Introduction to Pumps

Basic Terms
• Volumetric Flow rate: Flow rate /Capacity of a pump is the amount of liquid
delivered by the pump per unit of time (m3/hr).
• Total Head: It is term that defines how high the pump can lift a
liquid./Pressure in terms of height.
• Hydraulic Power: Power transferred by the pump to the liquid.
• VACUUM: Pressure lower than the atmospheric pressure.
 Definition
• Pump: When a fluid has to be "moved" in a system, pumps are used. The
pump is a machine which has the function of increasing the total energy of a
liquid; this means that the pump transfers energy to the fluid that it receives
from the driving motor”.

• Pumps operate by some mechanism and consume energy to

perform mechanical work by moving the fluid.

• Pumps operate via many energy sources.

• Today, uncommon to find efficiency greater than 93%
for large pump.
Need Of a Pump:

 Used to pump a liquid from lower pressure area to a High pressure area.
 To increase Flow rate.
 To move liquid from lower elevation to higher elevation.
When selecting a pump for a particular
application, there are few factors must be
considered.
90 % OF CENTRIFUGAL PUMP IS USED IN THE
PLANT.
Parameters involved in Pump Selection

The nature of the liquid The type of system to which

to be pumped the
pump is delivering the fluid

The required capacity

(volume flowrate) The type of power source:
electric motor, diesel
engine, steam turbine
The conditions on the
suction Space, weight, and
(inlet) side of the pump position limitations

The conditions on the Cost of pump purchase

discharge (outlet side of and installation
the pump

The total head on the

pump Cost of pump operation
(h A )
 Determination of size of pump
Given the dimension of small room in a chemical plant is 5 m x 5 m. You are required
to purchase pump with a given head, h and speed, N of the pump at 80 m and 1500
rpm, respectively. Estimate the size of the pump and determine whether the pump fit
in this small room or not.
Total Dynamic Head, TDH
Two main pumping principles
 Type of pump

Dynamic Pump/ Positive Displacement Pumps

Centrifugal Pump
Rotary Reciprocating pump
Radial Mixed Axial

Gear Lobe Vane Screw Peristaltic Metering Power

Piston Diaphragm

Piston Diaphragm
 Principle of Operation
• Dynamic Pump: . In dynamic pumps, energy is added to the fluid
continuously through the rotary motion of the blades. This increase in
energy is converted to a gain in Pressure Energy when the liquid is allowed
to pass through an increased area.
• https://www.youtube.com/watch?v=WUal9LXc0iM
 Centrifugal Pump
Working Principle:
• Works on the principle of centrifugal force. This is the force that pushes the liquid away from the
centre (in tangential direction).
• Converting Prime Mover energy into Mechanical energy through shaft.
• Converting Mechanical energy into fluid energy impeller.
• Converting kinetic Energy into pressure energy through the volute casing.
Radial Flow pump:-
Centrifugal pumps are used to transport fluids by the
conversion of rotational kinetic energy to the
hydrodynamic energy of the fluid flow.
Application:-
• Petrochemicals: Pure or filled bitumen, pitch, diesel oil,
crude oil, lube oil etc.
• Oil - refineries, power plants
• Building Services
• Chemical and Process
Industries Industry and
Water engineering
Axial flow pumps:-
These are also referred to as All fluid pumps. The fluid is
pushed outward or inward and move fluid axially. They
operate at much lower pressures and higher flow rates than
radial-flow (centripetal) pumps.
Application:-
 In power plants, they are used for pumping water from a
reservoir, river, lake or sea for cooling the main condenser
 In the chemical industry, they are used for the
circulation of large masses of liquid, such as in
evaporators and crys.
 In sewage treatment, an AFP is often used for internal
mixed liquor recirculation tallizers
 In agriculture and fisheries very large horsepower AFPs
are used to lift water for irrigation and drainage
Mixed-flow pumps:-
• Mixed-flow pumps function as a compromise
between radial and axial-flow pumps.
• The exit is in between 0 to 90 angle .
• Higher pressures than axial-flow pumps while
delivering higher discharges than radial-flow
pumps.
• Radial Pumps: High Pressure& For low flow rate/Centrifugal pump.

• Axial Pumps: Axial-flow pumps operate at much lower pressures and higher flow
rates than radial-flow pumps.

