General Technical

Information For
Pump Handbook
 Pump handbook

INDEX

SR. No Contents Page no

1 Defination of pump 1
2 Classification of centrifugal pump 2
3 Concept of vaccum 4
4 Definations of various pressures 5
5 Properties of water 5
6 Properties of matter 6
7 Vapour pressure 6
8 Concept of head , capacity ,power ,efficiency 8
9 Pump characteristic curves 14
10 Types of impellers 21
11 Affinity laws 24
12 Specific speed of the pumps 24
13 Cavitation …..It,s causes and how to avoid it 26

14 Net positive suction head (NPSH) 28

15 System head ( S.H.) 33
16 Parallel and series operations 36
17 Minimum safe flow 38
18 Temperature limit 38
19 Factors affecting the pump performance 40
20 Various losses in the pump 41
21 Moment of inertia (GD2) 43
22 Tip speed 43
23 Applicable standards for pump 44
24 Vibration and noise in the pump 45
25 Priming 47
26 Critical speed 48
27 Axial and radial thrust 49
28 Moment and nozzle loads 52
29 Reverse runaway speed 54
30 Starting torque of the pump 55
31 Pump performance test 56
32 Quality assurance plan (QAP) 56
33 Types Of Bearing 57
34 Coupling 61
35 Pump Prime movers 64
36 Non destructive testing (NDT) 66
37 Mechanical seal 68
38 Gear box 74
39 Material of construction (MOC) 75
40 General instruments required for pump 77
41 Baseplate 78
 Pump handbook

FIGURE PAGE
SUBJECT
NO. NO
Generation Of Centrifugal Force
1 2
Graphical representation of atm. Pressure, gauge
2 3
pressures etc.
Concept Of Vapour Pressure.
3 6
Gauge Readings Related To Liquid Specific Gravity
4 7
Total Suction Head.
5 10
Total suction lift.
6 11
Typical Pump Performance Curve
7 14
Radial Flow Pump
8 15
Mixed flow pump.
9 16
Axial flow pump.
10 16
Iso Efficiency Curve
11 17
Capacity Power Curve
12 19
Type of impellers.
13 20
Single suction impeller.
14 21
Double suction impeller.
15 22
Semi open impeller.
16 22
Impeller design vs. Specific speed.
17 24
Phenomenon Of Cavitation
18 25
Concept Of Npsh
19 27
System Head Curve
20 32
 System Head Curve When No Lift
21 33
System Head Curve Mainly Static Head
22 33
System Head Curve Combined Static And Friction Head
23 34
System Head Curve When Flooded Suction
24 34
Parallel Operation Of Pumps
25 36
Series Operation Of Pumps
26 36
Minimum Safe Flow
27 38
Labyrinth Type Of Sealing
28 41
Maximum Tip Speed Of Impeller
29 42
Simultaneous Loads On Pump Shaft
30 48
Radial Reaction In Single Volute Pump
31 49
Double Volute
32 49
Diffuser Type
33 49
Elements Of Axial Thrust
34 50
Moments And Nozzle Loads
35 52
Torque Vs Speed Curve
36 54
Single Row Deep Groove Ball Bearing
37 57
Similar Contact Angle ,Variation Contact Angle
38 57
Face To Face And Back To Back Angular Contact Ball Bearing
39 58
Double Row Angular Contact Ball Bearing
40 58
Cylindrical Roller Bearing Nu,Nup
41 59
Taper Roller Bearing
42 60
 Pump handbook

Pump Handbook
Definition of pump:
Pump is defined as a machine which converts the mechanical
energy into the hydraulic energy. It consists of a set of rotating vanes
enclosed within the casing to impart the energy to the fluid through
centrifugal force.
Working principle of centrifugal pump
Working principle of a centrifugal pump is based on conversion
mechanical energy of a prime mover (electric motor or engine or turbine)
into kinetic energy and then into pressure energy of a fluid that is being
pumped.
The energy changes occur by virtue of two main parts of the
pump, the impeller and the volute or diffuser. The impeller is a rotating
part that converts prime movers mechanical energy into the kinetic
energy. The volute or diffuser is a stationary part that converts kinetic
energy into useful pressure energy.
Generation of Centrifugal Force
The process liquid enters the suction nozzle and then into eye of an
impeller. When the impeller rotates, it spins the liquid in the cavities
between the vanes outward and provides centrifugal force. As liquid
leaves the eye of the impeller a low-pressure area is created causing more
liquid to flow toward the inlet. As the impeller blades are curved, the fluid
is pushed in a tangential and radial direction by the centrifugal force.
 Pump handbook

v o lu te
c asin g

im p elle r
su c tio n
ey e

Fig.1 Generation of centrifugal pump.

CLASSIFICATION OF CENTRIFUGAL PUMP

Atmospheric pressure:
It is pressure exerted by the atmosphere on the Earth surface.
Atmospheric pressure balances a column of mercury (Hg) to the height of
760 mm at sea level or water column of 10.33 meters. The atmospheric
pressure at sea level is 1.033 kg/cm2 at normal temperature (15.55 0c)
The atmospheric pressure drops at the rate of about one meter for
every 1000 meters increase in altitude above mean sea level.
 Pump handbook

ATMOSPHERIC PRESSURE CHART:

Table 1:
ALTITUDE ABOVE SEA LEVEL BAROMETRIC PRESSURE
EQUIVALENT HEAD OF WATER
FEET METER AIR (PSI ) FEET METER
0 0 14.7 34 10.33
1000 305 14.2 32.8 10.00
2000 610 13.7 31.5 9.6
3000 914 13.2 30.4 9.27
4000 1219 12.7 29.4 8.9
6000 1829 11.8 27.2 8.29
8000 2438 10.9 25.2 7.68

Concept of vacuum
The pressure below the normal atmospheric pressure is called as
vacuum. Theoretically zero atmospheric pressure would be attained in a
perfect vacuum. This is known as absolute zero pressure.

Any pressure above atm ospheric pressure

Gauge pressure

Absolute pressure Vaccum

= gauge (A negative pressure)
+ barom etric Barom etric
pressure pressure
Absolute
pressure

Absolute zero
pressure

Fig.2 Graphical representation of atm. pressure, gauge

pressures etc.
 Pump handbook

Definition of various pressures

Absolute pressure:
It is the pressure above absolute zero. It may be above or below
atmospheric pressure
10 kg / cm2 abs. (above atm pressure +ve)
0.5 kg/cm2 abs. (below atm. pressure –ve)
Barometric pressure
It is atm.pressure at the locality being studied and varies mainly with the
altitude and slightly with atmospheric conditions.
Gauge pressure
It is pressure above atmosphere at the locality and is a physical measure
of liquid pressure either in static or dynamic condition.

PROPERTIES OF WATER
a) Specific Gravity (sp-gr-):
It is the ratio of density of a substance to density water at
4ºCelsius.
For clear cold water It is taken as 1 for practical purpose at room
temperature (15.55°C/60°F) but it gradually reduces with the rise in
temperature.(at 1000C It is 0.96)

b) Boiling Point:
At sea level it is 100º C. The boiling point of water decreases as
the pressure above its surface is reduced and vice versa.

c) Specific Weight:
Water weighs 1000 kg / m3
1Cubic Metre = 1000 Litters
 Pump handbook

PROPERTIES OF MATTER
1) Specific Weight (γγ)
The specific weight of a substance is the weight per unit of volume such
as kg per cubic metre.
Specific weight is denoted by a symbol γ
γ = w/V
Where w = weight of fluid in kgf
V= volume of fluid in m3
Specific weight of water at 4Deg. C is 1000 kg /m3

2) Density (ρ
ρ):
Density is the mass of the substance per unit volume.

3) Viscosity
It is the property of a liquid which resists the flow of the liquid;
(Opposite of fluidity). Viscosity decreases with rise in temperature.
VAPOUR PRESSURE
Term V.P. (vapour pressure) is frequently used in connection with
centrifugal pumps, particularly in Thermal Plants and Process Industries.
All liquids have a tendency to evaporate when exposed to
atmosphere. The rate at which this evaporation occurs depends on the
molecular energy of the liquid. (i.e. type of liquid and its temperature) and
the condition of pressure adjoining the liquid surface.
The vapor pressure of a liquid at a given temperature is that at which it
will flash into vapor if heat is added to the liquid or conversely, that
pressure at which vapor at the given temperature will condense into liquid
If heat is subtracted.
 Pump handbook

Forced to re-enter the

vapour into liquid by
Enter in vapour form partial air pressure Equilibrium condition

Pressure exerted by the saturated vapour in contact with the

surface of liquid at that temperature.

Fig 3. Concept of vapour pressure.
Consider a liquid contained in a sealed beaker 'a’. Assume a constant
temperature is maintained. Some of the liquid molecules have sufficient
energy to break away from the liquid and enter the air in the vapour form
as in 'a'. As the time passes the air will contain vapour molecules to the
extent that some of them will be forced to re-enter the liquid by the
partial air pressure as shown in ‘b’. Eventually an equilibrium condition
will exist, when the rate at which molecules are leaving the liquid will be
equal to the molecules re-entering the liquid (as in 'c').
Under such conditions the air above the liquid is saturated with
liquid molecules and the pressure on the liquid surface is called its vapour
pressure at prevailing temperature. (Common example- V.P. of water at
100 Deg. C. is 1 kg / cm2 abs. at sea level).In physical terms it is the
pressure exerted by the saturated vapour in contact with the surface of
the liquid at that temperature.
Under vacuum, however the process of vaporization is accelerated. The
boiling point of a liquid has a direct relation with the pressure above its
surface. At higher pressure, the boiling point increases and vice versa.
Volatile liquid:
When a liquid has a very high vapour pressure it evaporates readily
even at room temperature. It is called as “volatile liquid”. (like petrol)
 Pump handbook

Head:
Head is the expression of the total energy content of the liquid
referred to a datum. It is expressed in units of energy per unit weight of
liquid. The measuring unit for head is meter of liquid.
A column of water or any liquid in a vertical pipe exerts a certain
pressure on a horizontal surface at the bottom; this pressure is expressed
in kg/cm2 or metres of liquid column (m/c)
The height of a liquid column is known as HEAD.
A water column of 1m will exerts a pressure of 0.1kg/cm2 at the
base (specific gravity of water is 1).
The relation between Head in metres of liquid column and pressure
in kg/cm2 can be expressed as under:

H in m/c = (p *10)/r
Where, p=Pressure in kg/cm2
r=sp.gr. of liquid.
1kg/cm2 =10m of water column.

