Workshop 1

PUMPSENSE
FLUID
ENGINEERING
PVT. LTD.
A product of Mather & Platt, Manchester, exported to

Poland in 1870.
PUMPSENSE
BEST PRACTICES OF CENTRIFUGAL PUMPS - MALAYSIA

JULY 2011
INTRODUCTION TO PROGRAMME STRUCTURE &

SCHEDULE
Workshop - 1
Malaysia July 2011

SCHEDULE
PUMP MASTER CLASS - MALAYSIA JULY 2011
Practical Approach to Centrifugal Pump Design, Sizing, Selection & Performance analysis
DAY - 1
Time Topic
9.00 am 9.15 am Introduction of program - structure and schedule
9.15 am 10.30 am Centrifugal pumps
Principle of working of centrifugal pumps
Centrifugal pump components
Range of operation
Selection considerations
Multi-stage operation in centrifugal pumps
Abnormal operation
Power requirements, efficiencies and losses in centrifugal pumps
Pump characteristic curves
Improving pump reliability
Performance calculations
10.30 am 11.00 am Morning tea break
11.00 am 12.45 pm Hydraulic principles and concepts
General liquid characteristics and properties
Concepts related to pressure, head and flow
Bernoullis equation and Eulers equation
Velocity triangles
Hydraulic power and pump efficiency
Specific speed
Cavitation, recirculation and Net Positive Suction Head (NPSH)
Part flow operation of centrifugal pumps
Performance characteristics
DAY - 1
Time Topic
12.45 pm 2.00 pm Luncheon & Networking
2.00 pm 3.00 pm Pump specification and selection (with case studies and data sheets with
varying NPSH)
System analysis
Data sheet & the pump specification document
Bid request
Bid review/analysis
Conclusion
3.00 pm - 3.30 pm Forces in centrifugal pumps
Axial thrust
Radial loads
3.30 pm- 4.00 pm Afternoon Tea Break
4.00 pm- 5.00 pm Optimizing pump-to-system performance
Performance curves & characteristics of mixed, axial, and radial flow impellers
Critical dimensions, tolerances and their effects on pump performance
Developing a system performance curve based on field measurements
5.00 pm- 5.30 pm Understanding the pumping system and materials of construction (Case study
sharing)
5.30 pm Wrap up & End of Day-1 Workshop
DAY - 2
Time Topic
9.00 am -10.30 am Case studies of calculations of the performance of a centrifugal pump by
changes in speed or impeller diameter (Affinity Laws)
10.30 am 11.00 am Morning Tea Break

11.00 am 12.30 pm NPSH calculation exercise in the following industries (P&ID with all types of
fittings, elbows, filter, strainer, meters, etc will be provided)
Water treatment plant
Hydrocarbon fuel terminal
Petrochemical plant (corrosive fluid)
2.00 pm 3.00 pm (Continue) NPSH calculation exercise

3.00 pm 4.00 pm Friction loss and pressure calculation in different pump system (P&ID with
detailed information will be provided)
1
Benefits of a training Decide how to operate the pump within the intended
program on pumps: service condition envelop.
2
Carry out mechanical, hydraulic and installation review
of your existing pumping plants.
3 Understand and evaluate hydraulic performance of your

existing centrifugal pumps. Determine whether the pumps are
performing optimally.
4
Understand the failure modes - power, temperature, corrosion, leakage,
pressure, vibration, etc.
After attending a 5
Decide on monitoring frequency and control
training program you limits.
will be able to:
6
Familiarize yourselves with various means of
monitoring pump performance and health
parameters.
7
Avoid common operator errors and improve MTBF.
8 Estimate cost of spares and the best ways of procuring them .
9
Change materials of construction of pump components based on field
experience.
10
After attending a Identify opportunities for energy optimization in
training program you your existing pumping systems.
will be able to:
11
Use most energy-efficient way of controlling flow
through your existing pumps and decide when to use a
variable-speed driver.
12 Decide whether to replace an inefficient pump or retrofit

the pump with a custom-designed impeller.
13
Identify energy optimization projects with low risk but high energy
saving potential.
14 Understand critical pump parameters you need to
review when evaluating the offers for pumps for
After attending a training new projects.
program you will be able Do cost-benefit analysis of any energy
to: optimization project involving pumping systems
15
Compute life cycle cost of your pumping system.
16
Decide on specific energy efficient and environment friendly
construction features for your application.
17 Understand and quantify environmental impact of your pump

specification.
TYPES, CONSTRUCTION & APPLICABLE PUMP
STANDARDS
PRINCIPLE OF WORKING OF CENTRIFUGAL PUMPS
CENTRIFUGAL PUMP COMPONENTS
RANGE OF OPERATION
SELECTION CONSIDERATIONS
MULTI-STAGE OPERATION IN CENTRIFUGAL PUMPS
ABNORMAL OPERATION
POWER REQUIREMENTS, EFFICIENCIES AND LOSSES IN

CENTRIFUGAL PUMPS
PUMP CHARACTERISTIC CURVES
IMPROVING PUMP RELIABILITY

HYDRAULIC PRINCIPLE OF A CENTRIFUGAL PUMP
h = U2/2g
WHEN A LIQUID MASS IS ROTATED IN A VESSEL A PRESSURE RISE (h) THROUGH THE MASS
OCCURS. THIS RISE IS PROPORTIONAL TO THE SQUARE OF THE CIRCUMFERENTIAL VELOCITY (U).
CENTRIFUGAL PUMP & ITS WORKING MECHANISM To be replaced
14
DISCHARGE
GENERATION OF CENTRIFUGAL FORCE
rotation of impeller
transfer of angular momentum to the
VOLUTE/ liquid according to eulers energy equaion
CASING
liquid pushed outward in tangential &
VANES
radial directions (as the vanes are curved).
low pressure zone is created at impeller
eye.
more liquid rushes to the eye of the
impeller due to pressure gradient
SUCTION EYE developed .
CONVERSION OF KINETIC ENERGY TO PRESSURE

ENERGY
energy conversion according to bernoulis
priciple.
IMPELLER
conversion takes place through volute,
diffuser, discharge nozzle.
CENTRIFUGAL PUMP To be replaced
15
OVER-HUNG IMPELLER IMPELLER BETWEEN BEARINGS TURBINE TYPE
CLOSE- SEPERATELY SEPERATELY SEPERATELY VERTICAL AXIAL FLOW

COUPLED COUPLED SINGLE COUPLED SINGLE COUPLED TYPE SINGLE IMPELLER(PROPELLER)
SINGLE & & TWO STAGE STAGE MULTISTAGE & OR MIXED FLOW(HOR.
TWO STAGE MULTISTAGE OR VER.)
AXIALLY SPLIT-CASE
DEEP WELL TURBINE
END-SUCTION RADIALLY SPLIT-CASE (INCLUDING SUBMERSIBLES)
(INCLUDING IN-LINE
SUBMERSIBLE) BARREL OR CAN PUMP
FRAME MOUNTED
SHORT SETTING OR
CENTERLINE CLOSE COUPLED
IN-LINE
SUPPORT API 610
FRAME MOUNTED AXIALLY SPLIT-CASE

ANSI B73.1
RADIALLY SPLIT-CASE
WET PIT VOLUTE
AXIAL FLOW
IMPELLER(PROPELLER)
VOLUTE TYPE(HOR. OR VER.)
END SUCTION PUMP (OVER-HUNG IMPELLER)
VERTICAL TURBINE PUMP

SPLIT CASE PUMP (BETWEEN BEARING IMPELLER)
Split Case Pumps- Advantages & Disadvantages Evaluating Type Options
Easy inspection without disturbing suction & delivery piping and

electric motor
ADVANTAGES Simpler maintenance- lower maintenance downtime
Lower shaft deflection- between- bearings design
Lower NPSH- each eye handles half the flow
No/little axial thrust
Higher efficiency- Power is not lost in balancing hydraulic thrust
High allowable nozzle loads - rigidity of the lower portion of the
casing
Heavier than end suction- due to large split flange

DIS Shaft through eye requires larger eye area and tighter turn for the
ADVANTAGES liquid entering the impeller
More sensitive to orientation and geometry of elbows in front of
pump suction
Two shaft seals
Chances of volute mismatch- upper & lower
STANDARD
VERTICAL
SPLIT-CASE
PUMP
STANDARD HORIZONTAL SPLIT-CASE PUMP
SPLIT CASE PRODUCT VARIANTS
SIDE SUCTION SIDE DELIVERY BOTTOM SUCTION TOP DELIVERY SIDE SUCTION TOP DELIVERY
SPLIT-CASE PUMP - PRODUCT VARIANTS
NFPA 20
4P Fire
Pump
Compact Air
Con Pump
Large Two
Stage Pump
NFPA 20 High
Speed Fire
Pump
Center Line
Mounted
High Temp
Pump
Water Supply Pump High Head Mine Drainage Pump

SPLIT-CASE PRODUCT VARIANTS
Special Side
Three Impeller Suction
Parallel Flow Discharge
on Top
Bottom Suction Water Supply Pump

Vertical Shaft
High Head
Split Case Two Stage
with Double
Suction
Impellers
Side Suction Top

Delivery Marine
Fire Pump
Standard Split
Case Pump Side Suction Top Delivery Marine Fire Pump
Mirror Image
END SUCTION PUMP - PRODUCT VARIANTS
C/L Mounted, Compact

Bottom Suction Foot Mounted
MAJOR COMPONENTS OF A CENTRIFUGAL PUMP
STATIONARY PARTS
CASING(TOP & BOTTOM)

ROTATING ELEMENT
BEARING HOUSING IMPELLER ACCESSORIES
BEARING BRACKET SHAFT STUFFING BOX SEAL
CASING WEAR RINGS SHAFT SLEEVE SEAL FLUSHING LINE
SHAFT SLEEVE NUTS LUBRICATING /

BEARING END COVER
COOLING
MECHANICAL SEAL (ROTATING ARRANGEMENTS
ELEMENT)
BEARING (INNER RACE)
BEARING LOCK NUT

MAJOR COMPONENTS OF AN END SUCTION PUMP
MAJOR COMPONENTS OF A SPLIT CASE PUMP
CASING BEARING
BRACKET
PACKING WEAR
RING
STUFFING
SLEEVE BOX UNIT
IMPELLER
LANTERN
RING
FUNCTIONS OF CENTRIFUGAL PUMP COMPONENTS
COMPONENTS FUNCTIONS
IMPELLER TO DEVELOP DYNAMIC HEAD
SINGLE SUCTION DOUBLE SUCTION
TO CONVERT KINETIC ENERGY INTO PRESSURE ENERGY WITH

CASING MINIMUM HYDRAULIC LOSSES BY MEANS OF VOLUTE, DIFFUSERS OR GUIDE VANES
INCORPORATES NOZZLES TO CONNECT SUCTION & DISCHARGE PIPING
DIRECTS FLOW INTO & OUT OF THE IMPELLER.
PROVIDES SUPPORT TO THE BEARING BRACKET
IN-LINE
SPLIT-CASE END SUCTION
TO PROTECT THE ROTATING IMPELLER FROM RUBBING WITH

WEAR RING THE STATIONARY CASING. TO PROVIDE A REPLACEABLE WEAR JOINT
TO CONTROL THE LEAKAGE LOSSES ACROSS THE ANNULAR PATH
BETWEEN IMPELLER AND WEAR RING
WEAR RING
IMPELLER NUT TO LOCK THE IMPELLER IN ITS PROPER AXIAL POSITION

TO PREVENT AXIAL MOVEMENT DUE TO HYDRAULIC THRUST
IMPELLER NUT
SHAFT TRNSMITS TORQUE TO THE IMPELLER FROM THE DRIVER

SUPPORTS IMPELLER AND OTHER ROTATING ELEMENTS
SHAFT
TO ENHANCE THE STIFFNESS OF THE ROTATING ELEMENT

SLEEVE TO PROTECT THE SHAFT FROM ABRASION WEAR AT PACKED
SLEEVE
STUFFING BOX OR AT LEAKAGE JOINTS
TO PROTECT THE SHAFT FROM EROSION & CORROSION
TO FASTEN THE SLEEVES TO THE SHAFT

SLEEVE NUT TO PREVENT MOVEMENT OF THE SLEEVE SLEEVE NUT
CAUSES PRESSURE BREAKDOWN AS THE LIQUID THROTTLES

THROTTLE BUSH ACROSS IT THUS BOOSTING THE SERVICE LIFE OF PACKING
SERVES AS A LANDING FOR THE LOWEST RING OF THE PACKING
RESTRICTS SOLID PARTICLE IN THE PUMPED LIQUID FROM
GETTING EMBEDDED INTO THE PACKING AREA AND THUS PROTECTING
SHAFT OR SLEEVE FROM WEAR THROTTLE BUSH
ACTS AS ADDITIONAL HYDRODYNAMIC BEARING SUPPORT FOR THE

ROTATING ELEMENT AND REDUCES SHAFT DEFLECTION
PREVENTS SOME AMOUNT OF LIQUID LEAKING OUT FROM THE
STUFFING BOX TO FLOW BACK
PACKING RING/ TO SEAL THE ROTATING SHAFT FROM THE ATMOSPHERE
MECHANICAL SEAL MECHANICAL
SEAL
PACKING RING
PRESSES THE OUTSIDE RING AGAINST STUFFING BOX BORE

GLAND THUS ALLOWING THE PACKING RING TO CREATE A RADIAL
REACTION FORCE ON THE SHAFT FOR SEALING GLAND
TO ACCOMODATE THE STATIONARY SEAT OF MECHANICAL SEAL AND TO

GLAND PLATE SUPPORT IT AGAINST AXIAL MOVEMENT
ALLOWS PROVISION FOR SEAL QUENCHING GLAND PLATE
TO CIRCULATE OR DISTRIBUTE THE COOLING WATER TO THE PACKING RINGS

SUPPLIED BY INTERNAL OR EXTERNAL SEAL FLUSHING LINE
LANTERN RING PREVENTS INGRESS OF AIR INTO THE STUFFING BOX
FOR HIGH PRESSURE APPLICATION, LANTERN RING IS LOCATED
AT THE BOTTOM OF THE STUFFING BOX ALLOWING HIGH
PRESSURE LIQUID RELIEVE BACK TO THE SUCTION
FOR THE APPLICATION OF ABRASIVE LIQUIDS LANTERN RING IS LANTERN RING
LOCATED AT THE BOTTOM OF THE STUFFING BOX TO
PREVENT SOLIDS GETTING INTO THE PACKING AREA
BEARING HOUSING HOLDS THE BEARINGS

PREVENTS THE BEARING FROM RADIAL BEARING HOUSING
DEFLECTION
BEARING PROVIDES SUPPORT FOR THE ROTATING ELEMENT

CARRIES HYDRAULIC RADIAL AND AXIAL LOADS BEARING
BEARING END COVER PROTECTS THE BEARINGS FROM ENVIROMENTAL DUST OR POLLUTION
TO LOCATE THE ROTATING FACE FROM BOTH SIDES OR AGAINST THE
BEARING HOUSING, TO PREVENT AXIAL MOVEMENT
END
COVER
BEARING BRACKET SUPPORTS THE WHOLE BEARING ASSEMBLY

FASTENS THE WHOLE ROTATING ASSEMBLY TO THE CASING
THROWS OUT THE ADHERING WATER LAYER
WATER THROWER WHICH TRAVELS ALONG THE ROTATING SHAFT
WATER THROWER
PROTECTS BEARINGS BY PROTECTING ITS LUBRICANT
FROM CONTAMINATION WITH WATER
KEY IMPELLER KEY TRANSMITS THE TORQUE FROM

IMPELLER KEY
SHAFT TO THE IMPELLER
COUPLING KEY TRANSMIT THE TORQUE FROM
DRIVER SHAFT TO THE PUMP SHAFT COUPLING KEY
TYPES OF IMPELLERS BASED ON MECHANICAL CONSTRUCTION
- USED DEPENDING ON THE NATURE OF THE LIQUID PUMPED
SECTIONAL VIEWS OF IMPELLERS SHOWN BELOW
CLOSED IMPELLER SEMI-OPEN IMPELLER PARTIAL SHROUDED OPEN IMPELLER

IMPELLER
SEMI-OPEN IMPELLER
SHROUDED IMPELLER
IMPELLERS FOR BOILER FEED

PUMPS
TYPES OF IMPELLERS BASED ON NUMBER OF
SUCTION EYES
SINGLE SUCTION IMPELLER DOUBLE SUCTION IMPELLER

TYPES OF IMPELLERS BASED ON THE MAJOR DIRECTION OF FLOW
WITH RESPECT TO THE AXIS OF ROTATION
RADIAL VANE IMPELLER MIXED FLOW IMPELLER PROPELLER

SUITABLE FOR DISCHARGING SUITABLE FOR DISCHARGING SUITABLE FOR DISCHARGING
RELATIVELY SMALL QUANTITY OF LARGE QUANTITY OF FLOW LARGE QUANTITY OF FLOW
FLOW AGAINST HIGH HEAD AGAINST MEDIUM HEAD AGAINST SMALL HEAD
TYPES OF IMPELLERS BASED ON THEIR RELATIVE
POSITIONS ON THE SHAFT
OVER-HUNG IMPELLER
IMPELLER BETWEEN BEARINGS

PUMP TYPES BASED ON THE ORIENTATION OF THE PUMP SHAFT
VERTICAL SHAFT PUMP
HORIZONTAL SHAFT PUMP
RESTRICTED FLOOR SPACE

REQUIRES VERTICAL SHAFT
PUMPS.
PUMP TYPES BASED ON THE NUMBER OF IMPELLERS
SINGLE-STAGE PUMP
SCALE MODEL OF A THREE STAGE PUMP
SATGE3
CROSS-OVER
STAGE 1
STAGE 2
SUCTION
TWO-STAGE PUMP ROTATING ELEMENT ASSEMBLY
Multistage Pumps
Essentially a High Pump having two or more Impellers Mounted

on a Common Shaft in Series
Multi-stage Pump
Vertical Multistage Can Pumps

Multistage Pump Thrust Balancing Mechanism
In a single stage impeller an unbalanced hydraulic thrust is directed axially

towards the suction side
Methods of balancing thrust in a multistage unit
Natural Balancing Achieved by means of opposing impellers
Mechanical Balancing Achieved by use of balancing disk & drum

Natural Balancing
Probable Arrangements
Arrangement 1
Natural balancing is achieved in a two stage pump by two back to back

single suction impellers or by use of double suction impellers
Arrangement 2
Natural balancing is achieved in a three stage pump by means of two

opposed single suction impellers (left & right) and one double suction
impeller
Arrangement 3
Natural balancing is achieved in a five stage pump by means of an assembly

by a couple of opposed impellers (left & right) and one double suction
impeller at the center
Arrangement 3
Natural balancing is achieved in a six stage pump by means of an assembly

of four single suction impellers (left & right) and one double suction
impeller at the center
Mechanical Balancing
Use of Balancing Drum

Use of Balancing Disk
A Combination of Balancing Disk & Drum
VARIOUS TYPES OF H-Q CURVE SHAPES
FLAT CURVES
SHOWS LITTLE VARIATION OF HEAD AT ALL FLOWS BETWEEN

DESIGN POINT & SHUT-OFF
HEAD
FLOW
DROOPING CURVE
HEAD DEVELOPED AT SHUT-OFF IS LESS THAN HEAD DEVELOPED AT

SOME FLOW BETWEEN B.E.P & SHUT-OFF
HEAD
FLOW
STEADILY RISING CURVE
HEAD RISES CONTINUOUSLY FROM DESIGN POINT TO SHUT-OFF

HEAD
FLOW
STEEP CURVE
HEAD LARGE INCREASE IN HEAD DEVELOPED AT SHUT-OFF FROM

B.E.P.
FLOW
STABLE CURVE
HEAD
ONLY ONE FLOW RATE AT ANY ONE HEAD
FLOW
UNSTABLE CURVE
HEAD
THE SAME HEAD IS DEVELOPED AT MORE THAN ONE FLOW

RATES
FLOW
SPECIFIC SPEED OF A CENTRIFUGAL PUMP
ITS A DESIGN INDEX THAT DETERMINES THE IMPELLER

TYPE AND GEOMETRIC SIMILARITY OF PUMPS.
Ns = N x Q / (H)0.75 Ns = N x Q / (H)0.75
WHERE , WHERE ,
Ns = SPECIFIC SPEED IN Ns = SPECIFIC SPEED IN
METRIC UNITS. US CUSTOMARY UNITS.
Q = FLOW IN M3/HR. AT Q = FLOW IN US GPM AT

B.E.P. B.E.P.
N = ROTATIVE SPEED IN N = ROTATIVE SPEED IN
R.P.M . R.P.M .
H = HEAD DEVELOPED IN H = HEAD DEVELOPED IN
M. AT B.E.P. FT. AT B.E.P.
EFFECT OF SPECIFIC SPEED ON ACCECTABLE OPERATING ZONE OF A PUMP
LOW SPECIFIC SPEED PUMPS B.E.P
HEAD COMPARATIVELY WIDER

ACCEPTABLE OPERATING ZONE
BKW
EFFICIENCY
HIGH SPECIFIC SPEED PUMPS

FLOW-RATE
B.E.P
HEAD
BKW
COMPARATIVELY NARROWER
EFFICIENCY
FLOW-RATE
SPECIFIC SPEED & ITS EFFECT ON
PUMP PERFORMANCE
CHARACTERISTICS
COMPARATIVELY FLAT H-Q CURVE
COMPARATIVELY LOW NPSH

REQUIREMENT
HIGH
LOWSPECIFIC
SPECIFICSPEED
SPEEDPUMP
PUMP
RISING POWER CURVE

SPECIFIC SPEED & ITS EFFECT ON
PUMP PERFORMANCE
CHARACTERISTICS
COMPARATIVELY STEEP H-Q CURVE
COMPARATIVELY HIGH NPSH

REQUIREMENT
HIGH SPECIFIC SPEED PUMP
NON-OVERLOADING POWER CURVE

SUCTION SPECIFIC SPEED
Nss = N x Q / (NPSHr)0.75 Nss = N x Q / (NPSHr)0.75
WHERE , where,
Nss = Suction specific speed in Nss = Suction specific speed in
metric units us customary units.
Q = Flow in m3/hr at b.e.p Q = Flow in us gpm at b.e.p (use

(use half of the total flow for double half of the total flow for double
suction pumps) suction pumps)
N = rotative speed in r.p.m N = Rotative speed in r.p.m
NPSHr = Net +ve suction head NPSHr = Net +ve suction head
required in m (established by 3% required in ft (established by 3%
head drop test) head drop test)
USUAL VALUES OF SUCTION SPECIFIC SPEED FROM SULZER
Suction specific speed can vary widely depending on impeller design,
suction geometry and pump size - typical values are tabulated below :
PUMP Nss IN METRIC Nss IN US CUSTOMARY

UNITS. UNITS.
TYPE
LOW MEDIUM HIGH LOW MEDIUM HIGH
END SUCTION PUMP

11,400 13,800 16,200 9,800 11,900 13,950
PUMPS WITH SHAFT
THROUGH EYE AND
MODERATE SHAFT 10,200 12,000 14,400 8,800 10,330 12,400
BLOCKAGE SINGLE/TWO
STAGE SPLIT-CASE PUMPS
MULTISTAGE PUMP WITH
HEAD /STAGE ABOVE 9,000 10,800 13,200 7,750 9300 11,370
500M
INDUCERS FOR
INDUSTRIAL APPLICATION 21,000 30,000 42,000 18,052 25,870 36,166
To be replaced
54 SPEED LIMITATION AND SUCTION SPECIFIC SPEED
Increased pump speed without

proper suction conditions Abnormal pump wear
can lead to Failure due to excessive vibration
Noise
Cavitations damage
Suction specific speed has been found to be a valuable criterion in determining the
maximum speed
Hydraulic institute uses a value of 10,000 metric units (8500 us units) as a practical
value for determining the maximum operating speed.
In metric units,
n = 10,000 x npsha0.75 / q 0.5 In us customary units,
where , n = max. speed(r.p.m). n = 8,500 x npsha0.75 / q 0.5
npsha = npsh available in m.
q = flow in m3/hr. (take half of the flow for where , n = max. speed(r.p.m).
double suction pump). npsha = npsh available in ft.
q = flow in us g.p.m. (take half of the flow
for double suction pump).
SAFE OPERATING WINDOW Vs SUCTION SPECIFIC SPEED
Ttest of a 4 inch pump with different Nss impellers.

bep & impeller profiles are identical,only eye geometry is different for each Nss
Allowable Operating Region & Preferred Operating Region
Reference Source ANSI HI 9.6.3-1997
Preferred Operating Region - POR

The flow remains well controlled within a range of rates of flow designated as the
Preferred Operating Region ( POR). Within this region the service life of the pump will not
be significantly affected by hydraulic loads, vibration or flow separation.
Specific Speed POR

Metric US Units
< 5200 < 4500 Between 70% & 120% of BEP
> 5200 > 4500 Between 80% & 115% of BEP
POR Low Specific Speed Pump POR High Specific Speed Pump
Allowable Operating Region AOR A. AOR represents the range of flow
AOR > POR over which the service life of a pump
is not seriously compromised.
B. Minimum bearing life will be reduced and

noise, vibration and component stresses will be
increased when a pump is operated outside its
POR
C. At any point within the AOR
the minimum bearing life should
be more than two years
AOR / POR recommendations only consider non-

viscous, non- corrosive pure liquids, with no vapour, gas
suspended solids and abrasives
Factory test to ensure reliability at the specified rate of flow:

