Professional Documents
Culture Documents
Coupling and Coupling Guard. The actual coupling is under the guard and unseen in this picture.
Base
As the name implies, the pump takes suction from the end.
Bearings
Mechanical seal
Shaft sleeve
Impeller
Item and number Mechanical seal #27 Shaft sleeve Impeller Casing Case ring Bracket #25 #11 #6 #7 #35
Bracket
Motor
Bracket
Casing
Impeller
Mechanical seal
Case ring
Motor
Coupling Guard
BasePlate
Bearings Packing**
Shaft Sleeves
Pump Shaft
Case Rings
Upper Half Pump Casing Impeller Shaft Sleeves Packing** Mechanical Seal** Pump Shaft
Items & Number Upper case #8 Lower case #69 Shaft sleeve #57 Shaft sleeve #64 Bearing Bearing Shaft Impeller Case ring Case ring #38 #47 #65 #59 #28 #28
Mechanical Seals
Mechanical seals are one method used to seal the pump shaft where it exits the pump casing. Mechanical seals are the preferred method of sealing a pump when the liquid being pumped is clean and clear, because they typically do not allow any leakage from the pump. The rotating face turns on the surface of a stationary face, along with gaskets, o-rings and bellows to form a seal. The following slide shows a two stage pump (two impellers) with mechanical seals on one side and packing on the other side. This is done for display purposes only. For actual applications, pumps are always built with the same method of sealing on both sides of the pump. As an exercise on what we have already studied, can you name the first 5 numbered parts on the next slide as well?
Stationary Seat
Packing
Packing is another method used to seal the pump shaft where it exits the pump. Some liquid must leak past the packing rings to dissipate the heat generated by friction between the stationary packing and the rotating shaft sleeve underneath the packing rings. This leakage must be piped to drain, or collected in a sump to be pumped out of the pump room. Because of this necessary leakage, packing is not the preferred method of sealing a pump. However, packing is generally not subject to a catastrophic failure, and for this reason, packing is the only accepted method of sealing UL/FM approved fire pumps.
5 Packing Rings
This study will show the basic design criteria used by engineers to make pump selections, review basic pump terms and formulas, and give examples on proper and improper pump selection. You will learn how to convert PSI (pounds per square inch) to feet of head, how to calculate the horsepower required to operate any given pump, and how to read pump curves and properly make pump selections. You will also be given examples throughout the program on common mistakes that will cause premature pump failure.
Friction Loss
The first factor present in every pump application that we are trying to overcome is friction loss. Simply stated, this is the drag created when flowing water comes in contact with the inside wall of the piping, valves and fittings of a system. Friction loss can be calculated with formulas, friction loss charts or computer programs. As you can see by the friction loss chart on the next slide, increased flow in the same size pipe will increase friction loss. You will also notice that the friction loss given is per 100 of pipe, so more piping and valves in a system will also increase overall friction loss. These same types of charts are available for valves and fittings. The second slide depicts a system with 24 of friction losses in the discharge piping.
At 100 GPM, the friction loss is only .094 feet per 100 feet of 6 pipe.
At 650 GPM, the friction loss is now 3.38 feet per 100 feet of 6 pipe.
Final Goal
After we have overcome the friction loss and any static loss in the system, there is usually a fixture or some piece of equipment which requires a set water pressure and flow to operate properly. In the example on the next slide, we have a chiller which requires 600 gallons per minute, and 50 PSI to operate properly. This is a basic example. Most applications require different flow rates in the same system. In this case, the engineer is then going to do calculations using system head curves to determine pump selection. Please refer to the tool kit covering system head curves for further study.
Pump
Head
Head, or feet of head is the most common way to express pressure generated by a pump. Most pump curves use feet of head to express pressure. A formula to convert PSI to feet of head will be given later in the presentation. In the example on the next slide, the pump design point selected shows a pump operating at 600 GPM @ 80 feet of head (80).
