PUMPS

PUMP PRINCIPLES

• All pumps use basic forces of nature to move a liquid.

• As the moving pump part (impeller, vane, piston
diaphragm,etc.) begins to move, air is pushed out of the
way. The movement of air creates a partial vacuum (low
pressure) which can be filled up by more air, or in the case
of water pumps, water.
Example:
• This is similar to sucking on a straw. A partial vacuum is
created in your mouth when you suck on the straw. The
liquid is pushed up the straw because of the pressure
differences between your mouth and the atmosphere.
 PUMPS

The pump is a mechanical device which carries liquid from one place to another
place.

It can be defined as hydraulic machines which converts the mechanical energy
into hydraulic energy.

The pump is power absorbing machines.

Pumping means addition of energy to a liquid to move it from one place to

another.
 FUNCTIONS OF PUMPS

 Pumping water from a water source such as a river.

 For lifting water (high quantity, low pressure) from a well.

 For pumping water into a supply system, elevated water tank or water tower.

 To increase pressure.
PUMP- SYSTEM REQUIREMENT
 PUMP WORKING PRINCIPLE
• Generally fluids flow from area of high pressure to
low pressure.
• Pumps operates by creating low pressure at inlet and
which allows liquid to be pushed into the pump by
atmospheric pressure or pressure head.

Case:1
When the reservoir or tank placed above the centre line
of pump
• This situation creates a positive inlet pressure to the
pump and help the fluid flow into the pump
• Static head / pressure is the measure from pump
centre line to the tank.
• But most pump allows certain pressure / head , if it
exceeds a certain limit it damages the pump shaft
seals.
• Normally it must be less than 10 to 15 feet.
 PUMP WORKING PRINCIPLE

Case:2
When the pump is mounted higher than reservoir
• The height from fluid surface to pump centre line
is called suction head.
• Suction head should be kept minimum as possible
to create vacuum effect at pump inlet.
• Suction head is more than limit, then
• Vacuum Cavitation Problem: Lack of fluid at
pump inlet
 CAVITATION - REASON

Block near inlet Strainer block

More suction head More run Fluid frozen

 CAVITATION CAUSE

• Cavitation causes drop in pressure at pump inlet.

• If the pressure drop is below vapor pressure of fluid, a
vapor bubbles formed at pump and begins to boil.
• When vapor bubbles collapse, it removes metal from
pumps parts called pitting.
• Cavitation can be identified when your hear a large noise
(like grinding machine sound)
 PUMPS APPLICATION IN DISTRIBUTION SYSTEMS

 Low lift Pumps –

• Pumps that lift surface water and move it to a nearby treatment plant.
• These move large volumes of water at relatively low discharge pressures.
 High lift Pumps –
• Pumps that discharge treated water into arterial mains.
• These operate under higher pressures.
 Booster Pumps–
• Pumps that increase the pressure within the distribution system or raise water
into an elevated storage tank.
 Well pumps –
• Pumps lift water from under ground and discharge it directly into distribution
system.
 PUMPING SYSTEMS
• Pumping system objective is to transfer a liquid from a source to a destination.
• This may be filling a reservoir at a higher level or circulating liquid as in a heating
system.
• In either case a pressure is required to make this happen and this is generally
referred to as a head.
• Head is a measurement of the amount of pressure required to successfully
deliver the fluid pumped at the desired flow (how many gallons)
• Head Types
I) Static Head – Lift / elevation height
II) Friction Head – Friction loss
 HEADS – Types, calculation

Static Head: It is the vertical Friction Head / loss:

distance that the liquid has to be
lifted in order to achieve useful
work.
• It depends on size of pipe, material &
shape of pipe.
• Loss increases as square of increase in
flow.
• Charts are available for calculating losses.

