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A QUICK GUIDE TO PUMPS

by M Ramsy

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CHAPTER ONE: PUMPS 1.1 Function of Pumps All pumps have the same basic function to move liquids
through piping systems to where they are need in the plant. 1.2 Components of Pumps Pumps can vary greatly in
several ways but certain components are common to all pumps, for example all pumps have an inlet, casing and
an outlet. 1- Inlet OR Suction During operation, liquid enters the pump through the inlet where the pressure of
the liquid is lowest at it. 2- Casing The casing houses all of the pumps internal parts. The purpose of the pump
casing is to contain the liquid inside the pump during operation. 3- Outlet OR Discharge The liquid leaves the
pump through the outlet where the pressure of liquid is highest at it. 1.3 Types of Pumps Inside the pump, there
is a component that physically moves the liquid through the pump. The type of component that use determines
the types of pump. Basically pumps can be grouped into two a general categories, positive displacement pumps
and centrifugal pumps. 1- Positive Displacement Pumps A positive displacement pump uses a piston or some
other device to push or positively displace controlled a mounts of liquid through the pump. 2- A centrifugal
Pumps A centrifugal pump used rotating device called impeller to move fluid by stirring it faster and faster in a
circular motion and then changing the increase speed into pressure, as the impeller stirs the fluid in a rapid
circular motion, the centrifugal forces created that gives the pump its name. Centrifugal force is the force that
developed when something moves or spins in circular motion. Pump Shaft On most pumps shaft is used to
transfer power from a driver to the component in the pump that moves the liquid. The point at which the shaft
enters the pumps casing must be sealed to keep the process liquid inside the pump. The area between the shaft
and the casing is commonly sealed using either packing or mechanical seal. Packing The simplest way to seal
between the shaft and the casing is to use packing to preventing fluid leaks from the interior of the pump.
Packing is flexible material that fits into the space between the shaft and the casing. When packing is used a
small amount of process liquid is allowed to leak through, the leak off acts as a cooling mechanism to remove
heat from the packing. If too much leak off is allowed, the efficiency of the pump maybe affected. On the other
hand if too little leak off is allowed, the packing will overheat dry out and possibly burn. The packing on a pump
is held in place by a packing gland. The packing gland is bolted to the pumps casing and it can be adjusted to
maintain the proper amount of leak off. Mechanical Seal Another way to seal between a pump shaft and its
casing is to use a mechanical seal. Mechanical seals do the same basic job is packing but they provide a more
complete seal. A mechanical seal has two elements, a stationary element that is attached to the pump casing and
a rotating element that is attached to the pump shaft. Each element has its own seal rings, the two seal rings
positioned close together to form a nearly perfect seal that has virtually no leak off. To prevent the seal rings
from drying out, overheating and becoming damaged. Some type of lubricant must be supplied to the seal rings.
In some applications the liquid being pumped is used as a lubricant but that is not always the case, however if
 the liquid being pumped could be hazardous if the seal fails or if it contains abrasives or other solids such as in a
slurry, an external source of clean liquid be used to lubricate the seal rings Many facilities use an independent
system to provide lubricating liquid to the mechanical seals of several pumps. This is a simplified diagram of
atypical sealing system. For this process an oil is used to lubricate the mechanical seals. During operation, the
supply pump draws the oil from the storage tank through the filter. The filter removes contaminants from the oil
to prevent damage to sealing system pumps and mechanical seals being supplied. The pump supplies the oil to
the pressure regulators on each supply line. The pressure regulators control oil pressure and the amount of oil
flow to each of the mechanical seals. The flow meters allow the flow to the seals to be monitored. If the supply
pump fails to deliver the oil at the correct pressure, the pressure switch will sense this condition and
automatically start the backup supply pump to restore the pressure. At the mechanical seal, the oil lubricates the
seal rings. The oil then passes by the seal flows into the return header and is sent back to the storage tank from
there the oil can be reused. 1.4 Auxiliary Equipments All types of pumps have auxiliary equipment associated
with them. These pieces of equipment have specific functions that are necessary for proper pump operation. 1-
Drivers The purpose of a driver is to supply the power needed to produce the pumping action. The electric
motors of the most frequently used type of driver. In this picture an electrical motor drives the impeller inside a
centrifugal pump. 2- Coupling A coupling is a device that connects the driver shaft to the pump shaft. Coupling
can be divided into two categories fixed couplings and variable couplings. When a fixed coupling is used, the
speed of pump is fixed by the speed of the driver, to change the speed of the pump; the speed of driver has to be
change. On other hand when a variable coupling is used, the speed of the pump can be changed without
changing the speed of the driver. 3- Strainer Strainers are used to trap and remove solids from the process liquid
before they enter the pump and cause damage. Strainers can be found upstream or downstream of many
centrifugal pumps. Particles build up in a strainer it restricts the flow of process liquid and the difference in
pressure across the strainer will increase. If a strainer is located upstream of the pump, excessive particle build
up could cause the pressure at the suction of the pump to decrease, if the pressure becomes too low, the pump
could cavitate and be damage. If a strainer is located downstream of the pump, excessive amounts of solid
particles will decrease the flow of the fluid to downstream equipment. To determine if the debris in a strainer is
affecting flow through the process, the readings on pressure gauges upstream and downstream of the strainer can
be compared to each other, if the difference in pressure is goes above a predetermined limit, the strainer must be
cleaned or replaced. 4- Lubricate System A lubricating system is used to lubricate the pump bearings. Bearing
are used to support and align the moving parts of the pump. If the bearings are not sufficiently lubricated, they
will overheat and they could be damaged. There are two general types of lubricating systems, passive feed
systems and forced feed systems. Passive feed systems use delivery method such as gravity to deliver lubricants
to the bearings. This constant level oiler is one type of passive feed lubricating system. Oiler has a small
reservoir of oil that drains by gravity into bearing. Another passive feed system is used on bearings that use
grease as lubricant. Grease is supplied at periodic intervals through grease fitting on bearing’s housing. Some
pumps need a greater supply of lubricant to the bearings so they use a forced feed system, for example this
system pumps oil through these lines to constantly supply of oil to the bearings. The system also has devices that
filter contaminants from the oil.

