Axial and Mixed

Flow Pumps: A
Simplified
Engineering
Design Manual

CIMMYT-Bangladesh
Eric Lam

Introduction
What is an axial flow and mixed flow pump?
Axial flow pumps (AFP) and mixed flow pumps (MFP) are pumps designed for
pumping water at high flow rates against low lifts. These are ideal for crop
irrigation, aquaculture, flood control, and wastewater handling. The amount of
flow and lift capacity are dependent on how the pump is built. There are a few
commonalities between all AFP and MFP pumping systems.

1. Engineprovides power to the pump. Rated by horsepower and RPM.

2. Power couplingconnects the pump to the engine.
3. Bearing housingholds the bearings that keeps the shaft in alignment and
able to freely rotate. Contains a head shaft.
4. Discharge casingredirects flowrate out, while sealing the head shaft.
5. Delivery pipeallows for flow of water. Contains the line shaft and line shaft
bushings.
6. Impellerimparts energy on the water, causing it to flow. Housed
within the intake casing, in front of the stator,
and behind the intake screen.
2
3

Total Dynamic Head (meters)= Lift + Friction

Lift (meters)

Submergence (meters)
6

Bottom Clearance (meters)

Water and Diesel Power

How much power should I use to run the pump?
The power needed by the farmer, in terms of water delivery and engine capacity,
can be approached based on 1. the farmers need, 2. the engine available, or 3. the
pump available. In all three cases, the water-horsepower and break-horsepower
requirements should be well defined
Water-horsepower is the power needed to operate a pump if the pumping
system was 100% efficient.

w.hp

Q
g
tdh

= water-horsepower , kW
= density of water, 1000 kg/m3
= water flow, m3/s
= acceleration of gravity, 9.81 m/s2
= total dynamic head, lift plus friction

Break-horsepower is the power needed to operate a pump with inefficiencies

included.

b.hp
w.hp
pump
drive

Example

= break-horsepower, kW
= water-horsepower, kW
= pump efficiency
= drive efficiency

Known Values

Calculated Values

A farmer needs to irrigate a field, he has a b.hp = 12 horsepower or 9 kW

12 horsepower diesel engine, connected to
drive = 40%
2 V-belts. He will pump for 12 hours a day, pump = 70%
at an average 32C.

He needs a pump with a w.hp rating of 2.5

kW or 3.4 hp. If he uses direct coupling,
he can use a smaller engine with the same
pump or a smaller pump with the same
engine.

A farmer needs a pump that can do 25

liters per second, at a pressure of 6
meters.

He needs an engine with a b.hp flywheel

output rating of 1.5 kW or 2.0 hp.

Q = 25 l/s
tdh = 6 m

A farmer has a pumping system capable of w.hp = 2.0 kW or 2.7 hp

delivering 2.0 kW with a total efficiency of
0.30.

He can buy a pump rated to deliver 60 l/s

at 1 m tdh, 15 l/s at 4 m, or 9.0 l/s at 6 m.

Delivery Pipe and Coupling

What type of pipe should the pump use?
Pipes come in many different standard materials and sizes, often rated by
nominal diameters (DN). When selecting the appropriate pipe, the following
should be considered:

What environmental conditions will the pump be

operated and stored in?

How long does the pipe have to last?

How available and affordable is the pipe?

How will it connect to the discharge casing,

welded or bolted?
Can this connection support the weight of a fully filled pipe?

How much flowrate does the pump have to deliver? How much friction loss,
or pressure drop, is allowable? This will dictate the diameter needed, as
calculated by the empirically based Hazen-Williams equation.

Pipe Type

Suitability

= hydraulic slope

hf

= head loss, m

= length of pipe, m

= volumetric flow rate, m3/s

= pipe roughness coefficient

= inside diameter, m

Weight,
kg/m

Cost,
taka/m

Recommended
Velocity, m/s

Recommended
Flowrate, l/s

Engine Power
Needed at 3m lift
and 30% eff

Mild Steel 1 mm Rusts in 1 to 2 2.5

6 DN
years in
3.0
8 DN
humid
conditions.

130
155

0.9 to 1.4

15 to 20
20 to 25

2.0 kW or 2.7 hp
2.5 kW or 3.4 hp

UPVC
4 DN
6 DN
8 DN

540
610

1.5 to 1.7

10 to 25
25 to 35
30 to 45

2.5 kW or 3.4 hp
3.0 kW or 4.0 hp
4.3 kW or 5.8 hp

Doesnt rust.

3.2
8.0

Power Transfer
How is the pump connected to the engine?
There are two main types of power couplings available to farmers (in
Bangladesh). The first is a standard V-belt drive system, which uses different
diameter sheaves allowing for RPM to be easily stepped up or down. The second
is a direct coupling using three tire bands.

V-Belt

Direct Coupling

Belts are classified to fit different

profiles, horsepower ratings, and
sheave diameters.
These systems can provide up to
90% power transfer, but only if
manufacturer recommendations
are followed.
Each belt can only provide a
limited amount of horsepower.
The number of belts needed for
full power can be calculated.