Fig 4.Gauge readings related to liquid specific gravity.

The main reason for using head instead of pressure to measure a
centrifugal pump's energy is that the pressure from a pump will change if
the specific gravity (weight) of the liquid changes, but the head will not
change. Since any given centrifugal pump can move a lot of different
 Pump handbook

fluids, with different specific gravities, it is simpler to discuss the pump's

head and forget about the pressure.
So a centrifugal pump’s performance on any Newtonian fluid, whether
it's heavy (sulfuric acid) or light (gasoline) is described by using the term
‘head’ in metre of liquid column.

Different types of “HEAD”.

1. Static Suction Head (hss):
Head resulting from elevation of the liquid relative to the
Pump center line. If the liquid level is above pump centerline, hss is
positive. If the liquid level is below pump centerline, hss is negative.
2. Static Discharge Head (hsd):
It is the vertical distance measured in meter between the pump
centerline and the point of free discharge or the surface of the liquid in
the discharge tank.
3. Friction Head (hf):
The head required to overcome the resistance to flow in the pipe
and fittings. It is dependent upon the size, material of pipe, type of pipe
fittings, flow rate, and nature of the liquid (viscosity).

4. Vapor Pressure Head (hvp):

Vapor pressure is the pressure at which a liquid and its vapor co-
exist in equilibrium at a given temperature. The vapor pressure of liquid
can be obtained from vapor pressure tables. When the vapor pressure is
converted to head, it is referred to as vapor pressure head, hvp. The
value of hvp of a liquid increases with the rising temperature.

5. Pressure Head (hp):

Pressure Head must be considered when a pumping system either
begins or terminates in a tank which is under some pressure other than
 Pump handbook

atmospheric. The pressure in such a tank must first be converted to

metre of liquid column. Denoted as hp.
If the system is open, hp equals atmospheric pressure head.
But there are many applications in process industries where the suction
and delivery vessels are closed and under pressure (+ve/ -ve) like boiler
and condenser.

6. Velocity Head (hv):

It represents the energy of a liquid as a result of its motion at some
Velocity ‘v’. It is the equivalent head in meter through which the water
would have to fall to acquire the same velocity, or in other words, the
velocity head necessary to accelerate the water. In the absence of
velocity head the liquid will not flow in a pipe.
Velocity head (hv) is expressed by formula:
hv= v2/2g
Where,
v= Velocity of liquid in m/s
g = Acceleration due to gravity.(9.81m/s2)

7. Total or dynamic suction lift or head(hs):

In some installation it is necessary to determine total suction lift or
head accurately. Their values, through slightly more than static suction
lift or head, become critical when the difference between available and
required NPSH is marginal.
Two factors a) suction pipe friction losses
b) Suction velocity head
Have to be considered for determining total or dynamic head as under:
 Pump handbook

i) Total suction head:

hs = hsl – hfs

PUMP DRAWING WATER FROM SUCTION TANK

SITUATED ABOVE PUMP CENTRE LINE OPEN DISCHARGE
VESSEL 2
Ps = 0 Vd
LIQUID LEVEL 2g
hfd
OPEN SUCTION
VESSEL
Ps = 0
LIQUID LEVEL

hfs
hd

hs Vd hdl

hsl
Vs hgd
hgs

Zd
Zs
PUMP DATUM

TOTAL HEAD = H = hd - hs

Fig 5.Total suction head.

 Pump handbook

ii)Total suction lift:

hs = hss + hfs

PUMP DRAWING WATER FROM SUCTION SUMP

SITUATED BELOW PUMP CENTRE LINE
vd 2
2g
DISCHARGE TO
ATMOSPHERE
hfd

hsd
H

hss
ATM OSPHERIC
PRESSURE

TOTAL HEAD = H
2
hfs H = ( hsd + hfd + vd ) + ( hss + hfs )
2g
vs 2
2g

Fig 6. Total suction lift.

Capacity:
Capacity is the volume of liquid pumped out in unit time. It is commonly
measured in cubic meters per hour (m3 /hr)
The capacity depends on a number of factors like:
• Process liquid characteristics i.e. density, viscosity
• Size of the pump and its inlet and outlet sections
• Impeller size
• Impeller rotational speed RPM
• Size and shape of cavities between the vanes
 Pump handbook

The direct relationship between relationship between the rate of flow of

liquid and pipe diameter.
Q=A*V
Where

Q=Discharge in m3 / sec.
A = Area of pipe in square meters
V= Velocity of liquid in m/sec.
POWER:
1) Pump input power (Pp):
The power delivered by the driver to the pump input shaft. It
is also called brake horse power.
2) Electric driver input power (Pmot):
The electric input to the driver expressed in kilowatt (horse
power).
3) Pump output power (Pw):
The power imparted to liquid by the pump. It is also called
water horse power.
Pw= (Q*H*r)/102
Where Q=Discharge l/sec
H=Head in meter.
r =Specific gravity.
Pump efficiency (η
ηp):
The ratio of pump output power (Pw) to the pump input power
(Pp) i.e. the ratio of the water horse power to the brake horse power
expressed in percent.
ηp = (Pw/Pp) *100
Overall efficiency:
The ratio of pump output power (Pw) to the energy supplied to the
driver (Pmot) expressed in percent. This efficiency takes into account
losses in both the pump and the driver.
ηOA= (Pw/Pmot)*100
 Pump handbook

Pump Characteristic Curves

The performance of a centrifugal pump can be shown graphically
on a characteristic curve. A typical characteristic curve shows the total
dynamic head, brake horsepower, efficiency, and net positive Suction
head, all plotted against the capacity of the pump.
These are known as:
• Q-H Curve (Capacity and Head)
• Q-P Curve (Capacity and Power)
• Q-η Curve (Capacity and Efficiency)
• Q-NPSHR Curve (Capacity and NPSHR)
The pump performance curve is shown in fig.7

How to read pump performance curve

1. Fix the discharge required on X axis.
2. Use this as reference point for getting other values like Head,
Power required, efficiency and NPSHR.
3. Use a foot rule and keep it vertically on the X axis at required
discharge (Q), Go vertically on graph and find the cutting points
on other curves.
4. Move horizontally at intersecting points to left or right to get
the values.
 Pump handbook

Curve
KIRLOSKAR BROTHERS LIMITED no.
*Performance curve of pump type Suc. Del.
This curve relates to the liquid of specific gravity =

Duty point
is IS9137
guaranteed
as per

Fig.7 Typical Pump Performance Curve

 Pump handbook

Figures 8, 9, & 10 are curves which indicate the general shape of the
characteristic curves for the various types of pumps. They show the
head, brake horsepower, and efficiency plotted as a percent of their
values at the design or best efficiency point of the pump.
Fig. 8 below shows that the head curve for a radial flow pump is

PER CENT OF BHP AT DESIGN POINT

PER CENT OF HEAD AT DESIGN POINT

PER CENT OF BEST EFFICIENCY

160
140 140
120 120
100 100 100
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 20 40 60 80 100 120 140
PER CENT OF DESIGN FLOW

Fig 8.Radial flow pump

relatively flat and that the head decreases gradually as the flow increases.
Note that the brake horsepower increases gradually as flow increases.

Mixed flow centrifugal pumps and axial flow or propeller pumps have
considerably different characteristics as shown in Figs.9 and 10 below.
The head curve for a mixed flow pump is steeper than for a radial flow
pump. The shut-off head is usually 150% to 200% of the design head,
The brake horsepower remains fairly constant over the flow range. For a
typical axial flow pump, the head and brake horsepower both increase
drastically near shutoff as shown in Fig. 10.
 Pump handbook

PER CENT OF BHP AT DESIGN POINT

PER CENT OF HEAD AT DESIGN POINT

PER CENT OF BEST EFFICIENCY

160
140 140
120 120
100 100 100
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 20 40 60 80 100 120 140
PER CENT OF DESIGN FLOW

fig 9. Mixed flow pump.

320
300
280
260
240 240
PER CENT OF HEAD AT DESIGN POINT

220 220

PER CENT OF BHP AT DESIGN POINT

200 200

PER CENT OF BEST EFFICIENCY

180 180
160 160
140 140
120 120
100 100 100
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 20 40 60 80 100 120 140

P E R C E N T O F D E S IG N F L O W

Fig 10.Axial flow pump.

The distinction between the above three classes is not absolute, and
there are many pumps with characteristics falling somewhere
between the three.
 Pump handbook

ISO EFFICIENCY CURVE:

Fig.11 below shows a typical pump curve of split case pump SCT
250/30. It is a composite curve from which one can find performance of
a pump at a given speed with various impeller diameters from maximum
to minimum. Constant efficiency values are superimposed over the
various head curves. It is made up from individual test curves at various
diameters.

Fig 11.Iso efficiency curve

 Pump handbook

Shut off head:

When the discharge valve is completely closed, then discharge is
zero and at this zero capacity, usually the pump develops maximum head.
This is called shut off head.

Cut off head:

As Q-H curve reaches maximum discharge, (when delivery valve is
fully opened)the flow velocity in the suction pipe may becomes so high
that Q-H curve will drop abruptly in the vertical downward direction, the
points where this drops occurs is known as Cut off point.