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CHAPTER THREE: CENTRIFUGAL PUMPS One of the most common types of pumps that plants depend
on is a centrifugal pump. Centrifugal pumps use centrifugal force to move process liquids. Centrifugal force is
the force that exists an object or material moves in a circular motion outward away from the center of rotation.
In centrifugal pump, what moves outward is the process liquid. 3.1 Component of Centrifugal pump All
centrifugal pumps have a suction inlet, a casing and discharge outlet. Inside the pump’s casing is a circular
component called impeller which has a series of curved vanes that extend out from its center. The pump casing
is designed so that the area around the impeller creates a gradually widening spiral channel, this widening
channel is known as the volute. 3.1.1 Impeller Inside all centrifugal pumps an impeller create centrifugal force to
move liquid through the pump. Impeller is can be designed in different ways depending on factors such as the
type of liquid being pumped and the amount of pressure increase that’s needed. The impellers used in centrifugal
pumps can be divided into three categories closed, open and semi-open. 3.1.1.1 Types of Impeller A- Close
Impeller Its vanes are enclosed by shrouds on both sides. The shrouds direct the flow of liquid between the
vanes. Closed impellers are often used with low viscosity or thin liquids. Liquids that are thick or contain
suspended solids could clog a closed impeller. Closed Impellers can be further classified as single suction
impellers or double suction impellers. 1- Single Suction Impeller It has only one suction eye so there is only one
place that the liquid can enter the impeller. Single suction impeller is fine in applications where the pressure
change across the pump is relatively low. 2- Double Suction Impeller In applications where the pressure changes
higher, large amounts of axial thrust created and must be offset. To minimize the effect of the axial thrust some
centrifugal pumps use double suction impeller. A double suction impeller has two suction eyes so liquid can
enter the impeller from opposite directions; because of this the pressure on both sides of the impeller is the same
and axial thrust is minimized. B- Open Impeller This impeller has no shrouds to direct the flow of liquid while
this design helps prevent clogging. It’s less efficient at moving liquid than a closed impeller since the flow of
fluid is not directed between the vanes. Open impellers are used to pump thick liquids or liquids with solids such
as slurries and closed impellers are used to pump thin liquids. C- Semi-Open Impeller Semi-open impellers can
be used for pumping thin liquids since there is a shroud to direct the liquid between the vanes. They can also be
used for heavier liquids and slurries since they minimize clogging. 3.2 How Centrifugal Pump Works During
operation, the driver rotates the impeller, creating a centrifugal force that pushes the process liquid outward into
the volute. The outward movement of the liquid causes two things to happen. First it creates a reduced pressure
area at the center or suction eye of the impeller, this area of lower pressure draws more liquid into the pump and
provides a constant flow of liquid. Second it causes the liquid to gain speed; this happens because as the liquid is
forced to the outside of the rotating impeller, it must move faster to keep up with the impeller. As the liquid
flows away from the impeller it spreads out to fill the volute. The liquid contains a large amount of kinetic
energy or energy of motion, as the liquid expands in the volute it slows dawn and losses kinetic energy, because
energy cannot simply disappear the kinetic energy is converted into pressure which pressure the liquid out of the
pump and through the discharge piping. All centrifugal pumps work by creating a centrifugal force, this force
increases the liquid speed and the speed is converted into pressure. Animation Video for How Centrifugal Pump
Works https://www.youtube.com/watch?v=_mneJ592Z7A 3.3 Classifications of Centrifugal Pumps There are
some of design characteristics that can be used to classification centrifugal pumps. 3.3.1 According to whether
the Pump have Volute OR Diffuser When the casing of the pump is designed so that the area around the impeller
creates a gradually widening channel, that channel that is formed is called a volute. In some pumps the volute is
replaced by a structure that has a series of stationary vanes arranged around impeller, this structure is called a
diffuser. The vanes create a series of widening chambers that convert kinetic energy into pressure in the same
way that the volute does. The diffuser vanes direct the fluid outward in all directions as it leaves the impeller.