Total Head = Elevation (Static head) + Friction loss + Pressure

Note: Pressure need to be added in case if additional flow pressure required.
Types of Pumps
 TWO MAIN TYPE PUMP CATEGORIES
1) Rotodynamic / Velocity / Centrifugal Pumps-
Rotodynamic pumps (or dynamic pumps) are a type of velocity pump in which kinetic
energy is added to the fluid by increasing the flow velocity. This increase in energy is converted to a gain in
potential energy (pressure) when the velocity is reduced prior to or as the flow exits the pump into the
discharge pipe.
Most widely used for distribution system.
Ex. In municipality house, Water distribution & water treatment plants.
2) Positive Displacement Pumps-
Positive displacement pumps will move fluid at the same speed regardless of the pressure on the inlet end.
 Maintains uniform distribution of fluid each cycle.
 Commonly used to feed chemicals into the water or to move heavy suspension (such as sludge)
i) Reciprocating - Piston move front & back. high pressure, abrasive
Application: Used in water treatment plant to feed chemical.
iii) Rotary- Constant volume, without any increase in velocity
Difference between types of pumps
 POSITIVE DISPLACEMENT PUMPS
i) Reciprocating pump
 A piston that moves in a back and forth
motion within a cylinder.
 The cylinder will have check valves that
operate opposite to each other, depending on
the motion of the piston.
 One check will be located on the suction side
of the piston and will open as the piston
moves back, creating a larger cylinder area.
 After the piston has reached the longest stroke
position, the motion of the piston will reverse.
This action will open the discharge check
valve and close the suction check.
Disadvantage:
1) Uneven pumping action, Application: Used in water treatment plant to feed
2) limited capacity chemical and for high pressure & viscous application
 Reciprocating pump

Movement of crank 0 to 90 degree,

Pressure differences causes
the piston moves – volume increases
fluid flow in the cylinder
& pressure decreases

0 to 180 degree is the suction Crank moves from 180 to 270 180 to 0 degree is the delivery
stroke degree- volume decreases & stroke
pressure increases
 For even pumping action- To increase capacity – duplex
Double acting simplex pump pump
 ROTARY PUMP
• The rotary pump is a positive-displacement pump.
• Capable of pumping more fluid than reciprocating pumps of the same weight
• A fixed volume of fluid is moved regardless of the resistance against which the
pump is pushing
• But any blockage in the system could quickly cause damage to the pump or a
rupture of the system
• A rotary pumps require a relief valve to protect the pump and piping system. The
relief valve lifts at a preset pressure and returns the system liquid either to the
suction side of the pump or back to the supply tank or sump.
• They are essentially self-priming
 Working of rotary gear pump
 A rotary pump operates within limits with the pump located above the source of supply.
 A good example of the principle that makes rotary pumps self-priming is the simple drinking straw

• The illustration shows a gear pump located above the tank.

• The tank must be vented to allow air into the tank to provide
atmospheric pressure on the surface of the liquid. To lower
the pressure on the suction side of the pump, the clearances
between the pump parts must be close enough to pump air.
• When the pump starts, the air is pumped through the
discharge side of the pump and creates the low-pressure area
on the suction side, which allows the atmospheric pressure
to force the liquid up the pipe to the pump.
• To operate properly, the piping leading to the pump must
have no leaks or it will draw in air and can lose its prime.
The suction piping should be at least one size larger than the
pump suction connection.
• Rotary pumps are useful for pumping oil and other heavy
viscous liquids
 POSITIVE DISPLACEMENT PUMPS
ii) Rotary pumps-
Two screw pump External gear pump Internal gear pump

Lobe pump Sliding vane pump Progressive screw pump-

thick fluid transfer (sludge)
 CENTRIFUGAL PUMP
The centrifugal pump works in the same way as sucking
on the straw. As the engine starts, the impeller turns which
forces the water around it out of the pump's discharge
port.
The partial vacuum created, allows the earth's air pressure
to force water up the suction hose (straw), and into the
suction (inlet) side of the pump to replace the displaced
water.
When the water hits the rotating impeller, energy of the
impeller is transferred to the water, forcing the water out
(centrifugal force). The water is displaced outward, and
more water can now enter the suction side of the pump to
replace the displaced water.
PARTS OF CENTRIFUGAL PUMPS
 Parts of Centrifugal pump

