Pumps

Classification, Operation and Maintenance

Arranged by
Eng. Hossam Hassan
Technical Team Leader (Suez Base)
Petro Environmental Service Company (PESCO)
Sep 2010

Contents:
Introduction --------------------------------------------------------------------------------------------- -------3
What Are Pumps------------------------------------------------------------------------------------------------8
Pumps Classifications----------------------------------------------------------------------------------------11
Positive displacement pumps------------------------------------------------------------------------------13
Reciprocating Pumps-----------------------------------------------------------------------------------------14
Piston Pumps----------------------------------------------------------------------------------------------------17
Diaphragm pumps---------------------------------------------------------------------------------------------23
Rotary Pumps--------------------------------------------------------------------------------------------------28
Gear Pumps -----------------------------------------------------------------------------------------------------32
Lobe Pump-------------------------------------------------------------------------------------------------------40
Screw Pump-----------------------------------------------------------------------------------------------------42
Rotary Piston Pump-------------------------------------------------------------------------------------------46
Vane Pumps-----------------------------------------------------------------------------------------------------50
Rotary Pump Selection Guide------------------------------------------------------------------------------57
Centrifugal Pumps--------------------------------------------------------------------------------------------60
Cavitation--------------------------------------------------------------------------------------------------------73
Comparisons between Rotary and Centrifugal Pumps---------------------------------------------76
Special Pumps---------------------------------------------------------------------------------------------------77
Jet Pumps --------------------------------------------------------------------------------------------------------79
Air Lift pump----------------------------------------------------------------------------------------------------85
Peristaltic Pump -----------------------------------------------------------------------------------------------89
Ram Pump-------------------------------------------------------------------------------------------------------92
Dutch Pump------------------------------------------------------------------------------------------------------97
Selection Criteria for Centrifugal Reciprocating, and, Rotary Pumps-------------------------99
Pumps Efficiencies---------------------------------------------------------------------------------------------100
References--------------------------------------------------------------------------------------------------------103

Introduction

What are Pumping Systems?

20% of worlds electrical energy demand.

25-50% of energy usage in some industries.

Used for

Domestic, commercial, industrial and agricultural services

Municipal water and wastewater services

Objective of pumping system:

Transfer liquid from source to destination.

Circulate liquid around a system.

Main Pumping System Components:
Pumps.

Prime movers: Electric motors, Diesel Engines, Air system, Turbine

Valves to control flow in system.

Hydraulic Motors or Cylinders.

Heat Exchangers, tanks, hydraulic machines.

Other fittings, control, instrumentation.

Pumping System Characteristics

Pump operating point

Duty point: rate of flow at certain head.

Pump operating point: intersection of pump curve and system curve.

Pump performance
curve

Head

Pump
operating
point

System
curve

Static
head

Flow

Pump performance:

Dynamic Pump Performances:

 

What are Pumps?

Pumps:
Fluid Machines that convert mechanical energy into fluid energy & handle
incompressible fluids (Liquids)

Or
A Mechanical device used to add kinetic and potential energy to a
Liquid for the purpose of moving it from one point to another. This
energy will cause the liquid to do work such as flow through a pipe or
rise to a higher level and Pump gives pressure to fluid passing
through it and discharges the fluid to the Outside.
:
.         

Important notes
i.

A Pump doesnt create pressure it only provides flow. Pressure is a just an

indication of the amount of resistance to flow.
. !/ + ,-. , *%.   !  $  %& '()  

ii.

Pumps can Pump only liquid not vapor

% 1 2  3  2  

9

iii.

Pumps create flow by reducing atmospheric pressure on water (by creating

a vacuum)

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iv.

The main reason for using head instead of pressure to measure a pumps
energy is that the pressure from a pump will change if the specific gravity
(weight) of liquid changes but the head not change.

*%  !    + pressure !  9head !/3 <, M1

.,%/I  head(  .. S,Q$=  ),%/9 ,%/I

10

 T()

Pump Classifications

According to the method of energy transfer between liquid & the machine.