The main advantage of the diffuser is the radial thrust is minimized. 3.3.2 According to Number of Stage A-
Single-Stage Pump This type of pumps has only one impeller and one volute. B- Multistage Pump Multistage
pumps generally produce higher discharge pressures than is normally possible with single-stage pump of similar
size. A multistage pump contains two or more impellers in a single casing. 1- Three Stage Centrifugal Pump
Each stage of the pump has its own impeller and volute. In the volute, the fast moving liquid slows down and its
pressure increases. Each of the first two volutes discharges into the suction eye of the stage that follows it. The
third stage volute discharges into the pumps outlet so in this pump; the liquid flow path is from one end to the
other. 2- Five Stage Centrifugal Pump It has five impellers and five volutes. The liquid flow path is different
from that of the three stage pump. Liquid enters through the suction and flows into the impeller of the first stage;
this impeller has section eye on both sides and is often called double-suction impeller. From the discharge of the
first stage volute, the liquid flow into the second suction eye then out of the second stage discharge and enter the
third stage suction eye and out of the third stage discharge to the suction eye of the fourth stage, the liquid from
the fourth stage is routed to the suction eye of the fifth and final stage. After the liquid passes through the fifth
stage, it leaves the pump through the discharge piping. 3.3.2.1 Thrust 1- Axial Thrust Regardless of how the
impellers on a centrifugal pump are arranged or how many stages of pump has, the liquid pressure increases as it
passes through each stage, this creates a thrust or push across the impellers in each stage. This thrust known as
axial thrust; is caused by difference in pressure between suction eye and the volute, because there is a difference
in pressure a cross the impellers axial, thrust is created and it tries to push the pump shaft toward the suction
eyes. In order for the pump to operate properly, the thrust must be offset. On some pumps the thrust is offset by
using a thrust bearing or a device known as a balanced piston or balance drum. On other pumps, the thrust is
offset by arrangement of the impellers. This pump has a balance piston. During operation, some of the fluid
leaving the pump, flows along the shaft and exerts pressure against the balance piston, that pressure tends to
force the pump shaft away from the suction eye and reduces the total thrust. Any fluid that passes by the balance
piston is returned to the suction side of the first stage. On this pump, the arrangement of impellers is used to
offset axial thrust. Process liquid enters the first stage impeller from both sides, so the pressures on both sides of
the impeller are equal. The suction eyes for the second stage and third stage impeller in the opposite direction
from the suction eyes of the fourth stage and fifth stage impellers. Since the forces caused by axial thrust are in
opposite directions, they tend to cancel each other out, as a result axial thrust in this pump is kept to a minimum.
2- Radial Thrust Radial thrust is a type of thrust that tends to move a pump shaft perpendicular to its axis. In a
pump with a volute, the thrust is created by the difference in pressure across the volute. Some centrifugal pumps
are equipped with a component that accomplishes the same speed to pressure conversion as a volute but
minimizes radial thrust, its called diffuser. A diffuser consists of a series of stationary vanes that surround the
impeller. The distance between the outer tips of the vanes is greater than the distance between the inner tips as a
result, the vanes create a series of small volutes all around the impeller. This arrangement of vanes balances the
radial thrust around the impeller. 3.3.3 According to the Direction of the Flow Path through the Pump in
Relation to the Shaft A- Radial Flow Pump In centrifugal pumps that have a radial flow design, the impeller
causes the liquid to make a 90o turn and flow outward or radially from suction eye to the tips of the vanes. A
radial flow pump takes the advantage of maximum amount of centrifugal force that impeller develops, making
maximum use of centrifugal force makes it possible for radial flow pumps to operate at higher discharge
pressures than other types of centrifugal pumps but don’t move as much as other types of centrifugal pumps. B-
Axial Flow Pump In centrifugal pumps that have an axial flow design, the impeller moves the liquid through the
pump along a straight path that is parallel to the pump shaft. In this type of pump, the liquid is moved mainly by
the propeller action of impellers vanes. This impeller uses only a small amount of centrifugal force to move the
liquid as a result; the discharge pressure of an axial flow pump tends to be lower than that of a radial flow pump
however an axial flow pump may be able to move large quantities of liquid. C- Mixed Flow Pump Mixed flow
pumps combine the characteristics of radial flow pumps and axial flow pumps. They use centrifugal force and
the propeller action of impellers vanes to moves process liquid, for that reason, a mixed flow pump can develop
a relatively high discharge pressure and still move a large quantity of liquid. 3.3.4 According to the Orientation
 of the Shaft Centrifugal pumps can be classified by the orientation of the shaft either horizontal or vertical. A-
Horizontal Centrifugal Pump Most centrifugal pumps are mounted horizontally that is the motor is beside the
pump and the shafts orientation is parallel to the ground. B- Vertical Centrifugal Pump A major advantage of
vertically mounted pumps is that they can be used in locations where the pump must be submerged in fluid
without causing damage to the motor. Vertically mounted pumps can also be used where floor space is limited.
The pump itself is submerged in a tank containing the liquid being pumped. The driver which is an electric
motor is mounted above the pump on top of the tank. Its shaft connected to the pump shaft by a coupling, this
pump shaft is much longer than those found on must other centrifugal pumps. On any pump with along shaft, it’s
important to keep the shaft in its correct position so that the pump will operate properly so several bearings are
used to keep the shaft properly aligned. On this pump, there is no suction piping, instead the suction of the pump
is submerged in the liquid being pumped and the suction is covered by strainer which prevents trash or debris
from clogging the pump and causing excessive wear. The pump impeller is also submerged in the liquid, this
helps to ensure that the pump is always primed, this means that the casing is filled with the process liquid.