Casing: Spiral shape (increase in Impeller: Has eye for suction & Nozzle: Discharge & Suction
space as it spirals other side hole for shaft fixing nozzle

Packing / Stuffing Box Shaft- for power transmission Bearing

 Different Types of Impeller

• Enclosed Impeller: The vanes are

located between the two discs, all in a
single casting.
Enclosed Double eye: To minimize axial
trust
• Semi-Open Impeller: The vanes are
free on one side and enclosed on the
other.
• Open Impeller: The vanes are cast free
on both sides.
Enclosed Semi open Open

Enclosed Double eye

 STUFFING BOX

Stuffing Box
1) Packing material- to prevent leakage of
fluid through shaft
2) Lantern ring – for lubricating shaft
3) Gland follower- for adjusting fluid leakage
METHODS OF LUBRICATION IN STUFFING BOX

Water jackets Lantern rings

 BEARING HOUSING

Thrust bearing at end- to stop

movement- parallel to shaft (to & fro)

Bearing Housing

Radial bearing at end- to stop movement-

perpendicular to shaft (up & down)
 WORKING OF CENTRIFUGAL PUMP

Drive given & impeller

Always before start, the Pressure & Kinetic energy
Centrifugal pump with rotates, this rotation forms
impeller must be primed increase and moves water
impeller inside centrifugal force
(ie it should be immersed to discharge.
in liquid)

When water discharges,

Since, pressure is low water is
there creates a decrease in
pulled inside impeller eye and
pressure when compared to
it discharges
atmospheric pressure
 CENTRIFUGAL PUMPS CONFIGURATION

1) End suction centrifugal pumps: The center of suction line is centered on the
impeller eye. End suction centrifugal pumps are further classified as either frame
mounted or close coupled.
Close coupled: Impeller is placed
directly onto the motor shaft.
It require less space & less expense
than others

Frame mounted: This has a shaft

& bearings separate from the motor.
A coupling is required to get the
energy from the motor to the pump
 CENTRIFUGAL PUMPS CONFIGURATION

2) Split case pumps: Designed in such a way that volute case is split horizontally.
The case divides on a plane that cuts through the eye of the impeller.

• The case has a row of bolts that allow

half of the case to be removed, providing
access to the entire rotating assembly for
inspection or removal.
• These pumps are found as fire service
pumps & circulation pumps
 CENTRIFUGAL PUMPS CONFIGURATION
3) Vertical Turbine Pumps: In this the pump is primarily mounted with a vertical
shaft. The motor is commonly mounted above the pump.
• The styles of vertical turbine: A) Line shaft, B) Submersible turbine.
A) Line shaft:
The motor is mounted above the ground and the pump unit is
mounted below the water surface.
A column extends from the pump to a discharge head found
just below the motor.
A shaft extends on a straight line from the Centre of the
motor to the pump. The pump may be mounted a few feet to
several hundred feet away from the motor.

B) Submersible turbine:
A style of vertical turbine pump in which the entire pump
assembly and motor are submersed in the water. The motor is
commonly mounted below the pump
Line shaft
LINE SHAFT PUMPS SUBMERSIBLE PUMPS
 VERTICAL TURBINE PUMP
• Vertical turbine pumps are normally designed to operate in
wells or sumps.
• The pumps are usually driven by an AC electric induction
motor or by a diesel engine through a right angle drive.
• These pumps are available for handling clear water or
contaminated water.
• Vertical pumps take little space in plan since the liquid in
led away to the axis of shat.
• The Impeller is submerged, so pump does not require to be
primed and is always ready to use.
• It can single or more than one stages according to head
required
VERTICAL TURBINE PUMP
 VERTICAL TURBINE PUMPS - APPLICATION
• They are primarily used wherever a submersible pump is not possible, because the
flow is above the range of turbines, or because the owner prefers a conventional
motor mounted at the top of the pump.
• They are commonly used in wells that are bored to provide agricultural or turf
irrigation, or to provide water supply for municipalities that rely on ground water
rather than surface water. They are also used to provide plant make-up water and
fire water for industrial plants.
 Major parts of Vertical centrifugal pumps
• Inlet: Water enters the vertical turbine through the
suctions bell. It then passes into the pump bowl.

