Centrifugal Pump Training

Presented by:

Orlando, Florida- January 24

 Dr. Lev Nelik, P.E., APICS
Dr. Nelik has 30 years experience with pumps and pumping
equipment. He is a Registered Professional Engineer, who has
published over fifty documents on pumps and related equipment
worldwide, including a “Pumps” section for the Encyclopedia of
Chemical Technology (John Wiley), a section for the Handbook of
Fluids Dynamics (CRC Press), a book “Centrifugal and Rotary
Pumps: Fundamentals with Applications”, by the CRC Press, and a
book “Progressing Cavity Pumps”, by Gulf Publishing.

He is a President of Pumping Machinery, LLC company, specializing in pump consulting, training, and
equipment troubleshooting. His experience in engineering, manufacturing, sales, field and
management includes Liquiflo Equipment (President), Roper Pump (Vice President of Engineering,
and Repair/Overhaul), Ingersoll-Rand (Engineering), and Goulds Pumps (Technology).
Dr. Nelik is an Advisory Committee Member for the Texas A&M International Pump Users Symposium,
an Advisory Board Member of Pumps & Systems Magazine, Editorial Advisory Board Member of
Water and Wastewater Digest Magazine, and a former Associate Technical Editor of the Journal of
Fluids Engineering. He is a Full Member of the ASME, and a Certified APICS. He is a graduate of
Lehigh University with Ph.D. in Mechanical Engineering and a Masters in Manufacturing Systems.
He teaches pump training courses in the US and worldwide, and consults on pumps operations and
troubleshooting, engineering aspects of centrifugal and positive displacement pumps, maintenance
methods to improve reliability, efficiency and energy savings, and optimize pump-to-system
performance.

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Slide 2
 Michael C. Mancini

Michael Mancini is a graduate from Lehigh University with a BSME who has over
30 years experience in pump design, engineering, and repair.
He started work for Ingersoll-Rand in 1974 designing pumps for the SSN 688 and
Trident submarines. He worked side-by-side with many renowned pump
designers during his tenure with Ingersoll including: Dr. Paul Cooper, Igor
Karassik, Val Lobonoff, and Fred Antunes.
As VP of Worldwide Aftermarket for IDP, he had profit responsibility for a $370
million business and control over 22 repair centers.
As President of a large independent pump service company, he worked closely
with Dr. Elemer Makay and helped pioneer processes for inspection and repair to
reduce total life-cycle costs.

As President of his consulting company, he has provided training to over 500 mechanics and engineers.
He has completed work for over 25 separate customer organizations in various markets: performing root
cause analysis, developing specifications, and implementing strategic pump programs.

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Slide 3
 Purpose

Significantly increase pump-related operating profits by

understanding pump fundamentals, failure modes and their
detection; and applying state-of-the-art design and best-in-
class repair and manufacturing processes to improve or solve
deficiencies for improved pump performance and life.

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Slide 4
 Course Agenda
¾ Introductions
¾ Expectations
¾ Pump Type Configurations
¾ Pump Performance
¾ System Curve
¾ Suction Conditions
¾ Generic Failure Mechanisms
¾ Question & Answer Session

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Slide 5
 Objectives
¾ Understand pump fundamentals
¾ Understand the probable root causes of degradation or failure
associated with various pump problems
¾ Understand the state-of-the-art technologies to upgrade
existing designs to achieve improved operation and life
¾ Learn how to determine where a pump is operating and how
to modify its performance to achieve optimum performance

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Slide 6
 Suction Recirculation Video

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Slide 7
 Basic Centrifugal Pump Types
¾ Single Stage, Double Suction (SSDS)

¾ End Suction

¾ Horizontal Multi-stage, In-line Impellers

¾ Horizontal Multi-stage, Opposed Impellers

¾ Vertical Wet-Pit

¾ Vertical Can

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Slide 8
 Single Stage, Double Suction
Double Suction Impeller

Casing Ring
Radial Bearing

Volute Casing Packed Box

Shaft
Thrust Bearing

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Slide 9
 End Suction
Casing
Thrust Bearing
Single Suction Bearings
Impeller

Radial Bearing

Shaft

Mechanical Seal

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Slide 10
 Multi-stage In-line Impellers
Suction Nozzle

Discharge Nozzle Shaft

Balance Leak-off Line Mechanical Seal

Barrel
Discharge Head
1st Stage Impeller
Diffuser
KTB
Return Channel
Balance Device

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Slide 11
 Diffuser

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Slide 12
 Multi-stage, Opposed Impellers

Crossover

Discharge Nozzle Radial Bearing

Outboard Bushing
1st Stage Impeller
Seal

Suction Nozzle
Center Bushing
Volute
Thrust Bearing

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Slide 13
 Vertical Wet-Pit
Motor Support
Pump-to-Motor Coupling
Line Shaft
Discharge Head
Inner Column

Line Shaft Coupling

Turning Vanes

Line Shaft Bearing

Outer Column

Pump Shaft
Bowl Bearing

Casing
Impeller
Suction Bell Shroud

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Slide 14
 Vertical Can
Motor Support
Pump-to-Motor Coupling

Stuffing Box
Discharge Nozzle
Discharge Head
Line Shaft Coupling
Suction Nozzle
Line Shaft Bearing
Outer Column

Pump Shaft
Bowl Bearing
Casing
Impeller
Suction Head Suction Can

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Slide 15
 Basic Conversion Rules
¾ FLOW:
¾ GPM / 4.403 = M3/HR
¾ GPM / 15.9 = liters/sec

¾ VELOCITY:
¾ * FT/SEC = gpm x 0.321 / (π x in2 / 4)
¾ * M/SEC = m3/hr x 277.8 / (π x mm2 / 4) = m3/hr x 0.43 / (π x in2 / 4)

¾ PRESSURE:
¾ * PSI / 14.7 = atm
¾ PSI / 14.2 = kg/cm2
¾ kg/cm2 = atm / 1.033
¾ PSI / 14.5 = Bars
¾ PSI / 145 = MPa

¾ HEAD:
¾ FEET = psi x 2.31 / SG
¾ METERS = atm x 10.3 / SG = kg/cm2 x 10.0 /SG

¾ POWER:
¾ BHP = gpm x ft x SG / 3960 / EFF
¾ KW = m3/hr x m x SG / (367.5 x EFF)
¾ HP x 0.746 = KW

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Slide 16
 Fundamentals Theory
¾ As pan rotates, the fluid becomes dished and overflows
¾ Due to the centrifugal force, the fluid is lifted or pumped a
height “H”

Pan Partially Filled Pan Rotating on Shaft

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Slide 17
 Fundamentals Theory
¾ Water is thrown considerable distance
¾ The faster you whirl, the sooner the bucket will empty,
and the further the water will be thrown (greater head)

Bucket of Water with Hole in Bottom

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Slide 18
 Fundamentals Theory
¾ Exit velocity of BB Shot much greater than entrance velocity
¾ If BB’s are allowed to go free thru the air, no useful work is
done
¾ If a tin can is placed in line with the shot, the tin can will
move, and the shot will exert pressure as it loses its velocity

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Slide 19
 Fundamentals Theory

β W2
V2
α

U2

Vthroat

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Slide 20
 Fundamentals Theory
Summary
¾ Fluid is led to the eye or center of the impeller and is set into rotation
by the impeller vanes
¾ Via centrifugal force, fluid is thrown from the periphery of the
impeller with considerable velocity and pressure
¾ The casing, which surrounds the impeller, has a volute or diffuser
shaped passage of increasing area
¾ The casing collects the fluid leaving the impeller and converts a
portion of its velocity energy into additional pressure energy.
¾ The casing passage leads to the discharge nozzle of the pump where
piping conducts the fluid to its place of use

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Slide 21
 Pump Curve
¾ Curve Shape
¾ Pump Capacity
¾ Total Developed Head
− Suction Head
− Discharge Head
¾ Parallel Pump Operation
¾ Series Pump Operation
¾ Brake Horsepower
¾ Affinity Laws
¾ Specific Speed

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Slide 22
 Curve Shape
¾ Total developed head (TDH) is inversely proportional to capacity (Q)
¾ Totally efficient pump would produce straight line curve.
¾ Inefficiencies caused by shock losses and friction losses make the H-Q
curve parabolic.
¾ Pump’s best efficiency point (BEP) is where the parabolic curve is
closest to the ideal curve.

