Unit 1: PUMPS

Plant Equipment

UNIT OVERVIEW
Introduction
Function Of Pumps Classification Of Pumps

Basic Theory For Pumps

Terminologies NPSH Calculation

Centrifugal Pump
Type of Centrifugal Pumps Operating Principle

UNIT OVERVIEW
Positive Displacement Pump
Type of Positive Displacement Pumps Operating Principle

Pump Auxiliary System Operate and Maintenance Of Pumps

Start Up & Shut Down Maintenance

Common Problems & Troubleshooting

INTRODUCTION
Function of the Pump Provide (kinetic) energy to a liquid Used to transfer liquid
from one place to another

from low to high elevation

from low to high pressure

Increase liquid flow rate

INTRODUCTION
Pump Classification
Centrifugal Radial flow Axial flow Mixed flow Rotary Gear Screw Lobe Vane Peristatic Reciprocrating Piston Plunger Diaphragm

Pump

Positive Displacement

BASIC THEORY FOR PUMP

Terminologies
Pump capacity The amount of liquid that can flow through the pump at a specific time Unit = m3/h (SI unit); L/min Pump efficiency ( )
Power output/power input Represent how well pump running Usually measure in percentage

Pressure
Pressure is the force that is placed behind the fluid being moved by the pump. Unit = bar, PSI (Pound per inch square), Atm (atmosphere), Pa (Pascal)

BASIC THEORY FOR PUMP

Terminologies
Velocity
Speed of the fluid is moving Unit = ft/sec, m/sec

Head
Represents energy ( pressure, kinetic, height, etc) in term of vertical distance above a reference point unit = meter or feet

Suction Head A Suction Head exists when the liquid is taken from an open to atmosphere tank where the liquid level is above the centerline of the pump suction Discharge Head Discharge pressure is the liquid pressure at the pump discharge line It is the total liquid pressure after it is driven by the pump

BASIC THEORY FOR PUMP

Terminologies
Net Positive Suction Head (NPSH)
Required NPSH (Required) is the minimum suction pressure the pump must have to avoid cavitations. NPSH (Available) is the actual NPSH given by the system.

NPSH for liquid level higher than the pump suction:

NPSH (a) = Atmospheric Pressure (- ) Vapor Pressure (+) Liquid Height (-) Friction in the Suction Line.

5m

BASIC THEORY FOR PUMP

Terminologies
NPSH for liquid level below the pump suction: NPSH (a) = Atmospheric Pressure (- ) Vapor Pressure (-) Liquid Height (-) Friction in the Suction Line.

RECAP
Describe the basic function of the pump List the different type of Pumps

Explain the different term use in pump operation :

Pump capacity Velocity Net positive suction head Pump efficiency

Calculation of NPSH of a pump system

CENTRIFUGAL PUMP
Most widely used in process plant High volume &low pressure Impart kinetic energy to the liquid. Impeller moving at high speed in pump. Kinetic energy of liquid change to pressure energy.

CENTRIFUGAL PUMP
Consist of a set of rotating vanes, enclosed within a housing or casing, Energy is impart to a fluid through centrifugal force. Centrifugal pump is one in which the pressure is developed wholly by centrifugal force.

CENTRIFUGAL PUMP
A centrifugal pump has two main components: A rotating component comprised of an impeller and a shaft A stationary component comprised of a casing, casing cover, and bearings.

CENTRIFUGAL PUMP
Operating Principles
Fluid drawn into center of impeller. Impeller rotating at high speed. Whirling vanes throw incoming liquid outwards towards casing. Thrown water leaves pump at discharge nozzle

CENTRIFUGAL PUMP
Operating Principles
The two main components of a centrifugal

pump are the impeller and the volute. The

impeller produces liquid velocity and the volute forces the liquid to discharge from the pump converting velocity to pressure. This is

accomplished by offsetting the impeller in the

volute and by maintaining a close clearance between the impeller and the volute at the cut water. Please note the impeller rotation. A centrifugal pump impeller slings the liquid out of the volute. It does not cup the liquid.

CENTRIFUGAL PUMP
Type of Centrifugal Pumps
Radial Flow - Centrifugal pump in which the pressure is
developed wholly by centrifugal force.

Mixed Flow - Centrifugal pump in which the pressure is

developed partly by centrifugal force and partly by the lift of the vanes of the impeller on the liquid.

Axial Flow - Centrifugal pump in which the pressure is

developed by the propelling or lifting action of the vanes of the impeller on the liquid.