Impeller Diameter
(The correct answer on the previous curve was 1200 GPM @ 95)
The impeller is the heart of the pump, and as water enters and passes through the impeller, pressure is increased. Increasing the impeller diameter increases the centrifugal force being exerted on the water, and so increasing impeller diameter will also increase the pressure created by the pump. The following slide points out the different flow characteristics of various size impellers within the same pump. Only a few impeller diameters are shown, but the impeller can be trimmed to many diameters in between those shown. The actual impeller diameters are shown in inches on the left side of the curve near the beginning of the pump curve.
Curve Shape
You will notice that as the pump curve moves to the right, (flowing more water) the curve is also slowly dropping (less pressure). The reason for this is that as the flow increases, the same water remains inside the impeller for a shorter period of time, and the centrifugal force has less time to impact the passing water. You will notice in the future that some curves are flatter than others, and some curves drop off quicker as you flow more water. The reason for this difference is in the internal impeller design. The following slide points out the natural curve shape of a centrifugal pump from beginning to end for a 13 inch impeller.
Efficiency
A pumps efficiency is the ratio of input power to output power of the pump, and is expressed as a percentage. (%) Many factors affect a pumps efficiency which include, internal friction loss as water passes through the casing and impeller, and mechanical drag created by the bearings, mechanical seals or packing, and wear rings. A pumps efficiency is shown on the pump curve most commonly in one of two ways shown on the next two slides. In the two examples given, the same design point is selected using two different pumps, showing pump efficiencys of 80% and one of 68%. In todays world of energy conservation, it is usually very important to have a pump selection with a high efficiency rating. Many specifications will call out a minimum efficiency required to bid on a given project.
Every point within these boundary lines will have an efficiency of 80%
This is the other common way to show pump efficiency on a curve. The green curve is the efficiency curve, and the corresponding values are shown on the right side of the graph. This pump shows an efficiency of 68%
BEP
Shutoff
Shutoff, shutoff pressure or churn pressure, is the pressure developed when the pump is running, but not flowing any water. (0 GPM) This could be due to a closed valve, or a pump running in a system that is not currently requiring any water. The shutoff pressure for any given pump can be found by following the pump curve all the way to the left side of the curve. If the design point you have selected is between impeller diameters, follow an imaginary line to the left side of the curve. The curve on the following slide shows a shutoff head of approximately 114. Centrifugal pumps are very popular because shutoff pressures usually do not exceed 20% of the design pressure. This is important because it reduces the possibility of over pressurizing a piping system. Running pumps close to shutoff pressure for extended periods of time will increase shaft deflection and reduce pump service life. Running a pump without a casing relief valve at shutoff for more than a few minutes can cause serious heat build up and damage or destroy the pump. A casing relief valve is installed on the discharge side of the pump and piped to a drain, and it is set to open at a pressure slightly less than shutoff pressure to prevent the pump from operating at a zero flow condition.
Design point
Shutoff
Runout
Runout is a term used when a pump is operating to the far right of the pump curve. Efficiency is reduced, NPSHr is increased, and shaft deflection increases. For these reasons, it is not advised to operate a pump at this point on the curve. Follow the design point on the pump curve on the next slide to a runout condition. This would be near 1000 GPM.
Design point
Runout
Manufacturers Warning
Many pump manufacturers recommend that their product not be operated at certain points on the pump curve. This can be done in several ways, either by notes on the pump curve, or boundary curves. The example on the next slide shows boundary curves, and it is recommended that the pump not operate to the left of the curve near shutoff, or to the right of the curve near runout. Running a pump outside of the recommended operating range will usually void the manufacturers warranty.