  9  + +I, +1

11

Pumps

Positive Displacement Pump
9I

Dynamic Pump
(I!
Rotary Pumps

Reciprocating

Centrifugal Pumps

Special Pumps

Radial
pumps

Piston
Plunger

Axial
Pumps

Mixed
Pumps

Diaphragm

Jet
pumps

Air Lift
pumps

Vane
Pumps

Piston
Pumps

Peristaltic
Pumps
Ram
pumps

Dutch
pumps

Lobe
Pumps

Screw
Pumps

Radial
Pump

Axial
Pumps

Gear
Pumps

Balanced

Unbalanced

Internal

External

Positive Displacement Pump:

Reciprocating
pumps

Positive
Displacement
Pump
Rotary Pumps

 ,/:I

Reciprocating Pumps:

      

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Reciprocating
Pumps

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Diaphragm

Double Acting

Single Acting

,-
Plunger ,Piston

Single Acting

Double Acting

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Diaphragm Pump

 


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23


Cars often use a Diaphragm Pump to move gasoline from the gas tank to
the carburetor or fuel injection plugs. The gasoline diaphragm pump in a
car is operated by a cam geared directly to rotating parts of the engine. The
cam pushes a pushrod.

The brown rod shown in this drawing is moved by the pushrod. It pushes
the diaphragm in (a spring forces it back out(

Fuel pumps like this one operate continuously but have a safety valve
which returns fuel to the input side of the pump if pressure rises above a
set level.

The pump usually has a fuel filter built into it. (The fuel system will have
several other filters.)

Diaphragm pumps are very common and come in many sizes. Modern
plastics are flexible and long lasting making this an ideal low-maintenance
pump for many applications

24

Double Acting Diaphragm Pump

25


Double Diaphragm pumps offer smooth flow, reliable operation, and the
ability to pump a wide variety of viscous and impure liquids. The Air
Operated Double Diaphragm pump is illustrated on the right. This pump
uses a very simple valve system to move the DIAPHRAGM ROD. The
flexible diaphragms (shown in white here) are round disks attached at each
end of the Diaphragm Rod.

The PILOT SPOOL (the middle of the three horizontal rods) is pushed
back and forth whenever the Diaphragm Rod reaches the end of its throw.
The Pilot Spool allows air to move the Air Distribution Valve (the top rod
in this drawing) back and forth.

The AIR DISTRIBUTION ROD controls air flow to the left or right air
chamber, reversing on each stroke.

The four BALL VALVES are free-floating and operated by pressure
differences in the pumped liquid. Flapper valves are also commonly used.
In the pump shown, liquid flow is from the bottom to the top.

Sanitary Double Diaphragm pumps, often made of plastic and/or stainless
steel, are used in the food industry to pump everything from sliced fruit, to
sausage, to chocolate.

26

 !

Rotary pumps

27

Rotary Pumps

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Rotary pumps:
Operate on the principle that a rotating vane, screw, or gear traps the liquid in the suction
side of the pump casing and forces it to the discharge side of the casing
These pumps are essentially self-priming due to their capability of removing air from
suction lines and producing a high suction lift.
In pumps designed for systems requiring high suction lift and self-priming features, it is
essential that all clearances between rotating parts, and between rotating and stationary
parts, be kept to a minimum in order to reduce slippage.
Slippage is leakage of fluid from the discharge of the pump back to its suction.
Due to the close clearances in rotary pumps, it is necessary to operate these pumps at
relatively low speed in order to secure reliable operation and maintain pump capacity over
an extended period of time.
Otherwise, the erosive action due to the high velocities of the liquid passing through the
narrow clearance spaces would soon cause excessive wear and increased clearances,
resulting in slippage.

29

Gear Pump

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Screw
Pump

6e
 

Piston
Pump

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Rotary
Pumps

Vane
Pump
d( 

Lobe
(Root)
Pump

30

Gear Pump

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31

Gear Pump


 

Internal
Gear Pump

External
Gear Pump


 

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This type of rotary gear pump moves liquid in the same direction regardless
of the direction the gears turn. The valves (shown in yellow in this
drawing) are forced open and closed by the difference in pressure on the
input and output sides.

In this drawing, fluid in the higher-pressure output side is shown in light
blue while fluid in the lower-pressure input side is dark blue.

Notice that when the green gear starts moving clockwise, the fluid in the
outer circular tubes changes pressure but stops flowing, and fluid flows
more or less straight up.

When the red gear is moving clockwise, fluid travels in a sideways 'S'
shape through the outer circular tubes.

The pump in this drawing reverses direction about every 8 seconds.

36

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The screw pump is a positive displacement pump which comes with two or
three screws. (A single screw version is called a "progressing cavity"
pump(

The Quimby Screw Pump is a type of screw pump.

The pump forms hollow cavities which contain the fluid and move it along
the screws. One screw is the drive screw and the other screw or screws
is/are driven by the drive screw.

44

45

 

Axial Piston Pump

Radial piston Pump

46

47


Radial Piston Pumps can produce a very smooth flow under extreme
pressure. Generally they are variable-displacement pumps. In variable
models, flow rate changes when the shaft holding the rotating pistons is
moved with relation to the casing (in different models either the shaft or
the casing moves.) Output can also be varied by changing the rotation
speed.

