Pumps

PHILIPPINE SOCIETY OF MECHANICAL ENGINEERS

Professional Development Course

Resource Speaker
Pacifico Ortaliza
pme 828
 How to Select Pumps for Liquid Handling
One task of every mechanical engineer is to select
pumps that will convey liquids form one point to
another
 Safely

 Efficiently

 Reliably

 Economically

Pumps with rotating impellers are the most

commonly used types for handling liquids during
processing, filtering, or transfers between
containers. a
 FACTORS TO CONSIDER WHEN SELECTING A PUMP
PUMP SEDLECTION TYPES OF PUMP
CRITERIA CENTRIFUGAL POSITIVE FLEXIBLE IMPELLER
Pressure Range Low to High Low to High Low
Viscosity Range Low to Moderate Low to Very High Low to High
Temperature Range Low to High Low to High Moderate
Capacity Range Low to Very High Low to High Low to Moderate
Cost Low to Moderate High Low to Moderate
Materials Stainless steel Stainless Steel Stainless Steel
Bronze, Plastic Bronze\, Plastic
Continuous Service Yes Yes With Periodic
Maintenance
Self Priming No No Excellent
Pumps Air-Entrained Limited Yes Yes
Liquids
Pumps Delicate No Yes Yes
Suspended Solids
Ease of Cleaning Yes Yes Yes
Pressure Relief No Yes Not normally
Required
Speeds Limited to Low to Moderate Low to Moderate
Motor Speed
 FACTORS THAT INFLUENCED THE
SELECTION OF THE RIGHT PUMP
 CAPACITY, SPEED, AND SERVICE
- Capacity
- Speed of operation
- Kind of service (continuous or intermittent)
- Number of pumps needed

 LIQUID HANDLED
- Name or description
- Pumping temperature
- Specific gravity and viscosity
- Presence of solids or abrasives
- When acid or alkaline, give pH value
TOTAL DYNAMIC HEAD
DISCHARGE LINE
- Pressure
- Discharge head, and any variations
- Diameter of pipe
- Total length of pipe line
- Number of elbows
- Number of valves, tees, etc.
SUCTION LINE
- Suction lift, and any variation in lift
- Diameter of pipes
- Total length of pipe
- Number of elbows
- Number of valves, tees, etc.
 DRIVE
- Pump may be driven by electric motor,
internal combustion engine, steam engine,
steam turbine
- Power may be transmitted from the
prime mover to the pump by belt, chain or
gears or by direct connection.

PROPER SELECTION, INSTALLATION,

OPERATION AND MAINTENANCE OF
YOUR PUMPS WILL LENGTHEN THEIR
LIFE AND PREVENT TROUBLESOME AND
COSTLY SHUTDOWN.
 STEPS IN SELECTING PUMPS
1. Determine pump capacity required in GPM.
2. Estimate head requirements
3. Estimate NPSH available from the piping
system
4. Select a pump (NPSH available must equal to
or greater than NPSH required by the pump)
5. *Correct for specific gravity
6. * Correct for viscosity
7. Calculate horsepower required
*If liquid to be pumped is not water

