEED
• FUNCTION OF IMPELLER PROPORTIONS
• SPEED IN RPM AT WHICH AN IMPELLER WOULD OPERATE IF REDUCED PROPORTIONALLY
IN SIZE TO DELIVER 1 M3/h AND TOTAL HEAD OF 1 M
• DESIGNATED BY SYMBOL Ns
Ns = RPM(M3/h) 1/2
M 3/4
RPM = SPEED IN REVOLUTIONS / MINUTE
M3/h = CUBIC METERS PER HOUR AT BEST EFF. POINT
MH = HEAD IN METERS AT BEST EFF. POINT

PUMP TYPE VS. SPECIFIC SPEED
HEAD
HEAD, POWER
HEAD, POWER
HEAD, POWER
EFFICIENCY
EFFICIENCY
EFFICIENCY
EFFICIENCY
POWER
CAPACITY CAPACITY CAPACITY

CENTRIFUGAL VERTICAL TURBINE AXIAL FLOW
SPECIFIC SPEED, ns (Single Suction)
10 20 40 60 120 200 300 SI
500 1,000 2,000 3,000 6,000 10,000 15,000 US
RADIAL-VANE FRANCIS-VANE MIXED FLOW AXIAL FLOW

RADIAL FORCES ON IMPELLER
BEP
RADIAL LOAD
CUTWATER
125%
BEP 100%
FLOW
50%
% CAPACITY of BEP
150%
SHUTOFF 0%
Length of Line = Force
THE IMPORTANCE OF ALIGNMENT
Any degree of misalignment between the motor and the

pump shaft will cause vibration in the pump
Every revolution of the coupling places a load on the pump
shaft and thrust bearing
At 3500 RPM, there will be 3500 pulses per minute applied
to the shaft and bearing

MISALIGNMENT
MAY BE CAUSED BY:

Pipe strain
Thermal growth
Poor foundation / baseplate
Improper initial alignment
System vibration / cavitation
Soft foot on motor

NET POSITIVE SUCTION HEAD (NPSH)
One of the more difficult characteristics to understand
• In simplistic terms:
• Providing enough pressure in the pump suction to prevent vaporization of the fluid as
it enters the eye of the impeller
Two values to be considered:
• NPSH available
• Amount of pressure (head) in the system due to atmospheric or liquid pressure,
height of suction tank, vapor pressure of the fluid and friction loss in the suction pipe

NPSH cont.
• NPSH required
• Pressure reduction of the fluid as it enters the pump
• Determined by the pump design
• Depends on impeller inlet, design, flow, speed and nature of liquid
• NPSH available must always be > NPSH required by a minimum of 3-5 feet
(1-1.5m) margin

CAVITATION
• Results if the NPSH available is less than the NPSH required

• Occurs when the pressure at any point inside the pump drops below
the vapor pressure corresponding to the temperature of the liquid
• The liquid vaporizes and forms cavities of vapor
• Bubbles are carried along in a stream until a region of higher pressure
is reached where they collapse or implode with tremendous shock on
the adjacent wall
• Sudden rush of liquid into the cavity created by the collapsed vapor
bubbles causes mechanical destruction (cavitation erosion or pitting)

CAVITATION cont.
• Efficiency will be reduced as energy is consumed in the

formation of bubbles
• Water @ 70oF (20oC)will increase in volume about 54,000 times
when vaporized
• Erosion and wear do not occur at the point of lowest pressure
where the gas pockets are formed, but farther upstream at the
point where the implosion occurs
• Pressures up to 150,000 psi have been estimated at the
implosion (1,000,000 Kpa)

RELATIVE PRESSURES
IN THE PUMP SUCTION
E
D
A B C
TURBULENCE,
FRICTION, INCREASING
ENTRANCE FRICTION ENTRANCE PRESSURE
LOSS DUE TO
LOSS
AT VANE TIPS IMPELLER
VAPORIZATION STARTS
PRESSURE WHERE
POINT OF LOWEST
INCREASING
PRESSURE
A B C D E
POINTS ALONG LIQUID PATH

NET POSITIVE SUCTION HEAD
AVAILABLE
Hf
(friction in suction pipe)
PAtmospheric
NPSH Available = P Atm. - Pvap. pressure - Z - Hf

Correct for specific gravity
All terms in “feet (meters) absolute”

Results of Operating Off BEP
High Temp. Rise
Low Flow Cavitation
Discharge Recirculation
Low Brg . & Seal Life
Reduced Impeller Life
Head
Suction Recirculation
BEP
Low Brg . & Seal Life
Cavitation
Flow

TEMPERATURE RISE
Overheating of the liquid in the casing can cause:
• Rubbing or seizure from thermal expansion
• Vaporization of the liquid and excessive vibration
• Accelerated corrosive attack by certain chemicals
Temperature rise per minute at shutoff is:
T oF (oC) / min.= HP (KW)so x K
Gal (m3) x S.G. x S.H.
HPso = HP (KW) @ shutoff from curve
Gal. (m3) = Liquid in casing
S.G. = Specific gravity of fluid
S.H. = Specific heat of fluid
Ex.: Pump w/ 100HP (75KW) @s.o. , 6.8 gal casing (.03m3)
w/ 60oF (16oC) water would reach boiling in 2 min.
A recirculation line is a possible solution to the low flow or shut off operation problems....