During operation, liquid is draw in through the suction and then pumped through the discharge piping which
extends up and out of the tank.

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3.4 Operation of Centrifugal pumps 3.4.1 Centrifugal Pump Priming One basic requirement that affects the
operation of all centrifugal pumps large or small is they must be primed. In other words, the pump casing and
suction line must be completely filled with liquid before the pump is started. If centrifugal pump isn’t primed, it
won’t operate properly. Some centrifugal pumps stay filled with liquid when they are shut down, these pumps
are often called self-priming pumps. Sometimes they have components such as check valves that maintain the
primer after the pump is shut down. In other cases, the system is built so that liquid doesn’t drain out of the
pump after it is shutdown, So with some pumps, may not need to prime. 3.4.1.1 How to Priming the Pump A
common way to prime a centrifugal pump is to open the suction valve and vent valve, opening these valves
allows liquid to fill the pump and air to escape. In order for this to work however either the level of liquid to
pump must be higher than the casing of the pump or the suction pressure must be great enough to force the
liquid into the pump. If the pump is handling a hazardous liquid, the casing vent should be piped to equipment
that will prevent the escape of hazardous liquids. If the liquid level is below the pump casing or the suction
pressure is too low, a variety of devices can be used to prime the pump. In some applications, a vacuum system
is used to draw air out of the pump, by drawing air out, this system prime the pump. Once the pump casing is
full of liquid, the vent valve is shut and then the pump driver is started. 3.4.2 Procedures of Startup and
Shutdown the Pump The procedures that are used often depend on the type of centrifugal pump, the type of
driver and the company operating procedures. Here we go to look at some basic steps that can be followed to
startup and shutdown most centrifugal pumps. This is the pump will be using; it’s a single stage centrifugal
pump and its part of a system that supplies cooling water to a facility. The pump is driven by an electric motor.
Water flow into and out of the pump is controlled by isolation valves. The pump shaft is seal with packing. 1- At
Startup One of the first steps in the startup procedure is to check the pump suction pressure, in this case that is
done by checking the level in the system expansion tank and making sure that the level in the system expansion
tank is correct. On this pump the expansion ensure that there is sufficient suction head for the pump. Also the
pump and its driver should be checked for obvious signs of damage. On some pumps auxiliary equipment may
have to check before start up, for example the lubrication systems must be checked, also sealing liquid to
mechanical seal may need to be lined up to the seal. Once preliminary checks are done, the next step is to line up
the valves in the cooling water system. This step is based on the pumps startup procedures which specify the
valves to open or closed and the proper order. On this pump the suction isolation valve is opened; opening this
valve provides a path for the liquid to enter the pump. The discharge valve on this pump also remains open when
the pump is shutdown so it’s already in proper position to run the pump. On other pumps however the suction
and discharge valve may be shut when the pump is shutdown according to pump’s shutdown procedures, in this
case the suction valve is to line up and venting the air from the pump vent, while the suction valve is open will
fill the pump with liquid; this step is often referred to as priming the pump. The operator then closes the vent,
opens discharge valve. At this point the control room should be informed that the pump is ready to be started;
the operator then starts the pump and checks it to make sure that it’s operating properly. These checks often
include checking the pump suction pressure and discharge pressure. Checking the bearing for excessive
vibration or overheating. Listening for unusual noises and checking the pump for signs of leak. On some pumps
additional checks may have to be made to be sure that the pump is operating properly, for example it might to be
necessary to check the amount of current that the motor is drawing. 2- At Shutdown When the pump is no longer
needed, the operator receives permission and shuts off the pumps driver. Once the pump is stopped, its suction
isolation valve is closed, in this example that is all required to complete the pump shutdown. On some pumps,
the suction and discharge valves are both shut when the pump is shut down according to pumps shutdown
procedures, this will completely isolate the pump from the system. 3.4.3 Operation Problems of Centrifugal
pumps 1- Packing and Mechanical Seals Problems On most pumps, the point where the pump shaft leaves the
casing is a place where leakage can occur, to prevent process liquid from being lost or contaminated either
packing or mechanical seal is often used to seal this area. When packing is used, operator should check to make
sure that there is a small amount of leak off to lubricate and cool the packing, if there is too little leak off, the
packing can dry out and burn. If the packing dries out, the pump should be shutdown so that the packing can be
replaced. On other hand, if there is too much leak off, the efficiency of the pump may be affected, to control the
leak off, the packing must be tightened. This should be done by tightening the nuts on the packing gland one flat
at a time. Tightening the gland nuts one flat at time ensure that the gland does not become cocked also this
method ensures that the packing is tightening slowly and help to prevent over tightening. If the pump has a
mechanical seal, operator should check to make sure that there is no detectable leak off. Leak off from a
mechanical seal is an indication that the seal has been damaged and should be replaced. There are other checks
that operator may have to make on a pump that has a mechanical seal, for example, if the seal is supplied with an
external lubricating liquid, the lubrication system should be checked for proper operation. These checks may
include verifying that the lubricating liquid is being supplied to the seal at the proper flow rate and pressure. If
the lubricating liquid is not supplied correctly, the seal may fail prematurely. If the lubricating system flow rate
or pressure is not correct, there may be a problem, in this situation; the operator should check the pump that
supplies the lubricating system and make sure that the valves in the system are positioned correctly. 2- Bearings
Problems One of the easiest ways to check a bearing is to touch the bearing housing; this way can use to check
the bearing for both overheating and excessive vibration. If operator feels excessive vibration, it may be an
indication of a problem with the pump, problem such as bent shafts, broken impellers and bad bearings can
cause excessive amounts of vibration. The cause of excessive vibration can often be determined using vibration
analysis equipment. Devices such as thermometers temperature recorders and thermocouples can be used to
obtain accurate indications of bearing temperature that can be compared to previous values to see if there is a
problem. For example, if the temperature of a bearing is higher than normal, it may be an indication that the
bearing is not being properly lubricated or that it is worn out. How the lubrication of the pumps bearings is
checked depends on how the bearings are lubricated. Some pump bearings are lubricated with greases through
fittings like this. These bearing should be greases periodically in accordance with the plants lubrication program.
