PUMPS

and
PIPING
By. Engr. Yuri G. Melliza
PUMPS: It is a steady-state, steady-flow machine in which mechanical
work is added to the fluid in order to transport the liquid from one point to
another point of higher pressure.

Upper
Reservoir

Suction Gauge Discharge Gauge

Lower
Reservoir Gate Valve

Gate
Valve
 CLASSIFICATION OF PUMPS
1. Centrifugal: It consist essentially of an impeller arranged to rotate within
a casing so that the liquid will enter at the center or eye of the impeller and
be thrown outward by centrifugal force to the outer periphery of the impeller
and discharge into the outer case. It operates at high discharge pressure,
low head, high speed and they are not self priming.
 Centrifugal
 Mixed Flow
 single stage
 multi stage
 Propeller or axial flow
 Peripheral
2. Rotary:It is a positive displacement pump consisting of a fixed casing conta-
ining gears, cams, screws, vanes, plungers or similar element actuated by
the rotation of the drive shaft. A rotary pump traps a quantity of liquid and
moves it along toward the discharge point. For a gear type rotary pump the
unmeshed gears at the pump provides a space for the liquid to fill as the
gears rotate. The liquid trapped between the teeth and the pump casing is
eventually released at the discharge line. It operates at low heads, low dis-
charge and is used for pumping viscous liquids like oil.
 cam
 gear
 screw
 vane
3. Reciprocating: It is a positive displacement unit wherein the pumping action
is accomplished by the forward and backward movement of a piston or a
plunger inside a cylinder usually provided with valves.
 Piston
 Direct Acting
 single
 duplex
 Crank and Flywheel
 Plunger
 Power Driven
 simplex
 duplex
 triplex
4. Deepwell Pumps: It is used when pumping water from deep wells. The pump
is lowered into the well and operated close to water level. They are usually
motor driven with the motor being at the ground level and connected to the
pump by a long vertical line shaft.
 Turbine
 Ejector or centrifugal
 reciprocating
 Airlift
For a final choice of a pump for a particular operation the following data are needed.
 Number of units required
 Nature of liquid
 Capacity
 Suction conditions
 Discharge conditions
 Intermittent or continuous service
 Total dynamic head
 Position of pump, vertical or horizontal
 Location, geographical, indoor, outdoor, elevation
 Type of power drive
 Centrifugal Pump Reciprocating PUmp
Cylinder
impeller discharge

eye

Rotary Pump (Gear Type) Piston

Valves

Gear
FUNDAMENTAL EQUATIONS

1. TOTAL DYNAMIC HEAD

2 2
P2  P1 v 2  v1
Ht    Z 2  Z 1  HL meters
γ 2g

2. DISCHARGE or CAPACITY
Q = Asvs = Advd m3/sec

3. WATER POWER or FLUID POWER

WP = QHt KW

4. BRAKE or SHAFT POWER

2πTN
BP  KW
60,000
5. PUMP EFFICIENCY
WP
ηP  x 100%
BP

6. MOTOR EFFICIENCY
BP
ηm  x 100%
MP

7. COMBINED PUMP-MOTOR EFFICIENCY

WP
ηC  x 100%
MP
ηC  ηP ηm
8. MOTOR POWER
 For Single Phase Motor
EI(cosθ)
MP  KW
1000

 For 3 Phase Motor

3 EI(cosθ)
MP  KW
1000
where: P - pressure in KPa T - brake torque, N-m
v - velocity, m/sec N - no. of RPM
 - specific weight of liquid, KN/m3 WP - fluid power, KW
Z - elevation, meters BP - brake power, KW
g - gravitational acceleration, m/sec2 MP - power input to
HL - total head loss, meters motor, KW
E - energy, Volts
I - current, amperes
(cos) - power factor
 PIPES and FITTINGS