CASING GROWTH
DUE TO HIGH TEMPERATURE
ROTATION
10 inches
250 mm
COEFFICIENT OF THERMAL EXPANSION FOR 316 S/S
IS 9.7X10-6 IN/IN/°F OR 17.5 X10-6 MM/MM/°C
CALCULATION IS T x 9.7 X10-6 X LENGTH IN INCHES
T x 17.5X10-6 X LENGTH IN MILLIMETERS
EXPANSION
T° F T° C INCHES MILLIMETERS
100 F 55 C 0.0097 IN 0.245 MM
200 F 110 C 0.0190 IN 0.490 MM
300 F 165 C 0.0291 IN 0.735 MM
400 F 220 C 0.0388 IN 0.900 MM
500 F 275 C 0.0485 IN 1.230 MM
600 F 330 C 0.0582 IN 1.470 MM

IMPELLER CLEARANCE
Critical for open impellers

• Normal setting .015” (.38mm) off front cover
• High temperature requires more clearance
- Potential rubbing problem causes vibration
and high bearing loads
- Set impeller .002” (.05mm) add’l clearance
for every 500 F (280C) over ambient temp.
• Important for maximum efficiency

IMPELLER BALANCE
MECHANICAL
- Weight offset from center of impeller
- Balance by metal removal from vane
HYDRAULIC
- Vane in eye offset from impeller C/L
- Variation in vane thickness
- Results in uneven flow paths thru impeller
- Investment cast impeller eliminates
problem
- Careful machining setup can help

TYPICAL ANSI (or DIN) PROCESS PUMP
• Small dia. shaft with excessive overhang

• Stuffing box designed for packing
• Shaft sleeve
• Light to medium duty bearings
• Rubber lip seals protecting the bearings
• Snap ring retains thrust bearing in housing
• Shaft adjustment requires dial indicator
• Double row thrust bearing
• Cast jacket on bearing frame for cooling
• Small oil reservoir

ANSI (ISO/DIN) STANDARD PUMPS
Industry standards for dimensions based on

requirements for packed pumps
• Shaft overhang a function of # packing rings
and space for gland and repack accessibility
• Clearance between shaft and box bore based
on packing cross-section
If most pumps today use mechanical seals -

why do we continue to use inferior designs
made for packing ??

BEARING OIL SEALS
• Rubber Lip Seals Provided To Protect Bearings in standard ANSI pumps
• Have life of less than four months
• Groove shaft in first 30 days of operation
• External contamination causes bearing failure
• AUTOMOBILE
• 100,000 Miles @ 40 Miles /hr. = 2500 hrs. of operation
• PUMP
• 24 hrs./day x 365 days / year = 8760 hours
• 60% of lip seals fail in under 2000 hours
• Lip seals may be fine for automobiles, but not for pumps

• Thrust bearings in standard ANSI pumps are held in place with a snap ring
• Snap ring material harder than bearing housing
• Wear in bearing housing results in potential bearing movement
• Difficult to remove and install
• If installed backwards - potential loose bearing

SIMULTANEOUS DYNAMIC LOADS
Radial Thrust
ON PUMP SHAFT
Impeller Radial Thrust
due to Impeller
and Misalignment Hydraulically
Impeller Axial Induced
Thrust Forces due to
Coupling Recirculation
& Cavitation
Seal
Axial Load
from Misalignment Radial Thrust
and Impeller due to Impeller Hydraulic
and Misalignment Imbalance
Motor

• Radial movement of the shaft occurs in 3 forms:
• Deflection - under constant radial load in one direction
• Whip - Cone shaped motion caused by unbalance
• Runout - Shaft bent or eccentricity between shaft sleeve and shaft
It is possible to have all 3 events occurring simultaneously
• ANSI B73.1 and API 610
• Limit radial deflection and runout of the shaft to 0.002 T.I.R. at the stuffing box
face(0.05mm)
• Solid shafts are critical for pump reliability
• Eliminate sleeve runout
• Improved stiffness

PUMP FAILURE ANALYSIS
6 month period in a typical process plant
C AUS E NUM B E R % o f T O T AL
B e a r in g 25 1 0 .5 0
B e a r in g h o u s in g 1 0 .4 2
C a s e w e a r in g r in g 2 0 .8 4
Im p e lle r 8 3 .3 6
R o ta tin g fa c e 1 0 .4 2
S c r e w s /s e t s c r e w s 1 0 .4 2
S e a ls - m e c h a n ic a l 179 7 5 .2 1
S h a ft 12 5 .0 4
S le e v e 9 3 .7 8
T O T AL 238 1 0 0 .0 0 %

SHAFT STIFFNESS
500 Lbs.
(225Kg)
500 Lbs.
(225Kg)

Derivation of Stiffness Ratio
= Deflection of shaft
P = Load I = Moment of Inertia
E = Modulus of Elasticity
L = Length of Overhang P
= PL3 I=  D4 L
3EI 64
= PL3 = L3
3E P D4 D4 D
64
cancel all common factors

Stiffness Ratio Examples
D
L
D L
3 4 3 4
1.50" 8" L /D = 8 /(1.50) = 512/5.06 = 101
1.62" 8" L 3 /D 4 = 8 3/(1.62) 4 = 512/6.89 = 74
3 4 3 4
1.75" 8" L /D = 8 /(1.75) = 512/9.38 = 55
3 4 3 4
1.87" 8" L /D = 8 /(1.87) = 512/12.23 = 42