Friction losses

100% efficient
TDH

Shock losses

Q
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Slide 23
 Curve Shape
Individual Curve

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Slide 24
 Curve Shape
Family of Curves

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Slide 25
 Curve Shape
Function of Specific Speed, Ns

Efficiency

Total Developed Head BHP

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Slide 26
 Best Efficiency Point

BEP is defined as flow at which the sum of all losses is the lowest.
Overall efficiency is less to the right and to the left of BEP.

Power

Efficiency

Head

BEP Flow

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Slide 27
 Pump Capacity
¾ Pump capacity refers to a rate of flow typically expressed in
either gallons per minute (gpm), barrels per day, or pounds per
hour (lb/hr).
¾ GPM is independent of the fluid pumped.
¾ LB/HR is dependent on the fluid specific gravity

LB / HR
GPM =
500 × sp . gr .
500 = 60 min hr × 8.33 lb gal

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Slide 28
 Total Developed Head
¾ The total developed head is equal to the discharge head minus
the suction head, (TDH = hd – hs), and is typically expressed
in either “feet” or “psi”.
¾ Feet is independent of the liquid pumped
¾ PSI is dependent on the liquid specific gravity.

2.31 × psi
Feet =
sp . gr .

2.31 = 144 in 2 ft 2 / 62.4 lb ft 3

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Slide 29
 Pump Head

Discharge gage
Suction gage
Pump
SUCTION HEAD = Total Static plus Dynamic, measured at pump inlet
DISCHARGE HEAD = Total Static plus Dynamic, measured at pump exit
PUMP HEAD = DISCHARGE HEAD minus SUCTION HEAD plus
correction for the difference in gage elevations
Static Head is what the (absolute) gage reads, converted to feet of water
Dynamic Head is the same as Velocity Head

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Slide 30
 Suction Head (hs)

The suction head is equal to the static height that the liquid is
above the 1st stage impeller eye1 less all suction line losses
(including entrance loss) plus any gage pressure existing at the
suction supply source.

h S = z S − fS + p S ,G
1or any other datum plane consistent with measuring total discharge head

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Slide 31
 Suction Head (hs)
Static Height Measurement
Discharge
Tank
ZTDH = 50 – 10 = 54 – 14 = 40 ft.

Suction
Tank
= 10 ft
ZD = 50 ft.

ZS = 10 ft.

ZS = 14 ft. ZD = 54 ft.

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Slide 32
 Suction Head (hs)
Horizontal Configuration; Open Tank
P s,a = 14.696 psi
h S = z S − fS + p S ,G

68º water Zs = 10.00 ft.

fs = 2.92 ft.
Zs = 10 ft
fs = 2.92 ft
Pg = 14.696 psia = 0 psig

hs = 0 + 10.00 – 2.92 = 7.08 ft.

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Slide 33
 Suction Head (hs)
Vertical pumps, open pit:
HS = Zw
HD = hgd + hvd + Zd

H = HD - HS ~ hgd + (Zd – Zw)

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Slide 34
 Suction Head (hs)
Vertical Wet-Pit; Open Sump

h S = z S − fS + p S ,G

Zs = 10.00 ft.
fs = 0 ft.
Ps,a = 14.696 psi
Pg = 14.696 psia = 0 psig

1st Stage ZS = 10’ hs = 0 + 10.00 – 0 = 10 ft.

Impeller Eye

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Slide 35
 Suction Head (hs)
Vertical Can Pump; Closed Tank
CONDENSER

h S = z S − fS + p S ,G
Abs = 1.50”Hg
Vacuum = 28.42’Hg
Zs = 10.00 ft
Condensate
fs = 2.92 ft
91.72º F
Vacuum = 28.42” Hg = - 32.37 ft

10 Ft
hs = 10.00 - 2.92 - 32.37 = - 25.29 ft

1st Stage

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Slide 36
 Suction Head (hs)

On an existing installation, suction head would

be the reading of a gage at the suction flange
converted to feet of liquid and corrected to the
pump centerline elevation plus the velocity head
(in feet of liquid) at the point of gage
attachment.

Velocity Head = V2/2g = 0.00259 (gpm)2/d4

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Slide 37
 Discharge Head (hD)

The discharge head is equal to the static height that the

liquid is being pumped to above the 1st stage impeller eye1,
plus all discharge line losses (including exit loss), plus any
gage pressure in discharge chamber.

h D = z D + fD + p D ,G
1or any other datum plane consistent with measuring total discharge head

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Slide 38
 Discharge Head (hD)
P vp = 134.63 psia

h D = z D + fD + p D ,G
350º
350ºwater
water
ZD = 10.00 ft.
fD = 2.92 ft
fD = 2.92 ft.
ZD = 10 ft
PD = 310.69 ft.
hDD = 310.69 + 10 + 2.92 = 323.61

310.69 =
(134.63 − 14.696 ) × 2.31
0.892

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Slide 39
 Discharge Head (hD)

On an existing installation, discharge head would be the

reading of a pressure gage at the discharge flange
converted to feet of liquid and corrected to the 1st stage
impeller eye1 plus the velocity head (in feet of liquid) at
the point of gage attachment.
1or any other datum plane consistent with measuring total suction head

Velocity Head = V2/2g = 0.00259 (gpm)2/d4

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Slide 40
 Pump Head
Let’s Try an Example:

Discharge gage
Suction gage Pump
Flow = 70 gpm of water

Suction Gage reads 5 psig

Discharge Gage reads 80 psig
Suction pipe is 1.5”
Discharge pipe is 1”
Suction Gage is 1’ above pump centerline
Discharge Gage is 6’ above pump centerline
What is a Pump Head in this case?

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Slide 41
 Pump Head
Discharge line Velocity Head, as calculated earlier is 12.5 feet

Suction pipe area is 3.14 / 4 x 1.52 = 1.8 in2

Suction line Velocity is 70 x 0.321 / 1.8 = 12.4 ft/sec, and

Velocity Head at the suction pipe is 12.42 / 64.4 = 2.5 feet

In absolute units, Suction Pressure is 5+14.7 = 19.7 psiA (19.7 x 2.31 /1.0=45.5 ft)
In absolute units, Discharge Pressure is 80 + 14.7 = 94.7 psiA (94.7 x 2.31 /1.0 = 218.8 ft)

Suction Head = 45.5 + 2.5 = 48 ft

Discharge Head = 218.8 + 12.5 = 231ft
Gage Elevation difference = 6 – 1 = 5 ft

Pump Head = 231 – 48 + 5 = 188 ft

Note that in many instances the velocity head contribution is relatively small, and can be neglected for
rough estimates. Same goes for gage elevation correction.