PUMP PERFORMANCE CURVES
Show the relationship at a given speed between capacity
and
- total head developed by the pump
- efficiency of the pump
- horsepower required at the pump shaft, called “brake
horsepower”
- net positive suction head (NPSH)
 These curves are based on water having a specific
gravity of 1.0 and a viscosity of 30 SSU (no viscous
correction). Viscosity above 100 SSU reduces capacity
and require correction of the curve.
 Pumps are normally selected to operate in the region of
high efficiency.
 Head developed by the impeller of a centrifugal pump is
the same regardless of the liquid being pumped
regardless of their specific gravity.
 Horsepower required does vary with specific gravity, also
with viscosity above 100 SSU. Correct HP.
 TOTAL DYNAMIC HEAD – required
pumping head
Pumping Head = Pipe Friction Loss +or – altitude change +or- Static
pressure change.
1. List all pipe fittings in separate groups according to pipe size.
2. Convert fittings to equivalent lengths of pipe for each pipe size (use
chart).
3. Add actual pipe size length to equivalent pipe lengths to each pipe
size.
4. Convert total equivalent pipe length (result of Step 3) to head loss
for each pipe size
5. Add friction losses for all pipe sizes together (use chart)
6. Add head loss of special components.
7. Add altitude change.
8. Convert static pressure change to feet
9. Add static head change (step 8) to total (thru step 7). The resulting
figure is the required pumping head.
For liquids having a specific gravity other than water, this figure must
be corrected by dividing the number of feet of water by the specific
gravity of the liquid being pumped.
 NET POSITIVE SUCTION HEAD -
NPSH
Available Net Positive Suction Head (NPSHA) is the
DIFFERENCE between Barometric Pressure and
Dynamic Suction Lift (Sum of Vertical Suction lift
and all friction losses in the Suction Line).
Required Net Positive Suction Head (NPSHR) at the
suction inlet of the pump is shown at the bottom
of each performance chart and is in the form of
a curve, and has been determined from actual
test by manufacturer in the laboratory.
The Available NPSHA must be at least equal to or
exceed the Required NPSHR to avoid cavitation.
 SERVICE LIFE IS INFLUENCED
BY NPSH AND SPECIFIC SPEED
 Centrifugal pump with high suction specific
speeds can be expected to give satisfactory
operation only over a narrow operating range.
 One of the most common problems in pump
application is insufficient net positive suction
head available.
- Review the plant design to determine whether
decreasing length or increasing the size of
suction is feasible.
- Raising the suction vessel elevation.
- Decreasing liquid temperature.
- Select pumps for low NPSH.
- Use double suction pump.
- Use a deep well/multi-stage horizontal pump.
 HIGHLIGHTS OF LOW-COST
PUMPING
 Obtain the right pump for the job.
 Install pump & drive correctly.
 See piping is installed effectively.
 Check piping supports – no strain in pump
 Intake end of suction pipe is screened.
 Pump only liquids the pump is designed.
 Operate pump near its rated head only.
 Clean and maintain it in good running order.
 Lubricate the bearings with the right lubricants.
 Don’t run pump dry.
 Inspect the pump regularly, for wear and
damage
 SAFETY
 Pumps must only be installed in system designed by
qualified engineering personnel and conform with all
applicable regulations and codes.
 Before attempting to install, operate or service the
pump, familiarize with the manual and other literature
from the manufacturer.
 Comply to all PSME Code and industry standards.
 Do not apply at higher temperatures that the seal will
handle or liquids which may damage the pump.
 The pump and all piping or hose connection are secure
before operation.
 For all positive displacement pump, never operate
without pressure relief valve
 Before attempting to open or service the
pump:
- Familiarize yourself with the manual
- Lock out incoming power to the drive.
- Allow the pump to cool if overheated.
- Close suction and discharge valves.
 An overheated pump can cause burns and
injury. If overheating occurs:
- Stop pump immediately.
- Allow the pump to cool.
- Check before restarting the pump
 Do not remove plates, covers, gauges,
pipe plugs or fittings from an overheated
pump. Vapor pressure can cause parts to
be ejected with great force.
 Do not operate pumps without guards in
place
 For Centrifugal Pumps do not run against
“shut off” or near zero flow.
 For Positive Displacement Pump do not
operate with suction and discharge valves
closed. Check relief valve.
 Three types of pumps with
rotating impellers:
Pumps with rotating impellers are the most used
types for liquids in processing, filtering or
transfers between containers. a
 Centrifugal Pumps – selected when low-to-
moderate pressure must be pumped at high
capacities.
 Positive Displacement Rotating Pumps - for
handling high-viscosity liquids at moderate to
high pressure