D
L
D L
3 4 3 4
1.87" 8" L /D = 8 /(1.87) = 512/12.23 = 42
3 4 3 4
1.87" 6" L /D = 6 /(1.87) = 216/12.23 = 17

D
L
D L
3 4 3 4
38mm 200mm L /D = 200 / 38 = 8000000/2085136 = 3.84
3 4 3/ 40 4
40mm 200mm L /D = 200 = 8000000/2560000 = 3.13
3 4 3 4
45mm 200mm L /D = 200 / 45 = 8000000/4100625 = 1.95
3 4 3 4
48mm 200mm L /D = 200 / 48 = 8000000/5308416 = 1.51
L/D<2.0 is Adequate

D
L
D L
3 3 4
48mm 200mm L /D4 = 200 / 48 = 8000000/5308416 = 1.51
3 4 3 / 48 4
48mm 150mm L /D = 150 = 3375000/5308416 = .64
L/D < 2.4 Considered Adequate

PUMPS REDUCE BEARING LOADS
A 100 Lbs. A = Radial load on thrust bearing

B = Radial load on radial bearing
100 lb. = Impeller radial load on end of shaft
Standard
6 in. 8 in. ANSI Pump
B  M A =0=14(100)-6B 1400=6B B=233 lbs.

 M B =0= 8(100)-6A 800=6A A=133 lbs.
LD PUMP
 M A =0=11(100)-6B 1100=6B B=183 lbs.
A  M B =0= 5(100)-6A 500=6A A= 83 lbs.
100 Lbs.
• Radial Bearing
233 lbs. To 183 lbs.
6 in. 5 in.
22% Reduction in Load
2.1 x Improvement in Life
• Thrust Bearing
B 133 lbs. To 83 lbs.
4 x Improvement in life
Bearing rating life varies inversely as the cube of the applied load
LD PUMPS REDUCE BEARING LOADS
(Metric)
A 45.4. Kg A = Radial load on thrust bearing
B = Radial load on radial bearing
45.4 Kg = Impeller radial load on end of shaft
Standard
152 mm 203 mm ANSI (DIN/ISO) Pump
B  M A =0=355(45.4)-152B 16,117=152B B=106 Kg

 M B =0= 203(45.4)-152A 9,216=152A A=61 kg
LD PUMP
 M A =0=279(45.4)-152B 12,667=152B B=83 Kg
A  M B =0= 127(45.4))-152A 5,766=152A A= 38 Kg
45.4 Kg
• Radial Bearing
106 Kg To 83 Kg
152 mm 127 mm 2.1 x Improvement in Life
• Thrust Bearing
B 61Kg To 38 Kg
4 x Improvement in life
Bearing rating life varies inversely as the cube of the applied load
MAXIMUM STIFFNESS RATIO
• L3 / D4 RATIO
• Less than 60 (Inch)
• Less than 2.4 (Metric)

Length (L)
Dia. (D) 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
20 21,1 23,3 25,6 28,1 30,1 33,5
22 14,4 15,9 17,5 19,2 21 22,9 25,9
25 8,6 9,5 10,5 11,5 12,6 13,7 14,9 16,2
30 4,2 4,6 5,1 5,5 6,1 6,6 7,2 7,8 8,5
32 3,2 3,6 3,9 4,3 4,7 5,1 5,6 6 6,5 7,1 7,6
35 2,2 2,5 2,7 3 3,3 3,6 3,9 4,2 4,6 4,9 5,3 5,7 6,2
38 1,6 1,8 2 2,2 2,4 2,6 2,8 3 3,3 3,6 3,8 4,1 4,4 4,8 5,1
42 1,1 1,2 1,3 1,4 1,6 1,7 1,9 2 2,2 2,4 2,6 2,8 3 3.2 3,4 3,7 3,9
45 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5 1,7 1,8 2 2,1 2,3 2,4 2,6 2,8 3 3.2
48 0,65 0,70 0,77 0,85 0,92 1 1,1 1,19 1,29 1,4 1,51 1,62 1,74 1,87 2, 2,15 2,29 2,44
50 0,54 0,60 0,66 0,72 0,79 0,86 0,93 1,01 1,10 1,19 1,28 1,38 1,48 1,59 1,70 1,82 1,95 2,08
55 0,37 0,41 0,45 0,49 0,54 0,59 0,64 0,69 0,75 0,81 0,87 0,94 ,01 1,09 1,16 1,24 1,33 1,42
ZONE 1= POOR >3.2
ZONE 2 = QUESTIONABLE 2.4-3.2
System one LD 17
ZONE 3 = EXCELLENT 1.0-2.4
ZONE 4 = SUPERIOR <1.2
STIFFNESS RATIO CHART - METRIC

EFFECTIVE PUMP OPERATIONAL ZONES
PUMP CURVE
BEP
ZONE L3/D4
INCH
A > 80
B 60 > 80
HEAD
A C 26 > 60
B D < 26
METRIC
C A
> 3.2
D B 2.4 to 3.2
C 1.0 to 2.4
D < 1.0
80 40 20 10 0 10 20
15 25
PERCENT OF BEP
FLOW
• EVERY TIME A PUMP IS TORN DOWN, THE MOTOR SHAFT AND
PUMP SHAFT MUST BE REALIGNED
• UNPROFESSIONAL OPTION TO RE-ALIGN …USE A STRAIGHT EDGE
• PROFESSIONAL OPTION IS TO USE DIAL INDICATORSTO MINIMIZE
TOTAL RUNOUT
• MODERN METHOD IS LASER ALIGNMENT WHICH IS VERY ACCURATE