CENTRIFUGAL PUMP
Axial Flow pump
generate head pressure via axial motion Induces fluids to travel strictly along shaft axis

Very high capacity, low head

CENTRIFUGAL PUMP
Mixed Flow pump Impart both an axial and radial motion to fluids generates greater pressure axial pump

CENTRIFUGAL PUMP
Centrifugal Pump Components
Impeller

Casing
Impeller Eye

Impeller Blade

Outlet

Inlet

CENTRIFUGAL PUMP
Centrifugal Pump Components

CENTRIFUGAL PUMP
Centrifugal Pump Components (SideView)

CENTRIFUGAL PUMP
Centrifugal Pump Components

CENTRIFUGAL PUMP
Centrifugal Pump Internal View
2. Shaft
1. Discharge nozzle

3. Casing

Suction 4. nozzle

6.

7.
Bearing

8.
Pump motor

5. Impeller

Seal

CENTRIFUGAL PUMP
Advantage of Centrifugal Pump
Simpler configuration Smaller size Lower price Low maintenance expense Uniform flow (no pulsation) High discharge flow rate

Disadvantage of Centrifugal Pump

Require priming Cavitation Low pressure (require multistage)

CENTRIFUGAL PUMP
Thinking Point!! 1) What should I do to my pump or pump system if I want to increase my capacity and Pump Head? 2) By increasing my propeller speed, will my discharge pressure increase.

RECAP
Describe the operating Principle of a centrifugal pump List the different type of Centrifugal Pumps Explain the Operating principle of each type of centrifugal pump Identify the key Centrifugal Pump components

POSITIVE DISPLACEMENT PUMP

All positive displacement type pumps must have either built-in or external relief ... of pipe flanges to prevent pump damage during start-up.

POSITIVE DISPLACEMENT PUMP

Classification of Positive Displacement Pump Refer to Pump Classification

Operating Principle

Reciprocating positive displacement pumps are one that takes a suction, filling the pump cylinder on the stroke in only one direction, called the suction stroke, and then forces the liquid out of the cylinder on the return stroke, called the discharge stroke.

POSITIVE DISPLACEMENT PUMP

Classification of Positive Displacement Pump Refer to Pump Classification

Operating Principle
Displace or push out liquid that enters pump chambers Do not give additional energy to liquid Pumping volumes is fixed Able to discharge fixed volume even when discharge pressure changes

Maximum discharge pressure

depends on pump motor power

Can develop extremely high pressure, Hence Pressure relief valve usually installed on discharge line
To protect the piping & downstream equipment

TYPE OF POSITIVE DISPLACEMENT PUMP RECIPROCATING PUMP

Piston Pump
Flow with pulsation Uses check valves Produce high pressure Used for chemical injection Fluid drawn into cylinder thru a valve by forward action of piston Fluid discharged from cylinder thru another valve by backward action of piston

TYPE OF POSITIVE DISPLACEMENT PUMP RECIPROCATING PUMP

Diaphragm Pump
Consist of flexible membrane called diaphragm As diaphragm flexed, liquid pumped in, out of chamber Uses check valve Handle toxic and corrosive fluid Handle slurries and abrasive liquid Flow with pulsation

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Pump Characteristic

Consists of a rotating vane, screw, or gear. Traps the liquid in the suction side of the pump casing and forces it to the discharge side of the casing. Are essentially self-priming due to their ability of removing air from suction lines and producing a high suction lift.

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Pump Characteristic
Rotating element or elements
which squeeze or displace liquid that enters pump casing

Flow is smooth and pulse free

Capacity proportional to speed Capacity independent of discharge pressure

Constant speed and constant-capacity

No priming required
Capable of expelling the air or trapped gases.

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Gear Pump
Very often used compact & simple Handle viscous fluid - hydraulic oil Only clean fluid (impurities) Even delivery No priming necessary Cannot produce high pressure Need a relief valve danger of overpressure

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Lobe Pump
Impeller = A wheel with two to four lobes Pushes fewer but larger units of liquid compare to gear pump More lobes less pulsation Suitable for handling corrosive chemical & suspensions Used in food & beverage industry
Parts easily cleaned & installed

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Lobe Pump

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Vane Pump
Consist of a rotor placed slightly off center in casing
Rotor embedded with sliding or swinging blades

Negligible pulsation Self compensating for wear low cost For low and medium pressure duties Can be use for liquid & gas Application Self-priming NOT suitable for abrasive liquid

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Vane Pump

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Screw Pump
Consist of 1 to 3 threaded screws Handle liquid with high viscosity and solid slurries eg: sewage, cement Minimum wear & maintenance requirements Self priming & longer operating life (low RPM)