Characteristics to be monitored-
Stability of rate of flow being Bearing House
pumped
Shaft Vibration Vibration
Motor Vibration
Bearing Temperature Noise
ALWAYS
USE A CENTRIFUGAL PUMP
UNLESS The viscosity is greater than 1000 cp at pumping temperature
UNLESS The percentage of undisclosed gas by volume is greater than 5%
UNLESS The percentage of solids by volume is greater than 50%
UNLESS High heads & low capacities are involved
UNLESS The liquid incurs serious mechanical problem

Criteria for Selection of Suitable Type of Pump
Pumps Inherent Contradictions in Design Objectives
Achieve design flow rate and total head.
Attain optimum efficiency.
Obtain stable head-capacity characteristics.
Minimize NPSH required.
Ensure wide operating range.
Optimize pump size.
Attain non-overloading power characteristics.
Minimize vibration and noise.
Minimize hydraulic axial and radial thrust loads.
Design for ease of production.
Ensure maximum interchangeability.
Minimize cost.
Selection Considerations
Engineering of system requirements
Selection criteria of pump set
Specification of pump & drive
Floating enquiry
Evaluations of tenders
Placement of order for supply & installation of pump set

Pump Specification & Selection
SMALL
AGRICULTURAL Product complexity & Shift in Emphasis
PUMP, DOMESTIC
PUMP Standard Product
Customized Product
Mass produced
STANDARD Custom built
INDUSTRIAL END No interaction between
SUCTION PUMPS
EN733 / ISO2858 manufacturer & user Protracted interaction
amongst manufacturer,
user & consultant
Design skill
Design & application skill
API PROCESS PUMPS
/ OIL PIPELINES Team
PUMPS
excellence Small group
excellence
No / little
FEED PUMPS FOR specification Detailed
NUCLEAR POWER
STATIONS specification
CONCRETE VOLUTE Simple selection
PUMPS
criteria Complex selection
criteria
Competitive Environment of Pump Manufacturer
Threat of new Entrants
Chinese Pumps branded by Buyer Power
International Pump Makers
1. OEM Buyers are Pump
Makers - can switch
Industry Competition suppliers or
manufacture themselves
Air Con PACO, Ebara,
ITT, SPP 2. Regulatory UL/FM
Marine Fire Nijhuis, ABS, requirement.
KSB, UNITOR European / North
American origin
requirement acts as
Supplier Power barrier to entry
1. Limited no. of foundries for

Duplex stainless, Ni Al Bronze
2. Volatile prices of Bronze
Ingots Threat of Substitutes
1. End suction pumps for chiller duties
2. Rabbit Design of ITT Through bore pumps
Defining an International standard of Quality
for Centrifugal Pumps
Customer Correct Curves, GA Drawings, Sectional

Documentation Drawing, Parts List, Instruction Manuals, Data
Books, selection programs, web access.
Hydraulic performance Meet Guaranteed Q, H &Efficiency
Stable H-Q Curve
Stable part capacity operation
Acceptable Suction Performance
Mechanical Reliability Free Rotation
Vibration & Noise levels as per HIS
Seal reliability
Bearing Life in excess of 40,000 hours
Low Bearing temperature
Appearance / International quality fittings
Visual Appeal - Fasteners, Plugs, Seal water piping
- Shot blasted casing
- Internal & external painting standards
Packing Good Package design
Crating instead of fully boxed packing
Non wood packing
6
4
WHY DO WE NEED SPECIAL FOCUS FOR ENGINEERED PUMPS?
STANDARD PUMPS ENGINEERED PUMPS

DOMESTIC, AGRICULTURAL Large HSC, Vertical Wet-pit, BF
Mass Produced Customized
Automated Manufacturing Conventional Manufacturing
Product Range Optimasation Tender Optimisation
Design & Development Skills Applictions Engineering Skills

Product Adaptation / Modification Skills
Little interaction with users Prolonged interaction with consultants

and users
Basic R&D Empirical data on pumps tested is a

major source of product development
6
5
Pump Business - Process of Value addition
Value Adders Examples of services
Help in preparing Optimum speed, No. of pumps, pipe
N size, suction requirements, weight
E specifications data, budget costs, etc.

E Help during post bid Full technical specifications, driver
data, interface information, General
D discussions
From Womb to Tomb

arrangement Drawing.
Drawing & data submittals.
FO Data needed by driver and
Post order help Other associated equipment suppliers
R
GD2,TVA,Torque-Speed curve
S Installation help.
E Post delivery Commissioning help.
Training of operators.
R
Condition monitoring support, spares,
V Post commissioning trouble-shooting.
I
Services for

C performance change / Retrofit services for changed system
E parameters.
Performance Help in disposal of pump.
enhancement
6
6
EEFFICIENCY OF A CENTRIFUGAL PUMP
I COMPONENTS OF PUMP EFFICIENCY
M
P I) HYDRAULIC EFFICIENCY
O II) VOLUMETRIC EFFICIENCY
R III) MECHANICAL EFFICIENCY
T
A
N
C
E
OF
E
F
F
C
I
E
B.E.P OF A PUMP IS A MEASURE OF OPTIMUM ENERGY
N
C CONVERSION. EFFICIENCY IS ALSO AN INDICATOR OF
Y MECHANICALLY STABLE & RELIABLE OPERATION.
SPECIFIC SPEED Vs EFFICIENCY
SPECIFIC SPEED
RANGE (US) EFFECT ON EFFICIENCY
BELOW 2000 EFFICIENCY DROPS DUE TO

HIGHER DISK FRICTION,
LEAKAGE & FLOW LOSSES.
HIGHEST EFFICIENCY
2000-3000 POTENTIAL
ABOVE 3000 EFFICIENCY DROPS DUE TO

HIGHER CASING HYDRAULIC
LOSSES.
SPECIFIC SPEED
&
EFFICIENCY
CHANGE OF IMPELLER SHAPE WITH SPECIFIC SPEED
SPECIFIC SPEED
&
EFFICIENCY
PUMP EFFICIENCY CHART
CLASSICAL WORTHINGTON CHART
SPECIFIC SPEED
&
EFFICIENCY
OPTIMUM EFFICIENCY AS A FUNCTION OF SPECIFIC SPEED &
FLOWRATE
FRASER-SABINI CHART
SPECIFIC SPEED
&
EFFICIENCY
INFLUENCE OF PUMP TYPE ON EFFICIENCY
PUMP TYPE Ns RANGE - METRIC (US) FACTORS AFFECTING

EFFICIENCY
MANUFACTURING
SEVERE DUTY END SUCTION, 500-1600 (400-1400) CONSIDERATIONS
METAL SLURRY PUMP
MANUFACTURING
MEDIUM DUTY END 900-2300 (800-2000) CONSIDERATIONS
SUCTION METAL AND
RUBBER LINED SLURRY
PUMPS
THE EFFICIENCY IS
800-3500 (700-3000) COMPROMISED TO
END SUCTION - 2 VANED PASS LARGE SOLIDS
SEWAGE PUMPS.
THE EFFICIENCY IS
END SUCTION - 3 OR 4 1250-6400 (1500-5500) COMPROMISED TO
VANED SEWAGE PUMPS. PASS LARGE SOLIDS
INFLUENCE OF PUMP TYPE ON EFFICIENCY
OPEN IMPELLER DESIGN FOR
END SUCTION PAPER STOCK 800-4600 (700-4000) PUMPING FIBROUS AIR-
PUMPS. ENTRAINED MIXTURES
HAMPERS EFFICIENCY
HORIZONTAL MULTI-STAGE CLEARANCES, INTERSTAGE
PUMPS - AXIALLY SPLIT, 800-2300 (700-2000) BUSHINGS, SHAFT STIFFNESS
SEGMENTED RING DIFFUSER, & SURFACE FINISH AFFECT
BARREL PUMPS EFFICIENCY
LOW HP PUMPS WITH
SPECIAL MECHANICAL SEALS
END SUCTION ANSI & API 350-3500 (300-3000) THAT CAUSE HIGH
PUMPS MECHANICAL LOSSES WILL
HAVE LOWER EFFICIENCY
THAN FIGURES GIVEN IN HIS
CHART.
LARGE SHAFT DIAMETER
API DOUBLE SUCTION THROUGH IMPELLER EYE,
BETWEEN BEARING PUMPS 800-2300 (700-2000) LARGE IMPELLER RING
CLEARANCES & SUCTION
INLET REDUCES EFFICIENCY.
LARGE DIAMETER SHAFTING.
DOUBLE SUCTION PUMPS 500-5200 (400-4500)
OPTIMUM
ATTAINABLE
EFFICIENCY
CHART
(HIS)
SPECIFIC
SPEED
&
EFFICIENCY 74
DEVIATION OF EFFICIENCY FROM THE CHART - SUMMARY
SOME OF THE REASONS FOR DEVIATIONS ARE :
DESIRED CURVE SHAPE (EXAMPLE - HEAD RISE TO SHUT-OFF,

NON-OVERLOADING POWER CURVE, ETC.).
DIMENSIONAL CONFORMANCE & QUALITY ( EXAMPLE - SHAFT
RUN-OUT).
SURFACE ROUGHNESS.
INTERNAL CLEARANCES.
DESIGN COMPROMISE FOR MANUFACTURABILITY.
MECHANICAL LOSSES.
SOLID HANDLING CAPABILITY.
TEST TOLERANCES.
DEVIATION AS A PERCENT OF GENERALLY ATTAINABLE EFFICIENCY
DEVIATION
FROM
GENERALLY
ATTAINABLE
EFFICIENCY
SPECIFIC
SPEED
&
EFFICIENCY
SPECIFIC SPEED AND PUMP PERFORMANCE- SUMMARY
S
P
E
Low Medium High
C Specific speed Specific speed Specific speed
I
(500-1600 US units) (1600-4100 US units) (4100-7800 US units)
F
I
C Efficiency begins to
Low efficiency due
S drop due to large
to high disk
P Optimum efficiency. diffusion losses.
EE friction & leakage
D losses.
&
Steep H-Q pump
E Flat H-Q Stable H-Q pump characteristics.
F characteristics characteristics
F
I
C Power tends to be
I Overloading Non overloading high at closed
E
N power curves. power curves. valve.
C
Y7
7
SPECIFIC SPEED & EFFICIENCY - EXAMPLE
Specific Attainable
BEP Duty Design Point
Speed Efficiency
SL. PUMP FLOW FLOW HEAD HEAD US METRIC FRASER ACP

H.I.S
NO. MODEL (M3/HR) (USGPM) (M) (FT) UNITS UNITS SABINI CURVE
1 100C 184 813 53 174 610 709 71 70 73
2 100G 162 713 65 212 698 811 78 79 81
3 150E 360 1585 120 394 462 537 70 72 72
4 200E 767 3377 139 456 604 701 78 84 82
5 300A 1400 6165 24 79 3046 3538 89 91 86
6 300B 1710 7530 38 125 2385 2770 89 91 86
7 300D 2025 8918 102 335 1238 1438 86 83 85

EFFECT
OF
SPECIFIC
SPEED
ON
PUMP
CURVE
SPECIFIC
SPEED
&
EFFICIENCY
AFFINITY LAWS
FOR A PARTICULAR PUMP THE HEAD DEVELOPED & THE DISCHARGE CAN BE CONTROLLED,
WITHIN CERTAIN LIMITS, ACCORDING TO THE AFFINITY LAWS:
WHEN ONLY IMPELLER DIA. WHEN ONLY SPEED
CHANGES & SPEED CHANGES & IMPELLER DIA. WHEN BOTH DIA & SPEED CHANGE
REMAINS THE SAME REMAINS THE SAME
Q2 = Q1 x (D2/D1) Q2 = Q1 x (N2/N1) Q2 = Q1 x (D2/D1) x (N2/N1)
H2 = H1 x (D2/D1)2 H2 = H1 x (N2/N1)2 H2 = H1 x { (D2/D1) x (N2/N1) }2
BKW2 = BKW1 x BKW2 = BKW1 x (N2/N1)3 BKW2 = BKW1 x { (D2/D1)

(D2/D1)3 x(N2/N1)}3
Q1, H1, BKW1, D1 & N1 ARE CAPACITY, HEAD, INPUT POWER IN KW, IMPELLER DIA. & SPEED AT
INITIAL CONDITION.
Q2, H2, BKW2, D2 & N2 ARE CAPACITY, HEAD, INPUT POWER IN KW, IMPELLER DIA. & SPEED AT
CHANGED CONDITION.
APPLICATION OF AFFINITY LAWS
ONE PUMP IS USED TO SERVICE DIFFERENT DUTIES
REDUCING THE DIAMETER OF THE IMPELLER MAKES AN EXISTING PUMP RUN MORE
EFFICIENTLY AT LOWER FLOWS WITHOUT THE NEED FOR THROTTLING.
SAME PUMP WITH A RANGE OF IMPELLER DIAMETERS TO SAME PUMP WITH DIFFERENT MOTOR SPEEDS
MEET DIFFERENT DUTY H & Q. THROUGH VSD TO ALLOW ONE PUMP TO BE USED
OVER A MUCH WIDER RANGE OF DUTIES.
IMPELLER TRIM CORRECTION FOR AFFINITY LAWS
CALCULATED DIAMETER % OF ORIGINAL
REQUIRED DIAMETER % OF ORIGINAL

SPEED REDUCTION TO MEET LOWER DUTIES - A MORE ENERGY
EFFICIENT WAY THAN IMPELLER TRIMMING OR THROTTLING
HEAD
FLOW
USE OF VSDs TO MATCH THE PUMP WITH VARIABLE SYSTEM NEEDS

LOSSES IN A CENTRIFUGAL PUMP & THEIR
EFFICIENCY(%) IMPACT ON EFFICIENCY
100%
FLOW
IMPORTANCE
OF
EFFICIENCY
POWER LOSSES IN A CENTRIFUGAL PUMP
IMPORTANCE
OF
EFFICIENCY
POWER BALANCE IN A CENTRIFUGAL PUMP
POWER INPUT TO THE PUMP DRIVE SHAFT (IP)
POWER TRANSMITTED BY THE IMPELLER
USEFUL HYDRAULIC POWER, O/P POWER LOSSES
DISK FRICTION LOSS MECHANICAL LOSSES HYDRAULIC POWER LOSS POWER LOSS DUE
TO LEAKAGE
LOSSES
IN CENTRIFUGAL
PUMP
HEATS UP PUMPING MEDIUM
LOCATIONS OF VARIOUS LOSSES IN A CENTRIFUGAL PUMP
Casing Leakage loss

Hydraulic loss Mechanical losses
Entrance
shock
loss
Disk friction loss

LOCATIONS OF VARIOUS LOSSES IN A CENTRIFUGAL PUMP
Casing Leakage loss

Hydraulic loss
Entrance
shock
loss
Mechanical losses
Disk friction loss

CLASSIFICATION OF LOSSES
LOSSES IN A CENTRIFUGAL PUMP ARE CLASSIFIED INTO FIVE TYPES:
MECHANICAL LOSSES
IMPELLER LOSSES
DISK FRICTION LOSSES
LEAKAGE LOSSES
CASING HYDRAULIC LOSSES
MECHANICAL LOSSES
LOSSES
LOSSES
EXCLUSIVELY POWER LOSS. TAKES PLACE PRIMARILY IN
ININCENTRIFUGAL
CENTRIFUGAL BEARINGS, MECHANICAL SEALS OR GLAND PACKING
PUMP
PUMP
CONTD..
IMPELLER HYDRAULIC LOSSES
I) SHOCK LOSSES AT INLET TO THE IMPELLER

II) SHOCK LOSSES LEAVING THE IMPELLER
III) LOSSES DURING CONVERSION OF MECHANICAL ENERGY
TO KINETIC ENERGY
DISK FRICTION LOSSES
FRICTIONAL LOSSES AT THE IMPELLER SHROUDS
GENERAL EXPRESSION FOR

DISK FRICTION POWER
CONSUMPTION:
D2 n PD = k x n3 x D25
WHERE, PD = POWER
ABSORBED BY DISK
FRICTION
k = CONSTANT
n = SPEED (R.P.M)
D2 = IMPELLER OUTER
DIA.
LOSSES
IN CENTRIFUGAL
PUMP
LEAKAGE LOSSES
CAUSED BY LIQUID FLOWING PAST WEAR RINGS, INTER-STAGE BUSHES,

MECHANICAL SEALS, GLANDS & BALANCING DEVICES.
CASING
WEAR RING THE GENERAL EXPRESSION FOR
DETERMINING THE AMOUNT OF
IMPELLER
WEAR RING LEAKAGE ACROSS AN ANNULAR
CLEARANCE IS
MAIN FLOW
PATH
QL = x Acl x (2.g.Hcl)
HERE, QL = LEAKAGE FLOW
LEAKAGE
FLOW PATH = LEAKAGE GAP LOSS CO-EFFICIENT
g = GRAVITATIONAL ACCELERATION
Hcl = HEAD LOSS ACROSS ANNULAR PATH
FLOW PATH Acl = AREA AT CLEARANCE ZONE
DIAMETRAL CLEARANCE & MACHINING TOLERANCE AT LEAKAGE JOINT
CASING HYDRAULIC LOSSES
I) RECIRCULATION LOSSES
II) LOSSES DURING CONVERSION OF K.E TO P.E
III) LOSSES DUE TO SKIN FRICTION IN CASING
GENERAL EXPRESSION FOR DEFINING

FRICTIONAL LOSSES:
Hf = f x v2/2g x L/DH
WHERE, Hf = FRICTIONAL HEAD LOSS
f = FRICTION CO-EFFICIENT
v = FLUID VELOCITY
L = PASSAGE LENGTH
DH = HYDRAULIC DIA. OF THE PASSAGE
POWER BALANCE DIAGRAM FOR DOUBLE- SUCTION PUMPS AT B.E.P
LOSSES
IN CENTRIFUGAL
PUMP
PUMP RELIABILITY FACTORS
RELIABILITY
TYPE INSTALLATION APPLICATION OPERATION MAINTAINANCE
END BASEPLATE
SUCTION
ALLIGNMENT START-UP TRAINING
DOUBLE SHUT-DOWN TOOLS

SUCTION PIPING CONFG.
PIPE STRAIN MAX. FLOW FACILITY

MULTI-STAGE
HYDRAULIC
MECHANICAL MIN. FLOW RECORDS
ANSI
B.E.P
SEAL PARALLEL OPERATION
API R.P.M
BEARING SERIES OPERATION
VERTICAL IMP. DIA.
LUBRICATION
NPSH MARGIN
COUPLING
SUCTION ENERGY
SHAFT
Rules for Preventive Maintenance - SELECTION
3 7
Advise what type of power is best
SELECTION suited for the drive. Should speed Advise the manufacturer
be constant or variable? whether service is continuous or
intermittent
4 8
Advise any space , weight , or Advice any significant effect of
transportation limitations involved location of installation ( elevation
1
above sea level, geographic location,
Advise the manufacturer of and immediate surroundings)
the exact nature and 5
characteristics of liquid 9
Analyze suction or inlet

conditions Be sure that sufficient spare or
2
standby equipment is available
6
Check into required capacity 10
Analyze discharge Keep sufficient spare parts on

conditions hand
Rules for Preventive Maintenance - Installation
3 7
Equipment and driver alignment Provide vent valves at high points
INSTALLATION must be checked under operating and drain connections for pumps
conditions
4 8
Provide warm-up
Bed plate should be grouted & bypass connections for
1 centrifugal pumps , relief valves for
positive displacement
Install equipment in light, dry, pumps
and clean locations whenever 5
possible 9
Piping should not
impose excessive
2 Provide a suitable source of
strains on equipment
cooling water
6
Foundation should be rigid 10
Use as direct piping as Install suitable gauges, flow

possible ,especially at meters and thermometers
inlet
Rules for Preventive Maintenance - OPERATION
1 2 3 4
5
7
6
OPERATION
8
9 10
DOUBLE
SUCTION
IMPELLER
VANE CLARITY INFLUENCES EFFICIENCY

HYDROSTATIC
PRESSURE
TEST
CHANGE OF SECTION IS VULNERABLE

TO LEAKAGE
COMPACT
SPLIT CASE
PUMP
(MINIMUM
FOOT PRINT)
SEAL FITTED
COMPACT
CASING
THROUGH
BORE FEATURE
REDUCES
MACHINING
TIME
AN ALL
BRONZ
MARINE FIRE
PUMP
BRONZE,
NIAL-BRONZE,
DUPLEX SS
ARE USED FOR
SEA WATER
WEAR RINGS
SLEEVE
SLEEVE NUTS
ROTATING ASSEMBLY & COMPONENTS

SLEEVE IS
LOCKED IN
PLACE BY
THE
EXTENSION KEY & KEY
WAY
OF
IMPELLER
KEY
ROTATION SLEEVE NUT
OF THE SLEEVE
IS
PREVENTED
BY
TWO SLEEEVE
NUTS AT EACH
END
SLEEVE NUT EXTENDS BEYOND GLAND
SLEEVE
ASSEMBLY
COMPLETELY
FITTED
TONGUE
&
GROOVE
TYPE
WEAR
RING
PREVENTION OF OVALITY IS A CONCERN

A PAIR
OF
WEAR
RINGS
UPPER CASE PREVENTS ROTATION HERE

STUFFING BOX BUSH
LANTERN RING
INTER STAGE BUSH
TWO STAGE ROTATING ELEMENT

TWO SINGLE ENTRY
OPPOSED IMPELLERS
ENSURE BALANCING
OF AXIAL THRUST
TWO
STAGE
SPLIT
CASE
PUMP
SECOND STAGE
STUFFING BOX
SUBJECT TO
HIGH PRESSURE
TWO
STAGE
SPLIT
CASE
PUMP
TWO
STAGE
PUMP
CASING
INTER-STAGE
PASSAGE
MECHANICAL
SEAL
STUFFING
GLAND
BOX PLATE
AREA
THROTTLE BUSH
STUFFING
BOX WITH
MECHANICAL
SEAL
GLAND PLATE ABUTMENT RING
INLET AREA OF END
SUCTION PUMP
CASING
STIFFENERS
FRANCIS VANE IMPELLER INSIDE
LARGE END SUCTION PUMP

BALANCING HOLES
ENDSUCTION FRANCIS VANE

IMPELLER
END SUCTION PUMP POWER END

CASING WITH
WEAR RING
DELIVERY VOLUTE
CORE MAKING AT THE

FOUNDRY
SUCTION VOLUTE
DELIVERY VOLUTE
SPLIT-CASE
PUMP
DELIVERY VOLUTE
CORES
AT
THE
SUCTION VOLUTE
FOUNDRY
DELIVERY VOLUTE
PACKED
GLAND
HIGH
PRESSURE
FIRE PUMP
VALVE TO CONTROL SEAL WATER

PRESSURE
MOBILE CW PUMP
UNIT WITH MOTOR
SIZES
DIFFER
RANGE OF OPERATION
MULTI-STAGE OPERATION IN
CENTRIFUGAL PUMPS
ABNORMAL OPERATION

CENTRIFUGAL PUMPS

HYDRAULIC PRINCIPLES & CONCEPT
GENERAL LIQUID CHARACTERISTICS AND PROPERTIES
CONCEPTS RELATED TO PRESSURE, HEAD AND FLOW
BERNOULLIS EQUATION AND EULERS EQUATION
VELOCITY TRIANGLES
HYDRAULIC POWER AND PUMP EFFICIENCY
SPECIFIC SPEED
CAVITATION, RECIRCULATION AND NET POSITIVE SUCTION HEAD (NPSH)
PART FLOW OPERATION OF CENTRIFUGAL PUMPS

GENERAL LIQUID CHARACTERISTICS & PROPERTIES
Characteristics of the Pumping Fluid to be considered
1 2
Specific Gravity Vapor Pressure at
or Density Operating
temperature
3 5
4
Viscosity at
Operating Corrosiveness Volatility
temperature
6 7
Chemical Stability Gas Content
Solid Content
Different Head Figures
1
Static Discharge Head
The vertical distance from the the free surface of the water in the
centre line of the pump to discharge tank
is called The Static Discharge Head
2
Total Static Head
The vertical distance from the surface of the surface of the water in the
the source of supply to discharge tank
is called Total Static Head
The total height the water is raised by the pump

This is the sum of static suction lift static discharge head
When the water is discharged above the level of the water in the tank, the discharge head is
measured from the centre line of the pump to the point of free discharge
3
Static Suction Head
In many pump systems the source of supply is located above the pump and the water flows
toward the pump by gravity .
The distance from the free surface of the supply tank to the centre line of the pump
is called Static Suction Head
static discharge head

The total static head is the difference between
static suction head
4
Friction Head
When the pump puts the water in motion
water will meet resistance in the pipes, valves and fittings
To overcome this resistance a certain amount of pressure is required

This pressure is called The Friction Head Is expressed in metres or
feet of water. This
pressure
To be
replaced
Different Head Figures 140+141
5
Velocity Head
A force is required to put the water in motion. is called Velocity Head
Dynamic Head
Friction Head required the water from the source of supply

to move
Velocity Head into
the discharge vessel
Pressure Head
The sum of these heads is called Dynamic Head (force in motion)

7
Pressure or Equivalent Head
The extra pressure imparted is called Pressure or Equivalent Head
When the pump discharges the water into a vessel under pressure, such
as a boiler, it has to impart additional pressure to the water in order to
overcome the boiler pressure
8
Total Head
The total head is the sum of Static Head Dynamic Head
The total head required to move the water from the source of supply to the point of
discharge
The power required to drive a pump determined by the amount of liquid pumped
the total head against which

the pump operates
DIFFERENT HEAD TERMS IN A PUMPING SYSTEM
TOTAL HEAD IN A +VE

SUCTION SYSTEM
TOTAL HEAD IN A -VE SUCTION SYSTEM

UNDERSTANDING PRESSURE & HEAD IN A PUMPING UNIT
ALL PRESSURES CAN BE VISUALIZED AS

BEING CAUSED BY THE WEIGHT OF A
H H H
COLUMN OF LIQUID AT ITS BASE.
P1 P2 P3
THREE IDENTICAL PUMPS DESIGNED TO DEVELOP SAME