Some bearing are supplied be a greased cup so when operator check these bearings, the lubrication program may
require from operator to tighten the grease cup so the additional grease is provided to the bearing. Not all
bearings use grease as a lubricant, many pump bearings are lubricated with oil. On some pumps an oil reservoir
is part of the bearing housing and there is a sight glass that operator can use to determine the oil level. On other
pumps an oiler is used to supply oil to the bearings, when an oiler is used, the level in the oiler’s bottle should be
checked, if the oil level is too low, the reservoir or the bottle should be refilled. Under the heavier loads, the
bearing in these pump is require a forced feed system to ensure proper lubrication. A force feed system may
contain its own pump reservoir, cooler and filters. The pump should be checked to make sure it is producing the
correct pressure. The oil level in the reservoir should also be checked, this can be done using a level indicator or
through a sight glass, if the level is too low, the force feed system may not adequately lubricate the bearings and
they could be damaged, in this case, oil should be added to the reservoir. If the force feed system contains a
cooler, it should be checked for proper operation otherwise the pump’s bearings could be damaged. If the
temperature of the oil is too low, there may be too much cooling water flow or the system‘s cooler may not be
operating properly, on other hand if the temperature is too high, there may be too little cooling water flow or
there may be a problem in the cooler or in the cooling water system. In either situation, the temperature of the oil
leaving the cooler must be adjusted so that the pump’s bearings can be properly lubricated. The oil temperature
is often controlled by adjusting the amount of cooling flow. Many forced feed systems also contain filters or
strainers that are used to remove solid particles from the oil; these particles could enter a bearing and cause
damage. During normal operation there is a drop in pressure as the oil passes through a strainer or filter. Drop in
pressure is often referred to as a differential pressure or ΔP, as a filter or a strainer collects particles, the
pressure drop across it will increase. If the pressure drop becomes excessive, there may not be enough oil
flow through the force feed system and the pumps bearing will be damage. To prevent this, the strainer or
filter element must be cleaned or replaced. 3- Air Bound Problem If a centrifugal pump is not completely
filled with liquid, that is if it’s not primed, it does not have the ability to pump liquid. One way that a
centrifugal pump can lose its prime is for air to enter the pump causing the pump to become air bound and
there are several ways that air can become trapped inside a pump casing. For example, during startup, the
casing and suction piping may have to be vented, if a sufficient amount of air remains trap, the pump will
not operate properly. Another way that air can get into the casing is through a leak. The suction of
centrifugal pump is normally at a low pressure and this low pressure could draw air into the pump through
leaks or the packing. On some pumps, the packing is exposed to the same low pressure that exist at the
pump suction, on these pumps, the packing is often supplied with liquid from the discharge of the pump,
this liquid cool and help seal the packing. If the flow of the liquid to the packing is not adequate, air could
be drawn in through packing. Air can also get into a pump after maintenance, for example, if piping has
been worked on, air in the pipes could make its way to a pump. If the air becomes trapped inside, the prime
could be lost. There are several ways to tell if a pump is air bound, one way is to listen to it, a pump that is
partially filled with air may produce a rattling noise similar to the noise of pump makes when its cavitating
however the noise caused by air bounding may be heard only intermittently. There are other noises that
may be associated with air being drawn into a pump, for example, if the pump has leaks on the suction
side, operator may be able to hear air being drawn into the pump. In some cases it may be possible to see
the flow path for the air being drawn into a pump, with some pumps, vortex may form is liquid is pumped
from the pump, if the vortex is drawn into the pump suction; it provides a path into the pump. When the
pump is partially filled with air, the discharge pressure gauge may vary greatly (not stable), also a pump
that has an electric motor is a driver, the amount of current drawn by the motor may vary greatly. On other
hand, when the pump is filled with air, the discharge pressure nearly gauge may drop to zero and the pump
noise may become a very quiet. In this situation, when an electric motor is used as the driver, the amount
of current drawn by the motor will drop significantly. 4- Vapor Bound Problem A problem that is similar to
air bounding is vapor bounding, with vapor bonding many of the same symptoms may be noticed however
the causes of vapor bounding with vapor bounding are slightly different from the causes of air bounding.