• Bowl: The case that function as volute case on an end

suction centrifugal. This is where energy is transferred
to the water by the impellers.

• Impellers: Most line shaft & submersible turbines

have more than one impeller. Each impeller and pump
bowl is referred ta as a pump stage. Adding stages
increases the discharge pressure of the pump, but not
its flow.
Continues…..
 Major parts of Vertical centrifugal pumps
• Column: Water passes out of the pump
bowl assembly and into the column. In the
center of the column is the pump shaft,
which may be lubricated with water or oil.
• Discharge Head: The large cast iron
component at the top of the pump is the
discharge head. It is here that the direction
of flow is change from vertical to
horizontal. This also contain stuffing box &
mechanical sealing or packing
• Motor: On the top of the discharge head is
the motor. The motor can be removed from
the pump for maintenance purpose
 PARTS OF VERTICAL TURBINE PUMPS
1. Headshaft: Stainless Steel
2. Discharge Head: High-strength head with
large windows for easy access
3. Packing Assembly: Also available with
Mechanical Seal
4. Lines haft: Ground and polished high
strength steel. Available in carbon steel or
stainless steel
5. Column Pipe: Precision machined column
pipe insures proper alignment and ease of
installation. Available threaded or flanged
6. Column Pipe Collar
7. Bearing Retainer: Alternate materials
available
8. Lineshaft Bearing: Fluted Neoprene rubber
bearing allows debris to be easily flushed away
from the shaft
9. Lineshaft Coupling: Carbon steel or
stainless steel
10. Bowlshaft: High-strength stainless steel with
optional chrome-plating
11. Discharge Case: Close grain cast iron
12. Discharge Case Bearing (Upper): Bronze
13. Discharge Case Bearing (Lower): Bronze
14. Top Bowl: Close grain cast iron
15. Impeller: Lead-free Bronze. Balanced
and machined for the highest efficiency
16. Taper Lock: Steel collets lock the
impeller in place. Stainless steel optional
17. Bowl and Impeller Wear Rings
(optional): Wear rings provide added
protection for bowls and impellers
18. Intermediate Bowl: Close grain cast
iron. Glass-lined waterway provides
superior efficiency.
19. Intermediate Bowl Bearing: Bronze or
Neoprene rubber
20. Suction Case (Threaded or
Bell): Close grain cast iron. Basket or cone
strainers available
21. Sand Collar: Bronze. Prevents build-up
of abrasive materials near the Suction Case
bearing
22. Suction Case Bearing: Bronze Grease-
packed for long life
23. Grease Plug
Stuffing Box & Discharge head
 VERTICAL TURBINE PUMPS- WORKING
• The pumps are usually driven by an AC electric induction motor or by a diesel engine through a
right angle drive.
• The pump end consists of at least one rotating impeller that is attached to a shaft and directs the
well water into a diffuser casing called a bowl.
• Multi-stage configurations use multiple impellers on the same shaft to create higher pressure that
would be needed for deeper wells or higher required pressure (head) at ground level.
• Vertical turbine pumps work when water enters the pump at the bottom through a bell-shaped part
called the suction bell.
• From there it moves into the first stage impeller, which raises the water’s velocity. The water then
enters the diffuser bowl immediately above the impeller, where this high velocity energy is
converted into high pressure. The bowl also directs the fluid into the next impeller located
immediately above the bowl, and this process continues through all of the stages of the pump.
• After the water leaves the last diffuser bowl, it passes through a long vertical column pipe as it
rises up the well bore toward the surface. The spinning shaft inside this column is supported at
three- or five-foot intervals with sleeve bushings that are mounted inside the column and lubricated
by the water moving past them.
• At the surface is the pump discharge head, which allows the flow to change direction, toward the
discharge pipe. A vertical high thrust A.C. motor is mounted above the discharge head.
 INITIAL START UP AND OPERATING INSTRUCTIONS
• Always run pumps using according to Rated condition of service as given in
operation manual