HEAD PRODUCES DIFFERENT PRESSURES WHICH VARY IN
PROPORTION TO THEIR SPECIFIC GRAVITY.
H2 H3
H1 PUMPS SHOULD BE SPECIFIED IN TERMS
OF HEAD AND NOT IN TERMS OF
P P P
PRESSURE TO AVOID AMBIGUITY.
THREE PUMPS PRODUCE SAME DISCHARGE PRESSURE BUT DEVELOP HEADS INVERSELY
PROPORTIONAL TO THEIR SPECIFIC GRAVITY.
CENTRIFUGAL PUMPS PHYSICAL PRINCIPLES
LAW OF CONSERVATION OF ENERGY - BERNOULLIS EQUATION
LAW OF CONSERVATION OF MASS - CONTINUITY EQUATION

FOR INCOMPRESSIBLE FLUIDS
LAW OF CONSERVATION OF ANGULAR MOMENTUM - EULERS EQUATION

MAIN DESIGN PARAMETERS OF AN IMPELLER
NUMBER OF VANES
IMPELLER DIA.
IMPELLER WIDTH
VANE OUTLET ANGLE
VANE SPREAD
EYE DIAMETER
VANE INLET ANGLE

CENTRIFUGAL PUMP - DIRECTION OF FLOW AT IMPELLER OUTLET
VELOCITY TRIANGLES
THE COMPONENT VELOCITIES OF FLOW THROUGH THE IMPELLER PASSAGES CAN BE

GRAPHICALLY REPRESENTED BY VELOCITY VECTORS. THEY FORM TRIANGULAR SHAPES TERMED
AS VELOCITY TRIANGLES .
DIFFERENT VANE PROFILES WITH DIFFERENT VANE OUTLET ANGLES
CURVED BACK VANE RADIAL VANE CURVED FORWARD VANE

(<900) (=900) (>900)
EULERS ENERGY EQUATION FOR A CENTRIFUGAL PUMP
& IDEAL HEAD DEVELOPED
1, 2 = VANE ANGLES AT INLET & OUTLET
u1 & u2 = PERIPHERAL SPEEDS AT INLET & OUTLET
w1 & w2 = RELATIVE FLUID VELOCITIES AT INLET & OUTLET.
Vr1 & Vr2 = RADIAL COMPONENTS OF V1& V2 RESPECTIVELY.
V1 & V2 = ABSOLUTE FLUID VELOCITIES AT INLET & OUTLET.
Vu1 & Vu2 = WHIRL COMPONENTS OF V1& V2 RESPECTIVELY.
WORK DONE BY THE IMPELLER PER

SEC. = ENERGY TRANSFERRED TO
THE FLUID
= Q (Vu2.u2 Vu1.u1)
= .Q .Vu2.u2 , WHEN FLUID

ENTERS RADIALLY , Vu1 = 0
IDEAL HEAD DEVELOPED BY A CENTRIFUGAL PUMP, He = Vu2.u2/g

EFFECT OF VANE CURVATURE ON HEAD, DISCHARGE & POWER CURVES
EFFICIENCY OF A CENTRIFUGAL PUMP
HYDRAULIC OR MANOMETRIC EFFICIENCY - IT IS THE RATIO OF MANOMETRIC HEAD TO THE

HYDRAULIC EQUIVALENT HEAD OF THE MECHANICAL ENERGY IMPARTED TO THE ROTATING IMPELLER.
H = gHm / VW1u1 Hm = MANOMETRIC HEAD
MECHANICAL EFFICIENCY - IT IS THE RATIO OF THE POWER DELIVERED TO THE FLUID TO THE POWER
INPUT(SP).
M = (SP FP) /SP OR wQ(VW1U1/G) x 1/SP
SP = SHAFT POWER , FP = POWER LOSS DUE TO MECHANICAL
FRICTION & w = SPECIFIC WEIGHT OF THE PUMPING LIQUID.
VOLUMETRIC EFFICIENCY - IT IS THE RATIO OF THE QUANTITY OF FLUID RECEIVING THE ENERGY
FROM THE IMPELLER TO THE ACTUAL QUNTITY DELIVERED BY THE PUMP.
V = Q/(Q+Q), Q = ACTUAL DISCHARGE & Q = LEAKAGE
DISCHARGE OR CIRCULATORY DISCHARGE INSIDE THE
PUMP.
OVERALL EFFICIENCY - IT IS THE RATIO OF THE POWER DIFFERENCE IN THE FLUID BETWEEN THE
OUTLET & INTAKE ENDS OF THE PUMP TO THE INPUT POWER OF THE SHAFT.
O = wQHm/SP = H.M.V
PERFORMANCE CHARACTERISTICS OF CENTRIFUGAL PUMPS
FLAT CURVES
SHOWS LITTLE VARIATION OF HEAD AT ALL FLOWS BETWEEN

DESIGN POINT & SHUT-OFF
HEAD
FLOW
DROOPING CURVE
HEAD DEVELOPED AT SHUT-OFF IS LESS THAN HEAD DEVELOPED AT

SOME FLOW BETWEEN B.E.P & SHUT-OFF
HEAD
FLOW
STEADILY RISING CURVE
HEAD RISES CONTINUOUSLY FROM DESIGN POINT TO SHUT-OFF

HEAD
FLOW
STEEP CURVE
HEAD LARGE INCREASE IN HEAD DEVELOPED AT SHUT-OFF FROM

B.E.P.
FLOW
STABLE CURVE
HEAD
ONLY ONE FLOW RATE AT ANY ONE HEAD
FLOW
UNSTABLE CURVE
HEAD
THE SAME HEAD IS DEVELOPED AT MORE THAN ONE FLOW

RATES
FLOW
ITS A DESIGN INDEX THAT DETERMINES THE IMPELLER TYPE AND

GEOMETRIC SIMILARITY OF PUMPS.
Ns = N x Q / (H)0.75 Ns = N x Q / (H)0.75
WHERE , WHERE ,

B.E.P. B.E.P.
R.P.M . R.P.M .
SPECIFIC SPEED
&
EFFICIENCY
SPECIFIC SPEED Vs EFFICIENCY
SPECIFIC SPEED
RANGE (US) EFFECT ON EFFICIENCY
BELOW 2000 EFFICIENCY DROPS DUE TO

HIGHER DISK FRICTION,
LEAKAGE & FLOW LOSSES.
HIGHEST EFFICIENCY
2000-3000 POTENTIAL
ABOVE 3000 EFFICIENCY DROPS DUE TO

HIGHER CASING HYDRAULIC
LOSSES.
SPECIFIC SPEED
&
EFFICIENCY
SPECIFIC SPEED AND PUMP PERFORMANCE- SUMMARY
S
P
E
Low Medium High
C Specific speed Specific speed Specific speed
I
(500-1600 US units) (1600-4100 US units) (4100-7800 US units)
F
I
C Efficiency begins to
Low efficiency due
S drop due to large
to high disk
P Optimum efficiency. diffusion losses.
EE friction & leakage
D losses.
&
Steep H-Q pump
E Flat H-Q Stable H-Q pump characteristics.
F characteristics characteristics
F
I
C Power tends to be
I Overloading Non overloading high at closed
E
N power curves. power curves. valve.
C
1
Y4
7
EFFECT
OF
SPECIFIC
SPEED
ON
PUMP
CURVE
SPECIFIC
SPEED
&
EFFICIENCY
NPSHr & NPSHa
NPSHr IS A CHARACTERISTIC OF NPSHa IS A CHARACTERISTIC OF

YOUR PUMP. YOUR SYSTEM.
THIS IS A FUNCTION OF PUMP THIS IS A FUNCTION OF SYSTEM

SUCTION DESIGN. IT VARIES WITH THE CONFIGURATION ON THE SUCTION SIDE
SPEED & CAPACITY FOR A PARTICULAR OF THE PUMP.
PUMP.
THIS IS THE +VE HEAD IN M IT IS THE AVAILABLE TOTAL SUCTION

ABSOLUTE REQUIRED AT PUMP HEAD IN METRES ABSOLUTE
SUCTION TO OVERCOME PUMP DETERMINED AT THE INLET NOZZLE OF
INTERNAL LOSSES LOSSES DUE TO THE PUMP & CORRECTED TO THE PUMP
TURBULANCE (GENERATED AS THE DATUM LESS THE VAPOUR
LIQUID STRIKES THE IMPELLER AT PRESSURE HEAD OF THE LIQUID IN
IMPELLER INLET), LOSSES IN THE METRES ABSOLUTE AT THE PUMPING
SUCTION PASSAGE & VANE INLET TEMPERATURE.
PASSAGES TO MAITAIN THE PUMPING
FLUID IN LIQUID STATE.
FOR CAVITATION-FREE SAFE OPERATION, YOUVE TO KEEP, NPSHa > NPSHr

PRESSURE GRADIENT ALONG THE LIQUID PATH IN PUMP SUCTION
CALCULATION OF AVAILABLE NPSH (NPSHa)
CHARACTERISTIC OF THE PROCESS SUCTION SYSTEM.
AN ANALYSIS OF TOTAL ENERGY ON THE SUCTION SIDE OF A PUMP TO DETERMINE

WHETHER THE LIQUID WILL VAPOURIZE AT A LOW PRESSURE POINT IN THE PUMP.
CALCULATION OF NPSHA FOR SYSTEMS WITH SUCTION
HEAD & SUCTION LIFT
NPSHa (M) = ATMOSPHERIC PRESSURE(M) NPSHa (M) = ATMOSPHERIC PRESSURE(M) +

SUCTION LIFT(M) FRICTIONAL SUCTION HEAD(M) FRICTIONAL
HEAD LOSS(M) - V.P (M) HEAD LOSS(M) - V. P (M)
CO-RELATION BETWEEN CAVITATION & NPSH
TOTAL HEAD WITH

SURPLUS NPSHa
VAPOR PRESSURE
Ps
3% HEAD DROP
TOTAL HEAD WITH

SUCTION EYE DISCHARGE LIMITED NPSHa
TOTAL HEAD
SUCTION EYE
NPSHa
SURPLUS
NPSHr
NPSHa
Ps
LIMITED
TO DISCHARGE
NPSHr
NPSHa DEFICIT
SUCTION EYE DISCHARGE VAPOR PRESSURE
FLO-W RATE
WHEN SUCTION PRESSURE(Ps) FALLS BELOW
VAPOUR PRESSURE OF THE PUMPING LIQUID AT WHEN THE MARGIN BETWEEN THE NPSHa &
PUMPING TEMP - BUBBLE FORMATION BEGINS NPSHr REDUCES THE TOTAL HEAD DROPS
SAFETY MARGIN NPSHr Vs. NPSHa
FOR CAVITATION FREE SAFE OPERATION NPSHa OF THE PLANT SHOULD BE HIGHER
THAN NPSHr OF THE PUMP BY A MINIMUM MARGIN.
MINIMUM NPSH MARGIN RATIO = NPSHa /NPSHrMIN.
WHAT IS A SAFE MARGIN TO BE MAINTAINED BETWEEN NPSHr & NPSHa ?
THE ANSWER DEPENDS UPON THE FOLLOWING FIELD FACTORS:
HOW CONSERVATIVELY NPSHa HAS BEEN CALCULATED & FOR WHAT % OF THE PUMPS DUTY
CYCLE IS THIS LOW VALUE OF NPSHa ACTUALLY PRESENT
WHAT IS THE LEVEL OF NPSHr & THUS THE RELATIVE AMPLITUDE OF THE CAVITATION SHOCK
WAVES.
HOW RESISTANT IS THE IMPELLER MATERIAL TO CAVITATION DAMAGE?
WHAT IS THE NATURE OF THE LIQUID BEING PUMPED?
HOW OVER-SIZED IS THE BEARING SYSTEM FOR THE APPLICATION?
REQUIRED SAFETY MARGIN
INCREASES WITH RISING PERIPHERAL SPEED AT IMPELLER INLET

(U1=D1N/60)
RISES WITH INCREASINGLY CORROSIVE MEDIA.
DEPENDS ON THE TYPE OF PUMP & THE OPERATING CONDITIONS.
REDUCES WITH THE RISE IN TEMPERATURE OF THE PUMPED

LIQUID.
REDUCES WHEN CAVITATION-RESISTANT MATERIAL IS USED FOR PUMP

CONSTRUCTION.
NPSH MARGIN
HYDRAULIC INSTITUTE RECOMMENDS MINIMUM NPSH MARGIN FOR

VARIOUS LEVELS OF SUCTION ENERGY
SUCTION ENERGY LEVEL MINIMUM NPSH MARGIN

(NPSHa/NPSHr)
LOW 1.1 TO 1.3
HIGH 1.3 TO 2
VERY HIGH 2 TO 2.5
APPROXIMATE VALUES FOR SELECTING PLANT NPSH (NPSHa)
SULZER CHART
NPSH MARGIN
NPSHr (AT 3% HEAD DROP) AT OPTIMUM EFFICIENT POINT

INSPITE OF NPSH MARGINS...
High & very high suction energy pumps operating with specified npsh margins
may still be susceptible to impeller erosion & high noise levels.
Increase in wear ring clearances

Increases leakage flow
In addition to the Increased flow disturbs the inlet
npsh margin some flow pattern.
added suction
head becomes
necessary due to: dissolved gas content in the liquid
improperly designed inlet piping & casing can

cause non-uniform suction flow or turbulance
operating the pump far to the right side of b.e.p.

ITS A DESIGN INDEX THAT DETERMINES THE IMPELLER TYPE AND

GEOMETRIC SIMILARITY OF PUMPS.
Ns = N x Q / (H)0.75 Ns = N x Q / (H)0.75
WHERE , WHERE ,

B.E.P. B.E.P.
R.P.M . R.P.M .
SUCTION SPECIFIC SPEED
ITS A DESIGN INDEX THAT DETERMINES THE SUCTION CAPABILITY OF

A PUMP.
Nss = N x Q / (NPSHr)0.75 Nss = N x Q / (NPSHr)0.75
WHERE , WHERE,
Nss = SUCTION SPECIFIC Nss = SUCTION SPECIFIC
SPEED IN METRIC UNITS. SPEED IN US CUSTOMARY
UNITS.
Q = FLOW IN M3/Hr AT B.E.P
(USE HALF OF THE TOTAL FLOW Q = FLOW IN US GPM AT B.E.P
FOR DOUBLE SUCTION PUMPS) . (USE HALF OF THE TOTAL FLOW
FOR DOUBLE SUCTION PUMPS)
N = ROTATIVE SPEED IN R.P.M
N = ROTATIVE SPEED IN R.P.M
NPSHr = NET +VE SUCTION
HEAD REQUIRED IN M NPSHr = NET +VE SUCTION
(ESTABLISHED BY 3% HEAD DROP HEAD REQUIRED IN FT
TEST) . (ESTABLISHED BY 3% HEAD DROP
TEST)
LETS HAVE A SECOND LOOK
SAFE OPERATING WINDOW Vs SUCTION SPECIFIC SPEED
TEST OF A 4 PUMP WITH DIFFERENT Nss IMPELLERS

BEP & IMPELLER PROFILES ARE IDENTICAL, ONLY EYE GEOMETRY IS DIFFERENT FOR EACH Nss
WHEN THE PUMP IS OPERATED BEYOND THIS STABLE WINDOW
IT MAY EXPERIENCE:
IMPELLER & CASING EROSION

SHAFT DEFLECTION & STRESS GENERATION
RADIAL & THRUST BEARING FAILURE
SEAL PROBLEMS
RADIAL THRUST
IMPELLER CENTER LINE
BEARING CENTER LINE

OPERATION AT LOW FLOW MAY RESULT IN
OPERATION FAR TO
THE LEFT OF B.E.P
CASES OF HEAVY LEAKAGE FROM THE
POSSIBLE CASING, SEAL OR STUFFING BOX.
PROBLEMS DEFLECTION & SHEARING OF SHAFT.
SEIZURE OF PUMP INTERNALS.
CLOSE CLEARENCE EROSION.
SEPERATION / LOW-FLOW CAVITATION.
PRODUCT QUALITY DEGRADATION.
EXCESSIVE HYDRAULIC THRUST.
PREMATURE BEARING FAILURE.
VIBRATION & NOISE
HEATING OF LIQUID PUMPED.
IDEAL OPERATING ZONE

ONSET OF ADVERSE EFFECTS WHEN OPERATING AWAY FROM B.E.P
IDEAL OPERATING
ZONE
OPERATIONTO TO THE RIGHT OF B.E.P
PROBABLE PROBLEMS
SHAFT STRESS TORSION & BENDING

COMBINED TORSIONAL & BENDING STRESSES OR SHAFT DEFLECTION IN SINGLE VOLUTE
PUMPS MAY EXCEED PERMISSIBLE LIMITS.
SHAFT DEFLECTION
DUE TO HIGH THRUST VALUES SHAFT DEFLECTION IN SINGLE VOLUTE PUMPS MAY EXCEED
PERMISSIBLE LIMITS.
NPSHr > NPSHa

NPSH REQUIRED MAY BE IN EXCESS OF NPSH AVAILABLE FOR THE SYSTEM.
EROSION, NOISE & VIBRATION

EROSION DAMAGE, NOISE & VIBRATION MAY OCCUR DUE TO HIGH LIQUID VELOCITIES.
OPERATION TO THE RIGHT OF B.E.P. - NPSH PROBLEM
B.E.P OPERATING
POINT
HEAD PUMP
NPSH
CAVITATING
NPSHr
EFFICIENCY
NPSHa AT THIS POINT

IS LESS THAN THE
REQUIRED NPSH
FLOW-RATE
HYDRAULIC THURSTS GENERATED IN A CENTRIFUGAL PUMP
RADIAL THRUST
AXIAL THRUST
RADIAL THRUST
SUMMATION OF UNBALANCED HYDRAULIC FORCES ACTING RADIALLY. DUE TO UNEQUAL
VELOCITY OF THE FLUID FLOWING THROUGH THE CASING AT PART FLOW, A NON-UNIFORM
PRESSURE DISTRIBUTION EXISTS OVER THE CIRCUMFERENCE OF THE IMPELLER.
RADIAL THRUST IS AN IMPORTANT PARAMETER WHEN DESIGNING PUMPS MECHANICAL
ELEMENTS LIKE SHAFT AND BEARINGS.
SINGLE DOUBLE
VOLUTE VOLUTE
SECOND
CASING VOLUTE CASING
STATIC PRESSURE DISTRIBUTION

OVER THE IMPELLER OUTLET FOR
DIFFERENT CASING GEOMETRIES AT
PART FLOW REGIME
VANED
CONCENTRIC DIFFUSER
CASING
RADIAL THRUST IS A FUNCTION OF TOTAL HEAD OF THE PUMP
& WIDTH & DIAMETER OF THE IMPELLER
P = RADIAL THRUST IN POUNDS
K = THRUST FACTOR
P = K x H x D2 x b2 x S.G / 2.31 H = DEVELOPED HEAD/STAGE IN FT
D2 = IMPELLER DIA, IN INCHES
b2 = IMPELLER WIDTH IN INCHES(INCLUDING SHROUDS)
RADIAL REACTION VECTOR REPRESENTED BY

THE ARROWS AT DIFFERENT FLOW
CONDITIONS FOR A SINGLE VOLUTE CASING
RADIAL FORCE PERCENT OF FORCE AT SHUT
SHUT-OFF
FOR VOLUTE CASING
RADIAL FORCE FOR VARIOUS TYPES OF VOLUTES
AXIAL THRUST
SUMMATION OF UNBALANCED HYDRAULIC FORCES ACTING AXIALLY ON THE IMPELLER.
SEVERITY OF AXIAL THURST DEPENDS ON THE TOTAL HEAD, SUCTION PRESSURE &
MECHANICAL CONFIGURATION OF IMPELLER.
AXIAL PRESSURE ACTING ON THE IMPELLER SHROUDS TO PRODUCE AXIAL THRUST

While a double suction impeller appears to be in axial balance, it may not be
so. the following are some of the reasons :
The suction passages leading to the impeller eyes may not provide
uniform and equal flow to the two suction eyes.
SUCTION CORE
An external condition like an elbow fitted very close to the

suction nozzle with upstream pipe parallel to pump shaft, may
deliver unequal flow to two suction eyes.
BEND VERY CLOSE TO

PUMP SUCTION
Two sides of the discharge casing may not be symmetrical due to

casting errors or the impeller may be fitted off-center.
DELIVERY CORE IMPELLER INSTALLATION
UNEQUAL LEAKAGE THROUGH THE LEAKAGE JOINTS SUCH AS WEAR RINGS ON

BOTH SIDES WILL CONTRIBUTE TO THE AXIAL THRUST IMBALANCE.
LEAKAGE ACROSS TWO WEAR RINGS

FLOW SEPERATION
AN IMPORTANT PHENOMENON BUT NOT WIDELY UNDERSTOOD
Nss(US UNITS) = N x Q / (NPSHr)0.75
Q = FLOW IN US GPM AT B.E.P (USE HALF OF THE TOTAL FLOW FOR DOUBLE SUCTION PUMPS)
N = ROTATIVE SPEED IN RPM
NPSHr = NET +VE SUCTION HEAD REQUIRED IN FT (ESTABLISHED BY 3% HEAD DROP TEST)
A MEASURE OF PUMPS SUCTION CAPABILITY
Nss & FLOW SEPERATION PROBABILITY
Nss NPSHr INLET INLET PASSAGE FLOW

(US UNITS) VELOCITY P SEPERATION
POSSIBILITY
14,000 (HIGH) LOW LOW LOW HIGH
8,000 (LOW) HIGH HIGH HIGH LOW

FLOW RECIRCULATION A POTENTIALLY DAMAGING FLOW
PHENOMENON.
FLOW REVERSAL AT IMPELLER INLET OR DISCHARGE VANE TIPS CAUSING

DISTURBANCES IN THE MAIN FLOW.
POSITIONS OF FLOW RECIRCULATION WITHIN AN IMPELLER

FLOW RECIRCULATION & DIFFERENT FLOW REGIMES
BACK FLOW
REGIME DISCHARGE
RECIRCULATION NORMAL FLOW
REGIME
HEAD
FLOW
To be replaced 187
BOTH
Suction Discharge
recirculation & recirculation
Cause noise and cavitation like damages.
Percentage of b.e.p. capacity at which the suction recirculation starts

is a function of Both ns & nss
Eye geometry plays major role
Acceptable minimum flow as % of b.e.p capacity

varies with pump type
multi-stage pump > end suction pump > double suction pump
So, a single suction pump & a double suction pump

may both have the same specific speed but will Higher the value of the suction
have different % of flow at which flow recirculation specific speed smaller would be
starts. This is because they differ in their suction the safe operating zone of a pump.
specific speeds.
INFLUENCE OF Nss OVER PUMP PERFORMANCE PARAMETERS
PUMP CHARACTERISTICS AT LOWER Nss PUMP CHARACTERISTICS AT HIGHER Nss
IMPELLER WITH SMALL EYE SAME IMPELLER WITH LARGER EYE)
RECIRCULATION ZONE
HEAD
HEAD
COMPARATIVELY
HIGHER NPSHr
AT SAME HEAD OPERATING ZONE
OPERATING
FLOW POINT
COMPARATIVELY ZONE
LOWER NPSHr AT
SAME HEAD FLOW
POINT
EFFICIENCY
EFFICIENCY
NPSH
NPSH
QMIN QB.E.P QMIN QB.E.P
FLOW-RATE FLOW-RATE
CAVITATION
CAUSES SEVERE DAMAGE TO THE PUMP
CAVITATION MAINLY OCCURS ON THE SUCTION SIDE OF THE PUMP AT THE INLET PORTION
OF THE IMPELLER. HOWEVER, CAVITATION DAMAGES MAY ALSO OCCUR ON DISCHARGE
VANE TIPS & VOLUTE TONGUES ON THE DELIVERY SIDE OF THE PUMP.
CAVITATION BEHAVIOUR IS DESCRIBED WITH THE FOLLOWING TERMS
CAVITATION INTENSITY SUM OF IMPLOSION ENERGIES OF ALL BUBBLES.
CAVITATION RESISTANCE MATERIAL PROPERTY (STRENGTH) AGAINST BUBBLE

IMPLOSION.
CAVITATION EROSION EXTENT OF MATERIAL DAMAGE DUE TO IMPLOSION OF

VAPOUR BUBBLES.
BUBBLE INCEPTION & IMPLOSION MECHANISM IN A HYDRAULIC SYSTEM
DROP IN LOCAL PRESURE DUE TO THE VELOCITY INCREASE IN A FLOW AREA THE
LOCAL STATIC PRESSURE DROPS TO VAPOUR PRESSURE OF THE LIQUID AT THE
PUMPING TEMPERATURE.
FORMATION OF CAVITY A BUBBLE FILLED WITH VAPOUR IS FORMED.
PARTIAL EVAPORATION OF THE LIQUID
EQUILIBRIUM CONDITION BETWEEN LIQUID & BUBBLE TWO-

PHASE FLOW TAKES PLACE IN THE AREA OF FLOW FIELD.
IMPLOSION & MICRO-JET FORMATION AS THE BUBBLES FLOW INTO A REGION OF

HIGH STATIC PRESSURE(> V.P. OF THE LIQUID) BUBBLES IMPLODE FORMING
MICROJETS.
BUBBLE IMPLOSION PROCESS
VAPOUR BUBBLES IMPLODE ASYMMETRICALLY.