Types of Q-H Curve:

Each type of Q-H curve serves quite well in specific applications
because it has relevance to duty condition at site.
Flat curve
It is a Head-capacity characteristic in which head varies only
slightly with capacity from shut off to design capacity. The characteristic
might also be either drooping or rising.
Flat curve suit applications where total head has to remain almost
constant against wide variation in discharge. This is achieved by
operating delivery valve.
Stable curve:
Head increases continuously as the discharge goes on reducing up
to shut off head point. Only one capacity can be obtained at any one
head. Basically this has rising characteristic.
Steep curve:
A rising head characteristic in which there is a large increase in
head between that developed at design capacity and developed at shut
off.
 Pump handbook

Drooping curve:
Drooping head capacity characteristic indicating cases in
which the head developed at shut off is less than head developed at
some other capacities. This type of curve is not desirable.
Unstable curve:
A head capacity characteristic in which the same head is
developed at two or more capacities.
CAPACITY –POWER CURVE:
This shows the relation between power and capacity of the pump.
The curves are classified as
1) non overloading curve
2) overloading or rising curve
Non- overloading –
The curve which rises to the limited height in operating range near
BEP and then falls as the discharge increases.
Overloading –
The power increases continuously with the increase in the
discharge in the operating zone and beyond.

D es ign po in t R is in g o r o verlo adin g

Fig 12.Capacity power curve.

There are two main types of power curves. Flat power curve is
related to mixed flow type impeller, while the falling curve pattern is
related to axial type impeller.
 Pump handbook

IMPELLER TYPES:
Basically there are three types of impellers:
Radial flow:
Radial flow impellers are designed such that the liquid exits purely
radially or perpendicular to the shaft centerline. They have lower specific
speeds, in the range Ns(metric10 to 50).Most often used for lower flow,
high head application.
Geometry: D2/D1:2 or more. Narrow width.
W

Where,
D1= Inner Imp Dia.
D2 D2=Outer Imp Dia
W=Width between Shroud

D1

Fig 13. Type of impellers.

Mixed flow:
The flow direction is partly axial and radial. Hence as a result the
flow is diagonal. (Medium head and high discharge) The shut off head is
more by about 1.5times than at B.E.P. The power curve is fairly flat or
increasing towards shut off.
Geometry: D2/D1: less than 1.5.Wider width.
 Pump handbook

Axial flow:
As design flow increases, specific speed increases and the impeller
will become more axial in its configuration. The fluid flow is inline with
shaft axis. Fully axial impeller produce very high flow rates with little
head. Here both head and power curves rise sharply towards shut off
point.
Geometry: D2/D1:1

Single suction impeller:

Impellers of this type have a single inlet for liquid entry, from
where it is discharged either radially or semi axially. The casing can be
single volute, double volute, or diffuser casing. Axial hydraulic loads on
the shrouds of this type impeller are different due to the impeller’s
asymmetrical design.

Fig 14.Single suction impeller.

Double suction impeller:
Double suction impellers have dual, opposed inlets for liquid entry,
from where it is discharged radially into a common stream. The
symmetrical nature of impeller design balances the hydraulic axial forces
in each direction. The resultant axial thrust generated should there fore be
negligible when operating the pump under stable conditions.
Double suction impeller.
 Pump handbook

Fig 15.Double suction impeller.

Semi open impeller:

In this type impeller, the vanes enclosed with a full or partial
shroud on one side only. The semi open impellers require close clearances
to be maintained between the open face and its mating stationary
surface. The rotating element should axially adjustable in the pump to
control the clearance. Semi open impellers are used for fibrous or
potentially clogging material in the pumped liquid.

Fig 16.Semi open impeller.

Open type impeller:
This type impeller has no front or back shroud with vanes running
in close proximity to mating casing walls. Open impeller are used for high
speed pumps of over 10,000rpm.they are usually small in diameter. Open
impellers have the material and blade shape to support the developed
pressure. Axial adjustment should be possible same as the semi open
impeller.
 Pump handbook

AFFINITY LAWS:
It is frequently desirable to be able to predict the performance
characteristic of a pump when operating at speeds other than at which it
is tested. Let n1 be the speed in RPM at which the pump runs during the
test. To predict the corresponding curve for a reduced speed n2, it must
be considered that any point on the new curve has its quantity reduced in
proportion to speed and its head reduced as the square of the speed.
Power requirement is proportional to Q and H, hence power is
proportional to cube of speed.

Q1/Q2 = n1/n2

H1/H2 = (n1/n2)2

P1/P2 = (n1/n2)3
Where,
Q= Capacity in l/s
H=Total head in meters
n=Pump speed rpm
P= Brake horse power in Kw.
Suffixes 1 & 2 indicate initial and later values of the parameter.

SPECIFIC SPEED:
The specific speed is a term used to classify pumps on the basis of
their performance and dimensional proportions regardless of their actual
size or the speed at which they operate. It is the speed expressed in
RPM of an imaginary pump geometrically similar in every respect to the
actual pump under consideration and capable raising 75kg of water per
second to a height of 1 meter.
The mathematical formula for calculating the specific speed is:
0.5
Ns = (3.65 * N*Q )/ (H0.75)
Where,
Ns= specific speed (metric)
 Pump handbook

Q=Capacity in m3/s
H=Head in meter
N= Speed of the pump in RPM.
1. Consider the half the discharge in case of the double suction
impeller.
2. Consider head per stage in case of multistage pump.
Specific speed is a correlation of rate of flow, head, and speed at
optimum efficiency of a pump, which classifies the pump impellers with
respect to their geometric similarity. Specific speed is a measure of the
shape or class of the impellers.

Impeller shrouds

Impeller shrouds

Impeller shrouds Impeller shrouds

Impeller hub

Hub Hub Hub Hub

Vanes
Vanes Vanes Vanes Vanes Axis of
rotation
Radial-vane area Francis-vane area Mixed-flow area Axial-flow area

US Units US Units
500
600
700
800
900

10000

15000

20000
1000

1500

2000

3000

4000

5000

6000
7000

9000
8000

METRIC METRIC
20
10

200
100

300
40

80

400
150
60

Values of specific speeds

fig 17. Impeller design vs. specific speed.
Specific speed identifies the approximate acceptable ratio of the impeller
eye diameter (D1) to the impeller maximum diameter (D2) in designing a
good impeller.

Specific speed is also used in designing a new pump by size-factoring a

smaller pump of the same specific speed. The performance and
construction of the smaller pump are used to predict the performance and
used as model for the construction of the new pump.
 Pump handbook

Suction specific speed (Nss) :

Suction specific speed (Nss) is a dimensionless number that defines

the suction characteristics of a pump.
0.5
Ns = (3.65 * N*Q )/ (NPSHR0.75)

CAVITATION:
If the pressure at any point inside pump particularly at the suction
line, drops below the vapour pressure corresponding to the temperature
of liquid, the liquid will vaporize and appear as cavities of vapour or
vapour bubbles .These cavities are carried up stream along with the liquid
until a region of high pressure formed inside the impeller, where the
cavities collapse with a tremendous impact on the side walls of impeller
vanes. This phenomenon is called Cavitation.
Which causes noise, vibration in the pump, drop Head (H) and
Capacity(Q) .The overall effect is that the efficiency of the pump is
severally affected. If the pump works under such conditions continuously,
pitting, corrosion or erosion of impeller vanes at the inlet portion and
tongue of volute casing or inlet of diffuser occur, this reduces the life of
pump.
Discharge Pressure

Impeller

High Vacuum
Vapour Bubbles

Volute
Suction Cavitation

Fig 18. Phenomena of cavitation .

 Pump handbook

Causes of Cavitation:
1. Increases in static suction lift of the pump.
2. A decrease in atmospheric pressure due increase in altitude.
3. Increase in the temperature of water or liquid being pumped.
vapour pressure increases with increase of temperature.
4. If the speed of the pump is increased, the discharge of pump and
the velocity of flow increase, thus increasing the friction head
which adds to the total suction lift.
5. If there are abnormal obstructions to smooth flow like too many
bends, reducers, valve in suction pipe, there will be increase in
frictional head loss and thus causing increase in suction lift.
Remedies to avoid cavitation:
1. It is important that before selection of pump is made, the proposed
or existing suction conditions are carefully studied.
2. The permissible suction lift should be known.
3. The friction losses in the suction pipe and fitting should be
minimized by selecting suction pipes and fittings of larger size so
as to keep the velocity of flow low. Shortest possible suction pipe
should be used and sharp turns or bend with short radius of
curvature should be avoided.
4. When danger of cavitation is present, a pump at low specific speed
may be selected.
5. The edges of impeller carefully rounded and smoothened reduce
cavitation.
 Pump handbook

Net Positive Suction Head (NPSH):

Net positive suction head is the total energy (head ) at the inlet
nozzle of pump ( in relation to zero absolute pressure ) head of liquid ,at
pumping temperature corresponding to vapour pressure of the liquid.

Pressure at the pump inlet :

The fluid pressure at a pump inlet is determined by the pressure on the
fluid surface, the frictional losses in the suction pipe work and any rises
or falls within the suction pipe work system.

Fluid surface
pressure

Positive
head

Negative
Head NPSHr energy loss
occurs within the
Energy loss occurs due pump inlet system
to friction in the
pipework or within
the fluid

Fig 19. Concept of NPSH

The two different types of NPSH are defined below:

1) The available NPSH (NPSHA):
It is a function of system i.e. its static suction head or lift, friction head in
suction line and the vapour pressure of the liquid being handled. It is
available energy (head) at the inlet flange of the pump. It is possible to
control available NPSH by altering the physical arrangement of an
installation, like changes in the piping, level of the liquid supply etc.,for
satisfactory operation.
 Pump handbook

2) The required NPSH (NPSHR):

This is a function of pump design and varies from one make to
other and with the capacity and speed of any given pump. It is energy
(head) required to overcome pumps internal head losses, like for instance,
turbulence , frictional losses created in the suction passage of the pump
and losses incurred by the liquid passing the inlet edge of the impeller
vanes.
Different pumps will have different NPSH requirements dependant on the
impeller design, impeller diameter, inlet type, flow rate, pump speed and
other factors.