Point A
Horsepower curves
Point A
Max. BHP
Horsepower curves
Motor Enclosures
Motor enclosures mainly refer to the type of environment a motor is suitable to be used in. Common examples would be: ODP open drip proof to be used indoors and usually has a service factor of 1.15 TEFC totally enclosed fan cooled can be used in outdoor applications and commonly has a service factor of 1.0 Explosion Proof normally used in areas where hazardous or combustible vapor conditions can exist and usually has a service factor of 1.0
NPSH - Continued
NPSHa refers to the amount of net positive suction head that is available in any particular application. NPSHr refers to the amount of net positive suction head required by any given pump to operate properly. The NPSHa must always exceed the NPSHr if the liquid being pumped is to stay in liquid form. This tool kit contains a separate, in depth discussion on NPSH. Please refer to that section for more information. Most pump curves show NPSH requirements. Increasing GPM increases NPSH requirements. Most applications that take suction from a city main have more than adequate NPSHa. Hot water applications and cooling tower applications are two situations where NPSH can be critical. In the example on the next slide, the design point shown has an NPSHr of about 12. To be safe, this pump should not be used in an application that has less than about 16 of NPSHa. As we have discussed earlier, the pump has a good chance of operating to the right or left of the design point, and you should always have a margin of safety included in your selection.
Design Point
12 NPSH Curve
NPSH Curves
Vapor Pressure
Vapor pressure is the amount of pressure required to keep any given liquid in liquid form. As you can see in the chart on the next slide, the vapor pressure increases as the temperature of the liquid increases. 212 degrees Fahrenheit is the boiling point of water at sea level, since the vapor pressure at 212 degrees equals that of the atmospheric pressure at sea level or 14.7 psi absolute (psia). You will notice that at 300 degrees, the vapor pressure is 67 psia. What this means is that if you want to keep water in liquid form at 300 degrees F. you would need at least 67 absolute pounds of pressure being exerted on the water. The only way this is going to happen would be in a pressurized vessel.
Cavitation
Cavitation is the condition of pumping a mixture of liquid and air, either from entrained air, vortexing or an application with insufficient NPSH. Typical cavitation, due to a lack of proper NPSHa, will outwardly sound as if rocks are passing through the pump. Cavitation will eventually destroy a pump. In severe cases, an impeller can be destroyed in a week or two. Entrained air is air bubbles that are trapped in the water. This is usually caused by turbulent water that does not have time to let the bubbles rise to the surface and pop. We have all seen an example of a vortex in the bathtub at our homes. As the water drains, a tornado looking whirlpool appears. This allows air down into the drain in much the same way it would happen with a pump.
Specific Gravity
The specific gravity of a liquid is its density or weight compared to that of water at ambient temperature. Room temperature water has a specific gravity of about 1.0 The chart on the next slide shows the S.G. of various liquids. The specific gravity does affect pressure expressed in feet of head, along with the horsepower requirements of a pump. While it is important to know this, most applications involve water at room temperature and require no adjustments for S.G. From the chart on the next slide, you will notice the first liquid is over 150% heavier than water. If placed in water, it would sink. You will also notice the last liquid is over 20% lighter than water. If placed in water, it would float.
1.594
than water.
Shaft Deflection
Shaft deflection is the amount a pump shaft will bend due to radial, hydraulic or mechanical loads. Running a pump to the far left near shutoff, or to the far right near runout, will increase pump shaft deflection. Increased shaft deflection will cause premature bearing, and seal failure, and can also cause pump shaft breakage. Undersized pump shafts and running a pump at speeds higher than it was designed for will also cause increased shaft deflection and reduced pump life. The curve on the next slide reminds you of the shutoff and runout conditions.
Design point
Shutoff
Runout
Pump Formulas
Converting PSI to Feet of Head.
PSI X 2.31 = Feet of Head Specific Gravity (S.G.)
When pumping fresh water of ambient temperature, the specific gravity value will be approx. 1.0 and can be omitted from the equation. Pumping hot water or liquid other than water are notable exceptions. As you can see from the examples below, the hotter lighter liquid requires more feet of head to equal the same 100 PSI. Example: 80 degree F. water at 100 PSI 100 X 2.31 = 231 of head 1.0 100 X 2.31 = 244 of head .9464
Formulas Continued
Formula to calculate BHP.