Vapor bounding occurs when pump loses its prime because vapor has become trapped in the pump. The
vapor often forms in other parts of the process and is carried along or and entrained in process liquid until
it becomes trapped in the pump. Formation of vapor in a process is affected by the liquid temperature and
pressure. Process changes that increase the liquid’s temperature or decrease its pressure may cause vapor
bubbles to form and become trapped inside a pump. One condition that cause vapor to become trapped in
a pump is suction pressure that is too low. The pressure decrease in the pump suction can cause vapor
bubbles to form, when this happens, the vapor could separated from the liquid and become trapped in the
pump, as more vapor collects, the pump becomes vapor bound and may not able to pump any liquid. If the
liquid temperature is too high, the same basic process happens, the high temperature causes vapor bubbles
to form, when this happens vapor may collect inside the pump and pump could become vapor bound.
Venting an air bound or vapor bound pump can restore the pump to normal operation however this may
be only a temporary fix. If there are leaks in the suction piping, if the liquid’s temperature is too high or if
the suction pressure is too low some other corrective action must be taken. Some of the fixes are easier to
figure out than others and can be accomplished immediately for example if a pump has a packing leak that
is drawing an air then adjusting the packing may stop the problem. On other hand if the pump is vapor
bound and its due to low suction pressure or high liquid temperature then the way that process is operated
may have to changed or the problem may be an indication that a component in the system is not operating
properly and the component might have to be repaired or replaced. 3.5 Pump Performance Many factors
influence the operation of pumps, for example how well a pump move liquid from one location to another
depends on factors such as the mechanical condition of the pump and the properties of the liquid, another
factor that is often examined when looking at the operation of pumps is head. 3.5.1 Head Head is basically
a measurement of pressure, it’s the pressure caused by the weight of a column of liquid as a result of its
height. Head measurements are usually given in feet, for example in an open tank, if the liquid level is 25 ft
high then there is 25ft of head at the base of the tank. However the amount of head at the outlet pipe of
the tank is different. The outlet pipe is 2ft above the base of the tank so the amount of head at outlet pipe
is only 23ft. The head caused by a non- moving liquid as a result of its height is called static head. The
static head exerted on the inlet of the pump is measured from the center line of the inlet to the level of the
liquid; in this case there is 23ft of static head at the inlet of the pump. The head at the inlet of the pump is
usually called the suction head. The head at the outlet of the pump is usually called the discharge head.
Another way of looking at head is by relating it to pressure, for example the amount of pressure at the
discharge of a pump that is running can be viewed as the height of a column of the liquid that the pump’s
discharge pressure will support, this imaginary column of liquid represents head. If the pressure can
support a column of liquid 30ft high then pressure is equivalent to 30ft of head. The term head can be used
to describe many conditions at the pump regardless of whether or not the pump is operating, for example
let’s say that in this system the pump has been shutdown, under these conditions, the pressure exerted on
the inlet and outlet of the pump are results of height of the liquid above the pump’s inlet and outlet. In
other words, if head was measured at the discharge of the pump, it would be the same as the height of the
liquid in the tank above the discharge. The amount of head or pressure at the pump’s discharge and
suction will change when the pump is started and the liquid begins to flow. At startup the suction head will
drop momentarily then increased slightly as flow increases however its lower than when the pump is
 shutdown. The discharge head produced when the pump is running is higher than when the pump is
shutdown. The head that exist when a liquid is in motion is sometimes called dynamic head. The amount of
head or pressure produced inside the pump can be referred to as total head.

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3.5.2 Pump Curves Total head and other types of head are characteristics that are taken into consideration when
a process system is designed. Design engineers select pumps that will meet the requirements for each of the
processes that are planned; when pump is selected it is chosen for a specific combination of head and flow. Head
and flow are also examined to determine how well the pumps in a plant or performing. The values for proper
pressure and flow are often based on the pump’s characteristics. One way of examining a pump’s design
characteristics is with pump curve graphs. 1-Head Curve This one shows the pump’s head curve which
represents how much head or pressure the pump should produce for various flow rates. The horizontal axis of
this graph is market to represent flow rate. Flow rate can also be referred to as the pump’s capacity. It can be
market in units such as gallons per minute or as a percentage of pump’s capacity, for example one hundred
percent is equal to the maximum volume of liquid that is moved by the pump under normal conditions. This is
the pump’s optimum operating capacity. However many pumps can operated at capacities greater than optimum.
The vertical axis of this graph shows head in feet. The curve shows that the amount of pressure that this pump
produces decreases as the flow increases, since this curve represents what is expected of the pump, it can be
compared the actual values for the total head and flow to see if the pump is performing the way it should. 2-
Power Curve The power curve shows how much electrical power a manufacturer expects will be used to operate
a pump at given flow rates under normal conditions. We can see that this pump requires low power at a low flow
rate, as the flow rate increases, the power needed also increases. 3-Efficiency Curve The efficiency scale goes
from zero percent to hundred percent. Pump efficiency varies depending on the percentage of its capacity that is
being used. The efficiency curve begins at zero on both the efficiency and capacity scales and rises to a
maximum value near one hundred percent capacity before falling off again. The point of maximum efficiency is
the point where the pump provides the maximum flow for the least amount of power. Pump curves are often
provided by manufactures to help describe how pumps are supposed to perform, by comparing actual data from
a pump with the information provided by the curves, a pump’s performance can be determined.