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Slide 42
 Brake Horsepower

T × rpm
BHP =
5250
where:
T = Torque, ft-lb

5250 = 33,000 ft-lb/min/bhp / 2∏ radians/rev

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Slide 43
 Brake Horsepower

phases × I × E × pf × e Motor
BHP =
746
where:
I = Amperes
E = Volts
e = Motor efficiency
pf = Motor power factor

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Slide 44
 Brake Horsepower
Example
1. Using motor data, calculate BHP
2. Using horsepower equation1, calculate flow
I E emotor pf BHP TDH epump sp.gr. Q
(amps) (volts) (%) (%) (bhp) (ft) (%) (gpm)

79.0 7,065 91.5 0.880 1,043 325 39.2 0.9986 4,989

81.0 7,065 91.5 0.880 1,083 272 68.1 0.9986 10,737

91.0 7,065 92.2 0.880 1,224 253 84.7 0.9986 16,239

94.0 7,065 92.2 0.880 1,258 215 86.6 0.9986 20,080

Q × TDH × sp . gr . BHP × 3960 × e

1
BHP = Q=
3960 × e TDH × sp . gr .

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Slide 45
 Affinity Laws
What happens to Flow, Head and Power with Speed?

Flow changes DIRECTLY (linear) with RPM…

Head changes as a SQUARE of RPM…
Power is proportional to Flow times Head – it changes as CUBE of RPM…

Q ~ RPM
H ~ RPM2
BHP ~ RPM3

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Slide 46
 Affinity Laws

Example (speed change):

N 1 N 2 = D 1 D 2 = Q 1 Q 2 = (TDH 1 TDH 2 ) = (BHP1 BHP2 )

1/2 1/3

1800 rpm 1200 rpm

Q H e bhp Q H e bhp
0 1000 0.00 0 444 0.00
100 950 0.20 120 67 422 0.20 36
200 850 0.45 95 133 378 0.45 28
300 700 0.68 78 200 311 0.68 23
400 500 0.75 67 267 222 0.75 20

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Slide 47
 Affinity Laws

When impeller OD is trimmed – Flow, Head and Power follow

the Affinity Laws very similar to the case of speed change:
Q~x
ODnew
H ~ x2
BHP ~ x3

where x is a cut ratio: x = ODnew /ODold

(Note: additional correction applies for cuts over 10%)

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Slide 48
 Affinity Laws
Example: Construct a New Curve at 70% Pump Speed
(2520/3600 = 0.70)

Q, gpm 0 60 100 150

3600 RPM
H, ft H, ft 95 90 80 50
95
90
Read off Q, H pairs from
80 the curve and tabulate

50

0 60 100 150
Flow, gpm

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Slide 49
 Affinity Laws
This is how we do it:

New speed is 0.70 x 3600 = 2520 RPM

Speed ratio is 0.70 (70% slowdown)
Q ~ 0.70
H ~ 0.702 = 0.49
Multiply each value of Flow in the original table by 0.70,
and Head by 0.49:

Q, gpm 0 x 0.70 = 0 60 x 0.70 = 42 100 x 0.70 = 70 150x0.70 = 105

H, ft 95 x 0.49 = 46.6 90 x 0.49 = 44.1 80 x 0.49 = 39.2 50 x 0.49 = 24.5

Plot these new values:

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Slide 50
 Affinity Laws
H, ft
3600 RPM

2520 RPM Flow, gpm

…and draw a curve through new points…

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Slide 51
 Affinity Laws

Comments:
¾ The actual impeller diameter ratio
should be increased somewhat to
compensate for inaccuracies due to
other losses
¾ The accuracy of applying the affinity
laws decreases with increasing
specific speed

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Slide 52
 System Curve

¾ Static Head
¾ Friction Head
¾ Total System Head
¾ Pump Operation
¾ Application Examples

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Slide 53
 System Curve
Example
System Head comprised of: Pv = 67 psia
Static Head
•

Friction Head
• Discharge Tank
300°F
Z
Pa = 14.7 psia

Suction
Tank
= 10 ft
fD = 182 ft.

fS = 18 ft.

ZS = 14 ft. ZD = 54 ft.

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Slide 54
 Static Head
Static Head is constant with Flow and includes: Pv = 67 psia

Elevation Head, Z
•
Discharge Tank
Pressure Head, P
• Z 300°F

Pa = 14.7 psia

Z = 54 − 14 = 40 ft Suction
Tank
= 10 ft
fD = 182 ft.
67 × 2.31 14.7 × 2.31
P= − = 135 ft fS = 18 ft.
0.918 1 .0

ZS = 14 ft. ZD = 54 ft.

200
Total Static Head
TDH, ft

150 Pressure Head

100
50 Elevation Head

25% 50% 75% 100%

Q, gpm

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Slide 55
 Friction Head
Friction Head varies with Flow Pv = 67 psia

Discharge Tank
2 300°F
L V Z
hf = f × × Pa = 14.7 psia
d 2g
Suction

hf ∝ V 2
Tank
= 10 ft
fD = 182 ft.

fS = 18 ft.
Q
V =
A ZS = 14 ft. ZD = 54 ft.

hf ∝ Q 2
200
Total Friction Head
TDH, ft

150
100
50

25% 50% 75% 100%

Q, gpm

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Slide 56
 Total System Head

400 Total System Head

350
300

250
200
Total Static Head
TDH, ft

150
100

50

25% 50% 75% 100%

Q, gpm

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Slide 57
 Pump Operation
Matching the Pump to the System
A pump only operates at the intersection of the pump and
system curves.
Pump H vs Q
Curve Predicted System
Resistance Curve
TDH

Friction loss

Static Head

Q Design Flow

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Slide 58
 Parallel Pump Operation
Add Individual Pump Flows at Constant Heads

Q1 + Q2
Q1 + Q2

Pumps 1 & 2
Pump 1
Q1 Q2 H
Q1 Pump 2

Q2
Pump 1 Pump 2

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Slide 59
 Parallel Pump Operation
Minimum Flow Operation

H
∆ Q3
∆ Q2
∆ Q1
3
2
1

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Slide 60
 Series Pump Operation
Add Individual Pump Heads at Constant Flows

H1 + H2 Pumps 1 & 2

H2 Pump 2
H1 + H2
H

Pump 1

Pump 2
H1 Pump 1
H2 H1

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Slide 61
 Pump Operation

Valve Throttle Flow Control

Eff = 80%
170 ft
Head, ft
150 ft

Eff = 30%

40 100 Flow, gpm

Throttling is easy, but not efficient

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Slide 62
 Pump Operation

Varying Speed Flow Control

Eff = 80%
Head, ft
150 ft

24 ft

40 100 Flow, gpm

Speed control is efficient

Note: efficiency actually drops slightly at lower flows (80% would probably become about 77%), but
not nearly as significantly as when throttling.

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Slide 63
 Pump Operation

Let’s compare the difference in energy costs between the valve

throttling method and speed control, using the earlier example
(using SG=1):

a) Throttling:
BHP = Q x H x SG / 3960 / EFF = 40 x 170 x 1.0 / 3960 / 0.30 = 5.7 HP = 4.3 kW
Assuming 24-hour/7-day/52-week operation:
4.3 x 24 x 7 x 52 = 37,303 kW-hr
Let’s assume a $0.08/kW energy cost:
37,303 x 0.08 = $2984 per year

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Slide 64
 Pump Operation

b) Speed Control:
BHP = Q x H x SG / 3960 / EFF = 40 x 24 x 1.0 / 3960 / 0.80= 0.3 HP = 0.2 kW
Assuming 24-hour/7-day/52-week operation:
0.2 x 24 x 7 x 52 = 1,747 kW-hr
Assume the same $0.08/kW energy cost:
1,747 x 0.08 = $140 per year

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Slide 65
 Pump Operation
The cost difference, i.e. savings:

$2984 – $140 = $2844 per year

Just to get a feel for the numbers, a typical 5 hP VFD lists

under $1000.
This means that the investment into a VFD would pay for
itself within 1000 / 2844 x 12 = 4 months.
Considering also a possible elimination of the throttling valve,
the savings could be even better.