IMPLOSION INSIDE FLOW CHANNEL
Micro-jet directed towards low pressure
area (upstream) termed as supercavitation
No significant effect on the

equipment in most cases
PRESSURE INCREASE
High implosion pressure (depends upon
IMPLOSION NEAR THE METAL WALL the compressibilty of the liquid)
High velocity micro-jet

impinges on the metal wall
causing material damage
PRESSURE INCREASE
AREAS PRONE TO BUBBLE IMPLOSION
BUBBLE
IMPLOSION
LOCATION
MICRO-JET
When the bubble collapses near the metal surface destructive micro-jet moving at a
velocity of about 400 m/s (can go upto 1000ms-1) impinges the surface.
WHAT HAPPENS WHEN THE MICRO-JET IMPINGES THE
METAL WALL ?
1
Local ambient pressure rises up to almost 6000 atm.
2
Local metal temp rises up to 10,000 0c as the
experimental results suggest
3
Severely destroys the impeller vane material
(impeller vane pitting).
4
The effect becomes more detrimental when conditions
are favorable to chemical corrosion. cavitations removes
the protective cover & new surface gets exposed to the
action.
FOUR ADVERSE EFFECTS OF CAVITATION
METALLIC EROSION
Implosion of bubbles destroys metals protective cover loss of pump
material (pitting of material)
DETERIORATION IN PUMP PERFORMANCE

dramatic decline in pump performancecavitation break-down.
hydraulic design modification is required
FAILURE OF PUMP COMPONENTS

Shafts Wear rings
Seals
Impeller
Bearing
INSTABILITY IN FLOW PATTERN OF PUMPING LIQUID
Results in oscillating flow-rates & pressure that threatens the structural

integrity of pump(specially inlet & discharge ducts).
METALLIC EROSION DUE TO CAVITATION
EROSION OF MATERIAL
Considerably higher at part load or when operating
away from peak efficiency zone
Increases with the implosion energy of bubble
Increases with corrosive character of the media
Increases with the growth of cavitation bubble
zone formed in the viscinity of the metal surface
Decreases with the temperature of the pumping liquid
Decreases with the presence of non-condensable
gas as it reduces the implosion pressure
Decreases with the square of the hardness of the material
RELATIVE CAVITATION EROSION RATE AT OFF-DESIGN FLOW CONDITIONS
DETERIORATION IN PUMP PERFORMANCE
The flow range gets limited progressively as the

1 LIMITS THE FLOW-RATE
suction pressure at impeller inlet falls.
2 DROP IN HEAD & EFFICIENCY
A FOR LOW SPECIFIC SPEED PUMP Sharp sudden fall in H-Q & efficiency
curves
B FOR LOW SPECIFIC SPEED PUMP the H-Q & efficiency curve begins to fall
gradually along the whole range before it
meets the beak-off point.
CAVITATION EFFECT VARIES WITH THE SPECIFIC SPEED
CAVITATION EFFECT
BEST EFFICIENCY
POINT
CAVITATION INCEPTION
POINT
SUCTION ENERGY & ITS RELATION WITH CAVITATION CHARACTERISTICS OF A PUMP
SUCTION ENERGY(S.E) = De x N x Nss x SP. GRAVITY

De = IMPELLER EYE DIAMETER Inches
N = PUMP SPEED(R.P.M)
Nss = SUCTION SPECIFIC SPEED (US Units)
CATEGORIZATION OF SUCTION ENERGY WITH THE PUMP TYPES
PUMP TYPE LOW S.E. HIGH S.E. VERY HIGH S.E.
2 VANE SEWAGE < 100 x 106 100 x 106 TO 150 x 106 > 150 x 106
PUMP
DOUBLE SUCTION < 120 x 106 120 x 106 TO 180 x 106 > 180 x 106
PUMPS
END SUCTION < 160 x 106 160 x 106 TO 240 x 106 > 240 x 106
PUMPS
VERTICAL TURBINE < 200 x 106 200 x 106 TO 300 x 106 > 300 x 106
PUMPS
INDUCERS < 320 x 106 320 x 106 TO 480 x 106 > 480 x 106
CAVITATION CHARACTER OF PUMP VARIES WITH SUCTION ENERGY
LOW SUCTION ENERGY HIGH SUCTION ENERGY VERY HIGH SUCTION

PUMPS PUMPS ENERGY PUMPS
1. ARE NOT PRONE TO 1. ARE PRONE TO NOISE, 1. ARE VERY PRONE TO

NOISE, VIBRATION OR VIBRATION OR DAMAGE NOISE, VIBRATION OR
DAMAGE FROM FROM CAVITATION & DAMAGE FROM
CAVITATION & RECIRCULATION. CAVITATION &
RECIRCULATION. RECIRCULATION.
2. UNDER LOW NPSH 2. UNDER LOW NPSH 2. UNDER LOW NPSH

MARGIN CONDITION MARGIN CONDITION MARGIN CONDITION
MECHANICAL SEALS ESPECIALLY WHEN ESPECIALLY WHEN
MAY GET DAMAGED. OPERATED IN SUCTION OPERATED IN SUCTION
RECIRCULATION ZONE, RECIRCULATION ZONE
EXPERIENCES MINOR EXPERIENCES MAJOR
CAVITATIONAL CAVITATIONAL
DAMAGE. DAMAGE.
CAVITATION-DAMAGES OF PUMP PARTS
CAVITATION RESULTS IN MECHNICAL DEFORMATION OF THE FOLLOWING COMPONENTS
BENDING & LINE

DEFLECTION BEARING
OF SHAFTS DAMAGE
THURST
BEARING
DAMAGE
BREAKING OF SEAL FACE

IMPELLER DAMAGE
CHECK-NUTS
PUMP COMPONENT DAMAGES
HEAD
FLOW
TYPE OF CAVITATION
CAVITATION ON THE SUCTION SIDE OF THE VANE

i) Cavitation cloud is formed on the vane suction side near the vane inlet edge.
ii) Occurs at reduced flow rate or when the vane inlet angle is high.
iii) Cavitation damage can be observed at the areas of bubble implosion.
CAVITATION ON THE PRESSURE SIDE OF THE VANE

i) Cavitation cloud is formed on the vane pressure side near the vane inlet edge.
ii) Occurs at increased flow rate or when the vane inlet angle is very small.
iii) Cavitation intensity is comparatively higher.
CAVITATION DUE TO IMPELLER INLET RECIRCULATION

i) Cavitation damage takes place on the pressure side of the vane in the outer part
impeller flow channel.
ii) Occurs at part-load opeartion due to recirculating flow pattern.
CAVITATION IN THE CORNERS BETWEEN VANE & SHROUD/HUB
i) Happens due to thicker vane profile at the transition zone between the vane
& shroud or hub due to casting irregularities at connecting areas.
ii) Occurs at unfavorable flow condition, vortexing in the corners of the
impeller channel even at optimum operating regime
GAP CAVITATION BETWEEN VANES & CASING FOR THE OPEN IMPELLER
i) Happens due to vortexing of the fluid jet formed due to pressure difference
between the pressure & suction side.
ii) Occurs at gap between the vanes & the stationary casing wall especially near
the area at impeller entry
CAVITATION TYPE POSITION IN THE POSITION ON THE LOCAL FLOW PATTERN
MERIDIONAL PLANE BLADE
CAVITATION AT THE
SUCTION SIDE
OF THE VANE
2
CAVITATION ON
THE PRESSURE SIDE
OF THE VANE
2
CAVITATION DUE
TO IMPELLER INLET
RECIRCULATION
CAVITATION TYPE POSITION IN THE POSITION ON THE BLADE LOCAL FLOW
MERIDIONAL PLANE PATTERN
CAVITATION
IN THE CORNERS
BETWEEN VANE
& SHROUD/HUB
GAP CAVITATION
BETWEEN VANES &
CASING FOR THE
OPEN IMPELLER
HYDRAULIC DISTURBANCES
ARE A MAJOR CAUSE OF
REDUCTION IN PUMP RELIABILITY.
INDICATIONS OF HYDRAULIC DISTURBANCES
Liquid noise continuous or varying
High values of overall vibration Suction & discharge pressure pulsations
Drop in produced head of >3%

Possible high bearing temperature
Pressure pulsations in inlet & outlet piping
High values of vane passing frequency in overall spectrum

PREVENTING LIQUID DISTURBANCES BY ACCURATELY DEFINING PROCESS
REQUIREMENTS
Define operating range of

application
vapor pressure
PREVENTING LIQUID
DISTURBANCES BY Accurately define liquid chemical character
ACCURATELY characteristics pumping temperature
DEFINING PROCESS viscosity
REQUIREMENTS
head required
npsha
Perform all required
hydraulic calculations & npsh margin for max.
their conformability operating flow
approx. recirculation margin
at min. flow
npsh margin at min. operating
flow
SOLUTIONS FOR LOW FLOW HYDRAULIC PROBLEMS To be
replaced
208 w1
Increase pump flow rate until quiet operation is achieved
Modify inlet volute to increase inlet velocity (if

SOLUTIONS sufficient npsha is available)
FOR
LOW FLOW
HYDRAULIC PROBLEMS
Install impeller with reduced eye dia. (asuming
sufficient npsha exists)
Install min. flow bypass to increase flow rate & eliminate low flow temperature rise of
pumped liquid
RANGE OF OPERATION
MULTI-STAGE OPERATION IN CENTRIFUGAL PUMPS
ABNORMAL OPERATION

CENTRIFUGAL PUMPS

PUMP SPECIFICATION & SELECTION
STEPS IN SELECTING & PURCHASING PUMP
PUMP DATASHEET/SPECIFICATION
BID EVALUATION
BID EVALUATION POINT RATING SYSTEM
CONCLUSION
SMALL
AGRICULTURAL Product complexity & Shift in Emphasis
PUMP, DOMESTIC
PUMP Standard Product
Customised Product
Mass produced
STANDARD
Custom built
INDUSTRIAL END No interaction between
SUCTION PUMPS
EN733 / ISO2858 manufacturer & user Protracted interaction
amongst manufacturer, user
& consultant
Design skill
Design & application skill
API PROCESS PUMPS
/ OIL PIPELINES Team excellence
PUMPS
Small group excellence
No / little specification
FEED PUMPS FOR
NUCLEAR POWER Detailed specification
STATIONS
CONCRETE VOLUTE Simple selection criteria
PUMPS
Complex selection criteria
ENGINEERING a. Defining the pumping

THE requirement
PUMPING SYSTEM b. Designing the pumping
GENERAL STEPS system
IN THE SELECTION c. Preparing pump specification
& PURCHASE & data sheet
PROCESS PUMP SELECTION a. Pump selection
&
b. Pump configuration
CONFIGURATION
c. Pump quotation
EVALUATING & PURCHASING a. Evaluation of bid &
THE PUMPING EQUIPMENT negotiation
b. Purchase of the selected
pump & driver
SERVICE Booster pump, CW pump, fire pump
OPERATING CONDITIONS Total capacity, Elevation, Pressure

Change
SITE CONDITION Altitude, power supply system,
ENGINEERING ambient condition, seismic data,
THE PUMPING etc.
SYSTEM FLUID PROPERTIES Temperature, pressure, viscosity,
corrosiveness, solids, erosiveness,
toxicity, entrained gas
INDUSTRY SPECIFICATIONS API, NFPA, ANSI, ISO & EPC spec.
EVALUATION CRITERIA Technical, commercial, lead time,

LCC
SYSTEM HEAD CURVES From preliminary P&ID. Effect

of pipe corrosion, branch piping
system, effect of static head
MODES OF SYSTEM OPERATION Continuous / intermittent,

series / parallel operation
Influence no of pumps needed.
DESIGNING Stand by & redundancy.
THE PUMPING PUMP FLOW / HEAD MARGIN Likely change in process
SYSTEM conditions. Penalty for over-
sizing
TYPE OF PUMP CONTROL Control valves,VFD, minimum

flow recirculation, level control
FUTURE SYSTEM CHANGES Driver sizing & capability of

installing a larger impeller
diameter
Request for quotation (RFQ) Scope of supply, Applicable specifications &

datasheets, commercial terms & conditions,
project information
Pump Technical Performance requirement, industry codes &

Specification standards, list of , definition of technical
PUMP terms, documents list.
SPECIFICATION Pump Data Sheet Duty condition, material specification,
& accessories, power supply system, site data,
DATA SHEET instrumentation & control, performance data
PREPARATION required, inspection & test requirement
Other documents Alternates, vendor data requirement(VDR),QA

check list, noise data sheet
Cost Evaluation Equipment cost, energy evaluation, LCC

evaluation
Commercial Terms Terms of payment, bid & performance bond,
warranty period, liquidated damages, logistics,
Insurance
Bidders list Based on

Experience similar equipment
FORMALISING Ability to meet delivery schedule
THE RFQ Field support installation, commissioning,
SUBMITTED services
ISO 9000 / ISO 14000 / CE Certification
Location , spares supply
Evaluation criteria Technical Requirement
Evaluated total cost
Commercial terms & condition
1. Pump Selection Optimise pump selection-

Efficiency, range of operation, NPSH, driver
rating, proven experience, competition analysis
THREE STEP
PROCESS FOR 2. Pump Scope of supply, data sheets, GA drawings,
GENERATING A configuration sectional drawing, spares list, pump curves
PUMP
QUOTATION
3. Pump quotation Complete quote package with list of deviations
Technical & Commercial Short listing of quotes

EVALUTING Bid Evaluation Technical bid evaluation
Technical quote clarifications
&
Technical purchase recommendations
PURCHASING THE
PUMPING Final Purchase Decision &
Issue of Purchase Order
EQUIPMENT
Optimisation of Pumping Life cycle cost and environmental

System implications
Information Technology Flow of information user

consultant contractor pump
maker - seal maker inspection
agency.
EMERGING
Software Piping software, pump system
TRENDS IN PUMP analysis software, pump design,
SELECTION & software ( CFD/ FEA), pump
PROCUREMENT selection systems, electronic data
exchange
Age of Alliance & Trust Limited no of pump vendors.
Wiki World Age of co-creation of value.

STEPS IN SELECTING AND PURCHASING PUMPS
Engineering of System Requirements
Future
Fluid Type system
Alternate changes
modes of
operation Margins
System Head Wear
curve
Selection of Pump and

Code Driver Driver Type
Requirements
Pump Fluid Pump

characteristics characteristics materials
PUMP Technical Specification
1
SPECIFICATION 1
Specification Scope of work
Technical
Types
Specifications
2
2 Work not included
Codes &
Standards 3 4
Rating & service Design &
3
condition Construction
Alternates 5
5 6
Commercial Driver Cleaning & Painting
4 Terms
8
Bidding 7
Drawing & Data
Documents Performance Testing
5
10
9
Technical Tools Basis for evaluation
Specifications
DATA SHEET/ PUMP SPECIFICATION
Project INFORMATION CONTENT

Information
Fluid data Pumping Site conditions Design

Driver
System data operating
information
conditions
Pump Mechanical Bearing Materials

& of Weight data
construction Seal
requirement information lubrication construction
Inspection Drawing,
Coating Piping Accessories & Test design & data
requirement Connection
requirements documents
DATA SHEET/ PUMP SPECIFICATION
ADDITIONAL INFORMATION
1 List of Deviations
2 Start up & insurance spares

3 Minimum thermal & stable flows
4 Preferred & allowable operating regions

5 Impeller to volute tongue clearance
6 Details of special seals & bearings
7 Impeller eye area

10 Requirement of tortional vibration analysis
8 Volute throat area
11 Material test report
9 Noise limits
12 Weld repair procedure
13 Coating requirement
14 Painting & packaging specifications
BID EVALUATION
1 RATED FLOW AS A PERCENT OF B.E.P FLOW
2
SPECIFIC SPEED & SUCTION SPECIFIC SPEED
3
NPSHa & NPSHr MARGINS AT RATED & MIN. FLOW
BID EVALUATION
4 IMPELLER EYE AREA
HYDRAULIC PERFORMANCE
5
NUMBER OF IMPELLER VANES
6
PERCENTAGE HEAD RISE TO SHUT-OFF
7
PUMP EFFICIENCY AT RATED & NORMAL FLOW RATES
8
MINIMUM CONTINUOUS FLOW (THERMAL/STABLE
9
MAXIMUM POWER
10
GUARANTEED NOISE LEVEL
BID EVALUATION
CONSTRUCTION DETAILS &
MECHANICAL PERFORMANCE
PUMP TYPE
SUCTION & DELIVERY
FLANGES - ORIENTATION
& RATING
IMPELLER TYPE
VOLUTE TYPE
IMPELLER SIZE - RATED,
MINIMUM &
MAXIMUM
MATERIAL MECHANICAL
COMPLIANCE SEAL DETAILS
GURANTEED
VIBRATION LEVEL
BEARING LIFE
BEARING TYPE &
LUBRICATION SHAFT DIAMETER
SHAFT STIFFNESS - AT COUPLING
L2/D4
BID EVALUATION - POINT RATING SYSTEM
Attribute Point Remarks
Price 40 Lowest price = 40 2xlowest = 0

Energy evaluated price to be considered
Makers Reputation 10 History of innovation, reputation for service & application help,
experience list
Our Experience 10 What is our experience with this supplier for similar equipment
Engineering Evaluation 15 Hydraulic characteristics, mechanical reliability indicators, parts

interchangeability
Industries Experience 10 What is the experience of other users in our industry with this
equipment
Service 10 Ability of supplier to provide technical support, repair service,
spare parts
Delivery Period 5 Current backlog of manufacturer and their ability to meet
delivery commitment
Total 100
1 Guaranteed Performance Q. H, NPSHr, Efficiency
Parameters
2 Pump Characteristics Closed valve head, maximum power, shape
of H-Q, Q- efficiency & Power
CRITICAL AREAS 3 Impeller Dimensions Rated maximum & minimum diameter, eye
IN BID diameter , eye area
EVALUTION
4 Mechanical Indicators Bearing span, L^2/D^4, bearing size / life.
Shaft diameter
5 Pressure Data Case thickness, maximum working
pressure, flange rating
6 Materials of Construction Case, impeller , shaft, wear rings
7 Limits Minimum flow thermal / stable, maximum

fluid temperature, Maximum sphere size.
8 Accessories Mechanical seal, coupling
STEPS IN SELECTING & PURCHASING PUMP
PUMP DATASHEET/SPECIFICATION
BID EVALUATION
BID EVALUATION POINT RATING SYSTEM
CONCLUSION
FORCES IN CENTRIFUGAL PUMPS
RADIAL THRUST
AXIAL THRUST
HYDRAULIC THURSTS GENERATED IN A CENTRIFUGAL PUMP
RADIAL THRUST
AXIAL THRUST
RADIAL THRUST
SUMMATION OF UNBALANCED HYDRAULIC FORCES ACTING RADIALLY. DUE TO UNEQUAL
VELOCITY OF THE FLUID FLOWING THROUGH THE CASING AT PART FLOW, A NON-UNIFORM
PRESSURE DISTRIBUTION EXISTS OVER THE CIRCUMFERENCE OF THE IMPELLER.
RADIAL THRUST IS AN IMPORTANT PARAMETER WHEN DESIGNING PUMPS MECHANICAL
ELEMENTS LIKE SHAFT AND BEARINGS.
SINGLE DOUBLE
VOLUTE VOLUTE
SECOND
CASING VOLUTE CASING
STATIC PRESSURE DISTRIBUTION

OVER THE IMPELLER OUTLET FOR
DIFFERENT CASING GEOMETRIES AT
PART FLOW REGIME
VANED
CONCENTRIC DIFFUSER
CASING
RADIAL THRUST IS A FUNCTION OF TOTAL HEAD OF THE PUMP
& WIDTH & DIAMETER OF THE IMPELLER
P = RADIAL THRUST IN POUNDS
K = THRUST FACTOR
P = K x H x D2 x b2 x S.G / 2.31 H = DEVELOPED HEAD/STAGE IN FT
D2 = IMPELLER DIA, IN INCHES
b2 = IMPELLER WIDTH IN INCHES(INCLUDING SHROUDS)
RADIAL REACTION VECTOR REPRESENTED BY

THE ARROWS AT DIFFERENT FLOW
CONDITIONS FOR A SINGLE VOLUTE CASING
RADIAL FORCE PERCENT OF FORCE AT SHUT
SHUT-OFF
FOR VOLUTE CASING
RADIAL FORCE FOR VARIOUS TYPES OF VOLUTES
AXIAL THRUST
SUMMATION OF UNBALANCED HYDRAULIC FORCES ACTING AXIALLY ON THE IMPELLER.
SEVERITY OF AXIAL THURST DEPENDS ON THE TOTAL HEAD, SUCTION PRESSURE &
MECHANICAL CONFIGURATION OF IMPELLER.
AXIAL PRESSURE ACTING ON THE IMPELLER SHROUDS TO PRODUCE AXIAL THRUST

The suction passages leading to the impeller eyes may not provide
uniform and equal flow to the two suction eyes.
SUCTION CORE
An external condition like an elbow fitted very close to the

suction nozzle with upstream pipe parallel to pump shaft, may
deliver unequal flow to two suction eyes.
BEND VERY CLOSE TO

PUMP SUCTION
Two sides of the discharge casing may not be symmetrical due to

casting errors or the impeller may be fitted off-center.
DELIVERY CORE IMPELLER INSTALLATION
Unequal leakage through the leakage joints such as wear rings on

both sides will contribute to the axial thrust imbalance.
LEAKAGE ACROSS TWO WEAR RINGS

RADIAL THRUST
AXIAL THRUST
OPTIMIZING PUMP TO SYSTEM PERFORMANCE
CRITICAL DIMENSIONS, TOLERANCES AND THEIR EFFECTS ON PUMP PERFORMANCE
SYSTEM CURVE & VARIOUS PUMPING SYSTEMS
PUMP-SYSTEM INTERACTION
IMPORTANCE OF ENERGY
LIFE CYCLE COST ANALYSIS
LCC & ENERGY IMPLICATIONS
ENERGY USAGE IN PUMPING SYSTEMS
BENEFITS OF LCC ANALYSIS

Component Description Fit or clearance
Ball bearing ID to shaft 0.0001-0.0007 in. interference
Ball bearing OD to housing 0.0005-0.001 in. clearance;

Bush housing if >0.0005in. oversize
Sleeve to shaft 0.001-0.0015 in. clearance
FITS Impeller to shaft Metal- to-metal to 0.0005 in clearance

&
Wear ring to wear ring Next slide follows
CLEARANCES
FOR Impeller ring to hub & case ring to 0.002- 0.003 in. interference
CEBTRIFUGAL casing
PUMP REPAIR Throat bushing to case 0.002-0.003 in. interference
Throat bushing to shaft 0.015-0.020 in. clearance
Coupling to shaft Metal- to-metal to 0.0005 in clearance
Deflector to shaft (set screw 0.002-0.003 in. clearance

mounted)
Seal running faces Flat with three light bands
Alignment fits for case, covers , 0.004 in.max. clearance; weld pads and
bearing housings, stuffing box re-machine if over-size
Diameter of Rotating Member Minimum Diametral Clearance
at Clearance (inches) ( inches) API 610
RECOMMENDED <2 0.010 12.000-12.999 0.024
2.000-2.499 0.011 13.000-13.999 0.025

WEAR RING
CLEARANCES 2.500-2.999 0.012 14.000-14.999 0.026
3.000- 3.499 0.014 15.000-15.999 0.027

FOR
3.500-3.999 0.016 16.000-16.999 0.028
CLOSED IMPELLERS
4.000-4.499 0.016 17.000-17.999 0.029
4.500-4.999 0.016 18.000-18999 0.030
5.000-5.999 0.017 19.000-19.999 0.031
6.000-6.999 0.018 20.000-20.999 0.032
7.000-7.999 0.019 21.000-21.999 0.033
8.000-8.999 0.020 22.000-22.999 0.034
9.000-9.999 0.021 23.000-23.999 0.035
10.000-10.999 0.022 24.000-24.999 0.036
11.000-11.999 0.023 25.000- 25.999 0.037

Bearing Fits & Mounting Tolerances
Loose Fit
A loose fit between the shaft and bearing inner ring or the bearing housing
and bearing outer ring can lead to relative movement between these
parts. Creep wears out the matting surfaces, increasing the clearance
between them. Eventually, the process can generate abnormal heat,
vibration & possible contamination from accumulated wear particles.
Tight Squeeze
In this case, excessive interference causes further problems that decreases

the service life for the bearing.
Too much interference builds higher stress which some times fractures the
inner ring.
Standard recommended tolerance for the bearing housing is ISO H6

& for shaft is ISO k5.
SYSTEM HEAD CURVE
ITS YOUR SYSTEM THAT CONTROLS YOUR PUMP.
ALL PUMPS MUST BE DESIGNED TO COMPLY WITH OR MEET THE NEEDS OF THE
SYSTEM & THE NEED OF THE SYSTEM IS RECOGNIZED USING THE TERM TDH
HERE, TDH = TOTAL DYNAMIC HEAD
TDH = Hs + Hp + Hf + Hv
Hs = STATIC HEAD (DIFFERENCE IN
DUTY POINT THE LIQUID SURFACE LEVELS AT
SUCTION SOURCE & DISCHARGE TANK
HEAD
FRICTION HEAD + VELOCITY HEAD

Hp = PRESSURE HEAD (CHANGE IN
PRESSURE AT SUCTION & DELIVERY
PRESSURE
TANK)
HEAD
THE SYSTEM HEAD CURVE Hs & Hp BEGINS AT ZERO Hv = VELOCITY HEAD

FLOW AT THE SUM OF Hs & Hp & RISES
EXPONENTIALLY WITH THE SQUARE OF THE FLOW Hf = FRICTION HEAD (HEAD LOSS
STATIC HEAD
DUE TO FRICTION ACROSS PIPES,