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3.5.3 Head and Cavitation Problem One of the conditions that can be damage the pump is called cavitation.
Cavitation is directly related to the amount of head or pressure at the suction of a pump. If the suction head
drops below its design value for the system, the liquid being pumped can flash to a vapor, this when cavitation
happens. Cavitation is formation and subsequent collapse of vapor bubbles. Cavitation normally begins in the
suction of the pump where the pressure is the lowest and liquid is drawn into the pump. If the pressure of the
liquid decreases too much, the liquid will vaporize or boil, when this happens, bubbles form and travel with the
liquid in the pump, as thousands of these bubbles travel toward the higher pressure area in the pump, they are
compressed until they can no longer with stand pressure and collapse or implode violently. As liquid rushes into
fill the collapsing bubbles, it strikes the inside surfaces of the pump and gradually wears a way pump material,
the result is a sand blasting effect on internal pump components such as this impeller. This kind of damage
decreases the performance of the pump. To prevent cavitation, the amount of suction head or pressure must be
kept above a minimum value that has been determined for the pump by the manufacturer; this value is known as
the minimum net positive suction head or NPSH. Minimum net positive suction head is the pressure just above
where the liquid will boil for a given flow in temperature. If the suction head of a pump drops below the
minimum net positive suction head, cavitation will occur. It’s important to monitor suction pressure to ensure
that it does not drop below the minimum net positive suction head for the pump, however pressure is not the
only factor that determines whether a pump cavitates or not since cavitation occurs when the liquid begins to
vaporize or boil in the pump. The higher temperature of the liquid, the more likely it will boil and cause
cavitation at a given pressure and flow rate. The values for minimum net positive suction head for a pump are
normally based on the type of the liquid in the system and the temperature of the liquid expected to be at when it
enters the pump. In most cases the minimum net positive suction head is calculated for each pump then it’s
converted to units such as level or pressure, for example pump drawn liquid from any tank, before a pump is
started an operator checks to make sure that the liquid in the tank that feeds the pump is above a minimum level
to ensure that will be enough suction head to prevent cavitation. In a different situation, operators monitor a
pressure indicator to help maintain the inlet pressure for a pump; in this case the value for minimum net positive
suction head is converted to units of pressure. 3.6 Routine Checks Operator is responsible for monitoring pumps;
this involves making routine checks to make sure that they are operating normally and efficiency. Making these
routine checks is a good way to help avoid costly and unnecessary shutdowns, with experience operator be able
to tell right away when the pump is not working properly. Before operator go out to inspect any pump, he should
know how the pump normally operates, that includes knowing the pump’s normal flow rates, operating
temperature, and it’s normal suction and discharge pressure, he should also learn about any special features the
pump has and what type of liquid pumps. In addition it’s a good idea to become familiar with the pump’s
operating history; it will help him identify any recurring problems with the pump and may make trouble
shooting a problem easier. Pump can experience a variety of problems and each problem can have a variety of
symptoms. In spite of that, there are some general types of operating checks that can be made on all pumps,
these basic operating checks relate to three of operator senses. The checks involve looking, listening and feeling
for symptoms of pump problems. 3.6.1. Looking Abnormal reading and leaks are two symptoms that can be
seen. 1. Abnormal Reading One indicator of a problem in a pump is an abnormal reading, usually a low reading
that can be seen on the discharge pressure gauge or suction pressure gauge. One thing though if operator see an
abnormal reading make sure the gauge is functioning properly before assuming that the problem is in the pump
rather than the gauge. On some problems operator may be able to see abnormal readings on instruments that
indicate current draw by the motor or bearing in lubrication temperature or pressure in a forced lubrication
system. Improper pressure flow readings could be caused by a variety of problems, some deal with the process
fluid and other are more mechanical and nature. If instrumentation shows a slow gradual decrease in flow or
pressure, it could be a sign that the pump’s internal parts have worn or that condition is getting worse so it’s
important for operator to be alert to even subtle changes in instrumentation readings that may indicate a
problem. 2. Leaks Another visible symptom on operating pump is leaks. Checking for leaks is a routine part of
inspecting pumps and their related equipment where the operator begins with the suction piping, checking the
suction valve packing and gasket for process liquid leaks then he turns his attention to the pump itself. Leakage
from around the casing flange indicates that the casing bolts may need to be tightened or that the flange or that
the flange gasket may need to be replaced. Pumps that use packing often needs a small amount of leak off to
cool and lubricate the packing, a trickle of liquid is normal, too much leak off can mean that gland follower
needs tightening, if that doesn’t solve the problem then the packing is problem worn and must be replaced. Too
little leak off indicates that the gland followers too tight or that the gland sealing line or lantern ring is blocked
and must be cleaned out. Unlike packing mechanical seal should not have a noticeable leak off. If liquid is
leaking from a mechanical seal, the seal has failed and action should be taken to have the pump repaired. After
checking packing or seals the operator looks over the rest of the pump to checks the bearings to see if there are
any oil leaks. Lubricant leaking from a bearing housing could be caused by a cracked hosing or a faulty seal, this
loss of lubrication can cause damage to the bearings.. Finally he looks over the pump’s discharge piping for the
same things as with the suction piping, if he finds a leak will trace it to its source and then reported to his
supervisor. 3.6.2. Feeling Excessive vibration and high temperature are two symptoms that can be felt. 1.