PRESENT ALIGNMENT METHODS
WEAKNESSES
• All provide precision initial alignment
• Degree of accuracy varies
• Cost of system, training, and time involved in their use is dramatic
• Time consuming (possibly 2 workers, 4-8 hrs.)
• Difficult to compensate for high temperature applications
• Requires worker skill, dexterity, and training to achieve accurate
results
• After pump startup, cannot insure continued alignment due to
temperature, pipe strain, cavitation, water hammer, and vibration

• Machined component that connects a pump power end to “C”
face (D flg.) motor thru close tolerance fits on each end
• Not a new technology
• Used on machine tools and gear boxes
• Operate with highest level of accuracy and precision
• Mechanical seal in a pump is a high precision component
• Mechanical seal accounts for 75% of pump downtime

• Provides easy, accurate, and reliable alignment during operation
• Maintains near -laser alignment accuracy despite pipe strain, cavitation,
high temperature, and vibration
• A device that reduces vibration will prolong seal life and increase pump reliability
• Reduces labor hours for initial installation
• During teardown, maintenance cycle time is reduced dramatically
• vertical mounting capability

MOTOR ADAPTER ADVANTAGES cont.
• High temperature applications

• Motor grows with the pump
• More even temperature gradient across the pump and motor assembly
• For high speed (3000/3600 RPM) applications - Alignment more
critical
• Disadvantages
• Not as accurate as initial laser alignment due to inherent tolerance stackup
of the various components

LARGE BORE OLD STYLE
• Designed specifically for seals • Designed for packing

• 20 Times greater fluid volume •Small radial clearances
• Provides superior cooling,cleaning, -Seal contacting bore
and lubrication for the seal •Limited fluid capacity
• Solids centrifuged away from seal -Poor heat removal
•Eliminate seal rub problems •Easy to clog with solids

• Add no stiffness to shaft
• Runout tolerance between shaft and sleeve compounds motion of seal faces in
addition to deflection and shaft runout already present
• Deflection must be a maximum of .002” at the seal faces, yet faces are
lapped within 2 helium light bands
• Deflection or motion at seal faces is 1000 times greater than the face
flatness
• Sleeves are necessary for packed pumps, but with today’s new seals they
serve no purpose

BEARING OIL SEALS
Three basic types:

• Lip seal
• Inexpensive, simple to install, very effective when new
• Elastomeric construction
• Contact shaft and contributes to friction drag and temp. rise in bearing area
• After 2000-3000 hours, no longer provide effective barrier against
contamination
• Will groove shaft

BEARING OIL SEALS cont.
• Labyrinth seals
• Required by API 610
• Non-contacting and non-wearing
• Unlimited life
• Effective for most types of contaminants
• Do not keep heavy moisture or corrosive vapors from entering the bearing
frame (especially in static state)

UNDERSTANDING
MECHANICAL SEALS
INTRODUCTION
• Since their inception, mechanical seals have carried with them a mystique of “Gee Whiz”,
bizarre, physics defying properties that have baffled the untrained observer. But that
impression is really misplaced. Mechanical seals are not magic by any means and actually
perform well within the realm of easy to understand principles of physics and hydraulics.
• Mechanical seals are simply another means of controlling leakage of a process where other
means are deemed to be less capable of performing the task adequately. For the purposes of
this discussion, consider that a mechanical seal will out-perform common types of packing.
• As mechanical seals can be used to seal a myriad of different products on an equally vast
array of equipment, we will be primarily focusing on the use of mechanical seals on rotating
shaft pumps. Since our subject is dealing with pumps, let’s first explore a basic understanding
of the need to seal a process liquid in a centrifugal pump.

CENTRIFUGAL PUMPS
• A centrifugal pump is simply a shaft, suspended on bearings with an impeller

attached to one end. The impeller is encased in a housing that is filled with a
liquid. As the shaft is rotated, centrifugal force expels the liquid out through an
orifice, where it is typically piped into a process or another collection point. As
the expelled liquid exits the case, additional liquid is added to the case so that a
flow develops. That is basically how a centrifugal pump works.
• The next slide shows a photograph of a typical “End Suction Centrifugal Pump”.

PUMP SHAFT
IMPELLER BEARINGS
A LIQUID IS SUPPLIED TO THE PUMP “SUCTION”
CENTRIFUGAL FORCE EXPELS THE LIQUID OUT FROM THE

IMPELLER
AS THE PUMP SHAFT ROTATES

• The force of the expelled liquid creates pressure. This liquid under pressure will
seek areas of lower pressure. This is a known physical principle of hydraulics.
Some form of seal must be applied to keep liquid from leaking around the shaft
at the point where it enters the case to drive the impeller. This is where our
mechanical seal comes into play.
• Take a look at the same pump again. Can you see the mechanical seal behind
the impeller?