48

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Pump Selection Guide

Abrasives

Thin
Liquids

Viscous

Solids

Dry Prime

Diff.
Pressure

Internal
Gear

External
Gear

Lobe

Vane

E = Excellent, G = Good, A = Average, P = Poor


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Centrifugal
Pumps

Special
pumps

Ram
pumps

Jet
Pumps

Air lift
pump
 !A UB

Axial

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60

Centrifugal:
The pump casing provides a pressure boundary for the pump
and contains channels to properly direct the suction and
discharge flow.
The pump casing has suction and discharge penetrations for the
main flow path of the pump and normally has small drain and
vent fittings to remove gases trapped in the pump casing or to
drain the pump casing for maintenance.
The pump casing guides the liquid from the suction connection
to the center, or eye, of the impeller.
The vanes of the rotating impeller impart a radial and rotary
motion to the liquid, forcing it to the outer periphery of the
pump casing where it is collected in the outer part of the pump
casing called the volute.
The volute is a region that expands in cross-sectional area as it
wraps around the pump casing.
The purpose of the volute is to collect the liquid discharged from
the periphery of the impeller at high velocity and gradually
cause a reduction in fluid velocity by increasing the flow area.
61

This converts the velocity head to static pressure. The fluid is

then discharged from the pump through the discharge
connection.
Centrifugal pumps can also be constructed in a manner that
results in two distinct volutes, each receiving the liquid that is
discharged from a 180o region of the impeller at any given time.

Pumps of this type are called double volute pumps (they may
also be referred to a split volute pumps). In some applications
the double volute minimizes radial forces imparted to the shaft
and bearings due to imbalances in the pressure around the
impeller.
62

Diffuser:

It is a set of stationary vanes

that surround the impeller.
The purpose of the diffuser is
to increase the efficiency of
the centrifugal pump by
allowing a more gradual
expansion and less turbulent
area for the liquid to reduce
in velocity.

The diffuser vanes are designed in a manner that the liquid

exiting the impeller will encounter an ever-increasing flow area as it passes through the
diffuser.
This increase in flow area causes a reduction in flow velocity, converting kinetic energy into
flow pressure.

Impeller classification:
This increase in flow area causes a reduction in flow velocity, converting kinetic energy into
flow pressure.

Impeller classification:

A single-suction
impeller
allows liquid to enter the
center of the blades from
only one direction.
A double-suction impeller
allows liquid to enter the
center of the impeller blades
from
both
sides
63
simultaneously.

Impellers can be open, semi-open, or enclosed.

The open impeller consists only of blades
attached to a hub.
The semi-open impeller is constructed with a
circular plate (the web) attached to one side
of the blades.

The enclosed impeller has circular plates

attached to both sides of the blades.
Enclosed impellers are also referred to as
shrouded impellers.

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Axial

Centrifugal
Pumps
Radial

Axial flow

Mixed

Mixed flow
66

Radial flow

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Axial centrifugal flow pumps:

67

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Mixed centrifugal flow pumps:
Mixed flow pumps borrow characteristics from both radial flow and axial flow pumps. As
liquid flows through the impeller of a mixed flow pump, the impeller blades push the liquid
out away from the pump shaft and to the pump suction at an angle greater than 90o.

Mixed centrifugal flow pumps:

68

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Radial centrifugal flow pumps:

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72

Cavitation

v, Cavitation :-TY/

v,   TY/ ,Z_  I / . >  )9 = ,v !D !(> M1 YW&,
>  ),/ !V9 yD, (impeller  ,Yx>, >=<   ( ,+ GQ! >  z!, = =Z
)(case {hx, !  /7 >+ , $   $Q . Y M I< ! & *%!)9 ,1
(/ <=> 9$Q ! = =Z !  (| > ! M1I TY/ !V M9h   !/& *%HI,7/
=.

