2/14/2022 pump selection

and maintenance

Abdallah Ahmed Mohamed Ismail

SEC 4
Centrifugal Pump Selection
In choosing a pump, you firstly need to select a pump appropriate for your
application. Centrifugal or positive displacement? Is the fluid corrosive? Does
it have entrained solids? Does it need to be contained? However, having
made those decisions, and if you have identified centrifugal pump
technology as being the most suitable, how do you select a model to give
the required performance?

centrifugal pump curve

Historically, pumps were used to raise water for irrigation or drainage
purposes. It was important that the pump was capable of lifting the water
from the lower to the higher level. The delivery height became known as the
differential head (or simply head) and, despite the vastly extended range of
modern-day pumping applications, this term is still used to characterise
pump performance. Nowadays, it relates more to the difference in pressure
between the pump’s inlet and outlet and this can be affected by pipeline
design and valve configurations. As the pressure a centrifugal pump has to
overcome increases, the discharge flow decreases until, at a certain head,
the output drops to zero. Conversely, with no head to work against, a pump
can achieve the maximum possible output allowed by its design, impeller
selection and rotational speed. The range of performance between these two
points is specified in a pump curve (Figure 1a).For a particular pump design,
the performance can be modified by fitting a different impeller and/or by
operating it at a different rotational speed. Manufacturers often show the
range of possible performances in a ‘Tombstone’ chart (Figure 1b).
This illustrates the head pressure and capacities covered by a pump design
at a number of set rotational speeds, with a range of impeller sizes and
different pump casing designs. The upper line of each segment or tombstone
is the actual pump curve at the specified speed, impeller size and casing
design.

system curve
The pump curve describes how a centrifugal pump performs in isolation from
plant equipment. How it operates in practice is determined by the resistance
of the system it is installed in: restrictions in the pipework and downstream
frictional losses as well as static inlet or outlet pressures. A graphical
representation of these factors is called the system curve (Figure 2a). This
shows how the head pressure (at the location to be occupied by the pump)
increases with increasing throughput.

varies of the system curve

A key component of the system curve is the head loss resulting from
frictional effects as fluid is forced through downstream pipework. This arises
from valves, junctions, elbows, changes in pipeline diameter, and friction
between the fluid and the pipe walls. It is usually calculated using the Darcy-
Weisbach equation:
Where the head loss increases to the square of the volumetric flow
rate (hence system curves are parabolic); is the Darcy-Weissbach frictional
factor, is the pipe diameter and is the local acceleration due to gravity.
There can also be a fixed component to the system curve, introduced by any
inherent differences in pressure between the fluid’s source and its discharge.
This is called the static head and, in the conventional sense, is comparable
to pumping the fluid to a higher (or lower) reservoir.

operating point
By plotting the pump and system curves on the same graph (Figure 2b), the
intersection of the lines identifies the flow rate you can expect from the
pump in this configuration. This intersection is called the operating point. If
the lines do not intersect the pump is not suitable for your application.

Where is the most stable operating section of the pump’s

curve?
A centrifugal pump has a best efficiency point (BEP) somewhere on its pump
curve. These are the precise conditions, determined by the manufacturer,
where the pump operates with greatest efficiency and at which it can be
expected to have maximum working life and experience lower maintenance.
Ideally, when choosing a pump, you should attempt to match the operating
point and best efficiency points. Over the lifetime of the pump this can have
considerable cost benefits. In practice, it is acceptable to match the
operating point to within ±10% of the best efficiency point.

A pump operating at a lower capacity is often said to be “operating to the

left of the curve” and at a higher capacity is termed “operating to the right
of the curve”. These correspond to the relative positions on the pump curve
on either side of the BEP.

What happens if you run too far left of curve

To the left of the BEP, a pump’s throughput is lower than its design
specification and the fluid may not flow correctly through the system. There
is a danger of recirculation in both the pump’s inlet and outlet. This can lead
to vibration and seal wear.

Also, with a low flow, there can be problems with heat build-up. Heat is
produced by the driving motor and by friction in the pump itself. This heat
normally dissipates through the pumped fluid but under low flow conditions
this may not occur efficiently enough to prevent overheating. The impeller,
pump casing and bearings of a centrifugal pump are precisely engineered
with minimum clearances to reduce losses and maximise efficiency. At
higher temperatures, the gaps between these rapidly moving components is
reduced still further and any contact will result in wear and potential
damage.

What happens if you run too far right of curve

At the right-hand side of the BEP, a pump’s throughput is higher than its
design specification and there is a danger of cavitation in the impeller.

Cavitation is a process whereby bubbles of vapour, formed when a fluid is

under low pressure, spontaneously collapse as they are transported back
into a region of higher pressure. In a centrifugal pump the fluid’s pressure is
at a minimum at the eye of the impeller. If the pressure here is below the
saturated vapour pressure of the fluid, bubbles are formed which pass on
into and through the impeller vanes. The fluid pressure increases as the fluid
is discharged and the bubbles implode. The repeated shock waves can be a
significant cause of wear and metal fatigue on impellers and pump cases.