GPM X TDH X S.G. = BHP 3960 X pump efficiency (pump efficiency is found on the pump curve) Under normal conditions, pumping fresh water at ambient temperature, the S.G. is aprox. 1.0 and can be left off of the equation. Example: 1000 GPM @ 200 @ 78% efficiency pumping 80 degree water. 1000 X 200 X 1.0 = 200,000 = 64.75 BHP 3960 X .78 3088.8 If we use the same example as above, but use 240 degree water, the results change as follows because the S.G. of 240 degree water is .9464. 1000 X 200 X .9464 = 189,280 = 61.28 BHP 3960 X .78 3088.8
Formulas Continued
Velocity through a piping system is expressed in feet per second. As velocity increases, friction loss increases, and hydraulic noise through the piping will increase as well. In general, it is good practice to see velocities at or below 8 feet per second. Below is the formula to calculate velocity through a pipe. Velocity = .4085 X GPM (where d is the inside diameter of the pipe in inches) d2 Example: velocity. Pumping 700 GPM through a 8 pipe will have the following
Formulas Continued
The Affinity Laws are formulas showing the effects of changing the pump speed or impeller diameter of a given pump. Increasing the speed or impeller diameter, increases the conditions and BHP. Decreasing the speed or impeller diameter decreases the conditions and BHP. The example we are giving is with RPM, but you can use two different impeller diameters and determine the new operating conditions as well.
1 2
2800 3500
Using the example above, the new conditions of service at the new pump speed are: 1000 GPM X .80 = 800 GPM 200 X .64 = 128 64.75 BHP X .512 = 33.15 BHP
POP QUIZ
Its time to apply what you should have learned while studying this program. A potential customer calls your office with the following quote request. Please quote me a split case pump capable of pumping 1100 GPM @ 65 PSI. I will be pumping 80 degree fresh water and have 20 of NPSH available. --------------- Look over the following four pump curves, make the best selection based on the information given and determine what size motor you will use. The correct answer along with explanations will follow the four pump curves.
First things first. Hopefully everyone successfully converted the 65 PSI to 150 feet of head. The pump curves selected for your review were selected so that the best pump would not be overly obvious. If you did not pick the best pump, dont be discouraged. You have been exposed to a large amount of information, and it will take some time for everything to sink in and make sense. Please review all of the choices below to get the most out of this exercise. 8 X 8 X 11B - If this was your choice, this selection is a bit to the left side of the curve, but not too bad. The efficiency is fairly good, and the NPSHr is OK. But since this pump starts off so far to the left of the curve, the horse power at runout exceeds 75 HP, and so a 100 HP motor would be needed to insure a non overloading condition. Therefore, this selection would not be economically feasible. 4 X 5 X 11C - If this was your choice, this selection falls in a great spot on the pump curve. The efficiency is good, and we are at the BEP. At runout, we still only require a 60 HP motor, which looks good. However, we only have 19 of NPSH available, which is almost exactly what the pump needs to operate cavitation free. If any calculation is only slightly off, or if the pump operates any more to the right of the curve at all, this pump will certainly cavitate. Therefore, this is not a good selection. 5 X 6 X 15 - If this was your choice, this selection falls in a great spot on the pump curve. The efficiency is good and we are almost at the BEP. At runout, we are borderline between using a 60HP and 75HP motor. With a 1.15 service factor motor, it should be safe to use the 60 HP motor. The NPSHr of the pump is about 12 or 13, and we can run out to about 1500 GPM on the pump curve before NPSH becomes an issue. Of the four pumps given to choose from, this is the best selection. 4 X 5 X 10B If this was your choice, this selection falls in a poor spot on the pump curve. We are too far to the right of the curve near runout, the horse power requirement is good at 60 HP, but the biggest problem is that the NPSHr for this pump is over 35. Not only will this pump certainly cavitate, it probably wont last more than a week or two.