Hs & Hp EXISTS WHETHER THE PUMP IS RUNNING
VALVES, CONNECTIONS & SUCTION &
OR NOT WHEREAS Hf & Hv EXISTS ONLY AT THE
DELIVERY ACESSORIES).
RUN-TIME.
FLOW
NATURE OF SYSTEM CURVES
PUMP CURVE
TDH (M)
ALL FRICTION
INTERMEDIATE
STATIC DOMINANT
FLOW RATE(M3/HR.)
THREE DIFFERENT TYPES OF SYSTEM CURVES WITH A SINGLE COMMON FLOW
RATE/HEAD POINT
SYSTEM HEAD CURVE SUPERIMPOSED ON H-Q CURVE OF THE PUMP
H-Q CURVE
OPERATING
POINT
HEAD
SYSTEM
RESISTANCE
CURVE
FRICTION
TOTAL DYNAMIC HEAD

HEAD
(TDH)
STATIC
HEAD
FLOW
CHARACTERISTIC CURVE OF A PUMP IN AN ALL FRICTION SYSTEM
SHUT-OFF HEAD
SYSTEM CURVE
H-Q CURVE
BHP CURVE
HEAD
EFFICIENCY
CURVE
FLOW
VARIATION IN CAPACITY IN AN UNTHROTTLED SYSTEM TWO PUMPS
RUNNING IN PARALLEL
TWO PUMPS RUNNING IN SYSTEM CURVE

PARALLEL CORRESPONDING TO
LOWEST SUMP WATER
LEVEL
SYSTEM CURVE
OPERATING CORRESPONDING
POINTS TO HIGHEST
HEAD
SUMP WATER
LEVEL
ONE PUMP
RUN-OUT
FLOW
NORMAL FLOW
SHAPE OF SYSTEM CURVE CHANGES WITH APPLICATION BASED
SYSTEM CONFIGURATION
% FLOW AT B.E.P % FLOW AT B.E.P

% FLOW AT B.E.P
SYSTEM CURVES
PUMPING SYSTEMS - PUMPING STATION LAYOUT
TYPICAL LAYOUT OF A WATER SUPPLY PUMPING STATION

PUMPING SYSTEMS THERMAL POWER PLANT
SCHEMATIC DIAGRAM OF A CLOSED FEED WATER CYCLE

LIFE CYCLE COST ANALYSIS (LCC)
I Efficiency of a Centrifugal Pump
M
P
O
R Components of Pump Efficiency
T
A I) Hydraulic Efficiency
N
C II) Volumetric Efficiency
E
III) Mechanical Efficiency
OF
E B.E.P of a Pump is a Measure

F of
F Optimum Energy Conversion
I
C
I Efficiency is also an indicator
E of
N Mechanically Stable & Reliable Operation
C
Y
Importance of Pump Efficiency
I
m Computation of Cost of Additional Energy
p
o
r 1 n
t PWF = [1 + (1 + i) ]
a
n
(Present Worth Factor) i
Where, i = discounting / interest rate
c n = working life of pump in years
e
of
Cost of additional energy
E = PWF X DIFFERENTIAL POWER X ENERGY COST / KW-
KW-HR. X NO. OF
f HOURS OF PUMP OPERATION/YEAR
f
c
i
e Capitalized Cost of One Unit Difference in Efficiency is Equal to
n the Cost of the Pump
c
y
Check for the validity of the above statement
EXAMPLE . A petroleum refinery has finalized the following specification for eight
cooling tower pumps ( 6 working & 2 stand-by)
Q = 3600 m3/hr.
H= 45 m
N= 990 rpm
NPSHa = 13 m
The company is considering a minimum acceptable efficiency for inclusion in the
bid document. They are also considering inclusion of an energy loading figure for evaluating bids.
How do they go about specifying these two figures ?
Solution
To establish achievable level of efficiency, the refinery can use guide-lines of HIS.
Process will be as follows:-
1) Calculate pump specific speed - we assume that the pump will be selected at B.E.P
(Design point)& this will correspond to the duty point specified.
Specific Speed (Ns) = (NQ )/H3/4 or (9903600)/453/4 = 3418 (Metric) or 2943 (US
units)
For 3600 m3/hr. (15,854 Us G.p.m) & specific speed 3418 metric units (2943 US units)
HIS suggests Peak efficiency of 92% & variance of 2%.
Accordingly, the refinery may decide to impose the following ceiling:
Minimum acceptable efficiency = 91-2 = 89%
Maximum efficiency for evaluation = 91+2 = 93%

Calculating energy loading
The refinery can arrive at the energy loading figure on the following basis:-
Assuming, No. of hours of operation - 20 hrs./day
No. of days of operation - 300 days/year
Life of the project - 30 years
Cost of capital / interest rate - 9 %
Cost of power - US$ 0.08 / kW-hr.
Pump duty = 3600 m3/hr.@ 45 m head
Specific gravity of the pumping fluid = 1.0
Base power = 3600 x 45 x 1.0 / 3.67 / 89 = 496 kW.
Power with 90% efficiency = 3600 x 45 x 1.0 /3.67/ 90 = 490.5 kW.
Therefore power saving for 1 unit higher efficiency over the base = 5.5 kW.
Cost of power per kW = 1 kW x 20 hrs./day x 300 days/yr. x 0.08 US$/kW-hr.
Or US$ 480 per year.
PWF = (1/0.09) x [1- (1+0.09)-30] = 10.273
Energy loading = Cost of Energy per kW per year x PWF
= US$ 480 X 10.273 = US$ 4931
Or approximately US$ 5000 per kW
This means that a pump with efficiency of 90% will receive energy loading advantage
of 5.5 Kw x US$ 5000 = US$ 27,500
The price of a circulating water pump of the above specification is likely to be

around US$ 30,000.
We can therefore conclude that the following statement is largely true:

Utilized as a powerful management tool that helps
I in
m
Expert Evaluation of Industrial Process System
p
o
r LCC relates to maximizing efficiency not merely minimizing wastage
t
a Reducing Life Cycle Cost means Optimization of
n
c DESIGN
e
OPERATION DRIVER SYSTEM
of
MAINTENANCE FLUID DYNAMICS
E
f ENERGY SITE INTERFACES
f
c
i PIPING ACCESSORIES
e
n CONTROL INSTRUMENTATION
c
y
Total life-time cost to purchase, install, operate, maintenance & dispose
LCC = Cic + Cin + Ce + Co + Cm + Cs + Cenv + Cd
Where,
Cic = Initial Cost

Cin = Installation Cost & Commissioning Cost
Ce = Energy Cost
Co = Operating cost
Cm = Maintenance & repair cost
Cs = Down-time cost
Cenv = Environmental cost
Cd = Disposal/decommissioning cost
INITIAL COST (CIC)
COST COMPONENTS
INITIAL COST OF PUMP & PUMPING SYSTEM
COST FOR ENGINEERING (DESIGN, DRAWING & REGULATORY ISSUES
COST FOR BID PROCESS
COST FOR PURCHASE ORDER ADMINISTRATION

COST FOR TESTING
COST FOR INSTALLATION
COST FOR SPARE PARTS INVENTORY
COST FOR TRAINING & AUXILLIARY EQUIPMENT
INFLUENCING FACTORS
SIZE & DESIGN OF PUMP PIPINGS
PUMP OPEARATING SPEED
THE QUALITY & DUTY RATING OF EQUIPMENT
MATERIAL OF CONSTRUCTION
CONTROL SYSTEM
INSTALLATION & COMMISSIONING COST (CIN)
COST COMPONENTS
COST FOR FOUNDATIONS
COST FOR GROUTING
COST FOR CONNECTING TO PROCESS PIPINGS
COST FOR CONNECTING TO ELECTRICAL WIRINGS

COST FOR CONNECTING AUXILLIARY SYSTEM OR OTHER UTILITIES
COST FOR EQUPMENT ALLIGNMENT
COST FOR FLUSHING OF PIPINGS
COST FOR PERFORMANCE EVALUATION AT START UP
INFLUENCING FACTORS
ACCURACY INSTALLATION ACITIVITIES
SKILLS & TOOLS REQUIREMENT TO COMPLETE INSTALLATION
AVAILABILITY OF COMPETENT PERSONNEL FOR INSTALLATION
ATTENTION TO EQUIPMENT MANUFACTURERS INSTRUCTION FOR INSTALLATION

ENERGY COST (CE)
PREDICTED COST FOR SYSTEM OPEARATION INCLUDING PUMP DRIVER, CONTROLS &
AUXILIARY SERVICES
INFLUENCING FACTORS
PERFORMANCE OF PUMP/SYSTEM OVER THE O/P RANGE
OPEARATING POINT OF PUMP W.R.T TO ITS B.E.P
DRIVER SELECTION & APPLICATION
ENERGY LOADS DUE TO CONTROL/SENSING SYSTEM
USE OF CONTROL MECHANISM FOR VARYING THE O/P

OPEARATING COST (CO)
LABOUR COSTS RELATED TO THE SUPERVISION OF NORMAL SYSTEM OPEARATION
INFLUENCING FACTOR
COMPLEXITY & DUTY OF THE SYSTEM
MAINTENANCE & REPAIR COST (CM)
COST FOR ROUTINE & PREDICTED REPAIRS
OPTIMUM LIFE OF THE PUMP CAN BE ENSURED BY REGULAR & EFFECTIVE MAINTENANCE
INFLUENCING FACTORS
FREQUENCY & THE EXTENT OF ROUTINE MAINTENANCE
SELECTION OF MATERIAL OF CONSTRUCTION

EASE ACCESS TO PUMP PARTS
DOWN-TIME COST (CS)
COST OF UNEXPECTED DOWN TIME & LOST PRODUCTION
INFLUENCING FACTOR
DESIGN & TARGET LIFE OF A PUMP
OCCURANCE OF UNEXPECTED FAILURE
ENVIRONMENTAL COST (CE)
COST OF CONTAMINANT DISPOSAL DURING THE LIFE TIME OF THE PUMPING SYSTEM
INFLUENCING FACTORS
NATURE OF PUMPED PRODUCT (TOXIC/RADIOACTIVE OR OTHER)
COST OF ENVIRONMENTAL INSPECTION

LEAKAGE DISPOSAL OF COOLING WATER, SEALING FLUID & LUBRICATION
DISPOSAL/DECOMMISIONING COST (CD)
COST OF DISPOSAL & DECOMMISIONING INCLUDING RENOVATION OF LOCAL

ENVIRONMENT & DISPOSAL OF AUXILLIARY SERVICES
INFLUENCING FACTOR
DESIGN & APPLICATION OF PUMPING SYSTEM

PUMP RELIABILITY FACTORS
RELIABILITY
TYPE INSTALLATION APPLICATION OPERATION MAINTAINANCE
BASEPLATE MECHANICAL START-UP TRAINING

END
SUCTION SEAL
ALLIGNMENT SHUT-DOWN TOOLS
DOUBLE BEARING
FACILITY
SUCTION PIPING MAX. FLOW
LUBRICATION
CONFG. RECORDS
MULTI-STAGE COUPLING MIN. FLOW
PIPE STRAIN
ANSI SHAFT PARALLEL OPERATION
API HYDRAULIC SERIES OPERATION

VERTICAL B.E.P
R.P.M
IMPELLER DIA.
NPSH MARGIN
SUCTION ENERGY
RELATIVE PROPORTION OF LCC COMPONENTS IN A TYPICAL PUMPING SYSTEM
TYPICAL LIFE CYCLE COSTS (LCC) ANALYSIS OF A

PUMPING SYSTEM
25% MAINTAINANCE( 25%)

OPERATING( 10%)
40%
DOWNTIME( 3%)
ENVIRONMENTAL( 5%)
10% INSTALLATION( 7%)
PUMP( 10%)
3%
5% ENERGY( 40%)
10% 7%
Life Cycle Cost
Cost Total
Optimum
Pipe Diameter
To be
replaced
274+275
Economy of pump system installation
Minimum flow velocity required for the application to

avoid sedimentation
Minimum internal diameter required for the

application for solid handling
Maximum flow velocity to minimise erosion in piping

& fittings
Plant standard for pipe diameters

Energy Usage in Pumping System
The energy usage depends on
Design of the Installation

Pumping systems
account for 20% of the
worlds electrical energy The Way the system is Operated
demand
Design of the Pump
25-50% of the energy

usage in industrial Above three factors are independent &
plants. need to be carefully matched &
should remain the same throughout
the working life
Reduction of energy cost has

important environmental
benefits
PUMPING - SHARE OF ELECTRICITY USE IN INDIA
2.5%
POWER PLANT UTILITY

21.6% ( 2.5%)
AGRICULTURE ( 21.6%)
1.5% PUBLIC WATER WORKS

( 1.5%)
60.2% 14.2% INDUSTRY ( 14.2%)
ALL NON-PUMPING
END USES ( 60.2%)
Methods for Analyzing Existing Pumping Systems
Assemble a
complete document
inventory of the
items in the Determine the
pumping system flow-rates
required for Balance the system to
each location meet the required flow
rate of each location
Minimize system
losses needed to
balance the flow-
rate Affect changes
to the pump to
minimize Identify pumps with
excessive pump high energy and
head in the maintenance costs
balanced system
Estimated Component-wise Energy Consumption
(In a Typical Pumping Application )
MOTOR (8%)
8%
18%
PUMP (20%)
20%
THROTTLE (25%)
29% PIPING (29%)

25%
DELIVERED ENERGY (8%)
HELPS TO IDENTIFY DIFFERENT COST COMPONENTS & ESTIMATE

THEIR RELATIVE PROPORTION IN TOTAL COST OF A
PUMPING SYSTEM
CRITICAL DIMENSIONS, TOLERANCES AND THEIR EFFECTS ON PUMP PERFORMANCE
SYSTEM CURVE & VARIOUS PUMPING SYSTEMS
PUMP-SYSTEM INTERACTION
IMPORTANCE OF ENERGY
LIFE CYCLE COST ANALYSIS
LCC & ENERGY IMPLICATIONS
ENERGY USAGE IN PUMPING SYSTEMS

UNDERSTANDING PUMPING SYSTEMS
&
MATERIALS OF CONSTRUCTION
UNDERSTANDING PUMPING SYSTEMS
PUMPING SYSTEMS
VARIOUS SYSTEM CURVES
PROPER SELECTION OF PUMPS OPTIMISATION

OF PUMP-SYSTEM INTERACTION
CONTROL METHODS FOR VARYING PUMP

OUTPUT - ENERGY IMPLICATIONS
SUMP DESIGN GUIDLINES
SUCTION PIPING ARRANGEMENT

SYSTEM HEAD CURVE
ITS YOUR SYSTEM THAT CONTROLS YOUR PUMP.
ALL PUMPS MUST BE DESIGNED TO COMPLY WITH OR MEET THE NEEDS OF THE
SYSTEM & THE NEED OF THE SYSTEM IS RECOGNIZED USING THE TERM TDH
HERE, TDH = TOTAL DYNAMIC HEAD
TDH = Hs + Hp + Hf + Hv
Hs = STATIC HEAD (DIFFERENCE IN
DUTY POINT THE LIQUID SURFACE LEVELS AT
SUCTION SOURCE & DISCHARGE TANK
HEAD
FRICTION HEAD + VELOCITY HEAD

Hp = PRESSURE HEAD (CHANGE IN
PRESSURE AT SUCTION & DELIVERY
TANK)
PRESSURE
HEAD
THE SYSTEM HEAD CURVE Hs & Hp BEGINS AT ZERO Hv = VELOCITY HEAD

FLOW AT THE SUM OF Hs & Hp & RISES
EXPONENTIALLY WITH THE SQUARE OF THE FLOW Hf = FRICTION HEAD (HEAD LOSS
DUE TO FRICTION ACROSS PIPES,
Hs & Hp EXISTS WHETHER THE PUMP IS RUNNING
STATIC HEAD
VALVES, CONNECTIONS & SUCTION &

OR NOT WHEREAS Hf & Hv EXISTS ONLY AT THE
DELIVERY ACESSORIES).
RUN-TIME.
FLOW
NATURE OF SYSTEM CURVES
PUMP CURVE
TDH (M)
ALL FRICTION
INTERMEDIATE
STATIC DOMINANT
FLOW RATE(M3/HR.)
THREE DIFFERENT TYPES OF SYSTEM CURVES WITH A SINGLE COMMON FLOW
RATE/HEAD POINT
SYSTEM HEAD CURVE SUPERIMPOSED ON H-Q CURVE OF THE PUMP
H-Q CURVE
OPERATING
POINT
SYSTEM
HEAD
RESISTANCE
CURVE
FRICTION
TOTAL DYNAMIC HEAD

HEAD
(TDH)
STATIC
HEAD
FLOW
CHARACTERISTIC CURVE OF A PUMP IN AN ALL FRICTION SYSTEM
SHUT-OFF HEAD
SYSTEM CURVE
H-Q CURVE
BHP CURVE
HEAD
EFFICIENCY
CURVE
FLOW
VARIATION IN CAPACITY IN AN UNTHROTTLED SYSTEM TWO PUMPS
RUNNING IN PARALLEL
TWO PUMPS RUNNING IN SYSTEM CURVE

PARALLEL CORRESPONDING TO
LOWEST SUMP WATER
LEVEL
SYSTEM CURVE
OPERATING CORRESPONDING
POINTS TO HIGHEST
HEAD
SUMP WATER
LEVEL
ONE PUMP
RUN-OUT
FLOW
NORMAL FLOW
SHAPE OF SYSTEM CURVE CHANGES WITH APPLICATION BASED
SYSTEM CONFIGURATION
% FLOW AT B.E.P % FLOW AT B.E.P

% FLOW AT B.E.P
SYSTEM CURVES
PUMPING SYSTEMS - PUMPING STATION LAYOUT
TYPICAL LAYOUT OF A WATER SUPPLY PUMPING STATION

PUMPING SYSTEMS THERMAL POWER PLANT
SCHEMATIC DIAGRAM OF A CLOSED FEED WATER CYCLE

PUMPSENSE
NFPA 20 Fire Pumps - Hydraulic Performance Requirement
Closed valve B.E.P flow at full Maximum power Pump must

head should diameter should should correspond to pass 15 ft
not be higher be close to 150% the nearest available suction lift test
than 120% of of rated flow for motor rating. at both max.&
the rated head as many rated This means that the min. impeller
capacities as power curve should be dia. Head
possible flat or non-overloading. break down is
allowed at
Max. power for each 150% of rated
rated capacity can be flow as long as
identified based on it meets 65% of
available motor ratings. rated head with
15 ft total lift
NFPA 20 Fire Pumps -Special Challenges for The Pump
Designer
To obtain a steep H-Q

characteristic in a low
specific speed pump
To obtain, preferably, a
non-overloading power
curve in a low specific
speed pump
Design an economical
unit which meets the high
test pressure requirement
of UL (Maximum
pressure + 75 psi) x 2
Achieve 15 ft. suction
lift at 150% flow
without head breaking
below 65% of the rated.
This poses a design
challenge, particularly
for low impeller trims.
PUMPSENSE
Mechanical Performance Requirements of NFPA 20 Fire Pump
Shaft Stress &

Compliance to UL448 Split-flange Bolting Stress
The maximum combined The maximum stress on any bolt of a
shear stress in a pump pressure holding casting shall not exceed
shaft shall not exceed 30% of the elastic limit of the material as
of the elastic limit in computed by using the stress formula as
tension or be more than follows:
18% of the ultimate tensile As = 0.7854 (D 0.9743/n)2
strength of the shafting Where,
steel used As = Stress area inch 2
D = Nominal dia. of bolt in inches
n = No. of threads per inch
Bolting Stress = Split-flange area x Max.
working pressure/No. of Bolts/Stress
area per bolt (exposed to hydraulic
pressure)
PUMPSENSE
Typical Fire Pump Curve

CLAUSE NO. SUBJECT PUMPSENSE - COMPLIANCE STATEMENT
4.5 BOLT DIAMETER All bolts, studs, cap screws, etc used to assemble parts
Compliance to UL 448 Pumps for Fire Protection subject to stress due to water pressure is 3/8 (9.5 mm) or
more in diameter.
4.6 INTERIOR BOLTS / All internal bolts or screws expand to pumped fluid is made
SCREWS of bronze or other corrosion resistant material
4.9 DYNAMIC Rotating elements are dynamically balanced to G 6.3

BALANCING balance quantity as per ISO-1940.
Service
4.10 PUMP FLANGE Pump flanges conform to ANSI/ASME B 16.1-1989.

5.1 Pump casing can be dismantled easily to inspect the
impeller and other internals without disturbing the suction
PUMP CASING & delivery pipe work. Jack screws are positioned on top half
casing to facilitate dismantling.
5.3 DRAIN OPENING Drain opening are provided such that all parts of the pump
casing can be drained. Threaded drain openings are plugged
by SS plugs.
6.1 NON-GALLING Wear rings are made in BS1400LB2 material. This material is
WEAR RING chosen for its bearing and anti-galling properties.
MATERIALS
CLAUSE NO. SUBJECT PUMPSENSE - COMPLIANCE STATEMENT
Compliance to UL 448 Pumps for Fire Protection 6.2 CORROSION

RESISTANT
All pump internals coming in contact with the liquid
pumped are manufactured in corrosion resistant bronze
INTERNALS or stainless steel.
6.4 Impeller width at the outlet, b2 , is chosen to comply

with this clause:
b2 > 7.9 mm for Q upto 500 gpm
IMPELLER WIDTH b2 > 12.7 mm for Q between 500 & 700 gpm
b2 > 15.9 mm for Q greater than 750 gpm
Service
6.5 The radial clearance between the stationary and moving

RADIAL parts, such as impeller & wear ring is kept more than
CLEARANCE 0.0075 inch (0.191mm).
6.6 SECURING Impellers are positively secured by keys, sleeves & sleeve
IMPELLERS nuts against any axial movement.
6.7 CLOSED TYPE All impellers are fully shrouded.
IMPELLER
9.1 L-10 rating of bearings selected complies with this
BEARING LIFE clause. Bearing life is in excess of 17,500 hours when the
pump is operated within allowable operating region.
Selecting A Pump That Best Suits Your System
First Steps to Ensure Right Selection of Pump:
Correct Estimation of Duty Requirement
-Wrong estimation of duty parameters and multiple

margins force a pump to operate sub-optimally
Selection of Suitable Pump Type & Speed
-The type of the pump selected and its operating speed also
determine how efficiently the system demand can be met
Wrong Estimation of System Curve & its Effect on Pump Performance
ESTIMATED SYSTEM HEAD GREATER THAN THE ESTIMATED SYSTEM HEAD LESS THAN THE
ACTUAL HEAD ACTUAL HEAD
B.E.P
DUTY POINT
DUTY POINT
B.E.P
PUMP OPERATES TO THE RIGHT OF B.E.P PUMP OPERATES TO THE LEFT OF B.E.P
POSSIBLE SYSTEM ESTIMATION PROBLEMS & THEIR REMEDIES
PROBLEMS
OVER ESTIMATED HEAD REMEDY
SUB-OPTIMAL PUMP PERFORMANCE. TO REDUCE FLOW TO THE DESIRED LEVEL

PUMP DISCHARGES MORE THAN THE SOME FLOW CONTROL TECHNIQUE
DESIRED. CAN BE APPLIED.
MOTOR MAY GET OVER-LOADED
CAUSING FREQUENT TRIPPING .
NPSHa MAY NOT BE SUFFICIENT TO
PREVENT CAVITATION.
UNDER ESTIMATED HEAD REMEDY

SUB-OPTIMAL PUMP PERFORMANCE. REDUCING THE FRICTION HEAD BY
PUMP WILL DISCHARGE LESS THAN THE CHANGING THE DELIVERY PIPE - USING
DESIRED. LARGER SIZE OF PIPE.
CHANGING THE PUMP / IMPELLER WITH
ONE HAVING RELATIVELY STEEPER H-Q
CURVE THAT WILL GIVE MORE FLOW &
HEAD AT THE OPERATING POINT.
Criteria for Selection of Suitable Type of Pump
Pumps Inherent Contradictions in Design Objectives
Achieve design flow rate and total head.
Attain optimum efficiency.
Obtain stable head-capacity characteristics.
Minimize NPSH required.
Ensure wide operating range.
Optimize pump size.
Attain non-overloading power characteristics.
Minimize vibration and noise.
Minimize hydraulic axial and radial thrust loads.
Design for ease of production.
Ensure maximum interchangeability.
Minimize cost.
CONTROL POSSIBILITIES FOR CENTRIFUGAL PUMPS
THROTTLING
CONNECTION OR DISCONNECTION OF PUMPS

PUMP OUTPUT CAN BE - RUNNING IN PARALLEL
CONTROLLED BY THE - RUNNING IN SERIES
FOLLOWING METHODS
BYPASS REGULATION
SPEED REGULATION
IMPELLER VANE & WIDTH ADJUSTMENTS
PREROTATION CONTROL
CAVITATION CONTROL
FIVE VANE IMPELLER
SIX VANE IMPELLER