 Flexible Impeller Pumps – for low-to-high
viscosity liquids in low pressure applications
and where self priming is required
 CENTRIFUGAL PUMPS
 Preferred when low viscosity liquids, high
capacity and continuous duty applications. Most
common in industrial processes.
 Lower initial cost and less maintenance
compared to positive displacement rotary
pumps.
 Endurance life is limited mainly by the pump
seal. No fine abrasive in the liquid and seals,
keep cool at the upper limits of liquid
temperatures.
 Available in a wide range of material
construction for moderate to severe corrosive
applications and moderate to high temperature.
 POSITIVE DISPLACEMENT PUMPS
 Lobe type rotors are designed to handle viscous liquids,
with delicate solids in suspension and shear sensitive
liquids.
 Some are relatively expensive because they are made to
close tolerances.
 Rotary pumps in stainless steel constructions are used
widely in the food, beverage, dairy, pharmaceutical and
cosmetic industries where sanitary construction is
required.
 Well suited for continuous service.
 Pump speed is limited by the high viscosity the pumps
are designed to handle.
 Can be used for metering liquids during processing.
That is the volume of liquid pumped is closely related to
the speed rotor rotation.
 FLEXIBLE IMPELLER PUMPS
 Most economical choice for short transfer runs at
moderate pressure.
 Used mainly at low pressure when self priming is
essential.
 Single flexible impeller has blades of specially
compounded elastomer.
 Impeller has a smooth gentle cam-flexed
pumping action for liquids that are shear
sensitive or contain delicate solids.
 Develop and maintain high vacuum of about 22
inches (56 cm) of mercury for self priming.
 Can run dry for under one minute for self
priming.
 PREALIGNMENT REQUIREMENTS
Applicable for all types of pumps a
 FOUNDATIONS: Adequate size and good
condition: Rule of thumbs – concrete
equal to three times machine weight for
rotating machines and five times for
reciprocating machines.
 GROUT: Suitable materials, good condition
with no voids remaining under base plate.
 BASEPLATE: Designed for adequate
rigidity. Level, flat, parallel, clean?
 PIPING: Is connecting piping well fitted
and supported, and sufficiently flexible, so
that no more than 0.003 in. in vertical and
horizontal movements occurs at the
coupling when the last pipe flanges are
tightened.
 COUPLING: check alignment as
recommended by manufacturer.
 INSTALLATION: coupling cleanliness and
for some types, lubrication, are important
and should be considered.
 INSTALLATION – CENTRIFUGAL
PUMP
 LOCATION: Select a site as near as possible to
the source of liquid. a
 FOUNDATION: Set the pump with the base
plate on a firm foundation to support the pump
with the required prime mover.
 INSTALLATION: All pipe work should be correctly
aligned with the pump and firmly supported.
 SUCTION PIPING: Must be free from air leaks.
Same size or larger than that of the pump
flange. Tapered eccentric reducers should be
used. Straight length of pipe fitted to pump inlet.
Suction piping should have continual fall
 from pump to the liquid source. Avoid sharp turns by
using long radius bends and not elbows. End of suction
line is below the low level of the liquid. With suction lift,
a foot valve with water opening at least equal to that of
the pipe.
 DISCHARGE PIPING: Size suitable to carry the required
capacity, such that the friction head created is not
excessive.
 DIRECT COUPLED PUMPS: Flexible coupling should be
fitted and aligned in accordance with the coupling
manufacturer’s instructions.
 BELT DRIVEN: Pump pulley and speed must be in
accordance with the manufacturer’s specifications to
operate pump at the best efficiency.
 STARTING – CENTRIFUGAL PUMP
WARNING: Do not run the pump dry as the mechanical
seal / packing will be damaged.
 Ensure the gate valve is closed. Do not run the pump for
very long with the discharge valve closed.
 Prime the pump. The pump casing and suction line must
be filled with the liquid to be pumped.
 Direction of rotation. Ensure the drive shaft rotation
conforms to the direction arrow on the pump.
 The unit may now be started. When the pump reaches
full speed, open the gate valve on the discharge pipe
gradually until the required quantity of liquid is being
delivered. If no liquid, shutdown immediately.
 Check for abnormal noise, operating temperature and
check leaks on the mechanical seal.
 START-UP CHECKLIST
 Read and be familiar with the pump Installation,
Operation and Maintenance Manual. Check if
instructions have been complied with.
 Pipe connections must be securely fastened and
air tight. All piping must be clean and free of
debris.
 Is pump and all piping properly supported and
are all supports securely fastened? a
 Are required screens / filters in place?
 Are all valves in the system proper, open or close
position for start-up
 Confirm power source voltage matches the motor
nameplate.
 Does the impeller / shaft rotate freely?