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Slide 66
 Suction Conditions
¾ NPSHA
¾ Open System (fluid above pump)
¾ Open System (fluid below pump)
¾ Closed System
¾ Closed System (under vacuum)
¾ NPSHR
¾ Suction Specific Speed
¾ Damage Intensity
¾ NPSH, Condensate Pumps
¾ Submergence

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Slide 67
 NPSH
Basically, if there is not enough pressure – liquid boils!

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Slide 68
 NPSH
In your kitchen, the water boils at 100 oC (212 o F)
– and that is at atmospheric pressure

If pressure drops, the water will boil at lower pressure

On top of high mountain water boils at perhaps 95 oC ?

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Slide 69
 NPSH

If low enough vacuum is achieved - water will boil at room temperature

BOILING IS VAPORIZATION OF LIQUID…
Inside a pump, if pressure gets low enough (below vapor pressure), liquid will
boil. The lowest pressure zone is usually at the suction area. That is where the
first bubbles begin to form..
This initial formation is called incipient cavitation…
If pressure drops more – more bubbles emerge…
But the pump keeps pumping…
If too many bubbles – suction gets blocked by them, and no more pumping…
That is where “pump losses its head”…

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Slide 70
 NPSHA
Net Positive Suction Head Available (NPSHA) is the total suction head (in
feet of liquid absolute) at the 1st stage impeller eye less the absolute vapor
pressure of the liquid (in feet) being pumped.

NPSHA = PS ,A − vp + Z S − fS
where:

Ps = Absolute pressure acting on liquid (in feet)

vp = Vapor pressure of the liquid (in feet)
Zs = Static height from the suction source to the
1st stage impeller eye (in feet).
fs = All friction losses in suction piping (in feet).

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Slide 71
 NPSHA
Open System (Fluid above Pump)
Ps,a = 14.696 psi NPSHA = PS ,A − vp + Z S − fS
Zs = 10.00 ft.
68º water
fs = 2.92 ft.
Pg = 0
Zs = 10 ft hs = 10.00 – 2.92 = 7.08 ft.
f s = 2.92 ft
Pa = 14.696 psia = 33.96 ft abs
vp = .339 psia = .783 ft abs
NPSHA = 33.96 - .783 + 10.00 - 2.92
= 40.26 ft.

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Slide 72
 NPSHA
Open System (Fluid below Pump)
NPSHA = PS ,A − vp + Z S − fS

Zs = 10.00 ft.
fs = 2.92 ft fs = 2.92 ft.
Pg = 0
Zs = 10 ft hs = -10.00 – 2.92 = -12.92 ft.

Ps,a = 14.696 psi Pa = 14.696 psia = 33.96 ft abs

vp = .339 psia = .783 ft abs

68º water
NPSHA = 33.96 - .783 - 10.00 - 2.92
= 20.26 ft.

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Slide 73
 NPSHA
Closed System
P vp = 134.63 psia NPSHA = PS ,A − vp + Z S − fS

Zs = 10.00 ft
350º water
fs = 2.92 ft
Pg = 119.91 psig = 310.69 ft
hs = 310.69 + 10.00 – 2.92 = 317.77 ft
Zs = 10 ft
fs = 2.92 ft
Pa = vp

NPSHA = 10.00 - 2.92 = 7.08 ft

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Slide 74
 NPSHA
Closed System (under vacuum)
NPSHA = PS ,A − vp + Z S − fS
CONDENSER
Vacuum = 28.42” Hg = -32.37 ft
Abs = 1.50”Hg
Vacuum = Zs = 10.00 ft
28.42’Hg
fs = 2.92 ft
Condensate
91.72º F hs = -32.37 - (10.00 - 2.92) = -25.29 ft
vp = 1.50” Hg = 1.71 ft

10 Ft
NPSHA = 10.00 - 2.92 = 7.08 ft

1st Stage

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Slide 75
 NPSHA

Calculating, or estimating, suction losses is often a big

controversy…

It shouldn’t be – but it is

This is because it works very well in theory…but not so well in practice…

Because nobody knows if a dead mouse isn’t stuck in the suction pipe.

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Slide 76
 NPSHA

This is why it is best to have suction gage and read it

Then there is no guesswork

Hsuction= (Hg + Zg + Hatm) + Hvel

Hg = gage pressure, psig

Zg = correction for a gage elevation
Hatm = atmospheric pressure (34 ft)
Together, Hg + Hatm give us total static head in absolute.
(For example 5 psig is 5+14.7 = 19.7 psia)

Hvel = velocity (dynamic) head V2/2g

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Slide 77
 NPSHR
The Net Positive Suction Head Required (NPSHR) is the suction
capability of an impeller and is determined by:
ƒ Inlet Diameter
ƒ Rotating Speed
ƒ Inlet Blade Angle
ƒ Suction Inlet Approach

r1
(
NPSHR = U 21 2 g × 1.485Φ 2 + .085 ) ( ) Area of inlet
where:
U l = r lω
Ø = (Q/AREA) /U l

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Slide 78
 NPSHR

3% ∆ H 0% ∆ H, Incipient Bubble

NPSHR
Q = constant
5
H 4
3
2
1
1 2 3 4 5
NPSHR Q

NPSHR 0% ≈ 1.5 × NPSHR 3%

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Slide 79
 NPSHR
Eff

NPSHA
NPSHR

Trouble!

BEP Flow

Velocities are higher at higher flow – this lowers static

pressure, requiring more pressure to counteract that
As a result, NPSHR rises at higher flow..
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Slide 80
 NPSHR

Actually, at low flow bad things begin to happen…

Suction Recirculation starts here…

NPSHR

Flow

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Slide 81
 NPSHR

IMPELLER EYE SIZE EFFECT

NPSHR

recirculation

no recirculation
14 ft

10 ft

Flow
Smaller eye helps suppress suction recirculation, although with
some sacrifice of NPSHR at BEP

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Slide 82
 Suction Specific Speed
Suction specific speed (Ss) is a dimensionless parameter that pump
engineers use to define impeller suction inlet geometry. The higher
the suction specific speed, the larger the impeller eye, and the higher
susceptibility to fluid separation at off-peak operation.

rpm × Q eye
N SS = S S = 0.75
NPSHR
where:
Q = Suction flow per eye of the 1st stage impeller, @ BEP in gpm
(for double suction impellers, Q = 1/2 the total suction flow)

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Slide 83
 Suction Specific Speed

Design Flow
90
80 Very high Ss
70
60
NPSHR 50
40
30
High Ss Low Ss
20
10

500 1000 1500 2000 2500 3000

Q
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Slide 84
 Suction Specific Speed
Suggested Limits
Hydrocarbon Applications
ƒ Ss ≤ 11,000 based on NPSHR3% ∆H
ƒ Ss ≤ 9,100 based on NPSHR1% ∆H
Water Applications
ƒ Ss ≤ 9,500 based on NPSHR3% ∆H
ƒ Ss ≤ 7,800 based on NPSHR1% ∆H

4/3
rpm × Q eye ⎧⎪ rpm × Q eye ⎫⎪
SS = NPSHR = ⎨ ⎬
NPSHR 0.75 ⎪⎩ Ss ⎪⎭

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Slide 85
 Suction Specific Speed
Refinery Experience (J. L. Hallam)
1.40

1.20 1.15
1.07
Failure Frequency 1.04

1.00
0.91

0.80

0.61
0.60 0.53

0.44 0.44

0.40

0.20

-
< 8,000 8,000 - 9,000 - 10,001 - 11,001 - 12,001 - 13,001 - > 14,000
9,000 10,000 11,000 12,000 13,000 14,000

Suction Specific Speed Range

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Slide 86
 Suction Specific Speed

• Good ways to fight suction problems:

• Make sure a pump is as close to suction source as possible
• For double-suction pumps, suction valve stem should be
oriented for symmetrical feed flow
• Smaller eye impeller (lower suction specific speed) can help
• Inlet sump design – critical: vortexing and air entrapment
could be a nightmare
• Metallurgy – 316ss stainless work-hardens, while iron does not
very long

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Slide 87
 Damage Intensity
ƒ The performance NPSHR of a NPSH, 1st Bubble
pump is determined by
traditional 3% head reduction
testing
ƒ Significant amounts of vapor
present at NPSH higher than Increasing
NPSHR Damage Intensity Cavitation

NPSHA
Vapor Activity
ƒ Maximum cavitation damage
can occur at NPSHA = 2 x
NPSHR
NPSHR

0.0 0.5 1.0

Flow / Flow bep

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Slide 88
 Cavitation Damage

CAVITATION DAMAGE

Too many candies makes kids hyper.