THROTTLING & LOSSES DUE TO THROTTLING
WHEN THE REQUIRED DISCHARGE OF A

PUMP IS LESS THAN THE NORMAL
DISCHARGE OF A PUMP RUNNING AT
CONSTANT SPEED, THROTTLING IN THE
DISCHARGE LINE IS ADOPTED.
IT CAUSES AN INCREASE IN THE FRICTION
HEAD.
THE DELIVERY HEAD RISES WITH A
CONSEQUENT DROP IN THE DISCHARGE
QUANTITY THUS ULTIMATELY LOWERING
THE EFFICIENCY.
THROTTLING CONTROL SHOULD BE
APPLIED MAINLY ON RADIAL FLOW
PUMPS.
EXCESS FLOW
FOR HIGH SPECIFIC SPEED PUMPS THE
POWER INPUT RISES WHEN THROTTLING
IS DONE. THIS MAY CAUSE MOTOR OVER-
LOAD.
BYPASS REGULATION
BYPASS CONTROL SYSTEM
ANOTHER WAY OF CONTROLLING PUMP OUTPUT
PUMP DISCHARGE IS DIVIDED INTO TWO FLOW PATHS
ONE PART (REQUIRED O/P, (Q1))DIRECTED THROUGH THE DISCHARGE LINE
THE OTHER PART (SUPERFLUOUS PORTION, (Q2-Q1)) FED INTO THE SUCTION LINE AGAIN
PARALLEL OPERATION
DISCHARGE
HEADER
WHEN THE SYSTEM FLOW DEMAND

SUCTION HEADER VARIES OVER
A WIDE RANGE,
PARALLEL OPERATON OF SEVERAL
SMALL PUMPS INSTEAD OF A SINGLE
LARGE ONE MAY BE EMPLOYED.
COMBINED H-Q CURVE IS OBTAINED

BY ADDING THE DISCHARGES
GENERATED BY INDIVIDUAL PUMPS AT
THE SAME HEADS.
SERIES OPERATION OF PUMPS
SERIES OPERATION FOR SYSTEMS WITH

HIGH HEAD REQUIREMENT
Combined curve obtained by adding the

heads developed by individual pumps at
the same flow rates
SERIES Vs. PARALLEL OPERATION SELECTING THE RIGHT
COMBINATION
1. When the system head curve is When the system head curve is fairly flat
steep series pumping gives more parallel pumping may give more flow
flow
SERIES OPERATION
PARALLEL OPERATION
SERIES Vs. PARALLEL OPERATION SELECTING THE RIGHT
COMBINATION
2 . Using parallel pumps can be beneficial because these installations often:
Cost less to buy, install & maintain compared to a single large pump
Takes less space in the equipment room ( specially when one is using in-line
pumps that may be stacked.)
Uses less energy
Provides better than 50% flow redundancy during single pump operation
3. For small systems or the systems that rarely demand variability in flow parallel
operation may not be appropriate
Of course, if the system requires 100% flow redundancy the designer must provide
a single pump system with another 100% stand-by pump.
4 . WHEN THE SYSTEM HEAD CURVE IS OF FLAT TYPE (STATIC COMPONENT
REPRESENTS SIGNIFICANT PORTION OF THE HEAD) PARALLEL OPERATION IS
PREFFERABLE.
In two pump arrangement in series operation if one pump fails the other pump
developing only half of the total head required and may not over-come the static
component of the system head
SYSTEM HEAD CURVE

RESULTANT CURVE FOR SERIES OPERATION
RESULTANT CURVE FOR PARALLEL

OPERATION
INDIVIDUAL PUMP CURVE
(chosen for parallel operation)
INDIVIDUAL PUMP CURVE

(chosen for series operation)
SPEED REDUCTION TO MEET LOWER DUTIES - A MORE ENERGY
EFFICIENT WAY THAN IMPELLER TRIMMING OR THROTTLING
VARIABLE SPEED DRIVES CAN BE UTILIZED AS AN IMPORTANT ENERGY SAVING TOOL
HEAD
FLOW
USE OF VSDs TO MATCH THE PUMP WITH VARIABLE SYSTEM NEEDS

USE of VSDs
MAJOR CONSIDERATIONS
Annual saving in energy in kWh

VSDs ARE IDEAL
% reduction in energy usage WHEN
Annual savings in energy cost
System demand varies continuously over a
Initial & installation cost of vsd wide range of flows
Present value of annual savings in System static head constitutes a small

energy for the life of the project portion of the total dynamic head or total
head of the pump
Payback period
Normal flow rate is significantly less than the
max. flow rate
duration of operation at maximum flow

point is short
Benefits of VFDs
Saving in Energy Cost

Reliability Improvement
Soft Start & Stop
Reduced Maintenance
Simplified Pipe System (Elimination of
Control Valve & By-pass line)
GUIDELINES FOR PROPER SUMP DESIGN
The intake structure should be designed to allow the pumps to achieve their optimum hydraulic
performance for all operating conditions.
1 To ensure uniform velocity 2 To avoid submerged vortices.

distribution at pump suction
DESIGN
OBJECTIVES
3 To avoid free surface 4 To prevent excessive pre-
vortices swirling of flow entering the pump
5 To avoid air entrainment into

the system
A good intake design ensures that the

adverse flow phenomenon will be
within acceptable limits.
ADVERSE EFFECTS OF IMPROPER SUMP DESIGN
INADEQUATE SUMP DESIGN LEADS TO ENTRAINED

AIR BUBBLES & TURBULANCE
ENTRAINED AIR INSIDE PUMPS
USE OF BAFFLES
PROPER PIPING ARRANGEMENT ON SUCTION SIDE
MAKING SUCTION SMOOTH & EASY
ASYMMETRICAL VELOCITY PROFILE IS A MAJOR CAUSE OF HYDRAULIC DISTURBANCES.
THE PUMP SUCTION BELL
1. REDUCES THE CONTRACTION AND

ENTRANCE LOSSES BY SMOOTHENING THE
FLOW AND BY ELIMINATING SHARP INLET
EDGES.
2. REDUCES THE MEAN APPROACH

VELOCITY OF FLUID WHICH VARIES
DIRECTLY WITH THE MINIMUM
SUBMERGENCE . SUBMERGENCE ALSO
INFLUENCES FORMATION OF SUBMERGED
VORTICES.
BELL-MOUTH INLET
3. PREVENTS SWIRLING MOTION OF
THE FLUID APPROACHING THE BELL.
THE RULE OF 10D
THE SUCTION LINE SHOULD BE AS
SHORT AS POSSIBLE
1. OPTIMUM LENGTH OF A FULL-SIZE

STRAIGHT PIPE, DEVOID OF ANY FLOW-
OBSTRUCTION, IMMEDIATELY UPSTREAM
OF THE PUMP SUCTION CONNECTION,
SHOULD BE 10D.
2. THE MINIMUM LENGTH OF A FULL SIZE

STRAIGHT PIPE DEVOID OF ANY FLOW-
OBSTRUCTION, IMMEDIATELY UPSTREAM
OF THE PUMP SUCTION CONNECTION,
SHOULD BE 5D.
RELATION BETWEEN SUBMERGENCE DEPTH OF SUCTION PIPE & FLUID VELOCITY
(GOOD TO ABOUT 3000 GPM OR 680 M3/HR.)

SUCTION PIPE ARRANGEMENT
CORRECT SUCTION PIPING LEADING TO THE PUMP

PROPER PIPING ARRANGEMENT ON DISCHARGE SIDE
GUIDELINES FOR PROPER HEADER CONNECTION
CORRECT MANNER
SEPARATE &
DEDICATED SUCTION
LINES WHERE
MULTIPLE PUMPS
TAKING SUCTION
FROM A COMMON
SUCTION HEADER
PROPER
ARRANGEMENT
PROMOTES
STREMLINED
FLOW & REDUCES
FLUID FRICTION
AND
CONTRACTION
LOSSES
PLAN VIEW OF PIPE MANIFOLD ARRANGE MENT

USE CHECK VALVE & SUCTION STRAINER ONLY WHEN ITS
ABSOLUTELY NEEDED
HIGH AMOUNT OF ENERGY

LOSSES OF FLUID ENTERING
INTO THE PUMP
AREAS IN THE SYSTEM THAT ARE PRONE TO AIR-ACCUMULATION
SUCTION LINE SHOULD RISE CONTINUOSLY TOWARDS THE PUMP.
PIPING SHOULD RUN DIRECTLY

HIGH SPOT PRONE TO AIR VERTICALLY OR HORIZONTALLY INTO
ACCUMULATION THE PUMP WITHOUT HIGH POCKETS
( HIGH-SPOTS) THAT CAN CAUSE AIR
ACCUMULATION.
AREAS IN THE SYSTEM THAT ARE PRONE TO AIR-ACCUMULATION
AT SUCTION HEAD CONDITION
PUMPING SYSTEM SHOULD INCORPORATE

FLAT BOTTOM REDUCER WHEN THE PUMP IS
RUNNING AT SUCTION HEAD CONDITION.
AT SUCTION LIFT CONDITION

PUMPING SYSTEM SHOULD INCORPORATE
FLAT TOP REDUCER WHEN THE PUMP IS
RUNNING AT SUCTION LIFT CONDITION.
DOUBLE SUCTION PUMP SHOULD HAVE PIPE ELBOWS
PERPENDICULAR TO THE PUMP SHAFT.
POOR SUCTION PIPE ARRANGEMENT

HAVING BEND IN THE SAME PLANE AS OF
THE SHAFT
INCORRECT
GOOD SUCTION PIPE ARRANGEMENT

HAVING BEND PERPENDICULAR TO THE
PLANE OF THE SHAFT
CORRECT
PUMPING SYSTEMS
VARIOUS SYSTEM CURVES
PROPER SELECTION OF PUMPS OPTIMISATION

OF PUMP-SYSTEM INTERACTION
CONTROL METHODS FOR VARYING PUMP

OUTPUT - ENERGY IMPLICATIONS
SUMP DESIGN GUIDLINES
SUCTION PIPING ARRANGEMENT

MATERIALS OF CONSTRUCTION
FACTORS AFFECTING MATERIAL SELECTION
MATERIAL PROPERTIES
CORROSION, EROSION & WEAR
COMMON & SPECIAL MOC
MATERIALS GUIDELINES - HIS
MATERIAL FOR MAJOR PUMP PARTS

BASIS OF MATERIAL SELECTION
LIFE OF A PUMP LARGELY DEPENDS UPON A PROPER SELECTION OF MATERIALS, SPECIALLY
FOR AGGRESSIVE SERVICES.
EROSION
PROCESS COST
VARIATION
MANUFACTURING
TECHNIQUES
CORROSION
MATERIAL
&
MATERIAL
COMBINATION COMPATIBILITY
PROCESS UPSET
CONDITIONS
WEAR
CAVITATION
STRENGTH
OPTIMIZATION OF LIFE CYCLE COST
OPTIMIZATION OF LIFE CYCLE COST (LCC) REQUIRES OPTIMIZATION OF:
OPERATIONAL COST
REPLACEMENT COST
SERVICE DURATION & FREQUENCY
REPAIRING COST
GENERAL DESIGN OF THE PUMP & ITS SERVICE APPLICATION
THE GENERAL DESIGN OF PUMPS SELECTED FOR A PARTICULAR APPLICATION

DICTATES THE TYPE OF MATERIALS TO BE USED.
EACH DESIGN HAS ITS OWN STANDARD MATERIALS OF CONSTRUCTION AS THE

DESIGN IS SPECIALLY COMPATIBLE FOR THE INTENDED SERVICE .
TEMPARATURE OF THE PUMPED LIQUID
NEUTRAL LIQUIDS AT AMBIENT TEMPARATURE ADD TO THE LIFE OF PUMP
SELECTED MATERIALS NEED TO BE ASSOCIATED WITH AN ACCEPTABLE TEMPARATURE RANGE DURING

PUMPING.
TEMPARATURE OF THE PUMPED LIQUID AFFECTS
CHEMICAL NATURE OF THE MATERIALS - EROSION & CORROSION RESISTANCE
PHYSICAL NATURE OF THE MATERIALS - PHASE TRANSITION
THERMAL EXPANSION - FITS & ALIGNMENT

pH VALUE OF THE PUMPED LIQUID & ITS EFFECT ON MATERIAL SELECTION

pH IS ONE OF THE CRITICAL WATER CHEMISTRY PARAMETERS WHICH INFLUENCES MATERIAL
SELECTION
pH VALUE OF A LIQUID OR SOLUTION:
QUANTATIVE REPRESENTATION OF RELATIVE ACIDITY OR ALKALINITY OF A SOLUTION.
ITS THE NEGATIVE LOGARITHM OF H+ ION CONCENTRATION [H+].
pH = log [ H+ ]
pH VALUES OF COMMON LIQUIDS FOR PUMPING

APPLICATIONS
PUMPING LIQUID pH VALUES

NATURAL WATER 7-8
ACIDIC MINE WATER 2-6
ALKALINE MINE WATER 9 - 11

EFFECT OF TEMPERATURE ON pH VALUE OF THE LIQUID
THE pH OF A SOLUTION VARIES SOMEWHAT WITH THE TEMPERATURE CHANGE DECREASING

RATHER RAPIDLY UPTO 1490C(3000F) & REMAINING FAIRLY CONSTANT AT HIGHER
TEMPERATURES.
GENERAL RECOMMENDATION OF MATERIALS FOR ACIDIC & ALKALINE LIQUID SERVICES
FOR pH BETWEEN 6.0 & 8.5 AT PUMPING TEMPARATURE
STANDARD BRONZE FITTED PUMP

CASING CAST IRON
SHAFT STAINLESS STEEL
IMPELLER BRONZE
WEAR RING BRONZE
SLEEVE(IF NEEDED) BRONZE
FOR pH LESS THAN 6.00 (ACIDIC)
ALL BRONZE PUMP

STAINLESS STEEL FITTED PUMP / ALL STAINLESS STEEL PUMP
FOR pH GREATER THAN 8.5 (ALKALINE)
ALL IRON PUMP / ALL STAINLESS STEEL PUMP

MAXIMUM WORKING PRESSURE & MATERIAL SELECTION
WORKING PRESSUER,TEST PRESSURE & CASING THICKNESS

CASING THICKNESS IS GOVERNED BY
1. MAXIMUM TEST PRESSURE = 1.5 x MAXIMUM WORKING PRESSURE
2. CORROSION ALLOWANCE
3. MATERIAL OF CASING
LAMES EQUATION IS USED WITH THIN CYLINDER IDEALISATION FOR DETERMINIG THE MINIMUM
REQUIRED CASING THICKNESS,
t = p x r/s
WHERE, t = MINIMUM BASIC CASING THICKNESS
p = MAXIMUM TEST PRESSURE
r = CASING RADIUS AT VERTICAL SECTION THROUGH TOP-HALF CASING
s = MAXIMUM ALLOWABLE STRESS
THE FOLLOWING MATERIALS FOR CASING ARE SELECTED IN ASCENDING ORDER OF MAXIMUM TEST
PRESSURE
CI FG 220
CI FG 260
DUCTILE IRON GGG50
CAST STEEL WCB
MARTENSITIC STAINLESS STEEL CA 15
MATERIAL PROPERTIES - CHEMICAL & PHYSICAL
THE FOLLOWING MATERIAL PROPERTIES PLAY IMPORTANT ROLE FOR

MATERIAL SELECTION
CORROSION RESISTANCE
EROSION RESISTANCE
WEAR RESISTANCE
GALVANIC CORROSION
GALLING RESISTANCE
MICROSTRUCTURE OF METALS
MATERIAL EQUIVALENT CHART
DIN
PART PART STANDARD BRITISH ASTM DIN MATERIAL DIN
SPECIFICATI
NO NAME FITTED PUMP STANDARD STANDARD STANDARD NUMBER ON
1 Bearing Housing Cast Iron BS1452 Gr220 A48 Class 25 GG20 0.602 DIN1691
2 Gland Bronze BS1400 LG2 B584 C83600 G -CuSn 5 ZnPb 2.1096.01 DIN1705
3 Casing Cast Iron Bs1452 Gr 260 A48 Class 35 GG25 0.6025 DIN1691
4 Impeller Bronze BS1400 LG2 B584 C83600 G-CuSn 5 ZnPb 2.1096.01 DIN 1705
5 Casing Wear Ring Bronze BS1400 LB2 B584 C93700 G-CuPb 15 Sn 2.1096.01 DIN1705
6 Lantern Ring Bronze BS1400 LG2 B584 C83600 G-CuSn 5 ZnPb 2.182.01 DIN1705
7 Impeller Key Stainless Steel BS970 410 S21 A 182 Type 410 X 10 Cr 13 2.1096.01 DIN1705
8 Coupling Key Stainless Steel BS970 410 S21 A182 Type 410 X 10 Cr 13 2.1096.01 DIN1705
9 Gland Packing Graphite Impregnated
9A Mechanical Seal Burgmann or Equivalent
10 Shaft Stainless Steel BS970 410 S21 A182 Type 410 X 10 Cr 13 2.1096.01 DIN1705
11 Thrust Collar MS
Bearing End
12 Cover Inner Cast Iron BS1452 Gr 220 A 48 Class 25 GG20 0.602 DIN 1691
14 Shaft Sleeve Bronze BS1400 CT1 B30 C 90700 G-CuSn10 2.1050.01 DIN 1705
Baering End Cover
20 Outer Cast Iron BS1452 Gr 220 A48 Class 25 GG20 0.602 DIN1691
21 Seal piping Copper
OPTIONAL CONSTRUCTION
SPECIAL DIN
PART PART MATERIAL BRITISH ASTM DIN MATERIAL DIN
NO NAME STANDARD STANDARD STANDARD NUMBER SPECIFICATION

3 Casing Ductile Iron BS2789 Gr 500 A536 60-45-12 GGG50 0.705 DIN 1693
Cast Steel BS3100 Gr A1 A216 WCB GS- C25 1.0619 DIN17245
Stainless Steel BS3100-316 C16 A743 Gr CF -8M G-X6CrMo165 1.4008
GCl -
Ni Resist BS3468 L-NiCuCr 20 2 A436 Type 1 NiCuCr1562 0.6655
4 Impeller Cast Iron BS1452 Gr260 A48 Class 35 GG20 0.602 DIN1691
Zinc Free
Bronze BS 1400 CT1 B427 C90700 G-CuSn10 2.1050.01 DIN 1705
Stainless Steel BS3100-316 C 16 A743 Gr CF -8M G-X6CrMo165 1.4008
BS3100-410 C21 A743 Gr CA15 G- X 12 Cr 14 0.6655
5 Shaft HT Steel BS970-708 M40 A322 Gr4140 42 CrMo4 1.7225 DIN 17200
Stainless Steel BS970 316 S 16 A276 Type316 X5 CrNiMo1810 1.4404

BS970 304 S15 A276 Type 304 X5 CrNi189 1.4301
TYPES OF CORROSION
GENERALIZED CORROSION
LOCALIZED CORROSION
CREVICE CORROSION
PITTING
DE-ALLOYING CORROSION
STRESS CORROSION CRACKING
HYDROGEN EMBRITTLEMENT
MICRO-BIOLOGICALLY INDUCED CORROSION
INTERGRANULAR CORROSION
GENERAL CORROSION
PROCEEDS WITHOUT APPRECIABLE LOCALIZATION OF ATTACK
DOES NOT DEVELOP ANY EFFECTIVE PASSIVE FILM ON THE SURFACE
CORROSION RATE DEPENDS UPON SEVERAL CHARACTERISTICS OF THE PUMPED

LIQUID LIKE TEMPERATURE, O2 CONTENT, pH & FLUID CHEMISTRY
CORROSION MECHANISM MOSTLY INVOLVES OXIDATION WHICH RESULTS IN THE

FORMATION OF METAL OXIDE CORROSION PRODUCTS
CARBON STEEL & COPPER BASED ALLOYS ARE SUBJECT TO THIS TYPE OF CORROSION
PITTING
RESULTS FROM THE DEPLETION IN OXYZEN CONTENT AROUND A SMALL AREA
CAN INITIATE FROM SMALL SURFACE DEFECT, LOCAL CHANGE IN COMPOSITION OR DAMAGE OF
PROTECTIVE COATINGS
EXTREMELY LOCALIZED & LEADS TO SMALL HOLES ON THE METAL SURFACE
IT CAUSES LITTLE LOSS OF MATERIAL WITH LESSER EFFECTS ON THE SURFACE BUT DAMAGES THE
STRUCTURE OF THE METAL
ALLOYS SUSCEPTIBLE TO PITTING CORROSION
STAINLESS STEEL
NICKEL ALLOYS
ALUMINUM ALLOYS
PROTECTIVE MEASURE AGAINST PITTING CORROSION
PROPER SELECTION OF MATERIALS WITH KNOWN RESISTANCE TO SERVICE CONDITIONS
CONTROL OVER CHLORIDE CONCENTRATION, TEMPARATURE & pH OF THE SERVICE LIQUID
CATHODIC OR ANODIC PROTECTION
USE OF HIGHER ALLOYS LIKE ASTM G48 WITH INCREASED RESISTANCE TO PITTING
DE-ALLOYING
PREFERENTIAL REMOVAL OF ONE ALLOY FROM A MULTI-PASE ALLOY
COMMONLY REFERS TO GRAPHITIC CORROSION OF GRAY CAST IRON
GRAPHITIC CORROSION
ONE TYPE OF ELECTROLYSIS WHERE GRAPHITE PLAY AS THE CATHODE END
A GALVANIC CELL IS INDUCED BETWEEN THE GRAPHITE & IRON
IRON CORRODES AWAY LEAVING A POROUS STRUCTURE OF GRAPHITE BUT

RETAINING THE SAME SHAPE & DIMENSIONS
THE CASTING LOSES SOME OF THE MECHANICAL PROPERTIES AND THIS MAY RESULT IN BRITTLE
FAILURE DUE TO MODERATE SHOCK OR IMPACT LOADS
GRAPHITIZATION CAN ALTER GALVANIC RELATIONSHIP BETWEEN THE PUMP

COMPONENTS ORIGINAL IMPELLER LASTS LONGER THAN THE REPLACEMENT!!!
STRESS CORROSION CRACKING
CAUSES SUDDEN CATASTROPHIC DAMAGE
SEVERAL FACTORS NEED TO BE PRESENT FOR STREE CORROSION CRACKING
TENSILE STRESS APPLIED OR RESIDUAL
A SUSCEPTIBLE MATERIAL
A PROMOTING ENVIRONMENT
TIME
ALLOYS SUSCEPTIBLE TO STRESS CORROSION
AUSTENITIC & MARTENSITIC STANLESS STEEL
SOME COPPER BASED ALLOYS
OCCASIONALLY Ni-RESIST
EROSION RESISTANCE
TYPES OF EROSION
CAVITATION EROSION
CORROSION EROSION
CAVITATION EROSION
OCCURS WHEN THE LOCAL PRESSURE FALLS BELOW THE VAPOUR PRESSURE AT PUMPING
TEMPARATURE
MECHANICAL DEGRADATION OF SOLID MATERIAL DUE TO IMPLOSIONS OF CAVITATION BUBBLES &

CHARACTERIZED BY PITTING DUE TO CONTINUING EXPOSURE TO CAVITATION
PROTECTIVE OXIDE FILM IF PRESENT GETS DAMAGED & FRESH METAL SURFACE GETS EXPOSED TO THE
CORROSIVE EFFECT OF THE FLUID
THE CYCLIC LOADING CAN EVENTUALLY CAUSE MICROSCOPIC FATIGUE CRACKS RESULTING IN
METAL REMOVAL FROM THE SURFACE
SPONGY & POROUS IN APPEARANCE, CAVITATION EROSION CAN BE IDENTIFIED BY SPECIFIC

ROUGH MARKS IN SURFACES OF COMPONENT FLOW PATHS
PROTECTIVE MEASURES AGAINST CAVITATION EOROSION
LIST OF PUMP MATERIALS IN ORDER OF

DECREASING CAVITATION RESISTANCE
STELLITE SELECTION OF MATARIALS

WITH HIGH CAVITATION
CHROME - MANGANESE AUSTENITIC STAINLESS STEEL RESISTANCE NOT ONLY
WIDENS PUMPS OPEARTING
CARBURIZED 12% CHROME STAINLESS CASTING
RANGE BUT REDUCES
TITANIUM 6AL-4V MAINTENANCE COSTS
SIGNIFICANTLY
CAST NICKEL ALUMINIUM BRONZE
CAST DUPLEX STAINLESS STEEL
CAST PRECIPITATION HARDENING STAINLESS STEEL
DUCTILE Ni - RESIST
MANGANESE BRONZE
CAST CF8M
CARBON STEEL
CAST CA6NM
CAST CA15 LEADED BRONZE
MONEL CAST IRON

CORROSION EROSION
Corrosion increases due

to abrasive action of the
moving stream
The presence of
suspended solids
accelerates the rate of
abrasion action
Corrosion allowance for metallic centrifugal pumps

Application Corrosion Allowance Internal walls that are subject to
corrosive attack. Need to be
Water pumps 1.5 mm (0.06 inches)
provided with additional metal
Chemical pumps 3 mm (0.12 inches) thickness over & above to meet
the design criteria.
Boiler feed pump 3 mm (0.12 inches)
EROSION RESISTANCE
CAVITATION EROSION
EVIDENCE OF CAVITATION EROSION
CORROSION EROSION
CORROSION EROSION OF A CARBON STEEL SHAFT

EROSION DAMAGES OF PUMP PARTS
WEAR RESISTANCE
LOSS OF MATERIAL FROM A SURFACE DUE TO SURFACE INTERACTION (LOCALISED BONDING

BETWEEN TWO RUBBING SOLID SURFACES)
TYPES OF WEAR
ABRASIVE WEAR
WEAR DUE TO HARD PARTICLES OR HARD PROTRUBERANCES FORCED AGAINST & MOVING ALONG A
SOLID SURFACE
ADHESIVE WEAR
OCCURS WHEN TWO BODIES IN CLOSE CONTACT SLIDES OVER EACH OTHER OR PRESSED INTO EACH
OTHER WHICH PROMOTES MATERIAL TRANFER
To be replaced
EROSION 352 w1
Wear due to
Mechanical interaction
Impact of a multi-component fluid
Impinging liquid or solid particles
Occurs during
movement of Shape & size
Impingement distribution
slurries through
angle of fluid
the piping or
Pumping Hardness
equipment of the
Impact The rate of
particles
velocity or erosive wear is
the velocity dependent on
of pumpage
Quantity
Nature or of the
geometry particles
WEAR RESISTANCE
EVIDENCE THREE BODY ABRASIVE WEAR EVIDENCE OF FREETING DAMAGE
EVIDENCE OF FATIGUE FRACTURES