 Is pump primed?

 Verify that rotational direction is correct for pump by

VERY short “on-off’ at power source.
 For Centrifugal Pump – slowly open discharge valve to
obtain desired flow rate at pumping system.
 For Positive Displacement Pump – both discharge and
suction valves are open. Check relief valves.
WARNING: Do not start pump until above checks have
been made and all start-up instructions in the pump
I.O.M. have been complied with. Failure to do so may
result in severe damage to equipment, and cause
personal injury
 MAINTENANCE INSTRUCTION –
Follow manufacturer’s
recommendation
 Check the bearing temperature by hand.
Temperature should be about the same
whenever it is checked. Ball and roller
bearing have a maximum temperature of
75 C. Any substantial change may be due:
- Excessive lubrication
- Bearing damage
- Overload
 Listen to bearing abnormal noise with
stethoscope or similar equipment.
 Feel the pump for vibration. Can be due to
- Bearing damage.
- Impeller damage
- Cavitation
- Incorrect alignment or coupling wear
- Loose foundation bolt
 Look for leaks from pipe joints or flanges
and around valve seals.
 Check leaks in packing boxes. There
should be slight leakage for lubrication.
Tighten the gland or repacked. Check that
the packing box does not become hot
after tightening.
 Cleaning the Pump – A clean pump is easier to inspect,
lubricate, adjust and run cooler, plus it looks better.
 Any pump that has handled a corrosive, flammable, hot,
or toxic liquid has been drained, flushed, vented and / or
cooled before it is disassembled.
 Don’t drop parts during disassembly.
 Preventive Maintenance Procedure such as periodic
lubrication, adjustment, inspection etc., will extend the
service life of your pump.
 Strainers must be cleaned regularly.
 Follow all hazard warnings and instructions of the
manufacturer.
 Maintenance shall be performed by qualified technicians
only.
 Inspect all component parts for wear or damage, and
replace as required.
 Do have spare parts, pumps or standby units available, if
the pump is an essential part of a key operation or
process.
 CONDITION MONITORING-
detection of mechanical defects as
well as fluid-flow disturbances.
 Mechanical Defects: Bearing flaws, mechanical-
seal defects, coupling malfunctions, rotor
unbalance, erosion, corrosion and wear.
 Fluid-flow Disturbances: Inadequate NPSH,
insufficient flow, and gas entrainment or
cavitations.
Condition monitoring is the detection of any
abnormal parameters which must be corrected if
pump damage is to be avoided.
 HOW ABNORMAL PARAMETERS
CAN BE DETECTED
 Fluid-flow disturbances can best be measured by
pressure deviations or changes in the flow pattern and
temperatures.
 Mechanical distress can manifest as changes in lube oil
temperatures, lube-oil particulate contamination, bearing
noise and pump vibration.
 Measuring increase vibration levels.
 Low Frequency Vibration Monitoring. Excessive vibration
can lead to internal rubbing, over stressing of pipe
flanges and hold down bolts, grout failures, mechanical-
seal leakage, bearing damage, coupling wear, etc.
 High Frequency Vibration Monitoring. Measuring overall
vibration severity. Benchmark for following vibration
trends over time.
 PUMP DATA FILE
 Installation, operating, and maintenance manual
 Specification sheets
 Cross sectional drawing showing the equipment
assembly
 Bill of materials or complete parts lists identifying
components and materials of construction
 Required parts list – minimum to be stored by stores or
local vendor
 Performance curve
 Mechanical seal information (drawings, etc.)
 Design change data
 Computer input forms. Vendor must provide such
important maintenance information as impeller and
bushing clearances, manufacturing tolerances, and as
built internal dimensions.