But it also ruins their teeth.

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Slide 89
 Cavitation Damage

Impeller inlet – blades cavitation on a suction side

As bubbles flow from low pressure to higher, they implode

against metal surfaces. These micro-hammer-like impacts
erode the material, creating cavities – thus “cavitation”

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Slide 90
 NPSH, Condensate Pumps

1 NPSHA (@ 1st stage) >

NPHSR at 1 pump runout
3
Mounting
R
2 NPSHA (@ C Suction) > 2
R + 2.0 V2/2g
Suction Nozzle

3 NPSHA (@ Mounting) > 0

(distance from the minimum hotwell
level to the floor must be greater than all
friction losses in suction pipe) 1st Stage Impeller
1

8
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Slide 91
 NPSH, Condensate Pumps
Mounting Plate
Floor Elevation
7.0” Section A-A Grout
14.5”

¼” Carbon Steel Plate

Outer Column
Suction Can Inner Wall
Bowl Assemblies
14” Ø Suction Nozzle

1/8” Clearance
Suction Can

Section A-A

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Slide 92
 NPSH, Condensate Pumps
Example

NPSHR

Two Pump H-Q

TDH One Pump H-Q
e
System e

1 Pump 1 Pump Req’d System

Q Flow Run-out Flow

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Slide 93
 NPSH, Condensate Pumps
Hotwell Elevation (ft)
Example Normal 502
Minimum 500
Given the data shown: Mounting Elevation (ft) 492
Friction Losses (ft)
ƒ What is the design flow per pump for Without Strainer 5
100% operation? With Strainer 9
System Flow Requirements (gpm)
ƒ What is the required pump setting? VWO 9500
100% Load 9000
ƒ What is the required motor design hp? 80% Load 7200
One Pump Runout Flow (gpm) 6000
ƒ Should this be an above or below Flow TDH Eff. BHP npshr
ground suction design?
(gpm) (ft) (%) bhp (ft)

2000 920 60 774 11

3000 875 73 908 12

4000 780 81 972 14

5000 650 82 972 14

6000 480 71 1024 24

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Slide 94
 NPSH, Condensate Pumps
Example Hotwell Elevation (ft)
Normal 502
Minimum 500
ƒ What is the design flow per pump for Mounting Elevation (ft) 492
100% operation? Friction Losses (ft)
Without Strainer 5
4500 gpm ( = 9000/2) With Strainer 9
System Flow Requirements (gpm)
ƒ What is the required pump setting? VWO 9500
100% Load 9000
467 ft ( = 500 - 9 - 24 ) 80% Load 7200
One Pump Runout Flow (gpm) 6000
ƒ What is the required motor design hp?
Flow TDH Eff. BHP npshr
1250 bhp
(gpm) (ft) (%) bhp (ft)
ƒ Should this be an above or below 2000 920 60 774 11
ground suction design? 3000 875 73 908 12

No (npsha = -1’ @ mtg.) 4000 780 81 972 14

5000 650 82 972 14

6000 480 71 1024 24

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Slide 95
 Failure Mechanisms

¾ Generic Issues
¾ Hydraulic Instability
- Inlet Separation
- Discharge Recirculation
¾ High Impact Loading
¾ Acoustic Resonance
¾ Premature Opening of Ring Clearances

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Slide 96
 Failure Mechanisms

¾ Poor Pump Performance

¾ Hot Radial Bearings
¾ Hot Thrust Bearings
¾ Black Oil
¾ Casing Leakage
¾ Seal Leakage

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Slide 97
 Generic Issues

Lower Discharge
Impeller Life Best
Recirculation
Efficiency
Point
High
Low Bearing &
Temperature Low
Low Seal Life
Rise Flow Suction
Cavitation Recirculation
% Head

Low Bearing & Cavitation

Low Seal Life

Pump Curve

% Flow

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Slide 98
 Inlet Separation
Causes
ƒ Fluid stall occurs when the incidence angle – difference between flow angle
and impeller inlet angle—increases above a specific critical value. Stalled
area, which eventually washes out, reforms as rotation continues.
ƒ Backflow” interferes with
inlet flow, creating localized
pressure drops, that can drop
below fluid vapor pressure
causing separation/cavitation
ƒ Large areas “promote” fluid
swirl

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Slide 99
 Inlet Separation
Damaging Effects
ƒ Impeller inlet vane erosion
Damage

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Slide 100
 Inlet Separation
Damaging Effects
ƒ Pump surging (4-10 Hz)
ƒ Excitation of suction piping

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Slide 101
 Inlet Separation
Solutions
Biased-wedge Control
ƒ Vane Damage: thickness Area
development to next
Bias-wedge (anti-stall hump) Blade
Camber Angle
inlet vane re-contouring to Match
Flow
ƒ Fillet Damage:
Front hook
ƒ Fluid Swirl: Concave
Leading
Backflow catcher Elliptical Nose Edge
on Leading Edge
Impeller
hub wall

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Slide 102
 Discharge Recirculation
Causes
ƒ Fluid stall occurs when the incidence angle – difference between
flow angle and diffuser or volute inlet angle—increases above a
specific critical value. Stalled area, which eventually washes out,
reforms as rotation continues.
ƒ Large areas “promote” fluid swirl

Gap ‘A’
D3’ D2’ Gap ‘B’

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Slide 103
 Discharge Recirculation
Damaging Effects
ƒ Axial shuttling

Thrust Direction

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Slide 104
 Discharge Recirculation
Damaging Effects
ƒ Axial shuttling

Thrust Direction

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Slide 105
 Discharge Recirculation
Damaging Effects
ƒ Axial shuttling
16000
Thrust toward suction

With correct Gap ‘A’

Unbalanced Thrust

Thrust with large Gap ‘A’

-16000
0 0.5 1.0
Flow / Flow bep

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Slide 106
 Discharge Recirculation
Damaging Effects
ƒ Poor pump paralleling capability or rotor hunting due to a flattening
of the head-capacity curve at off-peak operation

Unstable

TDH
Stable

Q Design Flow
Reduced Flow

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Slide 107
 Discharge Recirculation

Damaging Effects
ƒ Reduced rotor damping Sub-synchronous
1X
ƒ Elevated pump vibration
(0.6 – 0.9 X; 1X)
ƒ Shaft failure
ƒ Seal failure
ƒ Bearing failure
ƒ Diffuser vane tip breakage
ƒ Impeller shroud erosion

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Slide 108
 Discharge Recirculation
Solutions
ƒ Operation at BEP
ƒ Provide a “filter” to straighten the flow – an orifice comprised of a
tight Gap A, and sufficient Overlap (Gap C)

Overlap

D '3 − D '2
Gap A =
2

Gap C (Overlap ) ≈ 4 to 6 × Gap A

Gap ‘A’
D3’
D2’

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Slide 109
 Discharge Recirculation

Gap A and
Gap C

Gap C (Overlap)