GALVANIC CORROSION
GALVANIZATION
PROTECTEDEND
CORRODED (e.g- Al)
END(e.g- Mg)
SALT BRIDGE
ELECTROLYTIC
SOLUTION
GALVANIC CELL
GALVANIC CORROSION
ACCELERATED ELECTRO-CHEMICAL CORROSION OF ONE OF THEMATERIALS

HAVING ELECTRO-CHEMICAL INTERACTION WITH ANOTHER WHEN IMMERSED IN A
ELECTROLYTIC MEDIUM (e.g. - SEA WATER)
EVIDENCE OF GALVANIC
CORROSION
COPPER
PROTECTED END (CATHODIC)
BRASSES
NICKEL
NICKEL-MOLYBDENUM-CHROMIUM-
(LEAST SUSCEPTIBLE TO
IRON ALLOY(ACTIVE)
CORROSION ATTACK)
NICKEL BASE ALLOY(ACTIVE)

GALVANIC SERIES ACCOUNTS FOR THE RELATIVE NOBILITY OF MATERIALS BELOW
NICKEL(ACTIVE)
TIN
LEAD
LEAD-TIN-SOLDERS
18
18-8-3 CHROMIUM-NICKEL-
LESS NOBLE MORE NOBLE
MOLYBDENUM STAINLESS
GALVANIC CORROSION
STEEL(ACTIVE)
GALVANIC SERIES
18-8 CHROMIUM-NICKEL
STAINLESS STEEL(ACTIVE)
AUSTENITIC NICKEL OR NICKEL
COPPER CAST IRON ALLOY
CHROMIUM STAINLESS
STEEL(ACTIVE)
CAST IRON
CORRODED END (ANODIC)
STEEL OR IRON
CADMIUM
(MOST SUSCEPTIBLE TO
CORROSION ATTACK)
ALUMINIUM
ZINC
Mg ALLOYS
MAGNESIUM
PROTECTED END(CATHODIC)
PLATINUM
GOLD
GRAPHITE
SILVER
TITENIUM
NICKEL-MOLYBDENUM
MOLYBDENUM-
CHROMIUM-IRON
IRON ALLOY(PASSIVE)
GALVANIC CORROSION
LESS NOBLE MORE NOBLE
18-8-3 CHROMIUM-NICKEL
NICKEL-MOLYBDENUM
STAINLESS STEEL(PASSIVE)
18-8 CHROMIUM-NICKEL
NICKEL
STAINLESS STEEL(PASSIVE)
NICKEL-BASE-ALLOY(PASSIVE)
ALLOY(PASSIVE)
NICKEL(PASSIVE)
CORRODED END(ANODIC)
SILVER SOLDER
COPPER-NICKEL
NICKEL ALLOY
NICKEL-COPPER
COPPER ALLOY
BRONZES
CURVE FOR GALVANIC CORROSION
WAYS TO MINIMIZE GALVANIC CORROSION
EFFECTIVE USE OF THE GALVANIC RELATIONSHIP
SELECTION OF COMBINATIONS OF METALS AS CLOSE AS POSSIBLE IN THE GALVANIC SERIES

LESSER THE POTENTIAL DIFFERENCE LESSER WOULD BE THE CORROSION RATE
GALVANIC CORROSION DEPENDS UPON THE RATIOS OF THE EXPOSED AREA OF THE COUPLED METALS
WIDER THE AREA EXPOSED OF A LESS NOBLE METAL LESSSER WOULD THE SEVERITY OF CORROSION
AN EFFECTIVE METAL COMBINATION FOR SEA WATER SERVICES
Ni- RESIST CASING & AUSTENITIC PUMP INTERNALS
USE OF DISSIMILAR METALS WHEREVER PRACTICALLY FEASIBLE
THE CORROSION POTENTIALS OF TWO DISSIMILAR MATERIALS USED FOR PUMP CONSTRUCTION FOR
CONDUCTIVE FLUID SERVICES SHOULD BE MORE OR LESS SAME TO AVOID CORROSION PROBLEM
WAYS TO MINIMIZE GALVANIC CORROSION
Use of coating can have a decisive role in the

altering galvanic relationship.
Application of
Coatings on Coating should be applied with caution in pumps having
Both The dissimilar metal coupling and pumping conductive liquid
Metals with
Small exposed area of a less noble metal coupled with a
Caution
more noble metal can experience a high rate of corrosion.
So, its generally advisable not to coat the anodic
component, usually the casing.
Proper periodic maintenance is required.
Severity of galvanic corrosion depends upon the conductivity of fluid

medium
Attenuation in
fluid conductivity Achieved by increasing the resistance of the liquid path by connecting
an external conductor or by incorporating chemical inhibitors to the
corrosive solution
AUSTENITIC STAINLESS
STEELS
AUSTENITIC CAST IRONS
(OTHER TYPES)
LOW HARDNESS STEEL
RANKING OF CLASSES OF MATERIAL IN GALLING RESISTANCE
BELOW 240 BHN

MORE RESISTANT LESS RESISTANT
NICKEL-COPPER
ALLOY
HARDENED STEELS
ABOVE 325 BHN
NICKEL BASED HARD
MICROSTRUCTURE OF METALS
SURFACING ALLOYS
UNALLOYED IRONS
GALLING RESISTANCE
GRAY & DUCTILE

TYPE 1& 2 OF AUSTENITIC
GRAY IRONS
COBALT-BASE HARD
SURFACING ALLOYS
BRONZES
OTHER FACTORS AFFECTING MATERIAL SELECTION
Either or
Pump should be operated within its safe operating zone
Mechanical otherwise
Situations in Hydraulic & mechanical disturbances will predominate
Pumping
Operation result
Rapid wear of materials Breakage of pump parts
Thermal Thermal or hydraulic shocks are damaging forces

or
Shock wave can severely affect the material
Hydraulic Shock
VELOCITY EFFECTS
MATERIALS CHOSEN FOR HIGH VELOCITY (DEVELOPED HEAD/ROTATIVE SPEED) NEED TO BE

MORE RESISTANT THAN MATERIALS CHOSEN FOR LOW VELOCITY.
VARIOUS LIMITING PERIPHERAL VELOCITIES ARE APPLIED TO IMPELLERS DEPENDING UPON THE
TYPE OF MATERIAL.
MATERIAL MAXIMUM PERIPHERAL VELOCITY

(TIP SPEED)
CAST IRON 140 FT/SEC. 42.7 M/SEC.
GUN METAL 160 FT/SEC. 48.8 M/SEC.

ZINC FREE BRONZE 185 FT/SEC. 56.4 M/SEC.
NOTE - THESE VALUES HAVE BEEN OBTAINED BY ASSUMING THE IMPELLER TO BE A ROTATING DISC & CALCULATING
THE PERIPHERAL VELOCITY REQUIRED TO GIVE THE MAXIMUM ALLOWABLE STRESS IN THE DISC.
COMMON METALLIC MATERIALS OF CONSTRUCTION FOR VARIOUS LIQUIDS
MATERIAL ASTM NO. REMARKS
SELECTION
A ALL BRONZE
B BRONZE FITTED CONSTRUCTION
C ALL IRON CONSTRUCTION
3 A126-WCB CARBON STEEL
4 A217-C5 5% CHROMIUM STEEL
5 A743-CA15 12% CHROMIUM STEEL
6 A743-CB30 20% CHROMIUM STEEL
7 A743-CC50 28% CHROMIUM STEEL
8 A743-CF-8 19-9 AUSTENITIC STEEL
9 A743-CF-8M 19-10 MOLYBDENUM AUSTENITIC STEEL
10 A743-CN-7M 20-29 CHROMIUM NICKEL AUSTENITIC STEEL WITH COPPER &
MOLYBDENUM
11 A SERIES OF NICKEL BASED ALLOYS
12 A518 CORROSION-RESISTANT HIGH SILICON CAST IRON
13 A436 AUSTENITIC CAST IRON -2 TYPES
13(a) A439 DUCTILE AUSTENITIC CAST IRON
14 NICKEL-COPPER ALLOYS
15 NICKEL
COMMON METALLIC MATERIALS OF CONSTRUCTION FOR SOME COMMON
LIQUIDS
LIQUID CONDITIONS OF LIQUID CHEMICAL SPECIFIC GRAVITY MATERIAL
SYMBOL SELECTION
ACID, HYDROCHLORIC DILUTE, COLD HCL 10,11,12,14,15
ACID, MINE WATER A,8,9,10,11

ACID, NITRIC DILUTE HNO3 5,6,7,8,9,10,12
ACID SULFURIC 10-65% 10,11,12

ACID SULFURIC 10% A,10,11,12,14
BRINE, SEA WATER 1.03 A,B,C

BRINE, SODIUM CHLORIDE OVER 3% SALT, COLD NACL 1.02,-1.20 A,8,9,10,11,13,14
GASOLINE 0.68-0.75 B,C
LIQUOR-PULP MILL : BLACK C,3,9,10,11,12,14

LIQUOR-PULP MILL : GREEN C,3,9,10,11,12,14
LIQUOR-PULP MILL : WHITE C,3,9,10,11,12,14
NAPTHA, CRUDE 0.92-0.95 B,C
OIL, CRUDE COLD B,C

OIL, CRUDE HOT 3
OIL, KEROSENE B,C
SEWAGE A,B,C
WATER, BOILER FEED NOT EVAPORATED pH>8.5 1.00 C

WATER, BOILER FEED HIGH MAKE UP pH<8.5 B
WATER DISTILLED CONDENSATE A,B

GENERAL RANKING OF CAVITATION EROSION RESISTANCE OF COMMON
CAST METALS WHEN PUMPING CLEAR WATER AT AMBIENT TEMPARATURE
A GENERAL GUIDE FOR MATERIALS IN VARIOUS ENVIRONMENTS
ENVIRONMENT MATERIALS
NON-CORROSIVE CAST IRON/LEADED BRONZE
MILDLY CORROSIVE MARTENSITIC STAINLESS STEEL
CORROSIVE CORROSION-RESISTANT, NON-GALLING
AUSTENITIC STAINLESS STEEL
SEVERELY CORROSIVE HIGHLY ALLOYED AUSTINITIC STAINLESS

STEEL WITH HARD-FACED MATERIALS
SUCH AS STELLITE OR COLMONOY
SELECTION CRITERIA FOR MATERIALS OF CONSTRUCTION
OF PUMP COMPONENTS
IMPELLER
ABRASIVE WEAR RESISTANCE
CAVITATION RESISTANCE
CASTING & MACHINING PROPERTIES
WELDABILITY FOR REPAIRING PURPOSE
COST OF MATARIAL
BRONZE IMPELLERS ARE PREFFERED BECAUSE OF THE FOLLOWING REASONS :-
EASIER TO CAST FOR COMPLICATED CROSS-SECTIONS
YIELDS RELATIVELY SMOOTHER SURFACE
DOES NOT RUST
BRONZE IMPELLERS SHOULD NOT BE USED IN CAST IRON CASING WHEN THE PUMPED LIQUIDS IS A
STRONG ELECTROLYTE
SELECTING CRITERIA FOR MATERIALS OF CONSTRUCTION OF PUMP
COMPONENTS
SHAFT
CASING Endurance limit

Corrosion resistance
Strength Notch sensitivity
Abrasive wear resistance
Casting & machining properties
Weld ability for repairing purpose
Cost of material WEAR RING
Abrasive wear resistance
Galling characteristics
Casting & machining properties
Suitability for coating
SELECTING CRITERIA FOR MATERIALS OF CONSTRUCTION
OF PUMP COMPONENTS
CASING
STRENGTH
WELDABILITY FOR REPAIRING PURPOSE
COST OF MATARIAL
SELECTING CRITERIA FOR MATERIALS OF CONSTRUCTION
OF PUMP COMPONENTS
SHAFT
ENDURANCE LIMIT
NOTCH SENSITIVITY
WEAR RING
GALLING CHARACTERISTICS
SUITABILITY FOR COATING
SELECTION CRITERIA OF PUMP PARTS AT A GLANCE
Impeller Casing Shaft Wear Ring

Corrosion Strength MAWP / Endurance Corrosion
Resistance Test Pressure limit Resistance
Abrasive Corrosion Corrosion Abrasive Wear

Wear Resistance Resistance Resistance
Resistance
Cavitation Abrasive Wear Notch Galling
Resistance Resistance Sensitivity characteristics
Casting and Casting and Casting and
machining machining machining
properties properties properties
Tip Speed Cost
Cost
FACTORS FOR MATERIAL SELECTION
MATERIAL PROPERTIES
CORROSION, EROSION & WEAR
COMMON & SPECIAL MOC
MATERIALS GUIDELINES - HIS
MATERIAL FOR MAJOR PUMP PARTS

PROGRAMME SUMMARY
QUESTIONS & ANSWERS

PUMPSENSE
BEST PRACTICES OF CENTRIFUGAL PUMPS - SINGAPORE

JULY 2011

SCHEDULE
Workshop - 1
Singapore July 2011

SCHEDULE
PUMP MASTER CLASS - SINGAPORE JULY 2011
DAY - 2
Time Topic
9.00 am -10.30 am Case studies of calculations of the performance of a centrifugal pump by
changes in speed or impeller diameter (Affinity Laws)
10.30 am 11.00 am Morning Tea Break

11.00 am 12.30 pm NPSH calculation exercise in the following industries (P&ID with all types of
fittings, elbows, filter, strainer, meters, etc will be provided)
Water treatment plant
Hydrocarbon fuel terminal
Petrochemical plant (corrosive fluid)
2.00 pm 3.00 pm (Continue) NPSH calculation exercise

3.00 pm 4.00 pm Friction loss and pressure calculation in different pump system (P&ID with
detailed information will be provided)
DISCUSSION OF CASE STUDIES
LIST OF CASE STUDIES
Sr. No Segment Topic

Pumping system / materials of Kolkata water supply scheme. Retrofit &
CS 1 construction / retrofit for energy upgrade of a raw water pump installed in
optimisation 1920s
Pumping system / forces in centrifugal Frequent shaft failure of circulating water
CS 2 pumps / materials of construction pump in an oil refinery, due to part flow
operation & radial loading
Affinity laws / pumping system Part flow operation & impeller damage
CS 3 due to increase in system loss - cooling
water pumps in a petrochemical plant
Affinity laws / pumping system Low discharge from cooling water pumps
CS 4 due to high pressure drops across chillers
Pumps at a coke plant in a still mill
Materials of construction Selecting appropriate materials of
construction for a sea water pumping
CS 5
application in Australia
Affinity laws Trimming impeller with or without shrouds
6 ISO 2858 end suction pump in SE Asia
CS
NPSHa CALCULATIONS &
PRACTICAL TESTING of NPSHr
AVAILABLE NPSH (NPSHa) OF A SYSTEM
HOW TO CALCULATE NPSHa OF A SYTEM
REQUIRED NPSH (NPSHr) OF A PUMP
PRACTICAL NPSHr TESTING
VARIOUS TYPES OF LOSSES IN A SYSTEM
P&ID DIAGRAMS
CALCULATION OF AVAILABLE NPSH (NPSHa)
CHARACTERISTIC OF THE PROCESS SUCTION SYSTEM.
AN ANALYSIS OF TOTAL ENERGY ON THE SUCTION SIDE OF A PUMP TO DETERMINE

WHETHER THE LIQUID WILL VAPOURIZE AT A LOW PRESSURE POINT IN THE PUMP.
CALCULATION OF NPSHA FOR SYSTEMS WITH SUCTION
HEAD & SUCTION LIFT
NPSHa (M) = ATMOSPHERIC PRESSURE(M) NPSHa (M) = ATMOSPHERIC PRESSURE(M) +

SUCTION LIFT(M) FRICTIONAL SUCTION HEAD(M) FRICTIONAL
HEAD LOSS(M) - V.P (M) HEAD LOSS(M) - V. P (M)
AVAILABLE NPSH CALCULATION IN VARIOUS TYPES OF SYTEMS
NPSHa & NPSHr
NPSHa IS A CHARACTERISTIC OF NPSHr IS A CHARACTERISTIC OF

YOUR SYSTEM. YOUR PUMP.
THIS IS A FUNCTION OF SYSTEM THIS IS A FUNCTION OF PUMP

CONFIGURATION ON THE SUCTION SIDE SUCTION DESIGN. IT VARIES WITH THE
OF THE PUMP. SPEED & CAPACITY FOR A PARTICULAR
PUMP.
IT IS THE AVAILABLE TOTAL SUCTION THIS IS THE +VE HEAD IN M

HEAD IN METRES ABSOLUTE ABSOLUTE REQUIRED AT PUMP SUCTION
DETERMINED AT THE INLET NOZZLE OF TO OVERCOME PUMP INTERNAL LOSSES
THE PUMP & CORRECTED TO THE PUMP LOSSES DUE TO TURBULANCE
DATUM LESS THE VAPOUR (GENERATED AS THE LIQUID STRIKES THE
PRESSURE HEAD OF THE LIQUID IN IMPELLER AT IMPELLER INLET), LOSSES IN
METRES ABSOLUTE AT THE PUMPING THE SUCTION PASSAGE & VANE INLET
TEMPERATURE. PASSAGES TO MAITAIN THE PUMPING
FLUID IN LIQUID STATE.
FOR CAVITATION-FREE SAFE OPERATION, YOUVE TO KEEP, NPSHa > NPSHr

PRACTICAL NPSHr TESTING OF PUMP
NPSHa OF A SYSTEM DEPENDS ON THE FOLLOWING VARIABLES FOR A LIQUID AT A FIXED

TEMPARATURE:-
PRESSURE IMPOSED ON THE SUMP WATER LEVEL
HEIGHT OF WATER LEVEL AT SUMP FROM PUMP CENTER-LINE
FRICTIONAL LOSSES IN SUCTION PIPINGS
ACCORDING TO GUIDELINES OF HYDRAULIC INSTITUTE NPSHr IS THE NPSH THAT CAUSES THE
TOTAL HEAD TO BE REDUCED BY 3% DUE TO THE FLOW BLOCKAGE FROM CAVITATION
VAPOUR IN THE IMPELLER INTERNAL PASSAGE.
PRACTICALLY NPSHR CAN BE CALCULATED BY REDUCING NPSHa BY REDUCING ONE OF THE

THREE KEEPING OTHER TWO CONSTANT.
THREE TEST PROCEDURES:-

CREATING VACCUM IN THE SUCTION VESSEL/SUMP.
VARYING THE LIQIUID LEVEL AT SUMP.
THROTTLING THE VALVE AT SUCTION SIDE.
PRACTICAL NPSHr TEST PROCEDURES
FIRST TEST PROCEDURE
THE PUMP IS SUPPLIED FROM A CLOSED PESSURE TANK.

THE LIQUID LEVEL AT THE TANK IS HELD CONSTANT.
NPSHa IS VARIED BY VARYING THE PRESSURE ON THE LIQUID SURFACE AT THE TANK.
SECOND TEST PROCEDURE
THE PUMP IS SUPPLIED FROM A SUMP THATS OPEN TO ATMOSPHERIC PRESSURE.

LIQUID LEVEL IS VARIED TO GET THE DESIRED NPSH.
SPECIAL CARE IS TAKEN WHEN ADJUSTING THE LIQUID LEVEL TO AVOID
VORTEX FORMING.
THIRD TEST PROCEDURE
ITS THE EASIEST AND ADOPTED MOST OFTEN
THE TEST PROCEDURE IS DESCRIBED BELOW-
AT FIRST, THE INLET VALVE IS MADE COMPLETELY OPEN.
THE PUMP IS STARTED IN CLOSED DISCHARGE-VALVE CONDITION.
AFTER THE MOTOR GAINS FULL SPEED THE DISCHARGE VALVE IS
GRADUALLY OPENED.
NOW THE DISCHARGE VALVE IS SET TO A CONDITION TO ACHIVE CONST. FLOW CONDITION.
THEN THE SUCTION CONTROL VALVE IS THROTTLED. THUS REDUCING THE EFFECTIVE PIPE
AREA. THE SUCTION PRESSURE IS REDUCED (K.E & FRICTIONAL LOSS INCREASED & TOTAL
ENERGY CONST.)
THE DISCHARGE VALVE IS ADJUSTED SUITABLY TO KEEP THE FLOWRATE SAME.
ONCE THE POINT IS ACHIVED WHERE TOTAL HEAD DROPS BY 3% THE FOLLOWING READINGS
ARE TAKEN & THE SUCTION GAUGE READING IS CONSIDERED AS NPSHr.
SUCTION PRESSURE SHOWN BY THE COMPOUND GAUGE FITTED.
DISCHARGE PRESSURE SHOWN BY THE PRESSURE GAUGE FITTED.
CAPACITY SHOWN BY THE MAGNETIC FLOW METER.
AMBIENT PRESSURE.
WATER TEMPT.
THE WHOLE PROCEDURE IS REPEATED FOR 3-4 TIMES AT VARIOUS FLOW POINTS(
GENERALLY LEFT OF B.E.P, AT B.E.P & RIGHT OF B.E.P).
CALCULATION OF NPSHr & IMPROVED NPSH CURVES
CALCULATED NPSHr FOR 3% HEAD DROP AT EACH FLOW POINT IS
= (SUCTION GAUGE READING AT THAT POINT (Kgf/CM2) x 10 ) M

OR
= (SUCTION GAUGE READING AT THAT POINT (PSI) x 2.31 ) Ft
PRACTICAL NPSHr TEST ARRANGEMENT
PRECAUTIONS TAKEN FOR THE TEST
TESTING AT LOW FLOWRATE (A SMALL FRACTION OF NORMAL CAPACITY), LOW VELOCITY

THROUGH THE PIPILINE PERMITS MORE TIME TO LIBERATE THE DISSOLVED GAS AT LOW
PRESSURE ZONE.
OPERATING PUMP NEAR THE SHUT-OFF CAUSES MOST OF THE POWER WASTED OWING TO
LOW EFFICIENCY TO HEAT-UP THE LIQUID RUNNING IN CLOSED LOOP.
PUMP PRESSURE GAUGE SHOULD BE LOCATED ONE PIPE DIAMETER FROM THE PUMP
FLANGES.
THERE MUST NOT BE ANY RESTRICTION BETWEEN THE PUMP FLANGES & PRESSURE
GAUGE.
FOR SYSTEMS WITH FREE SURFACE, THE APPROACH OF WATER TO PUMP INLET SHOULD BE
UNIFORM & FREE FROM ANY VORTICES OR EDDIES THAT MAY RESULT FROM VALVES,
BENDS, PIPE-JOINTS, INCREASER, REDUCER OR ANY OTHER OBSTRUCTION IN THE SUCTION
PIPE-LINE.
AIR-LEAKS INTO THE SYSTEM MUST NOT BE ALLOWED.
THE DISCHARGE LINE DIA. SHOULD BE CHOOSEN AS LARGE AS POSSIBLE SPECIALLY FOR
PUMPS WITH LOW HEAD WHEN TESTED AT LOW SPEED OTHERWISE HIGH VELOCITY MAY
RESULT IN LOWERING OF ABSOLUTE PRESSURE CAUSING THE LIQUID TO CAVITATE
SOMEWHERE DOWNSTREAM OF THE PUMP.
P&ID DIAGRAMS & SYSTEM NPSH TO BE
ADDED
AVAILABLE NPSH (NPSHa) OF A SYSTEM
HOW TO CALCULATE NPSHa OF A SYTEM
REQUIRED NPSH (NPSHr) OF A PUMP
PRACTICAL NPSHr TESTING
VARIOUS TYPES OF LOSSES IN A SYSTEM
P&ID DIAGRAMS
FRICTIONAL LOSSES &
PRESSURE CALCULATION IN
DIFFERENT PUMPING SYSTEMS
TESTING & QUALITY ASSURANCE
PUMPSENSE
INSPECTION & TEST STANDARDS
MATERIAL INSPECTION
DESTRUCTIVE & NON-DESTRUCTIVE TESTS
PRESSURE TESTS
PERFORMANCE TESTS
NPSHr TESTINFG PROCEDURES
ACCEPATANCE CRITERIA
QUALITY PLANS
INSPECTION AGENCIES
OBJECTIVES OF QA & TESTING
TO ACHIEVE & MAINTAIN A SATISFACTORY LEVEL OF QUALITY.
TO ENSURE COMPLIANCE WITH RELEVANT INTERNATIONAL STANDARDS

INSPECTION & TESTING REQUIREMENTS ARE BASED ON
STANDARD DESCRIPTION
ISO 9906 PERFORMANCE TEST STANDARD
IS 9137 INDIAN EQUIVALENT TEST STANDARD
ISO 5199 PROCESS PUMP STANDARD
HIS HYDRAULIC INSTITUTE STANDARDS, USA
API 610 10TH ED. REFINERY PROCESS PUMPS
NFPA 20 FIRE PUMP STANDARD, USA
ANSI B73.1M HORINZONTAL CENTRIFUGAL END

SUCTION CHEMICAL PUMPS
ANSI B73.2M VERTICAL INLINE CHEMICAL PUMPS

MATERIAL INSPECTION REQUIREMENT
MATERIAL CHECKS
CASTING DEFECTS & THEIR CLASSIFICATION
NON-DESTRUCTIVE TEST
REPAIR PROCEDURES OF CASTING & WELDING

MATERIAL CHECKS
THE MATERIAL SPECIFICATIONS OF PUMP COMPONENT ARE BASED ON THE

APPLICABLE STANDARDS - API, ASTM, ANSI, AISI, BS, DIN OR EQUIVALENT
STANDARDS.
CASTING DEFECTS & THEIR CLASSIFICATION
CASTING DEFECTS
POROSITY
CRACKS
BLOW HOLES
SHRINKAGES
SCALES
OTHER DEFECTS
AS PER ASTM, THE FOLLOWING REPAIRS ON A CASTINGS CLASSIFY AS
MAJOR REPAIRS:
CASTING FAILS IN THE HYDROSTATIC PRESSURE TEST
REPAIRS FOR WHICH THE DEPTH, OF ANY CAVITY PREPARED FOR WELDING,
EXCEEDS 20% OF THE WALL THICKNESS OR 1 INCH, WHICHEVER IS LESSER
THE CAVITY PREPARED FOR WELDING IS GREATER THAN 10 SQ. INCH.