1) Check whether the impeller is immersed in water (in case of centrifugal pump).
2) Check lubrication
a) Oil level – in case of oil lubrication system used
b) Open cooling water valve- in case the lubrication is water
c) Open warm water valve- in case the pump is used to transfer hot fluids.
3) Close drains
4) Open suction valve / open reciprocating valve
5) Start motor
6) Open discharge valve slowly
7) Check discharge head is normal & leakage in packing box.
 MONITORING & TROUBLESHOOTING
Observe the behavior of pump during operation
Monitor the following during running cycles:
i. Unit vibration or noise
ii. Driver and pump lubrication levels and flow
iii. Packing box leakage
 MONITORING & TROUBLESHOOTING
A. Low pressure or flow
i. Air or gas in water / ii. Low water level / iii. Wrong driver speed / iv. Wrong
rotation / v. Clogged suction or suction strainer / vi. Clogged impellers or bowls /
vii. Worn impeller or bowls / viii. Discharge column leaking.
B. Excessive power consumption
i. Improper voltage to driver / ii. High rotating speed / iii. Not operating at design
condition/ iv. Pumping foreign material/ v. Improper impeller adjustment causing
rubbing/ vi. Bent shaft/ vii. Column misalignment/ viii. Pump out of alignment / ix.
Bearing badly worn.
C. Water in oil tube
i. Plugged bypass parts in discharge bowl/ ii. Worn top intermediate bowl or lower
discharge bowl bush./ iii. Defective oil tube or connector bearing threads / iv.
Improper assembly of top tube tension nut.
D. Excessive leakage from packing box:
i. Gland not properly tightened/ ii. Ends of packing not staggered / iii. Worn
packings or sleeves
 PREVENTIVE MAINTENANCE
DAILY INSPECTIONS:
Perform following daily checks during routine maintenance activity:
i. Check and record pump operating parameters like discharge pressure gauge
readings, bearing temperature,
noise and vibrations. In case of increasing trend in vibration values, analyze cause
and take corrective steps.
ii. Check amount of lubricant in respective chambers to ensure adequate lubrication
of bearings and sleeves.
iii. Check dripping of lubricant from the lubricating line joints and take requisite
corrective action.
iv. Check the pump and piping for leaks and rectify as necessary.
v. Check for adequate leakage of liquid from the stuffing box. Excessive leakage
needs to be arrested.
 PREVENTIVE MAINTENANCE
QUARTERLY INSPECTIONS:
Following checks during tri monthly maintenance activities are recommended:
i. Check that the foundation bolts and the hold-down bolts are tight.
ii. Check the shaft alignment, and realign as required.
iii. Change the lubricant every six months or after 2000 operating hours whichever
is less.
iv. Change the lubricant more often if the pumps are operating under adverse
atmospheric or other conditions that might contaminate the lubricant.
v. Under special situations, it may be necessary to partly dismantle the pump for
attending to an adverse observation during any of the above inspection schedules
 PREVENTIVE MAINTENANCE
ANNUAL INSPECTION:
• Excessive drop in pump performance and persistent high levels of sound and
vibrations are reasons enough to go for detailed investigations under annual
inspection.
• Such an inspection will normally amount to complete dismantling of pump to look
for internal wear tear and damage to pump components. This also covers an
eventuality of rectification of a defect observed under daily and quarterly
inspections but could not be attended due to system requirement.
• Extent of dismantling needs to be carefully assessed based on work involved for
tackling the identified problem. Before taking a decision for dismantling the
pump, check and record the pump operating parameters as listed under daily
inspection
 Vertical turbine pump: Manufactures India
1) Flowmore – (Haryana, India)
Range: Flow (m³/hr) : up to 70000, Head (m):up to 300, sizes :100 to 2800.
2) Kirloskar Brothers Limited- (Pune, India)
Range: Delivery size up to 2200 mm, Capacity up to 40,000 m3 /hr, Head up to 200 m
3) Sintech Precision Products Ltd- (UP India)
Range: capacity (Maximum)25,000 m3 /hr, Head (Maximum):300 mtrs.,Temperature:
95°C, Working Pressure:35 kg/cm2