Gap ‘A’
D3’
D2’

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Slide 110
 Discharge Recirculation
Gap A and Gap C
Addition of Gap A/Overlap rings
required in cast iron volute designs

A-Gap Rings

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Slide 111
 Discharge Recirculation
Gap A and Gap C
Tight Gap A increases local
pressures requiring stronger
impeller exit shroud designs

Impeller

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Slide 112
 Discharge Recirculation
Solutions
ƒ Centerline compatibility

16000
Centerline
Compatibility

Unbalanced Thrust
0

∆ = 0.030”
Centerline
Non-compatibility
-16000
0 0.5 1.0
Flow / Flow bep

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Slide 113
 Discharge Recirculation
Solutions
ƒ Bias casing ring design for horizontal, single-stage pumps

Hydraulic Balance
Pd Pd

Ps Ps

Hydraulic Preload

Pd Pd

Ps Ps
DRING, 2
DRING, 1

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Slide 114
 Discharge Recirculation
Solutions
ƒ Large flange balance disc design on horizontal, multi-stage pumps

Balance Sleeve

Last Stage
Impeller
Balance Disk

Impeller Balance Disk

Split Ring Split Ring

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Slide 115
 High Impact Loading
Causes
ƒ Off-peak operation
ƒ Too-tight Gap B

D3 − D2
Diffuser Gap B =
D3 D2
D2
where:
Impeller
D3 = Diffuser or volute inlet
vane diameter
D2 = Impeller exit vane
diameter

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Slide 116
 High Impact Loading
Damaging Effects
ƒ Diffuser inlet vane tip breakage
ƒ Impeller exit shroud breakage
ƒ Elevated pump vibration
(vane pass – normally vertical)
ƒ Excitation of component natural frequencies

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Slide 117
 High Impact Loading
Solutions
ƒ Operation at BEP
ƒ Provide the proper Gap B
ƒ 360º bearing housings

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Slide 118
 High Impact Loading
Gap B
ƒ Diffuser Pumps: ~ 6%
ƒ Volute Pumps: ~ 10%
ƒ L/d3 ratio: 4:1

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Slide 119
 High Impact Loading
Gap B Modification
For turbine-driven pumps:
ƒ Cut impeller vane, thereby not
jeopardizing all important L/d3 ratio,
and not affecting Gap A to Gap C
ratio
Desired Gap B of 6%
ƒ Turbine will speed-up by the same
ratio as the impeller cut (affinity
laws) to achieve required hydraulics
ƒ Must ensure not to exceed turbine
over-speed limit

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Slide 120
 High Impact Loading
Gap B Modification
For motor-driven pumps:
ƒ Machine back diffuser inlet vanes to TDH, ft
TDH vs. Q, before
maximum allowable considering L/d3 cut
TDH vs. Q, after TDH vs. Q,
8000 cut underfile
limitations
ƒ Cut impeller D2 to eliminate “excess 7000
performance”
ƒ Cut and underfile impeller exit vanes 6000
to achieve balance of what is required
for proper Gap B 5000
System Curve Required Flow

1000 2000 3000 4000 5000 6000

Q, gpm

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Slide 121
 Acoustic Resonance
Causes
ƒ Poor vane combination – no “0” or “1” in the absolute value of the
impeller vane (and multiples) versus diffuser or volute vane (and
multiples)

Multiple of impeller blade #

Pressure x Area = Force
7 14 21 28
Multiple of diffuser #

13 1
26 Time for pressure wave to travel this Time for impeller
39 distance = to rotate this amount

Favorable Combination
Hydraulic Excitation

Unfavorable Combination
Force

Gap ‘B’ Clearance

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Slide 122
 Acoustic Resonance
Damaging Effects

ƒ Elevated pump vibration

(vane pass, 2 x vane pass – normally horizontal)
ƒ Excitation of component natural frequencies

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Slide 123
 Acoustic Resonance
Solutions
ƒ Modification of impeller or diffuser/volute vane numbers
ƒ Stiffening of volute/crossover passage
ƒ 360º bearing housings

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Slide 124
 Premature Opening of Clearances

Causes
ƒ Relative motion between rotor and stator
ƒ Imbalance
Increased
Increased
ƒ Misalignment Clearance
Clearance

ƒ Improper lift/setting Increased

Increased
Vibration
Vibration

ƒ Loose fit-ups
ƒ Poor concentricity, parallelism, Reduced
Reduced
Damping
Damping
perpendicularity tolerances
ƒ Discharge recirculation

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Slide 125
 Premature Opening of Clearances

Causes
ƒ Excessive shaft deflection
ƒ Galling materials
Increased
Increased
ƒ Operation at rotor wet critical Clearance
Clearance

ƒ Improper bearing design Increased

Increased
Vibration
Vibration

ƒ Non-rigid base
Reduced
Reduced
Damping
Damping

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Slide 126
 Premature Opening of Clearances

Damaging Effects
ƒ Increased internal recirculation
(loss of performance)
ƒ Rotor seizure
Efficiency
ƒ Catastrophic failure

MTBR = 5 yrs

MTBR = 3 yrs

1 2 3 4 5 6 7 8 9 10
Years of Operation

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Slide 127
 Premature Opening of Clearances

Solutions
ƒ Gap A/Overlap
ƒ Centerline compatibility
ƒ Lower L3/d4
ƒ 9th edition back pull-out upgrade
ƒ Increased shaft diameter
ƒ Lomakin grooving

.014

.040 .040

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Slide 128
 Premature Opening of Clearances

Solutions
ƒ Non galling materials
ƒ Laser hardened
ƒ Peek
ƒ ARHT
ƒ 420F (high sulfur)
ƒ Proper bearing design
ƒ Pressure dam
ƒ Tri-land

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Slide 129
 Premature Opening of Clearances

Solutions
ƒ Interference fits
ƒ Rotor
ƒ Stator
ƒ Proper bearing clearances
ƒ More stringent tolerances

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Slide 130
 Premature Opening of Clearances

Solutions
ƒ Removal of soft foot
ƒ Proper grouting
ƒ Polyshield baseplates
ƒ Proper field alignment

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Slide 131
 Premature Opening of Clearances

Solutions
ƒ More stringent balance requirements
- A hard bearing balance machine must be utilized
- The impellers must be individually balanced on
arbors
- All keys must be fitted to keyways with no
excessive stock or unfilled areas (as would occur
utilizing square in lieu of full-radius keys)
- Impellers must have a minimum interference fit-
1W/N
up to shaft between .000 - .0015”
- Shaft T.I.R. cannot exceed 0.001”
- Impeller hub turn T.I.R. cannot exceed 0.002”

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Slide 132
 Premature Opening of Clearances

Pump Vibration, Before & After Balancing

Pump Vibration Domestic H2O Pumps

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Slide 133
 Premature Opening of Clearances

Vibration vs Bearing Life

• Reducing the forces caused by unbalance, looseness and misalignment will
result in lower vibration levels.
• Reducing excessive belt tension will reduce machine forces but will not
produce an appreciable reduction in vibration levels.
Impact of Vibration Reduction on Bearing Life
(Assuming Dynamic Load is the Major Force Component)

% Increase in Bearing Life

% Reduction in Vibration Ball Bearings Other Rolling Element Bearings
5 17 19
10 37 42
15 63 72
20 95 110
25 137 161
30 192 228
40 363 449
50 700 908

Source:L. Douglas Berry, Vibration Versus Bearing Life, Reliability, Vol. 2, Issue 4,November 1995

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Slide 134
 Poor Pump Performance
Causes
ƒ Excessive running clearances
ƒ Low voltage, low speed
ƒ Improper impeller diameter(s)
ƒ Broken hydraulic components
ƒ Impeller inlet obstruction
ƒ Double suction impeller installed backwards
ƒ Insufficient l/d3
ƒ Wrong design/poorly replicated impellers