SEAL TYPE
• The mechanical seal shown in the pump
photograph is a Type “1” mechanical seal.
Probably the most widely recognized and also
most common mechanical seal used in
general service, low pressure applications.
• At Utex, we refer to this type as RS-1
• The assembly shown in the pump is
configured with a ceramic “O-ring” type
stationary seat and is also equipped with a
“set screw collar”.
SEALING THE LIQUID
• Mechanical seals were originally designed to lend a greater sealing capability
than could be achieved using common packing.
• Before the advent of mechanical seals, pump users relied primarily on “rope” or
braided style packing to achieve a “seal” around the shaft. A series of pieces or
“rings” were installed into the pump “stuffing box” and they were compressed
tightly so that they created a difficult leak path for the liquid to negotiate in order
to leak to atmosphere.

SEALING THE LIQUID
• Early packing styles did not seal very well. In fact, until recently, braided
packing styles required varying amounts of leakage for lubrication. If leakage
was not permitted to occur, the packing would literally “burn up” and often
cause severe damage to the pump shaft. Even with adequate leakage for
lubrication, pump shaft wear was a commonly expected occurrence and as the
shaft wore it would in turn, cause poor shaft packing life.
• As leakage becomes more excessive, the gland is tightened to reduce leakage.

SEALING THE LIQUID
• With the introduction of mechanical seals, this leakage could be controlled to a
much greater degree.
• Let’s look at the same pump with a mechanical seal installed. Note that the seal
shown is an RS-1 with O-Ring type stationary and a set screw collar.

SEALING THE LIQUID
• You have probably taken notice of the illustration showing minor leakage to
atmosphere. It is appropriate to point out at this time…

SEALING THE LIQUID
• It is a fact, all mechanical seals leak. Like packing, the mechanical seal “faces”
must also be lubricated. With proper application and design however, the
leakage is so minute that actual droplets of liquid are not detected. Instead, the
lubricating liquid will vaporize as it crosses the seal faces and the leakage is a
gas or vapor.
• Since we are discussing the sealing of the liquid at the faces, let’s take a look
at the sealing points of a typical mechanical seal. Again, viewing the same
pump and seal, note that there are four sealing points to consider.

The seal gland to the
stuffing box
O.D. of the stationary

Sealing on the shaft
And finally, the seal faces

BRIEF DISCUSSION ABOUT MECHANICAL SEAL FACE DYNAMICS
FACE FLATNESS
• The mechanical seal faces are obviously the most critical sealing point of a mechanical
seal assembly.
• Although the faces can be manufactured from a myriad of different materials, one is
typically carbon, while the other is usually a hard material. (i.e. Alox (Aluminum Oxide
Ceramic), Tungsten Carbide, Silicon Carbide, etc.)
• In order for a “seal” to be achieved, the faces must be very flat. This is achieved by
machining the faces, then “lapping” them to a fine finish.
• Flatness is measured in “Light Bands”. After lapping, the faces are placed on an “Optical
Flat”, a clear glass surface where a monochromatic light is shined on the face. This
single wavelength light will produce an image of rings or lines on the face. Each ring/line
is “One Light Band”. Each light band is equivalent to .000011” or eleven millionths of an
inch. This refers to the variations in the surface of the face. On most face materials, one
light band is Utex’s standard.

FACE FLATNESS
• This illustration shows a face being inspected
on an Optical Flat.
• Take notice of the light bands that are visible
on the reflection of the face.
• Laying a straight edge on a tangent to the
inside circumference of the face, how many
light bands are crossed?
Optically Flat Faces
100 psi
Rotary Stationary
Face Face
0 psi
FACE FLATNESS
• As was stated earlier, it is hoped that the application and design of the mechanical seal
is suited for the service. If so, there is leakage of only vapor through the seal faces.

Pressure Drop & Vaporization
Liquid 100 psi
Liquid + Vapor 50 psi
Vapor + Liquid 25 psi
Vapor 0 psi
TYPES OF MECHANICAL SEALS
SEAL TYPES
• There are obviously many different types and configurations of mechanical

seals. Shaft mounted and cartridge, balanced and unbalanced, pusher and
non-pusher, single and multiple, etc., etc.
• Here we will examine the basic differences without going into a great detail.

SEAL TYPES
• First, let us examine shaft mounted vs. cartridge.
• A shaft mounted seal requires the pump user or assembler to actually install
individual seal components into the equipment.
• Let’s look at the installation of the RS-1 that we were looking at previously.

The stationary seat must be
inserted into the seal gland.
The seal assembly is slipped onto the pump shaft
and the set screws tightened in the correct position
to insure proper “installed length” of the assembly.
The gland is tightened evenly so that the seal
is compressed to it’s recommended length.
SEAL TYPES
• A cartridge type mechanical seal is a pre-assembled package of seal
components making installation much easier with fewer points for potential
installation errors to occur.
• The assembly is “pre-set” so that no installed length calculations must be
performed for determining where to set the seal. This pre-set is achieved by the
use of “set tabs” that are removed once the seal is installed and the pump
assembled.

Although the assembly may look a little The same four sealing points exist
menacing, it is basically no different here.
than a shaft mounted arrangement as
far as sealing components and sealing Seal Gland Gasket
points are concerned.
Stationary O-ring
Shaft/Sleeve O-ring
One additional sealing Seal Faces

point exists in this
particular cartridge
The “set tabs” are
assembly. Have you
removed after
found it?
installation.
SEAL TYPES
• Remember the number of steps involved in installing the shaft mounted seal.
• Now let’s look at installing the cartridge seal that we just examined.