NPSHA CALCULATION:
The elements used to calculate NPSHa are all expressed in absolute head
units. The NPSHa is calculated from:
Available NPSHA = (ha)+/– (hss) – (hfs) – (hvpa)
ha = Atmospheric head corresponding to standard atmosphere
hss = static suction head
hfs = frictional losses in suction pipe
hvpa = vapour pressure of liquid at standard temperature and pressure
Plus sign applies to suction head and minus for suction lift. Also standard
atmospheric pressure expressed in terms of water column is 10.33
metres (at N.T.P. condition)
 Pump handbook

NPSHa WHEN THERE IS SUCTION LIFT

FLUID
SURFACE NEGATIVE FLUID NEGATIVE
PRESSURE HEAD SURFACE HEAD
PRESSURE

PIPEWORK PIPEWORK
FRICTION FRICTION

FLUID FLUID
VAPOUR VAPOUR
PRESSURE PRESSURE

ZERO ZERO
NPSHa PRESSURE NPSHa NPSHr
PRESSURE NPSHr
ABSOLUTE ABSOLUTE

NPSHa IS SUFFICIENT TO AVOID CAVITION NPSHa IS TOO LOW CAVITION WILL OCCUR

NPSHa WHEN THERE IS SUCTION HEAD

POSITIVE POSITIVE
HEAD HEAD

PIPEWORK PIPEWORK
FLUID FRICTION FLUID FRICTION
SURFACE SURFACE
PRESSURE PRESSURE

FLUID
VAPOUR FLUID
PRESSURE VAPOUR
PRESSURE
ZERO
ZERO
PRESSURE NPSHa
PRESSURE
ABSOLUTE NPSHr NPSHr
ABSOLUTE NPSHa

NPSHa IS SUFFICIENT TO AVOID CAVITION NPSHa IS TOO LOW CAVITION WILL OCCUR
 Pump handbook

Examples of calculating NPSH of typical pumping

systemes.

N P S H A C A L C U L A T IO N S
1 ) C A S E N o . 1 : P U M P D R A W IN G L IQ U ID F R O M A S U M P O P E N T O A T M O S P H E R E

DATA :
a ) S U C T IO N L IF T = 3 m e te r s

}
b ) F R IC T IO N L O S S E S IN
S U C T IO N P IP E L IN E , = 1 m e te r
F O O T V A L V E , S T R A IN E R
3 M.
c) TEM PER ATU R E O F W ATER = 21° C
d) VAPO UR PR ESSU RE = 0 .2 5 m e te r s
e ) A T M O S P H E R IC P R E S S U R E = 1 0 .0 0 m e te r s

T O T A L S U C T IO N L IF T = h s = h s s - h fs
= - 3 - 1
= - 4 m e te r s

NPSHA = ha ± hs - hvp
= 1 0 - 4 - 0 .2 5

NPSHA CALCULATIONS
1) CASE No. 2 : PUMP DRAWING WATER FROM TANK, LOCATED ABOVE
PUMP CENTRE AND OPEN TO ATMOSPHERE.

DATA :
1) HEIGHT OF WATER LEVEL IN SUCTION TANK, = 4 meters
ABOVE THE CENTRELINE OF THE PUMP
2) FRICTION LOSSES IN SUCTION PIPE SYSTEM = 1.2 meters
( PIPE LINE VALVE & FITTINGS )
3) TEMPERATURE OF LIQUID : = 21°C
4) VAPOUR PRESSURE OF THE LIQUID : = 0.25 meters
4 M.
5) ATMOSPHERIC PRESSURE : = 9.00 meters

METHOD :
SUCTION HEAD, hs = hss - hfs
= + 4 - 1.2 meters
= 2.8 meters OF WATER (SUCTION HEAD)

NPSHA = ha ± hs - hvp
= 9.00 + 2.8 - 0.25
= 11.55 meters
 Pump handbook

NPSHA CALCULATIONS
1) CASE No. 3 : PUMP DRAWING WATER FROM A CLOSED VESSEL UNDER VACUUM
DATA :
600 mm OF Hg VACUUM
1) VACUUM IN VESSEL = 600 mm of mercury
2) LIQUID TEMPERATURE = 40°C
3) LIQUID LEVEL ABOVE PUMP CENTRE = 10.2 meters
4) FRICTION LOSSES IN SUCTION = 1 meter
PIPE lLINE SYSTEM
10.2 M. 5) VAPOUR PRESSURE = 0.49 kg / cm2
6) SP. GRAVITY OF LIQUID = 0.72
METHOD :
10 x 1
ha = = 13.89 meters of liquid
0.72
10 x 0.49
hvp = = 6.81 meters of liquid
0.72
Ps = 600 mm of Hg
600 13.6
= x = 11.33 meters of liquid
1000 0.72
. .
( . 13.6 is specifie gravity of mercury )
hs = hsl - Ps - hfs
= 10.2 - 11.33 - 1
= - 2.13 meters of liquid ( suction lift exists )
NPSHA = ha ± hs - hvp = 13.89 - 2.13 - 6.81 = 4.95 meters

NPSHA CALCULATIONS
1) CASE No. 4 : PUMP DRAWING LIQUID UNDER PRESSURE FROM A CLOSED TANK.

0.5 kg / cm 2 DATA :
PRESSURE
1) PRESSURE IN CLOSED VESSEL = 0.5 kg / cm2
2) ATMOSPHERIC PRESSURE AT INSTALLATION = 0.9 kg / cm2
3) LIQUID LEVEL IN A VESSEL ABOVE THE = 0.2 meters
PUMP CENTRE LINE
4) FRICTION LOSSES IN SUCTION = 1.5 meters
PIPE LINE SYSTEM
0.2 M. 5) VAPOUR PRESSURE OF LIQUID = 0.45 kg / cm2
6) SP. GRAVITY OF LIQUID = 0.8
METHOD :
10 x 0.9
ha = = 11.25 meters of liquid
0.8
10 x 0.45
hvp = = 5.625 meters of liquid
0.8
10 x 0.5
Ps = = 6.25 meters of liquid
0.8
NOW
hs = hsl + Ps - hfs
= 0.2 + 6.25 - 1.5
= 4.95 meters of liquid ( suction head exists )
NPSHA = ha ± hs - hvp
= 11.25 + 4.95 - 5.625
= 10.575 meters
 Pump handbook

SYSTEM HEAD:
The total head of the system against which the pump must operate
is called as system head.
It depends on the following factors
• Static head
• Friction head
• Entrance and discharge losses
• Velocity head

SY STEM H EA D
C U RV E FRICTIO N LO SSES
HEAD

TO TA L STA TIC H EA D

FLO W

Fig 20.System head curve

There are different types of system curve which is explained as below

1) No static head :
This type of curve is obtained, when the pump transfer the liquid
from one container to another container in same level. In this type
of system the losses are purely frictional. There fore the system
resistance curve started from (o,o ).
 Pump handbook

PU M P

PU M P C U R V E

TH RO TTLED
HEAD

SY ST EM
C U RV E

0 FLO W R A TE

Fig 21.System head curve when no lift.

2) Mainly static head:

The system head curves involve a substantial static head with
minimum piping. Here losses due to friction is minimum, there fore
system head curve is nearly flat

PUM P CURVE
HEAD

H
FLA T
S Y S T EM

FLO W R A TE

Fig 22System head curve when mainly static head.

 Pump handbook

3) Combined static and friction heads :

This is most common type of system head curve, where static
head and head loss due to friction is major portion.

PUM P CURVE

TH RO TTLED
HEAD

SYSTEM
CURVE

FLO W RA TE

Fig 23.System head curve when combined static and friction

head..
4) Gravity head :
In this case the fluid transfer is by gravity head is also known as flooded
suction. Here the fluid transfer will continue till the gravity head is greater
than head loss due to friction. Here the system head curve started below
(o,o ).

H (N E G A T IV E )

P U M P C U R V E
HEAD

S Y S T E M
C U R V E

0 F L O W R A T E

-H
D IS C H A R G E

Fig 24.System head curve when flooded suction.

 Pump handbook

PARALLEL AND SERIES OPERATION

___________________________________
Two or more pumps may be arranged for parallel or series
operation to meet a wide range of requirements in the most economical
manner
Parallel Operation:
In many applications such as city and industrial water supply
schemes and circulating water system in fertilizer plants and thermal
power stations, to meet the capacity variation for which the parallel
operation of pumps provides a solution.
There are number of factors for the selection of pumps for
parallel operations.
1) As far as possible, pumps of similar characteristics are to be
selected.
2) Q-H curves should be raising nature, in case the selection of pumps
with the dropping characteristic is unavoidable to able special care for
combination at opening the valves has to be taken during the starting
the pumps . So that no pumps should run at its shut off head.
3) Duty points should lie in best efficiency zone or slightly towards the
left side of best efficiency point.
4) Pumps with dissimilar characteristics curves can operate in parallel,
if the system head does not exceeds the shut of head of any pump at
any capacity produced by a combination of other pumps on the
system.
The shut-off head of the pumps should preferably be equal, if
they are not, care should be to be taken, while starting the pump
 Pump handbook

COMMON HEADER

VALVE VALVE

PUMP 1 PUMP 2

Fig 25. Parallel operation of pump.

Series Operation:
Pumps in series increases the head developed at the same flow
condition point. One pump discharge is piped into the suction of the
second pump which increases the head capability. The second pump
however must be capable of operating at the higher suction pressure,
which is produced by pump number one.
This mode of operation is a very cost effective way of overcoming
high discharge heads when the flow requirement remains the same.

PUMP 2

PUMP 1

Fig 26.Series operation of pump.