Nominal Pipe Diameter: Pipe sizes are based on the approximate diameter and
are reported as nominal pipe sizes. Regardless of wall thickness, pipes of the same
nominal diameter have the same outside diameter. This permits interchange of
fittings. Pipe may be manufactured with different and various wall thickness, so
some standardization is necessary. A method of identifying pipe sizes has been
established by ANSI (American National Standard Institute). By convention, pipe
size and fittings are characterized in terms of Nominal Diameter and wall thickness.
For steel pipes, nominal diameter is approximately the same as the inside diameter
for 12" and smaller. For sizes of 14" and larger, the nominal diameter is exactly the
outside diameter.
SCHEDULE NUMBER: The wall thickness of pipe is indicated by a schedule
number, which is a function of internal pressure and allowable stress.
Schedule Number  1000P/S
where P - internal working pressure, KPa
S - allowable stress, KPa
Schedule number in use: 10,20,30, 40,60, 80, 100, 120, 140, and 160.
Schedule 40 "Standard Pipe"
Schedule 80 " Extra Strong Pipe"
FITTING: The term fitting refers to a piece of pipe that can:
1. Join two pieces of pipe
ex. couplings and unions
2. Change pipeline directions
ex. elbows and tees
3. Change pipeline diameters
ex. reducers
4. Terminate a pipeline
ex. plugs and valves
5. Join two streams to form a third
ex. tees, wyes, and crosses
6. Control the flow
ex. valves
VALVES: A valve is also a fitting, but it has more important uses than simply
to connect pipe. Valves are used either to control the flow rate or to shut off
the flow of fluid.
DESIGN OF A PIPING SYSTEM
The following items should be considered by the engineer when he is
developing the design of a piping system.
1. Choice of material and sizes
2. Effects of temperature level and temperature changes.
a. insulation
b. thermal expansion
c. freezing
3. Flexibility of the system for physical and thermal shocks.
4. Adequate support and anchorage
5. Alteration in the system and the service.
6. Maintenance and inspection.
7. Ease of installation
8. Auxiliary and standby pumps and lines
9. Safety
a. Design factors
b. Relief valves and flare systems
HEAD LOSSES
HL = Major loss + Minor losses
Major Loss: Head loss due to friction and turbulence in pipes
Minor Losses: Minor losses includes losses due to valves and fittings,
enlargement, contraction, pipe entrance and pipe exit. Minor losses are most
easily obtained in terms of equivalent length of pipe "Le". the advantageof this
approach is that both pipe and fittings are expressed in terms of
"Equivalent Length" of pipe of the same relative roughness.
Darcy-Weisbach Equation
Considering Major Loss only
2
f Lv
hf  meters
2gD
Considering Major and Minor Losses
2
f (L   L ) v
hf  e meters
2gD
Where; f - friction factor from Moody's Chart
L - length of pipe, m
Le - equivalent length in straight pipe of valves and fittings, m
v - velocity, m/sec
D - pipe inside diameter, m
g - gravitational acceleration, m/sec2
REYNOLD'S NUMBER: Reynold's Number is a non dimensional one which
combines the physical quantities which describes the flow either Laminar
or Turbulent flow. The friction loss in a pipeline is also dependent upon this
dimensionless factor
ρvD vD
NR  
μ ν
where;  - absolute or dynamic viscosity, Pa-sec
 - kinematic viscosity, m2/sec
For a Reynold's Number of less 2100 flow is said to Laminar
For a Reynold's Number of greater than 3000 the flow is Turbulent
Moody’s Chart
f

where
 - absolute roughness
D - inside diameter

/D - relative roughness
D

NR
VALUES OF ABSOLUTE ROUGHNESS  FOR NEW PIPES

Type of Material Feet Millimeter

Drawn tubing, brass, lead, glass
centrifugally spun cement, bituminous
lining, transite 0.000005 0.0015
Commercial Steel, Wrought iron 0.00015 0.046
Welded steel pipe 0.00015 0.046
Asphalt-dipped cast iron 0.0004 0.12
Galvanized iron 0.0005 0.15
Cast iron, average 0.00085 0.25
Wood stave 0.0006 to 0.003 0.18 to 0.9

Concrete 0.001 to 0.01 0.3 to 3

Riveted steel 0.003 to0.03 0.9 to 9

For Laminar flow:

64
f 
NR

Centrifugal Pumps
1. TOTAL HEAD
Ht = nH
where:
n - number of stages
H - head per stage
2. SPECIFIC SPEED: Is the speed in RPM at which a theoretical pump
geometrically similar to the actual pump would run at its best efficiency
if proportion to deliver 1 m3/sec against a total head of 1 m. It serves as
a convenient index of the actual pump type.
 where:
N Q Q - flow in m3/sec for a single suction pump
NS  3
H - heasd per stage
0.0194 H 4 N - speed, RPM
NS - specific speed, RPM

3. SUCTION SPECIFIC SPEED

N Q
S 3

0.0194 NPSH 4
3

NS  NPSH  4
 
S  H 

where: NPSH - Net Positive Suction Head

4. NET POSITIVE SUCTION HEAD: The amount of pressure in excess
of the vapor pressure of the liquid to prevent cavitation.
NPSH = Hp  Hz - Hvp - hfs , meters
where:
Hp - absolute pressure head at liquid surface at suction, m
Hz - elevation of liquid surface at suction, above or below the pump
centerline, m
(+) if above PCL
(-) if below PCL
Hvp - vapor pressure head corresponding the temperature of the
liquid,m
hfs- friction head loss from liquid surface at suction to PCL.