PUSHER VS. NON-PUSHER
• Both pusher and non-pusher types can be either shaft mounted or cartridge
assemblies.
• The basic difference between pusher and non-pusher types have to do with the
dynamics of the shaft packing or O-ring and whether or not it moves as the seal
wears.
• As the seal faces wear down over time, they must be closed to compensate for
lost face material. If the shaft O-ring must move when this compensation takes
place, it is pushed forward by the components of the seal and by stuffing box
pressure. If the seal is configured with a “dynamic” O-ring of this type the seal
is called a pusher type.

Illustrated here is a Type RS-81, a common pusher seal. As the seal
springs and other pressures in the stuffing box are exerted on the seal,
closure of the faces is achieved.
Rotating face and

dynamic O-ring.
Hard Stationary Face
Closing forces exerted

on the seal faces
As the softer carbon face wears down, the rotating face must move to maintain face closure.
Minute particles of carbon and solids from the process liquid
that migrate across the seal faces build up on the shaft.
This build up will ultimately cause the seal to “hang up” and in most
cases, failure will occur well before the seal is actually “worn out”.
PUSHER VS. NON-PUSHER
• There are seal types that have no dynamic O-rings. All O-rings are “static” and
the seal components compensate for face wear without “pushing” any sealing
points.
• One of these types is called a “Bellows Seal”. The bellows can be constructed
of metal, rubber or PTFE. The RS-1 seen earlier in this presentation is an
“Elastomer (or Rubber) Bellows Seal”.
• Let’s consider the metal variety.

METAL BELLOWS
• Metal bellows are constructed by welding
“leaflets” into a series of “convolutions”. This
series of convolutions is referred to as the
“Bellows Core”.
• The photo shown here is a shaft mounted
“Utex-MB”.
• Now take a look at how a bellows seal
compensates for face wear.
Hard stationary face
Carbon rotating face
Metal bellows
The bellows core expands to
compensate for face wear.
Debris can build up without causing hang up.
This feature is probably the most notable
selling point when comparing a bellows seal
to a pusher type seal.
BALANCED VS. NON-BALANCED
• When speaking of “Balance” in reference to mechanical seals, we are not

talking about Mechanical or Rotational Balance. Instead, we are referring to
Hydraulic Balance.
• Since mechanical seals are subject to stuffing box pressure, this pressure is
utilized to achieve and maintain seal face closure in a non-balanced seal.
• If stuffing box pressure is very high, typically over 100psi., then the closing
force may be too great to allow the “Boundary Layer Liquid” that lubricates the
faces to be sufficient and the faces will wear prematurely.
• A balanced seal compensates for higher pressures by locating the seal faces
such that stuffing box pressure has less effect on face closure.

Anon-balanced seal has faces located
outside the “Balance Diameter” of the
seal. Stuffing box pressure is applied
Face OD Line
to the faces virtually evenly.
Face ID Line
Balance Line
The faces of a balanced seal are located so that
a portion of the face contact occurs inside the
balance diameter resulting in reduced closing
force due to stuffing box pressure. This seal is
Face OD Line
a Type RS-8B1. (The “B” = balanced)
Balance Line
Face ID Line
Most metal bellows seals are balanced.
Face OD Line
Balance Line
Face ID Line
SINGLE VS. MULTIPLE
• Most rotating equipment is equipped with a single seal. This is what we have
been examining thus far. Single shaft mounted seals, cartridges seals,
balanced seals etc.
• Some applications call for a multiple seal configuration. These are typically dual
seal arrangements but can also be a series of three or more. For our purposes
we will examine dual seal arrangements since that really covers 99% of
multiple seal applications.

DUAL SEALS
• Dual seals can be either pressurized or non-pressurized. This is in reference to the artificial
environment that is provided to exist “between” the seals.
• A non-pressurized dual seal, also known as a “Tandem” arrangement, means that the inner, or
primary seal is functioning as would a single seal. It is subject to stuffing box conditions, i.e.
stuffing box pressure, process liquid to lubricate the faces and usually immersion of seal
components in the process liquid. The secondary, or outside seal runs in a non-pressurized
“Buffer” liquid that is supplied from an outside source, typically a nearby supply tank.
• In a non-pressurized dual arrangement, the outside seal is primarily there as a containment
device in the event that the inside or primary seal is lost. A “Back up” or safety mechanism if
you will.
• Let’s look at a Dual Cartridge Seal.

Buffer fluid warmed
by seal generated
heat returns to the
buffer supply tank
Inside or Primary seal
Outside or Secondary Seal
Cool buffer fluid

from the buffer
Immersed in process liquid supply tank enters
in the stuffing box via the inlet port
DUAL SEALS
• Since the outside or secondary seal runs in a non-pressurized clean lubricating liquid,
it will generally last for an extended period of time. When the inside or primary seal
fails, the leakage through the faces will be contained by the secondary seal until the
pump can be shut down for seal replacement.
• Failure indication and shutdown devices can be attached to the buffer supply so that
the pump operators know when the primary seal has failed.