 Pump handbook

MINIMUM SAFE FLOW:

The most frequent cause of operation of a pump at reduced flow
is, the reduction in demand of the process served by the pump.
Operation of centrifugal pump at reduced capacities leads to a
number of unfavorable conditions that may take place separately or
simultaneously.
If the pump has a single volute casing, its rotor will be subjected to a
higher radial thrust as flow decreases
As the capacity is reduced the temperature of the liquid increases.
To avoid exceeding permissible limits, a minimum flow bypass must be
provided. This bypass which can be either manual or automatic will also
protect the pump against the accidental closing of its check valve while
pump is running.
High specific speed pumps have power curve that rise with
reduced capacities. Unless the driver size has been selected with this fact
in consideration, it may be overloaded when operating capacities are
reduced.
If the liquid contains an appreciable amount of entrapped air or gas
and if the pump capacity is reduced below a certain minimum, the pump
can become air bound.
So it’s necessary to define minimum safe flow of pump.
The flow rate (capacity Q) at which the pump is likely to over
heat (that is exceeding the recommended temp. rise) is known as a
Minimum safe flow.
Temperature limit:
Heat is generated due to hydraulic and disk frictional losses
caused by rotation of impeller in the fixed casing. Hydraulic losses occur
in impeller and volute/diffuser passages, including leakages at wear ring,
inter stage or leak off bushing and hydraulic balancing devices. In general
this causes the liquid temperature to rise. This temperature rise is very
 Pump handbook

high at part capacities due to which sometime flashing may occur in

liquids of volatile nature.
Such temperature rise is calculated from following formula
T = (1-ηp) H/ 427*ηp
Where t = temperature rise in 0Celsius
ηp =efficiency at duty point (expressed in fraction)
H = Total dynamic head in meters.

Fig 27.Minimum safe flow

For finding out the minimum safe flow, temperature rise is to be

calculated from formula. and plotted over the Q-H and Q-η curve of pump
under consideration, to indicate the capacity at which temperature rise
exceeds the recommended value.
 Pump handbook

FACTOR AFFECTING PUMP PERFORMANCE:

SPECIFIC GRAVITY:
The pump develops the same head in meters of liquid column,
independent on the specific gravity but the pressure developed by pump
is directly proportional to specific gravity.
The pump delivers the same quantity by volume independent of
specific gravity but the quantity by weight will be proportional to the
specific gravity.
The efficiency is unaffected by the specific gravity of the liquid
pumped but the power absorbed by the pump is directly proportional to
the specific gravity.
ATMOSPHERIC PRESSURE:
The atmosphere pressure can be read from the barometer. The
atmosphere pressure depends on the height above sea level. At the sea
level the atmospheric pressure is 1 bar. There is a drop in the atmospheric
pressure above an altitude of more than 500 metres above the sea level.
The atmosphere pressure drops at the rate of one metre pressure for
every 1000 metes increase in altitude.
VISCOSITY
As Viscosity of the liquid increases, it reduces the capacity (Q),
head (H) of the pump, and increases power required for the pump.
 Pump handbook

VARIOUS LOSSES IN THE PUMP:

Following are the losses in the pump
• Friction losses
• Disk friction
• Leakage losses
• Mechanical losses

1) Friction losses:
When the liquid is flowing through the pipe, Due to rough surface
inside the pipe, the friction losses are occurred. This is calculated by
following formula.

Pipe losses in m = f L v2 /2 g D
Where,
F= frictional coefficient depending upon the internal surface
condition of the pipe,
L = length of pipe in meter.
v = Velocity of the liquid in the pipe in m/sec,
2
g = Gravitational acceleration constant, 9.81 m/sec
D= internal diameter of the pipe, in meter.
Friction losses are directly proportional to square of velocity as area
remains constant. The velocity is proportional to flow and these losses
increases with square of the flow.
2) Disk friction
The power required to rotate the disk in a fluid is called disk
friction. As impeller is having moment of inertia, due to which power is
consumed, while rotating impeller in liquid being pumped.
The disk friction has two parts
• The actual friction of liquid on the disc which is minor.
• A pumping action of the fluid which is in contact with disc
 Pump handbook

3) Leakage losses
In the casing the liquid at delivery side being at high pressure, has
tendency to leak through clearance between casing and impeller. This
leakage can be avoided by labyrinth type sealing. The leakage losses do
not affect on the head developed, but it reduces the capacity of the
pump. Also increases the brake hourse power of the pump.

FIG 28. Labyrinth type sealing

4) Mechanical losses:
The mechanical losses in pump consist of frictional losses in the
stationary elements of the pump and rotating shaft. The frictional -losses
in stuffing boxes, mechanical seals, bearings, and in couplings. In general
mechanical losses are taken 2 to 4 % of B.H. P.
 Pump handbook

GD2 VALUE:

Motor manufactures want to know the GD2 value of a driven

equipment to ensure that the motor gives enough torque to accelerate the
driven machine to full speed without damaging the motor winding.

The GD2 value of the pump should be less than that of the driver.

The GD2 value of pump is used to calculate the required starting torque of
the motor and to ensure that it is capable of accelerating the rotating
mass up to synchronous speed without stalling.

The GD2 value of the pump = 4 *(moment of inertia of the pump)

TIP SPEED:
The maximum allowable linear velocity attainable by the farthest
element in a rotating object without mechanical distortion or disturbing
molecular structure. The following chart gives guideline for limiting
speeds for various impeller materials.

Fig 29.Maximum tip speed of impeller.

 Pump handbook

Applicable Standard For Pump:

Following are some standards related to centrifugal pumps.
1) API 610:
This international standard specifies requirements for centrifugal
pumps, including pumps running in reverse as hydraulic power recovery
turbine, for use in petroleum, petrochemical and gas industry process
services.
This international standard is applicable to overhung pumps,
between bearings pumps & vertically suspended pump.
2) ANSI HI B 102:
This standard is for rotodynamic (centrifugal), regerative turbine &
pitot tube pumps of all industrial / commercial types except vertical single
& multistage diffuser pump types. It includes design and application.
3) ASME B73.1:
This standard covers centrifugal pumps of horizontal, end suction
single stage, centerline discharge design. This standard includes
dimensional interchangeability requirements and certain design feature to
facilitate installation and maintenance.
4) DIN EN 22858:
This standard specifies the principal dimensions and nominal duty
point of end suction centrifugal pumps having a maximum operating
rating of 16 bar.
5) IS 5120:
This standard covers the technical requirements for rotodynamic
pumps (such as centrifugal, axial flow, mixed flow), for handling various
types of liquids other than clear, cold, fresh water.
6) ANSI B 101:
This standard is for centrifugal regerative turbine pumps of all
industrial or commertial types, excepts vertical single and multistage
diffuser types.
 Pump handbook

VIBRATION AND NOISE IN THE PUMP

VIBRATION:
Vibration basically is the displacement of mass back and forth from
its static position. A force will cause vibration. The vibration can describe
in terms of acceleration, velocity, displacement. Then noise is the sub
product of the vibrations.
The causes of vibration
• Mechanical
• Hydraulic
• Peripheral

Mechanical
• Unbalanced rotating components
• Damaged impellers
• Bend shafts
• Pump and driver misalignment
• Poorly designed foundations
• Thermal expansion of shafts
• Loose holding down bolts
Hydraulic
• Operating the pump other than B.E.P
• Impeller vane running so closer to cutwater
• Internal recirculation
• Turbulence in the system
• Water hammer
Peripheral
• Harmonic vibration from nearby equipment and drivers
• Operating the pump at critical speed
• Temporary seizing of seal faces
 Pump handbook

MECHANICAL SOURCES
Unbalanced rotating components
Unbalance in the rotating shaft can cause large transverse vibration
at certain speed known as critical speed. This coinside with natural
frequencies of the shafts. Lateral vibration due to unbalance is most
common cause of failure of the pump.
Although the pump rotor is initially balanced, after a few
days of operation due to which rotor gets unbalanced.
Damaged impellers
The impellers get damaged due to cavitation. Wear of impeller and
shaft can cause the unbalance, which produces vibrations.
Misalignment:
Misalignment between pump shaft and motor shaft with a flexible
coupling that can produce lateral and torsional vibrations.
Piping and structure
Forces and moments from the piping to the pump can cause the
misalignment of the pump shaft and driver shafts and there fore it
increases the vibrations.

HYDRAULIC SOURCES
Flashing
Flashing is particularly common in hot water systems. When the
hot pressurized water experiences a decrease in a pressure through a
restricted area (i. e. flow control valves). This reduction in the pressure
allows liquid to suddenly vaporized or flash, which results the noise
similar to cavitation. To avoid the flashing after a restriction, sufficient
back pressure should be provided.
 Pump handbook

Water hammer
Water hammer is example of fundamental laws of physics, that is
conversion of kinetic energy into pressure energy. When a liquid flowing
through a pipe is abruptly stopped by a closing of a valve, Velocity of the
water column behind is retarded and its momentum gets dissipated due
to conversion of kinetic energy into pressure energy. This causes the
water hammer effect.

PRIMING:
Priming means removal of air from pump casing, suction piping. Or
filling with the liquid up to top of casing.
Centrifugal pumps can operate satisfactorily if the pump passages,
i.e. the flow passages of the impeller and volute casing are completely
filled with the liquid, and therefore, some means must be provided to fill
these passages.
When the pump starts if the water in the suction piping and pump
casing is not enough , then impeller will rotate without water which
churns the air, so pump does not produces the pressure, required to
overcome static and friction head on the delivery side and push the water
over the datum line.
Methods of priming
• Manual priming
• By using vacuum pump
• By flooded suction
• Priming tank method.
 Pump handbook

CRITICAL SPEED:
As the speed of rotation of a machine is increased, it is observed
that at certain speed, the shaft may vibrate violently. While at speed
below and above the critical speed, it will run relatively smooth.
The speed at which the severe vibration occur are known as the
Critical speed OR
It is the speed corresponding to the natural frequency of oscillation
of a rotor system.
When the rotor shaft assembly rotates at a speed equal to its
natural frequency, minor unbalance get magnified, causes excessive
vibration, noise, rubbing of wear ring. The critical speed may be placed
either above or below the operating speed.
If the unit operates at high speed, which does not vary widely, the critical
speed may be below the operating speed and the shaft is said to be
flexible.
If the operating speed is low and vary through wide ranges, the critical
speed is placed above it and the shaft is said to be rigid.