5. CAVITATION: The formation of cavities of water vapor in the suction side

of the pump due to low suction pressure.
 CAUSES OF CAVITATION
 Sharp bends.
 High temperature
 High velocity
 Rough surface
 Low atmospheric pressure
EFFECTS OF CAVITATION
 Noise
 Vibration
 Corrosion
 Decreased capacity
6. CAVITATION PARAMETER
4

NPSH  NS  3
δ  
H  S 
7. IMPELLER DIAMETER
where:  - peripheral velocity factor whose
60 2gH value ranges from 0.95 to1.09
D meter
πN

8. AFFINITY LAWS OR SIMILARITY LAWS FOR CENTRIFUGAL

MACHINES
a. For Geometrically similar pumps
Q  ND3 Power   N3D5
H  N2D2 T   N2D5
b. For pumps with Variable Speed and Constant impeller diameter
QN Power  N3
H  N2
c. For pumps at Constant Speed with Variable impeller diameter
QD Power  D3
H  D2
RECIPROCATING PUMPS
Specification: Ds x Dw x L
where: Ds - diameter of steam cylinder
Dw - diameter of water cylinder
L - length of stroke

1. VOLUMETRIC EFFICIENCY
Q
ηV  x 100%
VD

where: Q - discharge , m3/sec

VD - displacement volume, m3/sec
2. DISPLACEMENT VOLUME

 For Single acting

2
L(D W ) Nn' m 3
VD 
4(60) sec
 For Double acting without considering piston rod
2
L(D W ) Nn' m 3
VD  where: N - no. of strokes per minute
4(60) sec L - length of stroke, m
 For Double acting considering piston rod D - diameter of bore, .
d - diameter of piston rod, m
3
LNn' m
VD  2D W
2
-d
2
 n' - no. of cylinders
n' = 1 (For Simplex)
4(60) sec
n' = 2 (For Duplex)
n' = 3 (For Triplex)
3. PERCENT SLIP where: hs - enthalpy of supply steam, KJ/kg
% Slip = 100 - V he - enthalpy of exhaust steam, KJ/kg
ms - steam flow rate, kg/hr
4. SLIP WP - fluid power, KW
Slip = VD - Q
5. THERMAL EFFICIENCY
3600(WP)
e x 100%
m s (h s  h e )

6. FORCE PRODUCED and ACTING ON THE PISTON ROD

2
D S (Ps  Pe )
Fs  KPa where: Ps - supply steam pressure, KPa
4 Pe - exhaust steam pressure, KPa
Ds - diameter of steam cylinder, m
(Ps - Pe) - mean effective pressure
7. FORCE TRANSMITTED TO THE LIQUID PISTON

Fw  e m Fs where:
2
(Dw) (Pd  Psu ) em - mechanical efficiency
Fw  KPa Psu - suction pressure of water
4 cylinder, KPa
Ds (Pd  Psu ) Pd - discharge pressure of water
 cylinder, KPa
Dw e m (Ps  Pe )
8. PUMP DUTY: Work done on the water cylinder expressed in
Newton-meter per Million Joules
6
9.81m w (H d  H su ) x 10 N-m
Pump Duty 
1000m s (h s - h e ) Million Joules

where: mw - water flow rate, kg/hr

Hd - discharge head of pump, m
Hsu - suction head of pump, m
9. PUMP SPEED

V = 43.64(L)1/2(ft), m/min where: ft - temperature correction factor

L - length of stroke, m
2
(D W ) Vn' m
3

VD 
4(60) sec

10. TEMPERATURE CORRECTION FACTOR

ft = 1 For cold water

= 0.85 for 32.2C water
= 0.71 for 65.5C water
= 0.55 for 204.4C water

11. For Indirect Acting pumps

907 f t
N
L
Example no. 1
A mechanical engineer of an industrial plant wishes to install a pump to lift 13
L/sec of water from a sump to a tank on a tower. The water is to be delivered
into a tank 105KPa. The tank is 18 m above the sump and the pump is 1.5 m
above the water level in the sump.Tthe suction pipe is 100 mm in diameter, 8 m
long and will contain 2 - standard elbows and 1 - Foot valve. The discharge
pipe to the tank is 65 mm in diameter and is 120 m long and contains 5 - 90
elbows, 1 - check valve, and 1 - gate valve. Pipe material is Cast iron. If the
total head loss due to turbulence in pipes and fittings and valves amounts to
25 m, determine the KW power required by the pump assuming a motor-pump
efficiency of 75%.