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Slide 135
 Poor Pump Performance
Causes
ƒ Hydraulic instability (localized flattening)
ƒ Erosion of the volute cutwater/diffuser inlet vanes
ƒ Inlet cavitation
- Insufficient NPSHA
- Separation at off-peak conditions
- Inlet flow disturbances
Partially closed suction valve
Balance line leakoff too close to suction
Clogged strainer
- Air or steam vortices

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Slide 136
 Poor Pump Performance

Damaging Effects
ƒ Insufficient flow and/or pressure
ƒ Hydraulic imbalance
ƒ Poor paralleling operation
ƒ Separation/cavitation

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Slide 137
 Poor Pump Performance
Solutions
ƒ Operation at BEP
ƒ Maintaining design clearances
ƒ CMM technology
ƒ Hard metal overlays/coatings
ƒ Investment castings
ƒ In-depth inspections to drawings

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Slide 138
 Hot Radial Bearings
Causes
ƒ Parallel misalignment
ƒ Insufficient lubrication flow/pressure
ƒ High oil level (ball bearings)
ƒ Oil contamination
ƒ Too tight journal-to-shaft clearance (sleeve bearings)
ƒ Low flow operation
ƒ Too tight inner race-to-shaft fit (ball bearings)
ƒ Too tight outer race-to-bearing housing fit (ball bearings)
ƒ Defective ball and/or cages (ball bearings)

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Slide 139
 Hot Radial Bearings

Damaging Effects
ƒ Loss of bearing L-10 life
ƒ High vibration
ƒ Bearing failure
ƒ Catastrophic pump failure

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Slide 140
 Hot Radial Bearings

Solutions
ƒ Proper pump component tolerances
ƒ Operation at pump BEP

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Slide 141
 Hot Thrust Bearings

Causes
ƒ Angular misalignment
ƒ Insufficient lubrication flow/pressure
ƒ High oil level (ball bearings)
ƒ Oil contamination
ƒ Improperly sized balance device
ƒ Excessive axial clearance (disks)

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Slide 142
 Hot Thrust Bearings

Damaging Effects
ƒ Loss of bearing L-10 life
ƒ High vibration
ƒ Bearing failure
ƒ Balance device failure
ƒ Catastrophic pump failure

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Slide 143
 Hot Thrust Bearings

Solutions
ƒ Proper component tolerances
ƒ Rotor/stator dimensional analysis
ƒ Upgraded balance device Balance Sleeve

ƒ Proper bearing design Axial Clearance

(0.001 – 0.003”)
ƒ Gap A, B, Overlap/C Last Stage Impeller
Balance Disk
ƒ Operation at pump BEP
Balance Disk Impeller
Split Ring Split Ring

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Slide 144
 Black Oil
Causes
ƒ Oversized bearing
ƒ Insufficient pre-load
ƒ Improper oil level
ƒ Improper oil viscosity
ƒ Axial shuttling
ƒ Excessive thrust loads
ƒ Poor fit-up to shaft shoulder
ƒ Poor fit-up to shaft/bearing housing
ƒ Stray motor currents

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Slide 145
 Black Oil
Damaging Effects
ƒ Reduced bearing life
ƒ Elevated pump vibration

Fretting in the bore

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Slide 146
 Black Oil
Solutions
ƒ Schnorr springs Smaller bearing

ƒ Proper bearing size

410 stainless steel
ƒ Proper fit-ups insert
ƒ Proper oil selection
Schnorr springs

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Slide 147
 Casing Leakage

Causes
ƒ Excessive pipe strain
ƒ Non-parallel parting flanges
ƒ Deteriorated gaskets/o-rings
ƒ System upsets
ƒ Improper warming
ƒ Casting defects
ƒ Local fluid velocity exceeding
material limits (erosion)

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Slide 148
 Casing Leakage
Damaging Effects
ƒ Accelerated component erosion (wire drawing)
ƒ Environment contamination

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Slide 149
 Casing Leakage

Solutions
ƒ Dimensional analysis
ƒ Proper machining operations
ƒ Metal-to-metal fits

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Slide 150
 Seal Leakage

Causes
ƒ Improper tightening of packing
ƒ Improper packing material
ƒ Improper seal setting (mechanical)
ƒ Improper seal design
ƒ Insufficient space
ƒ Lack of seal chamber venting
ƒ Improper seal flush or seal flush cleanliness

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Slide 151
 Seal Leakage

Causes
ƒ Flashing in chamber
ƒ Excessive bushing clearance
ƒ Misalignment
ƒ Axial shuttling
ƒ Excessive shaft deflection
ƒ Pipe strain
ƒ High vibration

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Slide 152
 Seal Leakage

Damaging Effects
ƒ Reduced seal life
ƒ Environmental contamination

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Slide 153
 Seal Leakage

Solutions
ƒ Removal of hydraulic instability
ƒ Improved rotor stiffness
ƒ Improved alignment techniques
ƒ Upgraded coupling designs
ƒ Upgraded seal designs and metallurgy
ƒ Proper seal chamber space
ƒ Improved seal flush system and cleanliness

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Slide 154
 Seal Leakage
Improved Rotor Stiffness
DEFLECTION CALCULATIONS, API 610, 8TH EDITION, Par. 2.5.7. PUMP TYPES OH1, OH2

PUMP TYPE: 4UB-Orig SHOP ORDER #

PUMP SIZE: PeCO
INPUT (See Figure 1 for illustration & dimemsions!)
SPECIFIC GRAVITY OF FLUID 1.000

ƒ Radial load IMPELLER SPECIFIC SPEED (Ns) 1450 (U.S. units) Thrust brgs. Resultant loading @ im peller
IMPELLER WEIGHT 35.0 lbs.
L2 L1
IMPELLER DIAMETER (O.D.) 9.500 in.

increases to the IMPELLER EXIT WIDTH + SHROUDS

DIFF. HEAD @ SHUT-OFF (Hso)
DIFF. HEAD @ MIN. FLOW (Hmin)
1.375
370
370
in.
ft.
ft. d2 d1
Hydraulic

left of BEP DIFF. HEAD @ DUTY POINT (Hdp)

GPM @ MIN. FLOW (Qmin)
GPM @ DUTY POINT (Qdp)
325
200
1000
gpm
gpm
ft.

Resultant
GPM @ BEP (Qbep) 1200 gpm
Weight

ƒ L3/d4 < 100

LENGTH BETWEEN BRGS (L2) 10.61 in. X
LENGTH RAD BRG TO IMP CL (L1) 16.16 in. Radial brg. Seal face Impeller
LENGTH SEAL FACE TO IMP CL (X) 10.60 in.
SHAFT DIA BETWEEN BRGS (d2) 2.820 in. FIG URE 1
SHAFT DIAMETER AT SLEEVE (d1) 1.875 in.
SHAFT MODULUS OF ELASTICITY 2.70E+07 (See TA B LE) psi
VOLUTE? (S )INGLE/ (D )OUBLE D

INTERM EDIA TE RESULTS

Fhydraulic (so ) 75 lbf .

Fhydraulic (min) 64 lbf .
Fhydraulic (dp) 65 lbf .