Critical Speed = 30/π * (g/y)0.5 in rpm.

Where,

g = Acceleration due to gravity (981 cm/s2)

y = Deflection of the shaft in cm.

The running speed of shaft should be at least± 20% away from critical
speed.
 Pump handbook

Axial and radial thrust:

• Reliability of centrifugal pumps is defined on account of wear rate of
components and bearing durability.
• One of the important performance parameter for any centrifugal pump
is its bearing life.
• Bearing life of centrifugal pump depends up on two hydraulic forces
acting on the impeller of pump radial thrust and axial thrust.

Impeller Radial Thrust

Impeller Axial
Thrust

Seal or
Packing
Impeller Axial
Thrust Radial Thrust
Due to Hydraulic Imbalance Hydraulic
Imbalance

FIG. 30 Simultaneous loads on the pump shaft:

• The high pressure liquid trapped between impeller and casing
exerts pressure on the outlet width passages and shrouds of the
impeller resulting in generation of two forces. These forces are –
1. Radial Thrust –
The force generated in lateral direction is due to dissimilar pressure
generation in volute and called as Radial thrust. Radial thrust is
dependant solely on pressure generated by pump.
Radial thrust is a resultant of the pressure exerted by fluid at high
pressure towards the end of the volute.
 Pump handbook

Fig31:Radial reaction in single volute casing.

Radial thrust balancing:
1) Radial thrust can be balanced by using double volute casing

F1

Fig32: Double volute

2) Radial thrust can also be balanced by using diffuser type casings
DISCHARGE

CASING

DIFFUSER

IMPELLER

DIFFUSER TYPE

Fig33: Diffuser type

 Pump handbook

2. Axial thrust –
The axial thrust is a net force acting through the rotor on thrust
bearing, including dynamic loading from pressure and momentum acting
on impeller and other rotor component.
Axial thrust is dependent on the many aspects viz. shroud and
casing clearances, impeller peripheral speeds, head developed by the
pump, impeller geometry etc. Axial hydraulic thrust is the summation of
unbalanced impeller forces acting in the axial direction.
Elements of axial thrust –
- Force acting on front shroud due to liquid of delivery
pressure entrapped between pump casing and front shroud. (F1)
- Force acting on back shroud due to liquid of delivery
pressure entrapped between casing cover and back shroud. (F2)
- Force acting in the direction of the liquid flow due to its
momentum change. (Fm)

F F
1 2

Fm UNBALANCED

THRUST

Fig .34 Elements of axial thrust

Axial thrust influencing parameter:
• Clearances between casing cover and impeller back shroud.
• Clearances between casing and impeller front shroud
• Asymmetry of impeller shrouds.
 Pump handbook

• Radius of back vanes.

• Suction pressure.

Moments and nozzle loads:

Pumps are connected in system through flanges attached to nozzle.
When the liquid at high pressure flows through pipes, bends and elbows
results in forces & moments which act upon pump nozzle. This resultant
load consists of the forces in three co-ordinate axes and their
corresponding moments about the flange centerline. Higher permissible
values of stresses influence the thicknesses and ultimately the overall
weight of the pump.
Nozzle is subjected to combined loading due to internal pressure &
bending moments. Membrane stresses (local!) due to internal pressure are
primary stresses. The bending stresses due to internal pressure are
secondary stresses.
Piping loads:
Five basic factors that influence piping loads
1) Temperature – Thermal expansion or contraction in the piping system
2) Pre-stress – Stress will exist in every piping system
3) Force – force is the result of temperature and/or pressure acting on a
piping configuration
4) Pressure - The pressure in a piping system affects the wall thickness of
the pipe
5) Weight - Weight in a piping system is expressed normally as dead load

Moments due to piping loads

When the liquid at high pressure flows through these pipes, bends and
elbows moments sets up at those pipes due to forces.
 Pump handbook

Fig. 35 moment and nozzle load

Effect on the pump due to nozzle loads

Coupling misalignment,

Shaft movement,

Fatigue or failure of the shaft,

Catastrophic structural failure of pump hold-down bolts/supports
and pumps nozzles,

Pump casing gasket leaks,

Pipe-to-pump flange leaks,

Decreased mean time between repair and failure.

Allowable nozzle loads and moments:

API 610 specifies for designing the nozzle in terms of allowable
forces and bending moments

Allowable forces depends on geometry, nominal size of flange of
the pump, location of the nozzle

pump design criterion and ensure pump shaft displacement of less
than 0.254mm.
 Pump handbook

Reverse runaway speed:

Reverse runaway speed occurs when a pump runs in uncontrolled
reverse direction due to the reverse flow of liquid from an elevated or
pressurized source, such as a storage tank. It is most likely to happen
with Vertical Turbine Pumps when pumping from deep wells.
A sudden power failure and discharge valve or non-return valve
failure during operation against a static head may result in a flow
reversal, and the pump will operate as a hydraulic turbine in a direction
opposite to that of normal pump operation.
 Pump handbook

STARTING TORQUE:
During the starting period of a centrifugal pump the motor has to
overcome a torque which, when plotted in a system of co ordinates,
shows varying curves for various pump types.
In the left half of the diagram the starting torque is indicated in
relation to the rise in speed, where as in the right half, the torque at full
speed are shown as a function of the discharge. It is assumed that the
hundred percentage discharge point is within reasonable distance from
the maximum efficiency of the pump in question.

STARTING TORQUE SPEED CURVE

CASE I Starting up with open isolating or regulating

valve on delivery side

CASE II Starting up with a closed isolating or regulating valve with

opening the valves when nominal speed is attained.

CASE III Starting up with an open isolating or regulating

valve but against a static delivery head static on a non return valve.
T/TN %

n/nN
n - Speed
T- Torque at speed n
TN- Nominal torque
nN- Nominal speed
Note :- Case II is applicable to KPD pumps however
motor should be designed & suitable for all the 3 cases.

Fig.36Typical Torque vs speed curve.

 Pump handbook

PERFORMANCE TEST:

The performance test is conducted for verifying Head, Discharge,

power absorbed & efficiency. Noise level & vibration level of the pump
shall be recorded during performance test.

Lab motor is employed to test the pump. If contractually agreed job

motor can also be employed to test the pump. Water at ambient
temperature (45 Deg. Max.) is used for performance testing. The duration
of test is sufficient to attain accurate and consistent test results. Approx.
duration will be one hour. NPSHR test is conducted when difference
between NPSHA and NPSHR is less than 1 meter.NPSHR test is conducted
at extra cost.

Acceptance standard for testing parameters - ISO 9906 Gr.-2 or

as mentioned in the order. Tolerance at duty point - As mentioned in
relevant testing standard or order acceptance.

PG TEST:
Performance guarantee test is generally carried out at site in case
engineered pumps. This test involves demonstration of vibration free and
noise less operation of pump. The parameters that are verified are
operating head and power consumption .The tolerance accepectance
norms for this test will have to be mutually agreed between user and
supplier.

QUALITY ASSURANCE PLAN (QAP):

There are basically four quality assurance plans, are as follows
1. CAT I: In this QAP category there is only witness for performance
test, and verification for balancing, hydrostatic test, and material
compliance certificate.
2. CAT II: In this QAP category, there is witness for hydrostatic test,
performance test. and verification for material compliance
certificate, balancing.
 Pump handbook

3. CAT III: In this QAP category, there is witness for hydrostatic test,
performance test, and strip test. and verification for material test
certificate (chemical and physical test report), balancing.
4. CAT IV: In this QAP category, there is witness for hydrostatic test,
performance test, strip test, material test certificate (chemical and
physical test report), and verification for balancing.
Details Quality assurance plan as shown in annexure no. 1

BEARING:
Pump bearings supports the hydraulic loads imposed on the
impeller and shaft, and the loads due to the shaft coupling or belt drive.
Pump bearings keep the shaft axial end movement and lateral deflection
within acceptable limits for the impeller and shaft seal.
The hydraulic loads comprise of hydrostatic and momentum forces
from the fluid. The forces on the impeller are simplified into two
components: axial load and radial load.
Axial load:
The axial load is equal to sum of the forces
1) The hydrostatic force acting on the impeller’s front shroud and hub
shroud due to the hydrostatic pressure acting on the surface areas of the
shrouds.
2) The momentum forces due to the change in direction of the fluid flow
through the impeller and
3) The hydrostatic force due to the hydraulic pressure acting on the
impeller opening.
Radial load:
The hydraulic radial load is due to the unequal velocity of the fluid
flowing through the casing. The unequal fluid velocity results in non
uniform distribution of pressure acting on the circumference of the
impeller.
 Pump handbook

Different Types of Bearing:

1) Single row deep groove ball bearing:
Single row deep groove ball bearing are simple in
design, non separable, suitable for high and even
very high speeds and are robust in operation,
requiring little maintenance. This bearing has a
lowest frictional loss and therefore it is the most
widely used among all type of bearing.

Fig 37. single row deep groove ball bearing.

2) Double row deep groove ball bearing:
Double row deep groove ball bearings correspond in design to
single row deep groove ball bearing. They have deep uninterrupted
raceway and high conformity between balls and raceways. They are able
to carry axial loads acting in both directions in addition to radial loads.
Double row deep groove ball bearings are very suitable for bearing
arrangements where the load carrying capacity of a single row bearing is
inadequate.
3) Single row angular contact ball bearing:
Single row angular contact ball bearings are widely used in medium
and heavy duty centrifugal pumps, either as pure thrust bearing or for
combined radial and axial loads. Single row angular contact ball bearings
operate with a small clearance or light preload, providing good positioning
accuracy of the shaft.