Almost no pulsation (even flow)

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Screw Pump

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Peristaltic Pump
Main advantage cleanliness have a variety of medical applications
move blood through the body and lungs during open heart surgery. used to add nutrients to blood force blood through filters to clean it

Fragile blood cells not damaged by pump

rotating arms pinch tube against an arc, move the fluid along
3-4 sets of rollers

TYPE OF POSITIVE DISPLACEMENT PUMP ROTARY PUMP

Peristaltic Pump

RECAP
What are the 2 class of positive displacement Pump List the Types of positives displacement pumps Explain the Operating principle and characteristic of each type of Reciprocating and rotary pump

PUMP AUXILIARY
Strainer Install at the suction of the pump to prevent solid particle from entering into pump. Check Valve or One way valve Usually at the discharge of the pump to prevent back flow of liquid to the pump.

Pressure Relief Valve- Normally install for high pressure pump to release pressure in case of over pressure.

OPERATE AND MAINTENANCENCE OF PUMPS

Start Up For Centrifugal Pump
Proper line up
Open suction valve, close discharge valve Prime the pump

Ensure vent closed after priming

Inching test/rotates shaft Start pump, check discharge pressure & power Open discharge valve slowly

OPERATE AND MAINTENANCENCE OF PUMPS

Shut Down For Centrifugal Pump
Close discharge valve Stop pump (motor) Prepare for maintenance
Close suction valve Drain liquid Flushing/washing Electricity isolation

OPERATE AND MAINTENANCENCE OF PUMPS

Start Up For PD Pump
Check that sight-glass are commission. Check level in the vessel. Check that drain valves are shut. Line up suction valve. Prime the pump. Inform control room. Start pump. Check for abnormal temperature, vibration and noise Line up discharge valve. Check Lube oil cup and cooling water system

OPERATE AND MAINTENANCENCE OF PUMPS

Shut down For PD Pump
Inform control room.
Shut discharge valve slowly. Stop pump.

Shut suction valve.

OPERATE AND MAINTENANCENCE OF PUMPS

Maintenance Schedule

Hand test bearing housing for temperature rise.

Daily Checks

Listen for unusual noise. Note suction and discharge gauge readings for abnormality. Look out for loose bolts holding coupling guards.

OPERATE AND MAINTENANCENCE OF PUMPS

Maintenance Schedule
Check operating temperature of each bearing. Should not exceed 70C.

Monthly Maintenance

Check lubrication level. Change or adjust to required level appropriately. Check and correct any pump misalignment.

Quarterly Maintenance

Drain oil and flush the lubrication system and refill with correct grade of lubricant. Check bearings for wear and repack with fresh grease.

OPERATE AND MAINTENANCENCE OF PUMPS

Maintenance Schedule Six-Monthly Maintenance
Repeat all items in quarterly maintenance schedule.

Check shaft for leakage from stuffing box. Replace gland packing appropriately.
Perform a complete overhaul of the pump.

Annual Maintenance

Check every part with reference to the service manual. Replace all worn parts.

Test the performance of the pump after assembling.

COMMON PROBLEM AND TROUBLESHOOTING

Common Problem During Pump Operation: Loss of flow Cavitations
When the pump suction under low pressure/high vacuum where liquid turns into vapor in pump. Imploding action occurs violently and attacks the pump interior.

Overheated motor Seal leak

Abnormal noise, vibration, temperature.

COMMON PROBLEM AND TROUBLESHOOTING

Troubleshooting:
Loss of Flow
Suction strainer plugged. Suction valve are shut. Flow transmitter damaged. Tank level low.

If the Pump Does Not Deliver Enough Pressure

Engine may not be running at its rated speed.

Mechanical seal may be leaking. Check weep hole.

Excessive Power Consumption

Obstruction in discharge line Bent shaft

COMMON PROBLEM AND TROUBLESHOOTING

Troubleshooting:
If the pump does not deliver enough water
Engine may not be running at the rated speed. Strainer, inlet valve or suction line may be clogged. Suction line or fittings may be leaking air. Mechanical seal may be worn and leaking air or water. Check weep hole. There may be too much clearance between the impeller and the volute due to wear .

The suction hose may be too long, causing excessive friction loss and reducing pump capacity.
Discharge head may be too high. Check hose or pipe friction losses. A larger hose or pipe may correct this condition.

RECAP
List the auxiliary require for Pump operation. What the maintenance require for a pump running for a year? List the common problem faced during pump operation. What could be the possible caused for loss of flow in a pump operation?