• Mixed Flow Pumps: Mixed-flow pumps operate at higher pressures than axial-
flow pumps while delivering higher discharges than radial-flow pumps.
 Major Parts
Centrifugal pump is made of hundreds of parts no matter how big or tiny. However,
there are some major parts which are designed to perform specific tasks.
https://www.youtube.com/watch?v=3rqnXffrSmc
 Centrifugal Pumps - Shaft
Shaft:
• The main function of the shaft in a
centrifugal pump is to transmit the
input torque/power from the driver
into the impeller.
• Supporting the impeller and other
rotating parts. Shaft is protected from
erosion ,corrosion and wear at the
seal chamber through renewable
sleeve.
 Centrifugal Pumps - Impeller
Impeller:
• Centrifugal pumps use impeller as
the primary source for their pumping
action. Its function is to increase the
pressure of the liquid.
• An Impeller has vanes that pushes the
liquid through the impeller. Transmit
energy into the fluid (hydraulic energy).
 Types Of Impeller

OPEN SEMI OPEN CLOSED

 Centrifugal Pumps - Casing
Volute/Casing:
• The casing contains the liquid and acts
as a pressure containment vessel that
directs the flow of liquid in and out of the
centrifugal pump.
• Impeller are fitted inside the casing. Volute
casing is a curved shaped ,increasing in
cross sectional area. Volute reduces the
velocity of the liquid and increases the
pressure.
 Centrifugal Pumps - Seal
Centrifugal pump can be provided with packing rings or mechanical seal
which helps prevent the leakage of the pumped liquid into the atmosphere.
 Centrifugal Pumps - Bearing
The function of the bearing is to support the weight of the shaft (rotor)
assembly, to carry the hydraulic loads acting on the shaft, and to keep the
pump shaft aligned to the shaft of the driver.
 Centrifugal Pumps - Coupling
The function of couplings are to connect the pump shaft and the driver shaf
and to transmit the input power from the driver into the pump.
 PARTS

Gland Packing Wear Rings Lantern Ring

 GLAND PACKING

Lantern
Ring

Wear
Ring
• Why Centrifugal Pumps Need Priming?
Centrifugal pumps does not create suction at the start without impeller filled
with water. Hence Priming required . Priming is the process in which the
impeller of a centrifugal pump will get fully sub merged in liquid without any air
trap inside. This is especially required when there is a first start up. But it is
advisable to start the pump only after primping.
 Multistage Centrifugal Pumps.
• `In order to achieve a higher discharge pressure multiple impellers are used
within a single pump. Depending upon the requirement.
Vertical Pumps
 Positive Displacement Pumps
• Working Principle: Positive Displacement Pump has an expanding
cavity on the suction side of the pump and a decreasing cavity on the
discharge side. Liquid is allowed to flow into the pump as the cavity on the
suction side expands and the liquid is forced out of the discharge as the
cavity collapses.
• A positive displacement pump makes a fluid move by
trapping a fixed amount of fluid and forcing (displacing)
that trapped volume into the discharge pipe.
• Positive displacement pumps, unlike centrifugal or roto-
dynamic pumps, theoretically can produce the same flow at
a given speed (RPM) no matter what the discharge
pressure.
• A positive displacement pump must not operate against a
closed valve on the discharge side of the pump, because it
has no shutoff head like centrifugal pumps.
• A relief or safety valve on the discharge side of the positive
displacement pump is therefore necessary. The relief valve
can be internal or external.
• All operate on the principle of filling, trapping, transporting,
and forcing out
 Gear Pumps
Working Principle: a simple type of rotary pump where the liquid is
pushed between two gears.
Application:-
• Gear pumps are widely used in chemical installations to pump
high viscosity fluids.
• Petrochemicals: Pure or filled bitumen, pitch, diesel oil, crude oil,
lube oil etc.
• Chemicals: Sodium silicate, acids, plastics, mixed chemicals,
isocyanates, Polymers and Synthetic Rubber.
• Paint, Coatings, Resins, Print Inks and Asphalt
• Resins, adhesives, glues, Lubricants and Greases
• Soaps, Surfactants, and Personal Products
• Starch, Liquid Sugars, Vegetable Oil, & Chocolate
External Gear Pumps
 Internal Gear Pumps
Two Working Parts
• Rotor and Shaft
• Idler Gear