α α0

Fig 38.Similar contact angle Variation contact angle

 Pump handbook

Angular contact ball bearing has race ways in the inner and outer ring
that are displaced with respect to each other in the direction of the
bearing axis. The axial load carrying capacity of angular contact ball
bearings increases with increasing contact angle. The contact angle is
defined as the angle between line joining the points of contact of the ball
and the raceways in radial plane, along which the load is transmitted from
one raceway to another, and a line perpendicular to the bearing axis.
These bearings can be arranged in following ways,
A) Face to face b) back to back and c) tandem arrangement

Fig 39. Face to face Back to back

4) Double row angular contact ball bearing:
Double row angular contact ball bearing is used extensively in
medium duty centrifugal pump owing to good load and speed capabilities
and ease of mounting. Double row bearing have good radial and axial load
capabilities.

Fig.40 Double row angular contact ball bearing

5) Cylindrical roller bearing:
Cylindrical roller bearings are used in centrifugal pumps for their
high speed and high radial load capacity. They are manufactured in
several different designs, the main difference being in the configuration of
the flanges.
 Pump handbook

Typically NU and NUP types are used. The NU type bearing is

preferred because it can easily accommodate axial displacement due to
heat expansion of the shaft. This feature makes it possible to use an
interference housing fit. In pumps where impeller imbalance is
unavoidable, an interference housing fit should be used to avoid bearing
outer ring rotation. The NUP bearing is used in the free position and the
loose inner ring flange is abutted against the shoulder of the shaft and
retained on the bearing by fitting of the inner ring.
Cylindrical roller bearings are some what sensitive to misalignment.
The maximum allowable misalignment is three to four minutes, depending
on the bearing series.

Fig.41 NU NUP
6) Taper roller bearing:
Taper roller bearings are used in pump applications to support high
combined radial and axial loads and limit the axial play of the shaft. A
limiting factor is speed capability of the taper roller bearings. The speed
rating is limited by sliding friction between the roller and the inner ring
flange. Taper roller bearings can be used singly at a bearing position or in
matched pairs and are suitable for both oil and grease lubrication.
Matched pair of taper roller bearings with preset axial clearances
are used when the load carrying capacity of one bearing is insufficient
and accurate axial guidance of the shaft is necessary.
 Pump handbook

Fig.42 Taper roller bearing.

7) Spherical roller bearing:

Spherical roller bearings and spherical roller thrust bearings are
used in centrifugal pump applications having heavy loads. These bearings
are used for their high load capabilities and their ability to operate in
misaligned conditions.
Spherical roller bearings are most commonly used in applications
having low operating speeds. These bearings can be used at increased
speeds provided the lubrication and cooling are satisfactory.

COUPLING:
Centrifugal pumps are connected to their drives through coupling.
The principal purpose of a coupling is to transmit rotary motion and
torque from driver to driven. The secondary purpose of coupling is
accommodating misalignment between shafts, compensating for axial
movement of the shafts, and isolates the vibration, heat from one shaft
to another shaft.
The following are the general coupling used in pumps,
a. Pin bush coupling
b. Disk type coupling
c. Love-joy coupling
d. Tyre type coupling
 Pump handbook

1) Pin bush coupling :

This type of coupling is made of two cast iron or steel flanges. One
of the flange provided with a number of steel pins fitted with
natural rubber & bushes for flexibility. The rubber bushes take up
the irregularities in motion by cushioning action and get worn out
after number of operations and easily replaceable.
Normally these couplings are used for all for low power
applications

2) Disc type coupling :

This is most simple type of coupling, consisting of two outer
metallic flanged halves with pins and a central rubberized fabric
disk provided flexibility.
 Pump handbook

3)Love-joy coupling :
Love joy coupling is designed for radial split into two halves, each
having a hub and flange. The flanged portion of each half of a
coupling has several jaws which mesh for power transmission.

4)Tyre type coupling :

This coupling has got tyre type flexible element at the
circumferential rim of coupling. The flexible element is subjected to
shear in case of angular misalignment.
The tyre is internally reinforced by steel members to increase the
torque transmission capacity
 Pump handbook

PUMP PRIMEMOVERS:
Almost all types of prime movers with appropriate power
transmission devices are used in the pumping application.
Following are the popular pump prime movers.
1) electric motors especially induction and synchronous
2) I. C. engine , especially diesel ones
3) Steam , gas and hydraulic turbines
4) Steam engines
1) Electric motor:
Direct current motors are particularly well suited to plants in which
the duty of the pump is changed to periodically. The pump speed can be
adjusted to the required output in a comparatively simple manner.
Three phase A.C. motors: it is frequently impossible to calculate
the head losses of a plant exactly in advance, there for safety reason it is
assumed to be somewhat higher than is actually the case. If a pump
discharges more against lower pressure than calculated value, the power
requirement in most cases increase, as quantity of discharged increases
with the drop in head. This also applies when the suction head decreases
on account of rise in the suction level.
Depending upon the application and location of the units, a suitable
enclosure for electric motor should be chosen. Normally the following
main types are available:
• Totally enclosed
• Totally enclosed fan cooled ( TEFC)
• Screen protected ,Drip proof (SPDP)
• Flame proof
2) I.C. ENGINE:
Most of the I.C. engines are rated on the basis of the load they
carry continuously. Operation of the pump at heads below normal
increases the load on the drive and sometimes causes to overload. I.C.
engines can take this overload for some time.
 Pump handbook

An I.C. engine losses power at the rate of 4 % for every 300

0
metres of altitude above the mean sea level and1 % for every 3 c
rise in the temperature above 30 0 c
When an I.C. engine fails to develop required compression due to
worn out valves, pistons rings, cylinder liner etc., it does not develop
rated horse power resulting in the reduction in the speed of the engine
and pump. A pump running at a reduced speed gives the performance
below the required performance.
3) STEAM ENGINES:
This type of drive is rarely used in pump, but it is used in some
marine application.
4) STEAM TURBINE:
This type of drive is used in
• In large capacity pumps for supplying water to towns
• For boiler feed pumps
Pumps for large high pressure steam turbine sets require a driving
power approaching 8000 to 10000 Kw and high speed of rotation which
is greater than the speed obtained from motors in that case steam
turbines are required.
 Pump handbook

NON DESTRUCTIVE TESTING:

The word “Non Destructive Testing” explains the activity of this
method. Allow component to be fully examined for properties of flaws
without interfering with their usefulness.
At KBL we carry out four types of NDT
1) Liquid Penetrant Testing
2) Magnetic Particle Testing
3) Ultrasonic Testing
4) Radiography
1) Liquid Penetrant Testing
Purpose:
To detect discontinuities that are open to the surface of a solid and
nonporous materials which are not visible by naked eye.
Flaws can be detected regardless of the size, configuration & internal
structure of the work piece.
Defects like cracks, porosity, shrinkages, blow holes etc. can be
detected.
Principle:
Low viscosity liquid penetrant can seep in to various types of minute
surface discontinuities by capillary action.

2) Magnetic Particle Testing

Purpose:
For detecting surface & sub-surface discontinuities in ferromagnetic
materials.
Principle:
Low voltage and high ampere current is passed to magnetize the job.
Defect in the material causes greater reluctance to the current. The
magnetic flux created at defect point leaks into atmosphere. The
ferromagnetic particles spread on job are adhering to the discontinuities.
 Pump handbook

3) Ultrasonic Testing:
Purpose:
To detect sub-surface and internal defects in all types of wrought
materials.
Principle:
Ultrasonic frequencies (above 20,000 cycles / second) are used.
Ultrasonic sound waves from transducer are transmitted in the work
piece. The ultrasonic pulse travels through the part until it strikes a
reflecting boundary either a flaw or a far side of the test piece. It is then
reflected back to the transducer where the sound energy is converted in
to electrical energy.

4) Radiography:
Purpose: To detect internal defects in all types of cast & rolled materials.
Principle:
The source of “illumination” is radiation in the form of x-rays or gamma
rays. These rays are differentially absorbed by the object and the image
so formed is recorded on specially prepared radiographic film.
 Pump handbook

MECHANICAL SEAL:
In centrifugal pumps, sealing of the liquid past the shaft
where it passes through the stuffing box cavity is usually accomplished
by putting a set of soft gland packing followed by an adjustable gland.
However, in such a arrangement leakage of the liquid can not be arrested
fully and almost 60 to 90 drops per minute are deliberately allowed to
leak for heat dissipation. When liquid is corrosive or precious, the leakage
of the liquid poses further problems. Moreover environmental issues arise
due to leakage of corrosive liquids into atmosphere.
Mechanical seal is being looked as a better alternative for
Gland packing in recent past. There are variety of mechanical seals
which are suitable for different liquids under different operating conditions
of pressure and temperature.
CLASSIFICATION OF MECHANICAL SEALS
1) Single and double seal (Classification based on seal arrangement)
element)
a. Single inside mechanical seal:
This is the most common type of mechanical seal which operates in the
fluid being pumped. This type of seal is generally recommended on non
toxic liquids and non fibrous abrasive slurries with suspended solids
up to and including 5% by weight. Wastewater sludge, paper stock,
fibrous abrasives tend to wrap around the spring mechanism and
prevent the single inside seal from operating properly. Single inside
seals are not suitable for fibrous solids.
For non abrasive, non toxic liquids which do not have tendency to
crystallize, a single inside seal operates with good success without
flushing or other type of environmental control.
b. Double inside mechanical seal
Double inside mechanical seal, often with back to back arrangement, do
not operate in the fluid being pumped and are recommended for
toxic liquids whose leakage in to environment would be hazardous.
 Pump handbook

Liquids with suspended solids more than 5% by weight and corrosive

liquids require seals made of costly materials. Double inside back to back
mechanical seals must have buffer fluid (usually water) flowing in and out
of the area between both seats of seal faces. This buffer liquid must be
maintained between seats at a pressure 1-1.8 kg/cm^2 G higher than the
pressure in the stuffing box cavity which prevents the contact of the
product with the inner portion of the seal and provides lubrication to
both sets of seal faces.