M OM ENT OF INERTIA @ d1 0.607 in.^4

M OM ENT OF INERTIA @ d2 3.104 in.^4
RA DIA L THRUST FA CTOR @ SHUT-OFF (Kso )* 0.036
RA DIA L THRUST FA CTOR @ M IN FLOW (Kmin)* 0.030
RA DIA L THRUST FA CTOR @ DUTY P T (Kdp)* 0.036

RESULTANT DEFLECTION DEFLECTION

LOADING @ @ @
OUTPUT IMPELLER IMPELLER SEAL FACE
(lb f.) (in.) (in.)
SHUT-OFF 83 0.0081 0.0014
MIN. FLOW 73 0.0070 0.0013
DUTY POINT 74 0.0072 0.0013
L3/D4 341

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Slide 155
 Seal Leakage
Upgraded Seal Designs Bellows Seal
Process
Flange (Gland) Fluid
ƒ Seal Faces Gasket Injection Threads

- Different carbon resin or filler

- Switch Tungsten Carbide to Silicon Process
Fluid
Carbide
- Direct Sintered Silicon Carbide
instead of Reaction Bonded Silicon Sleeve Gasket
Seal Faces

Carbide
Adapter (Rotor) Gasket Stationary Face (Stator) Gasket
ƒ Secondary Seals Pusher Seal
- Various O-ring options such as Flange (Gland)
Process
Fluid
Injection
perfluoroelastomers Gasket Threads

- PTFE-based seals
ƒ Metal Process
Fluid

- High alloys such as Alloy C-276 or

Alloy 600
Seal Faces
- Bellows material selection is limited Sleeve Gasket

Rotating Face (Rotor) Gasket Stationary Face (Stator) Gasket

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Slide 156
 Ring Deflection

Twist angle due to moment, M:

12MR 2
h θ=
Ebh3
θ M
8 b θ = Twist angle
M = Moment per unit length
E = Elastic modulus
R R = Radius, axis to ring center
b = Radial width
h = Axial length

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Slide 157
 Alignment
Horizontal Offset Horizontal Angularity (Yaw)

Motor Pump/Fan/Gearbox/Etc. Motor Pump/Fan/Gearbox/Etc.

Vertical Offset Vertical Angularity (Pitch)

Motor Pump/Fan/Gearbox/Etc. Motor Pump/Fan/Gearbox/Etc.

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Slide 158
 Alignment

Effects of Misalignment

100
Impact of misalignment on the life of
a 309 cylidrical roller bearing with an
Percent of Standard Life

ideal crown.

50

Misalignment (minutes) 20
5

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Slide 159
 Vertical Alignment Process
Goals
Primary:
Motor
ƒ Align pump and motor bearing Bearings
centerlines (i.e., stator alignment)
Secondary:
Coupling
ƒ Check pump and motor rotors for
straightness

Pump
Bearings

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Slide 160
 Vertical Alignment Process
Issues
Discharge Head/Motor Support
ƒ Lack of adjustability
- Rabbet fits bind
- Body bound bolts
ƒ Loss of concentricity/parallelism
- Corrosion of fits
- Stress relief of weldments
- Incorrect from original manufacture
- Incorrectly repaired
- Not designed to replace parts
ƒ Add register / truth bands

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Slide 161
 Vertical Alignment Process
Issues
Motor:
ƒ Mounting face not perpendicular to
bearing centerline
ƒ Rabbet fit not designed to hold
concentricity [generally]
ƒ Add four jack screws

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Slide 162
 Vertical Alignment Process
Issues
Vertical Pumps depend on the stack up of tolerances for internal alignment

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Slide 163
 Vertical Alignment Process
Alignment Process
ƒ Check motor runout
ƒ Use motor as “alignment tool”
ƒ Move motor to minimize TIR to pump
ƒ Couple and check shafting

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Slide 164
 Vertical Alignment Process
Alignment Process
Check Motor Lateral Side play:
ƒ Sleeve bearing motors:
Four centering screws to Motor
hold shaft in center of Bearings Typical Sleeve
Bearing Clearance
bearing .005-.010 inch
Diametric
ƒ Not required for ball
bearings
Motor Half MILS
Coupling

Push/Pull

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Slide 165
 Vertical Alignment Process
Alignment Process
Check Motor Shaft Runout:

Motor
Bearings

Motor Half MILS

Coupling
MILS

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Slide 166
 Vertical Alignment Process
Alignment Process
Check Motor Mounting Face Runout:

Motor

MILS

Mounting
Surface

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Slide 167
 Vertical Alignment Process
Alignment Process
If The Motor Is Good…
ƒ The motor base is flat and
perpendicular to the bearing
centerline
ƒ Use the motor shaft
as an indicator of where the
motor bearing centerline is
[i.e. use the motor as
an alignment tool]

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Slide 168
 Vertical Alignment Process

Types of Misalignment
Motor
Bearings

Coupling

Pump
Bearings

Angular Parallel
Misalignment Misalignment

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Slide 169
 Vertical Alignment Process
Angular Alignment Check

MILS

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Slide 170
 Vertical Alignment Process
Alternate Angular Alignment Check

Check Gap at
Four Locations

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Slide 171
 Vertical Alignment Process
Angular Alignment Check
Options to correct:
ƒ Re-machine discharge head
ƒ Re-machine motor base
ƒ Shim between motor and base

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Slide 172
 Vertical Alignment Process
Parallel Alignment Check
Slide Motor to Align

MILS

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Engineered Solutions for Superior Pump PerformanceSM
Slide 173
 Vertical Alignment Process
Alternate Parallel Alignment Check

MILS
Use Wedges,
Bushing, or
Centering Plate
to Center Shaft
in Stuffing Box

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Slide 174
 Vertical Alignment Process
Shaft Runout Check

MILS

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Slide 175
 Vertical Alignment Process
Conclusions
Need to check alignment of vertical pumps and motors:
ƒ Angular [many skip]
ƒ Parallel [some skip]

Consider adding register fits/truth bands when doing repairs

Check vibration as final check
ƒ Top of motor two directions
ƒ Shaft above and below coupling
− Phase across coupling
ƒ Other points as applicable

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Engineered Solutions for Superior Pump PerformanceSM
Slide 176
 Pump-to-Piping Alignment

Step 1: Pre-installation stage (pump may not have even arrived to site yet)
– anchor the main piping properly. Leave room for the final spool pieces (to
be made later) by the pump.

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Engineered Solutions for Superior Pump PerformanceSM
Slide 177
 Pump-to-Piping Alignment

Step 2: Rough alignment phase. Pump has arrived. Position it and

make spool pieces.

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Slide 178
 Pump-to-Piping Alignment

Step 3: Remove all equipment. Level the baseplate to 0.025” from

end to end. Clean up and get ready for the grouting.

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Engineered Solutions for Superior Pump PerformanceSM
Slide 179
 Pump-to-Piping Alignment

Step 4: Grouting phase.

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Slide 180
 Pump-to-Piping Alignment

Step 5: Reinstall the pump and a motor on a baseplate. Inspect

and make sure nothing is binding up.

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Slide 181
 Pump-to-Piping Alignment

Step 6: Rough align pump to a motor.

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Slide 182
 Pump-to-Piping Alignment

Step 7: Make up final spool pieces.

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Slide 183
 Pump-to-Piping Alignment

Step 8: Install the spool pieces between piping and a pump. Leave
gaps (1/16” – 1/8”) for the gaskets. This gap is the only distance the
piping will be pulled during final bolting, and stresses will be
minimal. (The pump will thank you for that).

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Slide 184
 Pump-to-Piping Alignment

Step 9: Final alignment of a motor to pump.

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Slide 185
 Pump-to-Piping Alignment

Step 10: Final piping verification. Unbolt the pump from the driver.
Loosen up piping bolts and retighten. Indicator should not move more
then 0.002”. Otherwise modify, adjust or remake spool pieces.

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Slide 186
 Thank You!

Pumping Machinery (guy with the accent)

Phone: (770) 310-0866
Web: www.PumpingMachinery.com

Mancini Consulting Services (tall Italian – no accent)

Phone: (215) 348-8580
e-mail: [email protected]

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Engineered Solutions for Superior Pump PerformanceSM
Slide 187