Overheating Operator should check for overheating by feeling the pump and motor casings and the bearings to
get an indication of their temperatures however this must be done carefully because overheated components
could cause burns. Excessive heat usually indicates a problem with lubrication. When more precise temperature
readings are required, it’s usually necessary to use a temperature instrument such as a pyrometer to monitor
equipment temperatures. In addition some pumps have indicators for bearing and lube oil temperatures, an
increase in temperature could mean there is a problem with lube oil supply which is causing the bearing to
overheat. How hot is too hot, this will vary so operator will need to refer to the manufacturer’s manual and other
information about the pump. 2. Vibration Checking for unusual vibration is a common part of a pump
inspection. A quick check can usually be accomplished by carefully touching the motor and the pump with a
bare hand. For a more detailed examination of vibration, vibration detection instruments can be used. Excessive
vibration may be a sign of shaft and coupling misalignment, a bent shaft or some other shaft problem. Other
possible causes of excessive vibration include such things as damage bearings or wearing rings. The sound that
accompanies vibration can indicate what the problem is for example vibration along with the howling or
growling sound could indicate damaged bearings. 3.6.3. Listening The operator knows from experience that the
pump sounds the way it should. Symptoms that indicate problems include excessive noise or unusual sounds.
Some problems have their own distinctive sound, for example loud rattling or clanging sound could be caused
by broken pump part or other object loose inside the casing. Another is a howling or growling sound usually
indicates worn or damaged bearings; it usually means that there is a lubrication problem. A high pitched
screeching is commonly produced by metal to metal contact between rotating and stationary parts; it could also
indicate a lubrication problem or improper alignment or clearances between parts. Another abnormal sound that
may hear coming from a centrifugal pump is a loud rattling noise that sounds like marbles rattling around inside
the pump, it’s usually a sign of cavitation; other signs of cavitation include fluctuations in discharge pressure
and sometimes an overheated pump casing. Cavitation can also cause a decrease in flow; the extent to which
flow decreases depends on how bad the cavitation is. Cavitation is usually violent and if it’s not corrected, the
pump can be damaged. Cavitation is the formation and subsequent collapse of bubbles inside the pumps casing
during operation. Cavitation occurs when the fluid being pumped reaches the boiling point which can happen if
the pressure of the fluid becomes too low at the suction eye relative to the temperature of the fluid, when boiling
occurs some of the fluid turns to vapor which creates bubbles in the fluid. The bubbles caused by cavitation
move with the fluid from the suction eye out toward the edge of the impeller where there is increased pressure,
they collapse with great force resulting in a shock wave that can damage the metal surface of the impeller and
the casing. In pump moving cold fluid or moderately warm fluid, changes in pressure generally will not be
enough to cause the fluid to boil however if the fluid being moved is near its boiling temperature it’s possible
that it will begin to boil in the low pressure of the suction eye. Cavitation can occur however if the suction valve
is not open all the way or if the suction port is somehow blocked resulting in a further reduction of pressure at
the suction eye To stop or minimize cavitation the suction head or pressure at the suction eye must be
maintained above the pressure at which the fluid will boil, this pressure is usually a minimum predetermined
value for the pump which specified by the manufacturer. The technical term of this value is the pumps minimum
net positive suction head or NPSH, sometimes this can be done by cutting back the flow on the discharge side of
the pump. Restricting the flow of fluid as it leaves the pump basically increases the pressure in the pump,
 increasing the pressure will help keep the fluid from boiling and causing cavitation damage however restricting
discharge flow could affect processes in the plant so its normally done temporarily if plant procedures allow it
until other actions can be taken to stop the cavitation. In some cases cavitation can occur because the
temperature of the process fluid is too high this causes the fluid to boil when it experiences the drop in pressure
as it enters the pump. In this case the temperature must be lowered to eliminate the cavitation

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3.7 Positive Displacement Pump Vs Centrifugal Pump The difference between a positive displacement pump
and a centrifugal pump is not what the pump does but how it does it. A positive displacement pump uses a piston
or other device to push or positively displace controlled amounts of fluid. In general positive displacement
pumps are not designed to move high volumes of fluids as compared with centrifugal pumps however they have
the advantage of being able to exert greater amounts of pressure on the fluids they move and they generally do
not required priming that is they do not have to be full of liquid when they are started. Centrifugal pumps
operate on a completely different principle. Centrifugal pumps use a rotating device called an impeller to move
fluid by stirring it faster and faster in a circular motion and then changing the increase speed into pressure as the
impellers stirs the fluid in a rapid circular motion the centrifugal forces created that gives the pump its name .
Centrifugal force is the force that tends to push an object or material outward from the center of rotation.
Centrifugal force is generated by any object or material moving in a circle, compared with positive displacement
pumps, centrifugal pumps have the advantage of being able to move higher volumes of fluids however they
generally do not have the ability to exert as much pressure on the fluids as positive displacement pumps also
centrifugal pumps usually must be primed.