Ha
K1
K2
Htab

= allowable power, per belt

= angle-of-wrap correction factor
= belt length correction factor
= rated power, hp

Source: Gates Rubber Co., Denver, CO

The tire band connections are

common for centrifugal pumps.

Can provide up to 99% power

transfer with a stable platform.

The radial planes and center axes

of the pump and flywheel needs
to be as aligned possible.

Any damaged bands need to be

replaced immediately. Failure
during running is very dangerous
and can irreparably damage the
pump or operator.

Bearing Housing
What size bearings should the pump use?
When selecting the bearing mount configuration for the head shaft of an AFP/
MF irrigation pump, the most economically sensible option is to use one from an
existing pump, often a centrifugal pump. The selection criteria for an
appropriate bearing housing is as follows:

What is the operational rating of the existing bearing housing, bearings and
shaft?

RPM and dynamic load capacity of the bearings?

Direct coupling or V-belt?

Maximum applied force?

Maximum applied torque?

What is the operational rating of the existing pump?

Kilowatt or horsepower rating?

Flowrate or pressure capacity? If these are known, along with the

vectorization profile in the existing pump, the system capacity of the
whole housing can be reverse engineered.

Bearing

Dynamic Load
Cap., kg

Max RPM Cost,

taka

Thrust Bearing
25mm x 52mm

Radial 830
Thrust 530

1,000

Ball Bearing
25mm x 52mm

1,430

17,000

200

Ball Bearing
30mm x 62mm

1,900

14,000

300

Bearing Housing

Cost,
taka

Weight,
kg

3 DN Centrifugal 800

2,220

4.5

6 DN Centrifugal 2500

13,400

30.7

Theoretical
Applied
Torque, Nm

Discharge Casing
What discharge casing configuration is needed?
When designing the discharge casing, 1. the way it is mounted to the bearing
housing, 2. the coupling method to the delivery pipe, and 3. the redirection
needed for the flow are the primary constraints for the body of the casing.
Additionally, the following needs to be considered:

The discharge casing should be the same diameter as the delivery pipe to
reduce pressure losses. If the diameter is altered, a constricted discharge
will increase pressure delivery, while a expanded discharge will increase
flowrate.

The material chosen will dictate the thickness needed to support the
connection to the bearing housing, the thrust from the discharge, and the
weight of the pump. This in turn will determine the weight of the casing.

What angle does it need to be? Does it need a smooth transition? A 45

discharge will have less pressure losses and might be easier for farmers to
use. However, 90 bend is lighter, cheaper, stronger, and easier to
manufacture.

Will the discharge outlet couple to a flexible hose pipe or flanged fitting? Flanged
fittings are heavier, but are necessary for pressurized systems such as ones with
delivery manifolds.
7

Line Shaft and Bushings

What kind of bushings does the pump need?
Bushings are important for stabilizing the line shaft, which transfers energy from
the head shaft to the impeller. Bushing spacing is important to support the line
shaft. This helps to 1. provide a low friction contact surface, 2. reduce shaft
deflection, and 3. reduce vibration on the system.

What diameter should the line shaft be? Solid shaft or hollow pipe? These
decisions are based on applied torsion, allowable deflection, allowable
displaced volume, and resistance from the turning impeller.

The length/diameter ratio needs to be between 0.5 to 2.0. The distance

between bushings should not exceed 2 meters.

Metal bushings will last longer than plastic bushings, but are more
expensive and may have anodic reactions with the mounting.

Manufactured bushings will have ratings that are important for selecting
the right material and diameter needed for the pump.

The load at velocity (PV) rating is a combined of pressure and

rotational speed capacity.

Environmental ratings including temperature.

These factors can be used for a time-wear equation, which will

predict when the bearing will fail or need to be replaced.

Source: Oiles America Corp., Pymouth, MI 48170

= time before needing replacement, hr

= length of bushing, in

= diameter of bushing, in

= allowable wear, in

f1

= motion related factor

f2

= environmental factor

= wear factor, in3*min/lbf/ft/hr

= radial velocity, ft/min

= radial load, lbf

Impeller
What type of impeller does the pump use?
For these high flow, low head irrigation pumps, there are two types of impellers
to use: the axial flow and mixed flow impeller.

Axial Flow Impeller

Mixed Flow Impeller (open or shrouded)

The axial flow impellers only

impart axial forces on the water
flow (higher flow, lower
pressure).

The mixed flow impeller has a

conical shape, which imparts
axial and radial force on the
water flow (lower flow, higher
pressure).

Radial Direction
Rotating Shaft
Axial Direction

These should only be used if the

lift is 3 meters or less.

These should be used if the lift is

between 2 and 8 meters.

RPM range: 1500 to 1800

RPM range: 1000 to 1300.

Three blades will use less

energy, but deliver a lower
flowrate than four blades.

Thinner blades are more

efficient, but will reduce
strength.

High angulation blades (20

and 25 off the radial plane) will
deliver higher pressure, but
lower flowrates than low
angulation blades (10 and 15).

Geometries can be complex. A

30 cone with a 6 bladed helical
structure, with intake parallel to
radial and discharge normal to
the cone, works well

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