2) Pusher & Non-pusher Seals (Classification based on Position of

secondary sealing element)

a. Pusher type seals - In these seals the secondary sealing element (o ring
or wedge) is in dynamic condition i.e. slides in shaft sleeve on laterally.
Pusher type seals are further classified as us single coil and multi coil
seals.

i. Single coil seals - In this type of seals single spring around shaft sleeve
is used to generate spring force. Such type of construction is
recommended for those applications where liquid is viscous or congealing
& crystallizing in nature. The seals are also used for handling liquids with
certain solid particles. The disadvantage is that the reverse rotation may
cause loosening of spring resulting to reduction in spring force and seal
leakage
 Pump handbook

ii. Multi coil seals - In this type of seals 4, 6 or 8 springs are mounted
Symmetrically on the circumference as shown in the figure which
generates spring force. Such seals are best suitable for clear liquids and
handling light chemicals. These type of seals can not be used for handling
liquid with solid particles or crystallization tendency as such liquid can
jam the springs.
b. Non-pusher seals - In these seals secondary sealing element is in static
condition

The seals are further classified as,

Elastomer (rubber) bellows seals - for relatively light duty applications like
low to medium temperature clear water, oil, etc.
Teflon bellows seals - for extremely corrosive applications with slower shaft
speed. These are necessarily externally mounted & no metal parts are in
contact with the media.
Metal bellows seals - for high temperature applications like heat transfer
liquids

3) Balanced / Unbalanced seals - (Classification based on seal design)

 Pump handbook

a. Unbalanced seals
These seals are preferred for the application where the stuffing box pressure
is less than 8-10 kg. They are inexpensive, more stable when subjected to
vibration, misalignment, and cavitations. The disadvantage is their relative
low pressure limit.

b. Balanced seals
These seals are used for stuffing box pressure is above 10 kg. Balancing a
mechanical seal involves a simple design change, which reduces the
hydraulic forces acting to close the seal faces. Balanced seals have higher
pressure limits, lower seal face loading, and generate less heat.

4) Internal / External seals - (Classification based on position of

compression element)
a. Internal seals - In these seals the spring is in contact with the
pumping liquid. 90 to 95% applications are covered in this execution.
 Pump handbook

b. External seals - These seals are designed for special applications where
the pumping liquid is corrosive in nature. The corressive liquid corrodes
spring of internal seal resulting into the spring and seal failure. In these
seals are externally mounted and the spring is not in contact with the
pumping liquid.

5) Cartridge & non-cartridge - (Classification based on Construction)

a. Non cartridge seals- This is the traditional way of seal design. In non
cartridge seal design seal, shaft sleeve and seal cover are separate parts
and pump assembly person have to assemble all these parts using his
skills and experience. In this construction clamping / operating length of
seal is more important and wrong calculation may result into seal leakage
or seal face breakage

b. Cartridge seals- In case of cartridge mechanical seal, mechanical seal

cover and shaft sleeve are the integral part of mechanical seal and
the rotating portion of the seal is mounted on a cartridge sleeve
Pump handbook
 Pump handbook

GEAR BOX:

Helical gear drive Right angle pump drive

A gearbox uses mechanical advantage to increase output torque

and reduce RPM. The motor's shaft is feed into the gearbox and through
a series of internal gearing provides the torque and speed conversion
which is used to rotate the pump at a required speed.
Gearbox is the system that transmits mechanical power from a
prime mover (which can be an engine or electric motor), to some form of
useful output device i.e. Pump. Typically, the rotational speed of an input
shaft is changed & resulting in a different output speed i.e. Pump shaft
speed. However, some of the simplest gearboxes merely change the
physical direction in which power is transmitted.
Most transmissions will either reduce an unsuitable high speed and low
torque of the prime mover output shaft to a more useable lower speed
with higher torque.
Various Gear boxes are used in pump applications for speed
reduction. For low speed prime mover (i.e. motor), size will increase
compare to high speed prime mover. This leads to increase in cost of the
 Pump handbook

pump-set. Hence speed reduction Gear box are used to lower the Pump-
set cost & get a required low speed to run the pump from high speed
prime mover.
As in picture, In vertical turbine engine driven pumps, Right angle
gear drive is a mechanism having a hollow shaft to receive the head shaft
of the pump. The horizontal shaft of the gear drive receives its power
from the prime mover (Engine) & through a pair of bevel gears, transmits
it to the head shaft.

Material of constriction:
A wide variety of metallic materials are used in the construction of
pumps. Ranging from the basic cast irons and steels to the more exotic
titanium and zirconium alloys. However, materials of pump construction
are not confined to metallic. Non metallic in the form of engineering
plastics have found an important in the market because of they provide
excellent corrosion resistance and having light in weight.
The material of construction for a centrifugal pump depends on the
properties of the liquid to be pumped.

Various factors affecting on the material selection:

a. viscosity of the liquid
b. concentration of the liquid
c. temperature of liquid
d. density of liquid
e. PH value
f. Percentage of solids and size of solids.
g. Nature of liquid ,abrasive or non abrasive
 Pump handbook

The following are the most frequently used material designations

for pumps:
1) Bronze fitted pump:
The casting is made of cast iron and the impeller of bronze. the impeller
rings and shaft sleeves (if used ) are made of bronze.
2) All bronze pump
All parts of the pump in direct contact with the liquid pumped are made
of manufacturer’s standard.
3) Specific composition bronze pump
All parts of the pump in direct contact with the liquid pumped are made
up of bronze composition of suitable properties for specific application.
4) All iron pump
All parts of the pump in direct contact with the liquid pumped are made
of ferrous metal.
5) Stainless steel fitted pump
The casing is made of material suitable for the service. The impellers ,
impellers rings and shaft sleeves (if used) are made up of a corrosion
resistant steel of suitable properties for the specific application .
6) All stainless steel pump
All part of the pump in direct contact with the liquid pumped are
pumped are made of corrosion resistant steel of suitable properties for
the specific application. The shaft is made up of corrosion resistant
steel of a grade equal to that of the other part of pump.
 Pump handbook

GENERAL INSTRUMENTS REQUIRED FOR THE PUMP:

Many instruments are used to measure operating parameters such
as flow rate, pressure, power absorbed, speed and temperature.
1) Measurement of speed:
The speed shall be measured by a revolution counter or by means
of accurately calibrated tachometer.
2) Measurement of discharge:
The discharge will be measured either by electronic flow meter or
‘V’ notch / Rectangular weir or other device depending upon discharge at
full open flow of the pump.
3) Measurement of head:
a) Delivery head will be measured by suitable Bourdon type pressure
gauge.
b) Suction lift will be measured by manometer or compound gauge.
4) Measurement of Power Input:
The power input will be determined from measurement of the electrical
power input to the motor of tested efficiency coupled to the pump. The
electrical power input to the motor will be measured by Two Wattmeter
Method. Motor output will be computed by using graph of motor
efficiency.
6) Measurement of noise level and vibration level:
a) Noise will be measured by ‘sound level meter’. Noise level will be 90dB
for motor driven pumps and 110 dB for engine driven pumps at a
distance of 1.5 m from the pump set.
b) Vibration will be measured by ‘Vibration meter’ at DE & NDE bearings
location. Vibration level will be 100 microns for motor driven pumps and
250 microns for engine driven pumps.
 Pump handbook

TABLE NO.3
INSTRUMENTS USED AND ACCURACY OF MEASUREMENT

Quantity Instrument Overall Accuracy

Discharge Rectangular Weir / V Notch/ ± 1.5 %
Flow meter
Head Bourdon type Pressure ± 1 5 % of full scale
gauge deflection
Power Wattmeter, voltmeter, ± 0.5 % of full scale
ammeter. deflection
Speed Digital Tachometer ± 1.0 rpm
Vibration Vibration meter. ± 5 microns
Noise Sound level meter. ± 2 db

BASEPLATE:
Base plate is the structure on which the pump, motor and gear box
and all the auxiliary equipment are mounted. The purpose of base plate
is to provide a foundation under a pump and its driver that maintains
shaft alignment between two. Base plate must allow initial mounting
and alignment of the equipment and survive to handle during installation
and transportation.

FUNCTION OF BASEPLATE:
• To support the pump, driver and other auxiliary equipment.
• Allow the lifting and provide the foundation.
• To withstand all combinations of static and dynamic loads caused by
dead weight of the equipment
• To allow the thermal growth
 Pump handbook

Base plate type

1) Grouted baseplate

DEL
SUC.
Cross member
Grout
20 mm
( 0.75 in )

Foundation
Concrete Grout fills volume
bolt pocket
inside perimeter

Fig.45. Grouted baseplate.

The baseplate is designed to allow grout to be poured underneath the
base. The grout placed inside the contributes to the baseplate’s rigidity
and damping.
2)Nongrout type baseplate:

Nongrout baseplate
Fig 46. Nongrout baseplate
This baseplate is directly on a foundation without the use of grout to fill
the interior of the base to lock it to the foundation. As the loss of
stiffening normally provided by the grout, nongrout bases must typically
be structurally stiffer than comparable grouted bases.
 Pump handbook

3)Pregrouted baseplate:

DEL
SUC.

Final grout pour

20 mm
( 0.75 in )

Pregrouted volume
inside the baseplate Concrete

Fig. 47. Pregrouted baseplate

This baseplate is a variation of the grouted design. With this
design, the baseplate interior is prefilled with an epoxy grout prior to final
assembly of the pump and driver. To achieve this requires the base to be
inverted and epoxy grout poured into the cavity until it is full. Only the
closed type of baseplate (with a drain pan or deck plate)can be used with
this process.
4)Soleplate:

Angle grout to direct

20 mm liquid away from the
(0.75 in)
soleplate

Foundation
bolt
Grout
Concrete pocket

Fig 48. soleplate.

Soleplates are cast-iron or steel pads used in place of bedplate to mount a
large pump or a train of equipment. They are located under the feet of the
 Pump handbook

pumps or its drivers and are grouted directly to the foundation. The
equipment can be doweled or bolted to them.
On large horizontal units or equipment train with a pump, gear
reducer, driver, and couplings, soleplates are used to save the cost of a
large bedplate.
 Pump handbook

Annecxure no.1(Quality Plans):

CAT I

CAT II
 Pump handbook

CAT III

CAT IV
Pump handbook