• Crescent is attached to pump head

• Crescent is stationary and separates the rotor and
idler teeth, providing the pumping cavities during
Versatile Advantages Limitations
• Viscosity Ranges from • Not a high pressure pump,
32 - 1,000,000 ssu 200 psi (13.8 bar) differential
• Temperatures to 600ºF • Not a solids handling pump
(315.6°C) • Not a FDA/3A sanitary pump
• Pressures to 200 psi
(13.8 bar) Differential
• Moderate Fine Solids
Handling Capability
• Brief Period Run Dry
Capability
• Only 1 Shaft Seal
• Compact
• Easy to Service
 Screw Pumps
• Working Principle:the shape of the internals of this pump is
usually two screws turning against each other to pump the
liquid.
• Pumping element consists of a metal rotor rotating in an elastomeric
stator

Rotor turns in stator, moving flu

in and out of the cavities
Applications Limitations
• Yogurt • Intolerant of running dry
• Paper Coatings • First cost higher than gear
• Calcium Carbonate for Wallboard • Foot print is very long and narrow
• Caulk Compounds, Viscous • Seal-less designs are not available
Adhesives • Upper end temperature limitation is
• Sludge, Municipal Waste, and for practical
Industrial purposes about 275°F (135 °C)
Waste
Advantages • No compatible elastomer for
• Low Shear solvents and other chemicals
• Sanitary Designs Available
• Solids Handling Capability
• High Pressure Capability, up to
1000 psi
(68.95 bar)
• Handle Very Viscous Liquids up to
1,000,000 cps
• Versatility in handling low viscosity and
high viscosity liquids, e.g. flushing
• Special designs with augmenters and
hoppers available for very viscous liquids
• Mechanical seals are usually placed on the
Gear vs. Screw Pumps
• Compact Foot Print
• More Material Choices
• First Cost Generally Lower
• More Tolerant of Running Dry
• Seal-Less Designs are Available
• Avoids elastomer compatibility issues for pumping solvents or
handling higher temperatures
• Repair costs are generally much lower
• When using equivalent pump speeds, gear pumps have comparable shear imparted
compared to progressive cavity pumps.
 Lobe Pump
Reasons Why Customers Buy
• FDA or 3A accepted sanitary design
• Low Shear
• Solids Handling
Lobe Pumps
• Many Lobe pumps are sold in industrial
applications where low shear is the main criteria,
and sanitary construction is not important
• Properly sized and selected gear pumps can offer
the same low shear performance at about half the
cost
• Customer gets an easier to maintain pump
• 1 Seal vs. 2 Seals
• No Timing Gears
• Easily Rebuilt in the Field
 Vane
pumps

• As the rotor turns the vane moves outward at the

intake port creating a void/drawing liquid in
• Fluid is transferred between vanes
• At the outlet, fluid is discharged as pumping chamber
is squeezed (and vanes forced back)
• Fluid flow through
the pump
• Inlet - Expansion
• Transport - Static
• Outlet - Reduction
Applications
• Petroleum Based Fuels
• Kerosene, Solvents, Alcohols, Ammonia, and
Liquefied Gases

Limitations
• Abrasive solids are a challenge for vane pumps
• Size of pump increases substantially for viscous
liquids
 Peristaltic (Tube or Hose)
Pumps
Hose Pump Working Principal
• A pulsing flow is generated by
the pushing action of shoes on
the wall of an elastomeric hose
• Shoes are assembled on a
rotating wheel
• Sealing under the shoe is
performed by the compression of
a local area of the hose
• Friction between shoes and
hose is reduced by using a
lubricant which also acts as a
coolant
 Hose Pumps: Two Types of Pumps

Peristaltic Pumps Hose Pumps

Small units generally Process Services
used in laboratories Max. pressure
Max. Pressure ~200 psi (~13.8
22 psi (1.5 bar) bar)