DUAL SEALS
• When pumping volatile liquids, hazardous, corrosive, abrasive, etc. it is sometimes necessary
to insure that the process liquid does not enter the atmosphere or the artificial environment
created for the seal or even the seal faces.
• Pressurizing the artificial environment, 20 to 30 psi. above the pump stuffing box pressure will
prevent process liquid from crossing the primary seal faces. Instead, boundary layer film liquid
is supplied to the primary seal by the artificial environment or “Barrier”.
• The arrangement of seals can be the same as a non-pressurized in most cases. The difference
is in how the seals perform.
• In a pressurized dual seal, the outboard or secondary has the tougher job of the two. It
operates sealing high barrier pressure while the inboard or primary seal has clean lubricating
liquid applied at differential pressure of only 20 to 30 psi.
• Now let’s look at the environmental controls for operating dual seals.

Pressurized Non-Pressurized
Dual Seal Dual Seal
Artificial Environment Artificial Environment
“Barrier” System “Buffer” System
NON-PRESSURIZED TO FLARE / RECOVERY SYSTEM
BUFFER FLUID
PLAN 52 / 7352
DISCHARGE
SUCTION
PRESSURIZED GAS IN
PRESSURIZED BARRIER FLUID

PLAN 53 / 7353
DISCHARGE
SUCTION
DUAL SEALS
• There are many more types of environmental control arrangements that are discussed
in other programs. This presentation simply covers the basics. For more detailed
information on this topic, contact your supervisor or a Sealing Technologies
Representative.

SPLIT SEALS
• Some types of machinery are cumbersome to maintain. Large shafts, heavy
components, and immovable drivers are some of these concerns.
• Often, a typical mechanical seal is impractical to use by the nature of it’s installation
requirements.
• In these cases it is frequently beneficial to use a Split Seal.
• In a Split Seal, all components are literally cut or split in half and they are assembled
onto the equipment without removal or disassembly of the major equipment
components.
• Obviously, these seals are prone to leak more readily than non-split seals so they are
generally applied to processes where some leakage is acceptable. Even with some
leakage, they will out perform common packing.
• Split Seals are often used on mixers, agitators and large volume, large shafted pumps.

UTEX EZ-SEAL
• The Utex EZ-Seal is split radially as shown
in this photo.
• All internal components are also split and
they are assembled onto the equipment
shaft without removing the equipment from
it’s operating position or tearing down it’s
major components.
UTEX EZ-SEAL
SPLIT SEALS
• Aside from the fact that the components are split, split seals operate virtually the same
way that most single cartridge or shaft mounted seals operate.
• By nature of their split design, their application is limited to lower pressures and non-
volatile liquids.
• Now let’s move onto our final discussion topic, Gas Buffer Seals.

GAS BUFFER SEALS
• The final seal type that we will look at during this course is the Gas Buffer Seal.
• Gas Buffer Seals are the latest advancement in sealing technology. There are as many
different types as there are Sealing Product Manufacturers.
• They were designed to facilitate capabilities similar to a dual seal without requiring
elaborate environmental controls or in the case of pressurized dual seals, without
liquid contamination of the process liquid.
• We will briefly discuss the features of the Utex DCG Seal.

DUAL CO-AXIAL GAS SEAL
• The DCG Seal is a cartridge arrangement

that contains a “Gas Lift-Off Seal”.
• In a Gas Lift-Off seal, the faces theoretically
never contact. There is no fluid film between
the faces and since they never contact, there
is no need for it.
• A cut-away drawing of this seal will follow.
DUAL CO-AXIAL GAS SEAL
• This control panel is used to adjust the gas

flow (Nitrogen, Clean Plant Air, CO2, etc.) that
is inject into the seal gland port at 25 to 30 psi.
over stuffing box pressure. The gas flows
through holes in the carbon stationary,
separating the faces.
• As the seal operates, an envelope of gas
surrounds the seal faces keeping process
liquid out.
UTEX DUAL CO-AXIAL GAS SEAL
Cut away view of the

DCG shows the Stationary
Carbon Face
Rotating Face Gas inlet

port
Thumb not an integral

part of the seal assembly
UTEX DUAL CO-AXIAL GAS SEAL
Gas is supplied
to the inlet port.
The equipment
can then be started
and process suction
opened allowing
liquid into the
stuffing box.
• Through this program we have looked at the basic principles and designs of
mechanical seals.
• It is important to understand that detailed explanation of each topic discussed here is
available.
• Hopefully this presentation has helped to improve your understanding of mechanical
seals.
• Review this program again and as you have questions, comments or suggestions, ask
your supervisor or a Sealing Technologies Representative. We want this training
program to be as effective as possible and your input is valuable.
• Thanks, and enjoy working with mechanical seals.

SYSTEM ONE LABYRINTH SEAL
Stationary Element
LABYRINTH
Traps liquid and directs it to the
gravity drain
OIL TRAP Rotary Element

and DRAIN 316SS for corrosion
Helps retain resistance
lubrication
in bearing housing
GRAVITY DRAIN
Allows liquid
to drain

BEARING LIFE
• Bearing life calculations assume proper lubrication and an environment that
protects the bearing from contamination
• The basic dynamic load rating “C” is the bearing load that will give a rating life
of 1 million revolutions
• L10 Basic Rating Life is life that 90% of group of brgs. will exceed ( millions of
rev’s or hrs. operation)
• “Rating Life varies inversely as the cube of the applied load
• Reduction of impeller dia. from maximum improves life calculation by the
inverse ratio of the impeller diameters to the 6th power

BEARING LIFE cont.
90% of all bearings will fail prematurely and

not reach their rated L10 life
- Calculated life by design over 20 years
- Actual life maybe 3 years
Failures:
-Fatigue due to excessive loads (20-50% of failure)
-Lube failure - excessive temperatures &
contaminants
-Poor installation