(' Cavitation Prevention :-TY/

}   TY D >  ,%/ , I %1(I / ~) <=> YZ(x I$ )y9 (NPSHa
z1)I+I (NPSHr)  ,1 .TY/

 , I$ >(/(NPSHa):-

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I  *%,7 .I < I  *%,7.
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$I ) MD(NPSHa:- V
(NPSHa) = P suction P saturation
yD > Q, , > *%9 I79 ,D Q   *%& +I M1- $I ) ( NPSH
MDV >{.
-  ( >& 67  =V M9 = M )3 (NPSHa $I  3 NPSHr ,+I(E
>! , >& 67/ I$9 =V  ,1 !> 67 ( ) (elbow) i 1 67
 1.
 - +I .= (NPSHr) 67/9 TY/

xD :-
-  ),v } /9W } (V  (NPSHr  7=/( 6V9 <=> !/V YV ,$I )= (NPSHr
= _9 >(! I !V  ,1>  !/  Eh, !V 67 ,1>  !/ i (9  673 HI,7/
).=(NPSHr
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,%/  >,  >, )3 (NPSHr .67(I
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) , Y!V !   , >,! =! > ,  h , ( G& ~/I ,_, )> V
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73

13 Cavitation causes :-TY/

,% - ,% -:   = <  %.I
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-I, ,.
>= )/  9I) (NPSH) :-

 M(/)9 TY/ >:-

MI - *%& <+1I'  +  >=<  & *%1-.
- !+ !/   !I!/  & *%' h M(/ 13( G& ~/I TY/ >= )/  9I) .
- >= )/  9I (NPSHr) , / ,7 9 !(> *%)/ = & *%1- = h .G& ~/I
 M(/ MI TY/ I )(NPSHa) > (NPSHr

74

Comparisons Between Rotary

and Centrifugal Pumps
Rotary

Centrifugal

Max. Viscosity ( Cst / SSU)

Max. Capacity (CM/Hr/ GPM)

Pumping Efficiency

Energy Costs

Self-priming

YES

NO

Flow Control

Life-cycle Cost

Initial Cost

E = Excellent, G = Good, A = Average, P = Poor

Special
Pumps

Jet
pumps

Air Lift
Pumps

Dutch Pump

Special
Pumps

Other
Pumps

Peristaltic
Pumps

Ram
Pumps

77

Jet pump

A Jet Pump is a type of impeller-diffuser pump that is used to draw water from wells into residences. It can
be used for both shallow (25 feet or less) and deep wells (up to about 200 feet.) Shown here is the
underwater part of a deep well jet pump. Above the surface is a standard impeller-diffuser type pump. The
output of the diffuser is split, and half to three-fourths of the water is sent back down the well through the
Pressure Pipe (shown on the right here(

At the end of the pressure pipe the water is accelerated through a cone-shaped nozzle at the end of the
pressure pipe, shown here within a red cutaway section. Then the water goes through a Venturi in the
Suction Pipe (the pipe on the left)

The venturi has two parts: the Venturi Throat, which is the pinched section of the suction tube; and above
that is the venturi itself which is the part where the tube widens and connects to the suction pipe.

The venturi speeds up the water causing a pressure drop which sucks in more water through the intake at
the very base of the unit. The water goes up the Suction Pipe and through the impeller -- most of it for
another trip around to the venturi.

Jet Pump n 

80

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82

83

84

Air Lift Pump

The Air Lift Pump is a type of deep well pump, sometimes used to remove water from mines. It can
also be used to pump a slurry of sand and water or other "gritty" solutions. In its most basic form
this pump has NO moving parts, other than an air compressor. The efficiency of the air
compressor is a prime factor in determining the overall efficiency of the pump.

Increased efficiency in the pump itself can be achieved - but with added complexity. Shown here is
a simple Air Lift Pump.

Compressed air is piped down a shaft. The air then returns up a Discharge Pipe carrying water
with it. The pump works by "aerating" the water in the discharge pipe.

The added air lowers the specific gravity of the fluid mixture. Since it is lighter than the
surrounding water, it is pushed upwards.

This type of pump can lift 20 to 2000 gallons per minute, up to about 750 feet. The discharge pipe
must be placed deep into the water, from 70% of the height of the pipe above the water level (for
lifts to 20 feet) down to 40 percent for higher lifts.

85

 
! A UBAir lift pump

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86

 !A UB  
1
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6 8) W 
 !4& (sludge)
 '"LB1&'"

87

88

Peristaltic Pumps

One of the main advantages of the Peristaltic Pump is cleanliness. It also utilizes another
advantage: Fragile blood cells are not damaged by this pump. The flexible tube (in this drawing
its edges are blue and yellow for clarity) is connected on the inlet side to the patient's artery, and
on the outlet side to the patient's vein.

In this example three rollers on rotating arms pinch the tube against an arc and move the fluid
along. There are usually three or four sets of rollers.

Peristaltic pumps have a variety of medical applications. They can be used to add nutrients to
blood, to force blood through filters to clean it, or to move blood through the body and lungs
during open heart surgery.