Hose Construction
• Hose is made by piling layers of rubber material and weaves of
synthetic fibers.
• Only 4 to 5 manufacturers worldwide are capable of making these
Hose material:
hoses
• EPDM
• Hypalon
• NBR (Buna)
• NR (Natural Rubber)
• Teflon® and Viton Not Available
• Not suitable for many solvents
and corrosive chemicals
Hose Pump Advantages Hose Pump Disadvantages
• Low Shear • The flow has pulsations
• No Mechanical Seal • Relatively high first cost compared
• Capable of handling applications to other
with designs
wide ranges of viscosities • Frequent hose replacement is
• Better than average tolerance required
for • Relatively large foot print
running dry • Size is physically larger for higher
• Self priming pump with high suction lift range
of flow rates
(up to 29.5 ft./9 Meters of water)
• Appropriate for abrasive products
• Excellent volumetric capacity (dosing)
• Particles up to 15% of hose ID can be
pumped (not sharp)
Hose Life
Depends On
• Pump RPM
• Differential Pressure
• Typical hose life for 100 psi (6.9 bar)
differential pressure may be 1000-
2000 hours
Hose Pump Applications

• Ceramic - Ceramic Slips, Mould Filling, Filter Press

• Mining - Sludge up to 60,000 cps, Clay Slurry up to 6.67
lbs./gal. (800 grams/lt), Lead Sulfate, Pyrite Slurry
• Water Treatment - Lime Slurry, Flocculate Dispersion,
Sludge, and Slurries
• Building Industry – Fibrous Mortar, Liquid Plaster, Light
Concrete
• Chemical Industry - Acids, Alcohols, Detergent Pumping,
etc…
• Nuclear - Contaminated Slurries and Mud, Ammonium Dioxide, Uranyle
Nitrate
• Food Industry - Tomato Sauce, Mashed Potatoes, Gelatin, Beer Slurries, Fish
Paste, and Olive Oil
• Paint - Water Base and Acrylic Paint, Pigments, and Wall Coating
• Filter Press - Filling and Pressing
• Paper Industry - Latex, Slurries, Kaolin,
• Glue, Liquid Salt, Seed Fertilizer, etc...
 Reciprocating Pumps:
Working Principle: Reciprocating pumps move the fluid using one or more
oscillating pistons, plungers, or membranes (diaphragms), while valves
restrict fluid motion to the desired direction.
 Displacement Vs Centrifugal

• Centrifugal pumps are suitable for low head and high flow rate.

• PD pumps produce high head and low flow rate.

• PD are suitable for High Viscosity application.

• Centrifugal Pumps are not recommended for high viscosity application

because as viscosity increases its flow deceases.
• Usually a relieve valve is attached with the displacement pumps.
 Comparison of Centrifugal and PD Pumps

PD Flow Rate is Relatively Independent of

Viscosity
 Comparison of Centrifugal and PD Pumps

PD Flow Rate is Relatively Independent of

Viscosity
Why Positive Displacement Pumps?
• Viscosity is higher than 250 cps
• Desire for constant flow, independent of
pressure
• Efficiency for low flow, higher pressure
combinations
• Self priming capability
• Low cost and compact size for low flow,
higher pressure combinations
 Cavitation
Cavitation: It is the process in which bubbles are
formed due to sufficient Pressure drop at the suction
of the pump.
• Cavitation is the formation of “vapor”
bubbles at the pump inlet
• When the vapor bubbles return to liquid,
the vapour collapses violently…
>> Implosion
 How cavitation occurs?

• The fluid enters a pump through the suction port at the

central eye of the impeller and this where the lowest
pressure occurs.
• The rotation of the impeller then
accelerated the fluid outward along the
vanes toward the casing.
• Fluid pressure continues to rise
throughout this process.
• If vapour bubbles had formed in the
suction port because of excessively low
pressure there,
they would collapse as they flowed into
 Effect of cavitation

• When cavitation occurs, the

performance of the pump is severely
degraded as the volume flow rate
delivered drops.
• The pump vibrates and becomes
noisy, giving off a loud, rattling
sound as if gravel was flowing with
the fluid.
• If this was allowed to continue, the
pump would be
destroyed in a short time.
 Vapour Pressure