BEARING LUBRICATION FAILURE
OXIDATION
•Chemical reaction between oxygen & oil
•New compounds produced which deteriorate the
life of oil and bearings
•Reaction rate increases with the presence of water
and increases exponentially with temperature
CONTAMINATION
•Water breaks down lube directly reducing brg.
life - .003% water in oil reduces life of oil 50%
•Oil life decreases by 50% for every 20oF (11oC)
rise in temp. above 140oF (60oC)
SYNTHETIC OILS
• Lower change in viscosity with temp. change
-One synthetic can take place of several oils
• Provides good lube at high temps. 300oF (160oC)
-Does not oxidize (breakdown)
• At low temps.- good fluidity boosts efficiency and
reduces component wear during cold weather
• Achieves full lubrication quickly
• Offers longer life - less consumption
Lasts 1.5-2 times longer than conventional oils
• Maintains lube properties with water
contamination better than mineral oils

BEARING CLEARANCES
Normal clearance “C3”
6310 Radial Bearing (microns)
Radial .0003-.0011”(9-30) .0009-.0017”(27-51)
Axial .0016-.003” (48-90) .0016-.003”(48-90)
5310 Double Row Thrust Bearing
Radial .0005-.0014”(15-42) .0014-.0020”(42-60)
Axial .0005-.0014”(15-42) .0014-.0023”(42-69)
7310 Angular Contact Thrust Bearing
Axial -.0003 to +.0003” (line to line)
NOMINAL “0”
Radial approx .85 x Axial
ANGULAR CONTACT BEARINGS
• Used as thrust bearing in pairs (also carry radial load)
• Mounted back to back (letters to letters)
• Provides maximum stiffness to shaft
• Avoid ball skidding under light loads
• Small preload eliminates potential
• Line to line design clearances
• Shaft fit provides preload
• Eliminates shaft end play
• Greater thrust capacity
• Required by API 610 Specification

• Pump radial bearings have positive internal clearance
• Thrust bearings can be either positive or negative clearance (
5310 vs. 7310 pr.)
• Preload occurs when there is a negative clearance in the
bearing
• Desirable to increase running accuracy
• Enhances stiffness
• Reduces running noise
• Provides a longer service life under proper applications

BEARING CLEARANCES / PRELOAD
LIFE
Preload Clearance
MICROMETER IMPELLER ADJUSTMENT
• Micrometer adjusting nut allows impeller to be set to precise

clearance from the front of the casing
• Each line on the adjusting nut is a .003” (.08mm) graduation for
axial movement of the shaft
• Normal setting is .015” (.38mm) from the casing face
• For every 50 deg. above 100 deg. fluid temp... add .002” clearance

GOAL: IMPROVED PUMP AND
MECHANICAL SEAL RELIABILITY
Eliminate or reduce mechanical and environmental influences

that cause pump and seal problems
Specify proper pump design criteria to minimize the impact of
mechanical and environmental influences
Specify proper mechanical seal and environmental controls to
maximize seal life

OPTIMUM PUMP DESIGN SUMMARY
• Low L3D4 ratio as possible
• Solid shaft ( no sleeves)
• Large bore seal chamber
• Large oil capacity bearing housing
• Angular contact thrust bearings
• Retainer cover to hold thrust bearing (no snap rings)
• Fin tube cooling for bearing housing
• Labyrinth seals
• Positive / precision shaft adjustment method
• Investment cast impellers
• Magnetic drain plugs in oil sump
• “C” Frame motor adapter
• Centerline support for hot applications

• Shaft runout at impeller within .001” T.I.R. (.03mm)
• Coupling alignment within .005” T.I.R. on rim & face (.13mm)
• Operation of the pump at or close to best efficiency point (definition dependent upon pump size, speed, and LD ratio)
• NPSH available to be at least 5 feet (1.5m) greater than NPSH required
• Proper foundation and baseplate arrangement
• Absolute minimum pipe strain on suction and discharge flanges
• All impellers dynamically balanced to ISO G 6.3 spec.
• Face of seal chamber square to shaft within .002” T.I.R. (.05mm)
• Seal chamber register concentric to shaft within .003” T.I.R. (.08mm)
• Shaft end play less than .0005” (.015mm)

SYSTEM ONE PUMP WARRANTY
ONE YEAR FOR MECHANICAL SEAL

– SPARE SEAL KIT OR REBUILT SEAL OFFERED
FIVE YEARS ON SYSTEM ONE POWER END

– ANY FAILURE INCLUDING BEARINGS
– FREE REPLACEMENTS OF FAILED COMPONENT
SHAFT WARRANTIED FOR LIFE ON FRAME S AND A PUMPS
free replacements are one time only

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Centrifugal Pumps

Part 2 : Centrifugal Pumps

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• Centrifugal Pump can be defined as a mechanical device used to transfer liquid of

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Close Coupled Separately Coupled Separately Coupled Separately

Axial Split Case Axial Split Case

Radial Split Case Radial Split Case

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Part 2 : Centrifugal Pumps

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HOW Centrifugal Pump work ?

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Types of impellers of Centrifugal Pump

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Types of impellers of Centrifugal Pump

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Part 2 : Centrifugal Pumps

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Relationship between Head and Capacity

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