The higher discharge may also result in vibration and noise in the pump,
placing greater strain on its drive shaft and other components, and also in
downstream pipework. This can lead to greater maintenance costs and a
higher incidence of pump failures.

What are the Affinity Laws?

The Affinity Laws are a set of relationships that show how a pump’s capacity,
head and power are determined by the rotational speed or diameter of its
impeller. They allow you to extrapolate from the specified pump curve and
predict how the pump will perform at a different shaft speed or with a
smaller (or larger) impeller installed.

Fluid enters the rapidly rotating impeller along its axis and is cast out by
centrifugal force along its circumference through the impeller’s vane tips.
The output or volumetric flow of the pump (Q) is linearly related to the
rotational speed of the impeller (N). In addition, the head (H) is proportional
to the square of the impeller’s rotational speed, and the power requirements
(P) to its cube:
These three relationships lead to the first set of Affinity Laws. Knowing the
volumetric flow (Q1), head (H1) and power (P1) of a pump at one rotational
speed (N1), you can use these relationships to estimate how it will perform
(Q2 , H2 , P2) at a different speed (N2).

In the same way, the volumetric flow of the pump (Q) is linearly related to
impeller diameter (D), the head (H) is proportional to its square, and the
power requirements (P) to its cube:

So, if you know the capacity (Q1), head (H1) and power (P1) with one size of
impeller (D1) installed in the pump, you can use a second set of Affinity Laws
to estimate how it will perform (Q2 , H2 , P2) with a differently sized impeller
(D2).

It is important to note that different sizes of impellers may not have the
same efficiencies. Predictions using this set of Affinity Laws may not be as
accurate as those derived from changes in rotational speed using the first
set of laws.

Summary
To select the right pump for an application, it is important to understand
both system and pump curves. The system curve describes the increase in
head resulting from increasing fluid flow through the pipework and other
equipment in your plant. The pump curve describes the relationship between
the rate of fluid flow and head for the pump itself. When plotted on the same
graph, the point at which the system curve and pump curves intersect is
called the operating point – it identifies the capacity you can expect from the
pump in this particular configuration. Ideally, you should choose a pump
where the operating point matches the point of maximum efficiency on the
pump curve (BEP). The Affinity Laws allow you to predict how a pump will
 Pump Maintenance
Pump maintenance is needed to restore performance, reliability and ensure
process performance is restored to original design criteria.
There are 3 types:
Corrective (Reactive)
Preventative (Semi Proactive)
Monitoring (Proactive & Predictive)
Corrective Maintenance is undertaken when failure has occurred. The unit may
be leaking, efficiency reduced, pump stopped or motor tripped, leading to loss of
production resulting in an urgent situation where parts must be sourced and
fitted quicky.
Preventative Maintenance is inspection and repair scheduled at specific intervals
(daily, weekly, monthly, yearly) or based on the number of hours run. Visual
inspections are made externally and internally by dismantling the unit, replacing
seals such as gaskets and mechanical seals, with pump parts checked for wear.
A typical preventative Maintenance Checklist Consists of:
Differential Pressure: Check the operating pressure by calculating the difference
between the inlet and outlet pressure of the pump ensuring it is operating on
curve.
Vibration: Ensure vibration is minimal, and within
designed limits.
Noise: Check for high pitched squealing, grinding, or the
sound of gravel within the pump (cavitation). Check noise
limits are within design limits.
Excess Temperature: Check motor, bearing and casing
temperature. Thermal imaging cameras can detect excess
temperature quickly, without stoppage, dismantling or
contact with the unit.
Corrosion: Check for corrosion on parts such as
main body, flanges, impeller & casing plug.
Gaskets: Monitor swelling, Wear or leaks from
the casing.
Wearing Part Tolerance: Check parts are
within design tolerance through use of a
vernier. Measure Shaft OD and condition,
Impeller Diameter, bearing tautness around
the shaft and casing thickness.
Motor Measure current draw, continuity of
windings and condition, whether bearings should be renewed, grease & oil levels.
Mechanical Seal (barrier fluid): Check for contamination such as changes in
general colour or appearance, PH, presence of particles, viscosity, or if fluid is at
excess temperature during operation.
On dismantling units, some seals require replacing regardless of condition, and
excess spares can be required in case of gasket entrapment during assembly.
Rental of specialist lifting equipment may be required and there can be situations
where when inspected, pump parts do not require replacement.
Monitoring
The ideal situation is to ensure components are replaced before failure but not so
far in advance that they have experienced little wear with valuable time spent on
inspecting components which are otherwise fine.
This can be achieved through a monitoring device, where when the right data is
collected, pump failure can be anticipated between 3 and 12 months in advance
with an 80-95% accuracy.
With the average lead time on DN100 pumps, and units over 5 years old being 3
months or more, it is essential that spares are either on the shelf or failure is
anticipated through advance ordering.