• Vapour pressure Pvp determines the conditions

under which vapour bubbles form in a fluid.
• When both vapour and liquid forms of a substance
exist in equilibrium, there is a balance of vapour
being driven off from the liquid by thermal energy
and condensation of vapour to the liquid because
of attractive forces between molecules.
 Net Positive Suction
Head
• The importance of the net positive suction head,
NPSH:
a) To prevent cavitation
b) The NPSH R for the selected pump must be
satisfied
c) The piping system design affects the NPSH
 Net Positive Suction
•
Head
Pump manufacturers test each pump design to determine the level of
suction pressure required to avoid cavitation, reporting the result as the
net positive suction head required, NPSH R , for the pump at each operating
condition of capacity (volume flow rate) and total head on the pump.
• It is the responsibility of the pump system designer to ensure that available
net positive
suction head, NPSH A , is significantly above NPSH R .
• Standard have been set by the American National Standards Institute
(ANSI) and the Hydraulic Institute (HI) calling for a minimum of a 10
percent margin, M for NPSH A over NPSH R .
 Net Positive Suction Head
•
Margin
𝑀 = 𝑁𝑃𝑆𝐻 − 𝑁 𝑃 𝑆 𝐻
𝐴 𝑅

• Higher margin up to 100 percent are expected for critical applications such
as flood control, oil pipelines and power generation service.
• Based on ANSI and HI, minimum of 10 percent margin is used:
• 𝑁𝑃𝑆𝐻 𝐴 > 1.10𝑁𝑃𝑆𝐻 𝑅

NPSHA
• The value of NPSHA is dependent on the vapour pressure of the fluid being
pumped, energ y losses in the suction piping, the elevation of the fluid
reservoir, and the pressure applied t o the fluid in the reservoir.
• 𝑁𝑃𝑆𝐻 𝐴 = ℎ𝑠𝑝 ± ℎ𝑠 − ℎ𝑓 − ℎ𝑣𝑝
 𝑵𝑷𝑺𝑯 𝑨 = 𝒉𝒔𝒑 ± 𝒉𝒔 − 𝒉 𝒇 −
• 𝑃𝑠𝑝
𝒉 𝒗 𝒑 (absolute) above the fluid in the reservoir
= static pressure
• hsp = static pressure head (absolute) above the fluid in the
reservoir, expressed in meters or feet of the liquid; hsp = Psp/
• hs = elevation difference from the level of fluid in the reservoir
to the centerline of the pump suction inlet, expressed in
meters or feet
• If the pump is below the reservoir, hs is positive
• If the pump is above the reservoir, hs is negative
• hf = head loss in the suction piping due to friction and minor
losses, expressed in meters or feet
• Pvp = vapourpressure (absolute) of the liquid at the pumping
pressure
• hvp = vapourpressure head of the liquid at the pumping
temperature, expressed in meters or feet of the liquid: hvp =
Pvp/
Centrifugal pump performance curves
Affinity laws for centrifugal pumps
Pump Operating in series
Pump Operating in series
Pumps operating in parallel
Pumps operating in parallel
 Start Up Check
1. Verify pipe cleanliness*
2. Pump- driver alignment is correct*
3. All piping are connected properly- no piping stress*
4. Check lubricating system
5. Check position of pump suction and discharge valves
6. Ensure instruments (Pressure gauge, flow meter etc. connected are
functional
7. Check that cooling/ flushing/ quenching system is lined up for gland
packing/ mechanical seals
8. Cooling lines for Bearing housing (if applicable) are lined up
9. Verify that pump shaft rotates freely
10. Ensure direction of rotation of “Driver” is correct.
Start Up Procedure
1. Open suction valve and mini flow valve
2. Close discharge valve
3. Open casing vent valve/ drain until steady stream of liquid comes out (Ensure
priming)
4. Start the pump and observe the discharge pressure
5. Gradually open the discharge valve in the discharge line.
6. Mini flow valve may be closed after flow stabilizes
7. Monitor parameter and observe for any abnormality

Shutdown Procedure
8. Slowly open mini-flow (re circulating) valve
9. Once flow is diverted to re-circulation line (pump off-loaded), shutdown the driver
10. Close pump discharge valve completely
11. If needed, close pump suction valve also
12. Close flushing/ quenching/ cooling lines
13. Stop lube oil pump circulation (if applicable)
14. Open drain valves to drain the pump, if required.

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Important
Pump Support systems
Flow capacity control
Temperature & vibration control
Troubleshooting Technique
Conditioning Based Monitoring (CBM)
Purposes of CBM
CBM
CBM
Troubleshooting technique
Vibration technique: why vibration is
important?
Multistage maintenance pump
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Types of misalignment
QUESTIONS?