Peristaltic Pumps

(-
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89

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90

91

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93

Step by step

Look at the ball when it is in the lower position

Water flows in with a high velocity at "water in"

The water flows out at "waste water" but at the same time it pushes the ball up the curve

When the ball hits the top point it blocks the water flow and a short impulse is build up behind the
ball

The impulse presses a little amount of water through the one-way-valve at very high pressure

The impulse is very short and as air can be compressed very fast the air chamber act as an energy
buffer

The one-way-valve closes again

The air pressure pumps the water out at "water out"

The ball was forced up by the water flow but as the flow stopped it rolls back to the lower position

The cycle begins again

94

Hydram size
in inches

4" X 2"

6" X 3"

Head Ratio

10

15

20

10

15

20

Driven flow
(liters/sec)

8.96

9.7

10

9.02

20.2

17.2

17.1

19.3

Delivery
(m/day)
(m /day)

94

51

35

23

216

101

69

50

95

96

Dutch Pump

All three stations were based on standard Cornish pumps and were built essentially alike. One of
them, Cruquius, is still in existence as a museum and is illustrated here.

There are eight pumps surrounding the central steam cylinder, but at Cruquius only seven were
actually connected because the steam cylinder could not power all eight.

The cycle shown works as follows: First, steam is introduced into the center of the cylinder (at
about 45 P.S.I.) The steam pushes the piston up, pushing the upper valves in the pumps down (two
of eight are shown(

About halfway up the inlet steam valve is closed but steam continues to expand and push the
piston up. It slows to a stop at the top of the cycle.

Next the exhaust valve is closed and the equilibrium valve is opened. Steam then flows around to
the top of the piston and, with the aid of gravity, pushes down on the piston. The upper valves on
the pumps move up and water is raised.

The equilibrium valve closes and the cycle repeats about seven times a minute

97

Selection Criteria for Centrifugal, Reciprocating, and

Rotary Pumps:
Selection Criteria

Centrifugal

Reciprocating

Rotary

Avoids Emulsifying
the Fluids

Poor

Good

Good

Reliability

Good

Poor

Fair

Self - Priming

Poor

Good

Good

Handles abrasives

Good

Fair

Poor

Handles NPSHA

Good

Poor

Fair

Handles Entrained
Gas

Fair

Fair

Good

Pump Viscous Fluids

Poor

Fair

Good

Pump low viscosity

fluid

Good

Good

Poor

Energy Efficiency

Fair

Good

Good/Fair

Installed Cost

Good

Fair

Good

Maintenance Cost

Good

Poor

Fair

98

Pump Efficiencies:

Pump Efficiencies
1. Mechanical Efficiency
Difficult to measure
Calculated from the other two efficiencies
m = o / v
2. Volumetric Efficiency
Pump displacement
Theoretical flow rate
Volumetric efficiency

Vp = n A S
QT = Vp N = n A S N
v = QA / QT

Overall Efficiency :
The ratio of output horsepower to input horsepower.
o = HPOUT / HPIN
In USCS,
o ={(p Q)/1714} / {(T N)/63, 025}
99

 In SI units,
o = {(p Q)/60, 000} / {(T N)/9550}

100

101

References:
a) Glossary of Pumps Site (www.glossarypumps.com).
b) Pump Handbook (McGraw Hill) 3rd Edition.
c) Pump User Handbook (Heinz P.Bloch).

( )> l1 i _ = $,( d

( V  %_ i  )~ -)
e) Pump School Site (www.pumpschool.com).
f) Equipment Maintenance and Operation Course (PESCo).
g) GR Pump Manual.
h) SAUERSUNDSTRAND (Tandem pump) manual.
i) SAUERDANFOS (AXIAL PISTON PUMP) Manual.

( ,I(I S! V ,1  '9,! V )9,V( =  j

k) The site of (Energy Efficiency guide for industry in Asia)
www.Energyefficiencyasia.com
l) The Site of How staff work(www.howstaffworks.com)
m) The site of (www.lifewater.com).
n) Pump Selection: Progressing Cavity, Pumps and Systems (Platt, R.)
o) Centrifugal Pumps (Johann Friedrich Glich)

102

Dears,
I hope that material will have all of use abilities for every level of
mechanical engineers, mechanics, pumps operators and all pumps
lovers.
Kindly I need to see your comments on this material or any
modifications

With all my best washes

Eng. Hossam Hassan

Mechanical Engineer (Technical Team Leader for Suez Base)

Petro Environmental Service Company (PESCo)

Sesem_m@yahoo.com, sesem.m@live.com

0020189575297 / 0020105823765

103