DESTRUCTIVE & NON-DESTRUCTIVE TESTING
DESTRUCTIVE TESTING
AN INTENTIONAL ENGINEERING TESTING OPERATION OF AN EQUIPMENT UNTIL IT

FAILS TO REVEAL A DESIGN FAILURE OR TO INVESTIGATE STRUCTURAL
PERFORMANCE OR MATERIAL BEHAVIOUR UNDER DIFFERENT CONDITIONS
ONLY SUITABLE & ECONOMIC FOR MASS PRODUCTION
DESTRUCTIVE TESTING
THIS IS OTHER TYPE OF TESTING METHOD THAT INCLUDES TECHNIQUES TO

ANALYSE A COMPONENT, OR A SYSTEM WITHOUT CAUSING ANY DAMAGE TO IT OR
IMPAIRING ITS FUTURE USABILITY.
SAVES BOTH MONEY & TIME FOR PRODUCT EVALUATION

NON-DESTRUCTIVE TESTING
MATERIAL INSPECTION FOR CASTINGS & WELDING ARE CARRIED OUT TO

THE FOLLOWING STANDARDS :
VISUAL INSPECTION (VI) THIS HAS TO CONFORM TO MSS SP-55
MAGNETIC PARTICLE INSPECTION (MPI)
APPLICABLE CODE ASME E 709

ACCEPTANCE CODES
CASTINGS : ASTM E 125
WELDING : ASME SEC. VIII - DIV.1
DYE PENETRANT CHECKS (DP)
APPLICABLE CODE ASTM E 165 SEC. V

ACCEPTANCE CODES
CASTINGS : ASME SEC. VIII , DIV.1
ULTRASONIC EXAMINATION (UT)
APPLICABLE CODE ASTM A 609, SEC. V, ARTICLE 5
ACCEPTANCE CODES
RADIOGRAPHY(RT)
APPLICABLE CODE ASTM E 94, ASTM E 142, CASTING - E- 446, E- 186, E 280
ACCEPTANCE CODES

IMPACT TEST
ACCEPTANCE CODES ASME SEC. VIII, DIV. 1.

REPAIRING PROCEDURES OF CASTINGS & WELDING
THE PROCEDURE INCLUDE
HOW THE DEFECT WAS DETECTED
SKETCH/DRAWING INDICATING THE LOCATION & DEPTH OF THE DEFECT
THE METHOD OF REPAIR . THIS INCLUDES HEAT TREATMENT & INSPECTION

PROCEDURE AFTER REPAIR
THE WELDING GRADES OF STEEL MAY BE REPAIRED IN ACCORDANCE

WITH ASME SEC. VIII, DIV. 1 & ASME SEC. IX.
SHOP TEST
THE SHOP ACCEPTANCE TESTS AS PER THE API ARE CLASSIFIED AS :
WITNESSED
OBSERVED
SHOP TEST INCLUDES
HYDROSTATIC TEST
SHOP RUNNING TESTS

HYDROSTATIC PRESSURE TEST
PRESSURE TESTING OF ALL PRESSURE CONTAINING COMPONENTS, ASSEMBLY OR OTHER
AUXILLIARY SYSTEM COMPONENTS LIKE PIPING ACCESSORIES AT GENERALLY 1.5 TIMES
OF THE MAX. ALLOWABLE PRESSURE THAT IS ANTICIPATED BY THE DESIGNER.
TEST OBJECTIVE
CONFIRMS STRUCTURAL & MATERIAL INTEGRITY & BASIC STRENGTH OF THE DESIGN
ASSURES CASING CASTING PERFECTION & POROSITY OF CASTING CAN EASILY BE

DETECTED WITHOUT LENGTHY ULTRASONIC & COSTLY RADIOGRAPHIC INSPECTIONS
HYDROSTATIC TEST PARAMETERS
TEST PRESSURE
150% OF THE WORKING PRESSURE
EACH PART OF THE PUMP SHOULD WITHSTAND THIS WITHOUT INCURRING ANY
NOTABLE DAMAGE
TEST DURATION
THE HYDROSTATIC TEST PRESSURE CAN BE ASSUMED TO BE SATISFACTORY WHEN

THERE IS NO SEEPAGE OR LEAKAGE IS OBSERVED FOR
30 MINUTES AS PER API 610

10 MINUTES AS PER ANSI
3 MINUTES FOR PUMP < = 75 KW & 10 MINUTES FOR MORE THAN 30 KW - HIS
TEST LIQUID
GENERALLY WATER OR OIL HAVING MAX. VISCOSITY 150 SSU AT TEST TEMPARATURE
WHEN HYDROTESTING WITH STAINLESS STEEL PUMP ITS ADVISABLE THAT THE SALINITY
(CHLORIDE CONTENT) OF THE WATER SHOULD NOT EXCEED 50 P.P.M.
TEST PROCEDURE
THE TESTING ITEMS SHOULD BE ADEQUATELY SEALED.PROVISIONS SHOULD BE MADE TO VENT

ALL THE AIR AT HIGH POINTS WITHIN THE TEST ITEM BEFORE ITS FILLED WITH TEST LIQUID
THE LIQUID PRESSURE INSIDE THE ITEM IS MAINTAINED AT TEST PRESSURE A S LONG AS
THE TEST IS CARRIED OUT.
HYDROSTATIC TEST RECORDS
MODEL, SIZE, SERIAL NO.

TESTING LIQUID & TEST TEMPARATURE
MAX. ALLOWABLE WORKING PRESSURE
HYDROTEST PRESSURE & TEST DURATION
DATE OF TESTING & NAME OF PERSONNEL IN CHARGE
TEST ACCECTANCE LEVEL
NO LEAKAGE SHOULD BE VISIBLE FROM THE CASING
LEAKAGE FROM THE STUFFING BOX AREA IS PERMISSIBLE TO SOME EXTENT
LEAKAGE FROM PLACES OTHER THAN BOLTING OR THREADED JOINTS IS CONSIDERED AS A

MAJOR FAULT
HYDROSTATIC
PRESSURE
TEST
SEAL INTEGRITY TEST
OBJECTIVE
PRESSURE TEST SPECIALLY INTENDED FOR STUFFING BOX TO CHECK OUT ANY
LEAKAGE IN THE SEALING UNIT PACKING BOX OR MECHANICAL SEAL
TEST PROCEDURE
THE CASING INTERNAL PRESSURE IS MAINTENED AT THE MAX. PRESSURE THAT THE
SEAL SHOULD WITHSTAND.
ITS USUALLY DONE AFTER THE PERFORMANCE TEST OF THE PUMP.

PUMP PERFORMANCE TEST
Performance test
Performance test can be
witnessed, observed or not
wittnessed
Test objective
Running test conducted to
confirm the hydraulic
performance & mechanical
soundness of the pump
Test speed
Pump is tested at 50% to
TYPICAL PUMP TEST BED
120% of the rated speed.
PUMP PERFORMANCE TEST
TESTING PANEL
VFD FOR TESTING

PUMPSENSE
Pump Test Certificate
TYPICAL TEST SHEET
CUSTOMER: XYZ Date: 07-01-06
Pump Pump Motor Make : Full

8HS14 5245 Frame : 280M
Model: No: ALSTOM Load
Suction 250 Delivery Size: Motor Rating : Voltage : 415 Speed : 1450
Size: mm 200mm 90kW 6% rpm
Impeller Diameter: Frequency : 50
Phase : 3 Current : 147 amperes
360mm Hz.
Capacity measured by : Magnetic Flow Speed measured by : Atmospheric pressure : 14.7
Meter Tachometer psi
Suction head measured by : Power measured by : Temperature of test liquid :
Compound gauge Clamp Meter Ambient
Delivery head measured by : Motor efficiency reference : Specific gravity of test liquid
Pressure gauge Manufacturer's test data : 1.0
Head & Gauge Distance FLOW POWER
Suctio Total Pum Watt meter
Sl. Speed Delivery Velocity Flow Meter Reading Motor Motor Pump Pump
n Head p Reading
outp W1 W2 Efficie
No. of Gauge Gauge Head m Input Input Efficiency
ut KILO KILO ncy
Readi Correcti
Pump Reading Discharge in m3/hr KW Watts Watts KW % KW %
ng on
Kg/C
R.P.M Kg/Cm2 m
m2
1 1517.9 0.04 4.50 0.01 44.6 213 25.89 21.6 46.2 67.8 0.85 57.6 45
2 1512.8 0.03 4.20 0.04 41.7 454 51.63 28.9 51.7 80.6 0.89 71.7 72
3 1510.2 0.02 3.80 0.06 37.9 582 60.04 32.1 54.1 86.2 0.88 75.9 79
4 1505.1 0.02 3.60 0.07 35.9 642 62.76 32.2 55.5 87.7 0.86 75.4 83
5 1499.4 0.01 3.40 0.10 34.0 730 67.62 32.9 56.2 89.1 0.89 79.3 85
6 1498.4 0.01 3.20 0.11 32.0 780 68.03 33.1 57.2 90.3 0.90 81.3 84
7 1497.4 0.01 3.00 0.13 30.0 832 68.07 34.2 58.3 92.5 0.89 82.3 83
8 1519.4 0.05 4.80 0.00 47.5 0 0.00 24.8 38.2 63.0 0.88 55.4 0
CONTD.
AT RATED SPEED : 1450 R.P.M
Efficien 12:10
Sl. Total Head Flow Power Set Started at :
cy PM
Set stopped at 12:35
No. m M3/HR KW %
: PM
1 40.7 203.5 50.2 45
2 38.3 435.2 63.2 72
3 34.9 558.8 67.1 79 Pump Certified For :
Total
4 33.3 618.5 67.4 83 Head 33 Mtrs REPRESENTATIVES
:
Disch 612 Customer /
5 31.8 705.9 71.7 85 Manufacturer
arge: M3/HR Agency
Effici
6 30.0 754.8 73.6 84 85% PUMPSENSE
ency :
Pump
7 28.2 805.7 74.8 83 Input 64.7kW
:
1450
8 43.3 0.0 32.0 0 Speed
RPM
TEST TYPES & ASSOCIATE DETAILS
TYPE OF TEST DETAILS

CARRIED OUT AT MANUFACTURERS TEST BED TO AN
WORKS TEST AGREED STANDARD. USUALLY THIS TEST IS THE MOST
ACCURATE. MOST OFTEN THIS TEST IS THE ACCEPTANCE
TEST EITHER WITNESSED OR UNWITNESSED.
THIS TEST IS SUBJECT TO INFLUENCE BY PREVAILING

FIELD ACCEPTANCE TEST SERVICE CONDITIONS. CONTRACTUAL AGREEMENT IS
NECESSARY ON INSTRUMENTATION, TOLERANCES, ETC.
THESE ARE CARRIED OUT TO A FIXED SCHEDULE TO

PERIODIC FIELD TEST TRACK CHANGES IN PERFORMANCE.
THIS TEST CALLS FOR HIGHEST ACCURACY. A GEOMETRIC

MODEL TESTS SCALE MODEL IS TESTED AT THE AT THE MAKERS
WORKS
SHOP ACCEPTANCE CRITERIA
PUMP SPECIFICATION REQUIREMENTS

API 610 (7TH ED.) HYDRAULIC INSTITUTE STANDARD, ANSI
& INDUSTRY PRACTICE
A B
RATED CONDITION RATED SHUT-OFF
DIFFERENTIAL UNDER 200 FT, +5/-0% +5/-3%
HEAD 2999 GPM
Hd: 0-150M -2/+5% -2/+5% UNDER 200 FT,

3000 GPM & +5/0% +5/-3%
ABOVE
-2/+3% -2/+5%
150-300M 200-500 FT, ANY +5/-0% +5/-0%
FLOW RATE
OVER 300M -2/+2% -2/+5% 500 FT & OVER +3/-0% +3/-0%

PUMP SPECIFICATION REQUIREMENTS
API 610 (7TH ED.) HYDRAULIC INSTITUTE STANDARD,
ANSI & INDUSTRY PRACTICE
CAPACITY AT +10/- 0% +5/- 5%
RATED HEAD
0.5% FORMUL
EFFICIENCY 0% A
+ 4%
RATED POWER
NPSHr +0M
3% HEAD
DROP
WHEN REDUCTION IN IMPELLER DIA. WHEN REDUCTION IN IMPELLER DIA.
RETEST DEMANDS MORE THAN 5% OF DEMANDS MORE THAN 5% OF
ORIGINAL DIAMETER. ORIGINAL DIAMETER.
MECHANICAL
SEAL LEAKAGE MUTUAL AGREEMENT NOT SPECIFIED
TEST
TEST DATA INTERPRETATION
ISO STANDARD 5198 9906 9906
MEASURED ACCURACY PRECISION GRADE 1 GRADE 2
POINTS GRADES GRADE MIDDLE LOW
TOP
Q (QN, HN)
TO VERIFY GURANTEE FULFILLMENT A STRAIGHT LINE IS DRAWN
THROUGH THE POINT QN , HN & Q0, H0 GIVING THE DISTANCES Q &
H AS HORIZONTAL & VERTICAL DISTANCES FROM THE PUMP TEST
H
CURVE (H-Q).
A PERPENDICULAR THROUGH THE INTERSECTION OF THE STRAIGHT
LINE ADJOINING 0,0 & QN, HN WITH THE PUMP CURVE DETERMINES
THE EFFICIENCY .
H

SHOP TEST
CRITERIA
XH 0.015 +/- 0.03 0.05

XQ 0.025 +/- 0.045 0.08
> x > nN 0.978 0.97 0.95
Q XNPSH ~ 3% OR 0.03 < 0.15 M 0.03 <0.15 M 0.06<0.3 M
MAX. NPSH
DEVIATION
QA PLAN TABLE
PUMPSENSE QUALITY PLAN CUSTOMER : XYZ
Product
Description
Reference No. AXIALLY SPLIT CASE PUMPS WITH Order No
QAP/2003/05 MECHANICAL SEAL :
Characteristic Classi Quant Referen Accepta Inspection

Sl. Components & s fi - Type of um ce nce Form of Agency Remarks
of Docume
No. Operation cation Check Check nt Norm Record P W R
MATERIAL CONTROL
1 :
Physical & Chemical CI Lab.

1.1 CASING : Top half, Chemical CR Analysis 1/heat/ FG260 Report 3 2 1 Pouring Witnessed by
Properties,
Bottom Half. Dimensions. batch PFE.
Chemical Chemical BS1400

1.2 IMPELLERS Properties CR Analysis 1/heat/ Gr. LG2 ----do---- 3 2 1 Pouring Witnessed by
batch PFE.
Phy.
Physical & properties Identification by PFE
1.3 SHAFT chemical CR & 1/ Bar AISI 316 Mill T. C. 3 2 1 of
Properties, chemical Mfg. Mfg. or Lab
Dimensions, analysis Drg. Drg. Report test bars for chemical
Sub - Surface Measureme analysis. Phy.
defects nt properties
Ultrasonic ASTM A Cl. 8.1.3 will be provided at the
test 100% 388 to IR time
BW Cl. 8.1.5
ECHO of of identification.
100% ASTM
CONTD.
QA PLAN TABLE
IN - PROCESS
2 CONTROL
2.1 All components Visual defects, MA Visual exam. 100% Mfg. Drg. Mfg. Drg. Inspection 2 - -
under 1.0 dimensions. Measurement No harmful Report
defects
Tech. Hydrostatic
2.2 Casing Leak tightness CR Hydro Test 100% spec. No leakage Inspection 2 1 - Test Pr.
(Duration 30 Data
min. sheet Report 24 kg/cm2
minimum ) Hyd. Instt.

Stds.
Static,
2.3 IMPELLERS Dynamic, CR Static and 100% ISO 1940 ISO 1940 Inspection 3 2 1
Residual
Unbalance. Dynamic Gr. 6.3 Report
Balancing
SUB - ASSEMBLY
3 CONTROL :
3.1 Rotor Assembly Eccentricity MA Measurement 100% Mfg. Drg. Inspection 2 - -

Report
CONTD.
QA PLAN TABLE
PUMPSENSE QUALITY PLAN CUSTOMER :
Product
Description
Reference No. AXIALLY SPLIT CASE PUMPS WITH
QAP/2003/05 MECHANICAL SEAL Order No :
Classif Quant Referenc Acceptan Inspection

Sl. Components & Characteristics i- Type of um e ce Form of Agency Remarks
of Docume P W
No. Operation cation Check Check nt Norm Record R
Approve
Complete Pump Visual d drgs. & 2 -
3.2 Assembly Completeness, MA Exam. 100% Mfg. Inspection 1
Measureme standard Report/

Correctness, nt s. Check
Cleanliness, Lists
Clearance,
Freeness,
Alignment.
4 FINAL INSPECTION
TESTS & PACKING -
Test for pumps
DESPATCH CONTROL only :
Pump ( with test Tech. Tech. Performan 2 1
4.1 motor) Q Vs Efficiency CR Performance 100% spec. spec. ce - Minimum 6 points cover-
appd. Data Test
Q Vs Head Test data sheet Record, ing the range of Head/
at reduced Plotted
Q Vs Power speed sheets- ISO2548 Curves Capacity. Acceptance
appd. Class c Norms as per
curves- ISO2548 Class C
ISO2548
CONTD.
QA PLAN TABLE
Undue Wear, Visual 1/Type

4.2 Stripdown after Tear & CR Exam. / Tech. Inspection
after
performance test Breakage. stripping Size specn. Report
Appd.
Mfg.
Completion of all Verification Drgs.,
4.3 stages Completion MA of 100% Tech. ----do----
Inspn.
report, TC Specns.
Approve
d
Visual Procedur Inspn.
4.4 Painting & Packing Surface Finish, M1 Exam. 100% e Report 2 - -
ACP
Soundness of Measureme Check Mfrs.
packing, nt List Check
Marking, etc. List.
CONTD.
QA PLAN TABLE
PUMPSENSE QUALITY PLAN CUSTOMER :
Product
Description
Reference No.
QAP/2003/05 AXIALLY SPLIT CASE PUMPS Order No :
Classifi Quant Referenc Acceptan Inspection

Sl. Components & Characteristics - Type of um e ce Form of Agency Remarks
of Documen P W
No. Operation cation Check Check t Norm Record R
CLASSIFICATION : INSPECTION : The agencies are codified as 1, 2, & 3

where :
CR - Critical P - Performed by 1' - Stands for purchaser or third party
W - Witnessed acceptable to
MA - Major by purchaser .
2' - Stands for Vendor
R - Reviewed by (ACP)
3' - Stands for sub-
vendor of ACP.
NOTE :
1 : Material identification marks for all parts shall be maintained upto the time of
final assembly/ acceptance.
2 : Separate test bars as per standard would be cast, from the same ladle material as that used for
making casting, which shall be identified by
ACP.
3 : Physical testing shall be witnessed from sample drawn by ACP. Chemical test sample will be
drawn by ACP but testing shall not be witnessed
by ACP.
PUMPSENSE
Pump Test Certificate
TYPICAL TEST SHEET
CUSTOMER: XYZ Date: 07-01-06
Pump Pump Motor Make : Full

8HS14 5245 Frame : 280M
Model: No: ALSTOM Load
Suction 250 Delivery Size: Motor Rating : Voltage : 415 Speed : 1450
Size: mm 200mm 90kW 6% rpm
Impeller Diameter: Frequency : 50
Phase : 3 Current : 147 amperes
360mm Hz.
Capacity measured by : Magnetic Flow Speed measured by : Atmospheric pressure : 14.7
Meter Tachometer psi
Suction head measured by : Power measured by : Temperature of test liquid :
Compound gauge Clamp Meter Ambient
Delivery head measured by : Motor efficiency reference : Specific gravity of test liquid
Pressure gauge Manufacturer's test data : 1.0
Head & Gauge Distance FLOW POWER
Suctio Total Pum Watt meter
Sl. Speed Delivery Velocity Flow Meter Reading Motor Motor Pump Pump
n Head p Reading
outp W1 W2 Efficie
No. of Gauge Gauge Head m Input Input Efficiency
ut KILO KILO ncy
Readi Correcti
Pump Reading Discharge in m3/hr KW Watts Watts KW % KW %
ng on
Kg/C
R.P.M Kg/Cm2 m
m2
1 1517.9 0.04 4.50 0.01 44.6 213 25.89 21.6 46.2 67.8 0.85 57.6 45
2 1512.8 0.03 4.20 0.04 41.7 454 51.63 28.9 51.7 80.6 0.89 71.7 72
3 1510.2 0.02 3.80 0.06 37.9 582 60.04 32.1 54.1 86.2 0.88 75.9 79
4 1505.1 0.02 3.60 0.07 35.9 642 62.76 32.2 55.5 87.7 0.86 75.4 83
5 1499.4 0.01 3.40 0.10 34.0 730 67.62 32.9 56.2 89.1 0.89 79.3 85
6 1498.4 0.01 3.20 0.11 32.0 780 68.03 33.1 57.2 90.3 0.90 81.3 84
7 1497.4 0.01 3.00 0.13 30.0 832 68.07 34.2 58.3 92.5 0.89 82.3 83
8 1519.4 0.05 4.80 0.00 47.5 0 0.00 24.8 38.2 63.0 0.88 55.4 0
CONTD.
AT RATED SPEED : 1450 R.P.M
Efficien 12:10
Sl. Total Head Flow Power Set Started at :
cy PM
Set stopped at 12:35
No. m M3/HR KW %
: PM
1 40.7 203.5 50.2 45
2 38.3 435.2 63.2 72
3 34.9 558.8 67.1 79 Pump Certified For :
Total
4 33.3 618.5 67.4 83 33 Mtrs REPRESENTATIVES
Head :
Dischar 612 Customer /
5 31.8 705.9 71.7 85 Manufacturer
ge: M3/HR Agency
Efficienc
6 30.0 754.8 73.6 84 85% PUMPSENSE
y:
Pump
7 28.2 805.7 74.8 83 64.7kW
Input :
1450
8 43.3 0.0 32.0 0 Speed
RPM
QUALITY ASSURANCE & TESTING AGENCIES
FOLLOWING ARE A FEW NAMES OF THE INPECTION AGENCIES :-
LLOYDS
BUREAU VERITAS
SGS
ABS
DNV
RINA
QUALITY ASSURANCE & TESTING AGENCIES
FUNCTIONS PERFORMED BY THE QA AGENCIES
FORMULATION/APPROVAL OF QUALITY PLANS

WITNESS OF POURING OF CASTING
WITNESS OF DESTRUCTIVE & NON-DESTRUCTIVE TESTING OF MATERIALS
VERIAFICATION OF MATERIAL TEST CERTIFICATES
WITNESSING OF DYNAMIC BALANCING
WITNESSING OF HYDROSTATIC PRESSURE TEST
WITNESSING OF PUMP PERFORMANCE TEST
INSPECTION OF PUMPS FOR DIMENSIONAL COMPLIANCE
INSPECTION OF PUMPS BEFORE DELIVERY FOR CLEANLINESS, COMPLENESS &
CONFORMANCE TO SPECIFICATIONS
INSPECTION OF PACKING
FORMULATION/APPROVAL OF QUALITY PLANS
ADDITIONAL ROLES
ISO CERTIFICATION OF QUALITY SYSTEM & CONFORMANCE TO ENVIRONMENTAL STANDARDS

TYPE TESTING OF SPECIAL PUMPS e.g MARINE FIRE PUMP
EXPEDITING & AUDIT ROLES
INSPECTION & TEST STANDARDS
MATERIAL INSPECTION
DESTRUCTIVE & NON-DESTRUCTIVE TESTS
PRESSURE TESTS
PERFORMANCE TESTS
ACCEPATANCE CRITERIA
QUALITY PLANS
INSPECTION AGENCIES
PROGRAMME SUMMARY
QUESTIONS & ANSWERS

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PUMPSENSE

A product of Mather & Platt, Manchester, exported to

BEST PRACTICES OF CENTRIFUGAL PUMPS - MALAYSIA

INTRODUCTION TO PROGRAMME STRUCTURE &

Malaysia July 2011

10.30 am 11.00 am Morning Tea Break

2.00 pm 3.00 pm (Continue) NPSH calculation exercise

3 Understand and evaluate hydraulic performance of your

8 Estimate cost of spares and the best ways of procuring them .

12 Decide whether to replace an inefficient pump or retrofit

17 Understand and quantify environmental impact of your pump

CENTRIFUGAL PUMP COMPONENTS

MULTI-STAGE OPERATION IN CENTRIFUGAL PUMPS

POWER REQUIREMENTS, EFFICIENCIES AND LOSSES IN

PUMP CHARACTERISTIC CURVES

IMPROVING PUMP RELIABILITY

CONVERSION OF KINETIC ENERGY TO PRESSURE

OVER-HUNG IMPELLER IMPELLER BETWEEN BEARINGS TURBINE TYPE

CLOSE- SEPERATELY SEPERATELY SEPERATELY VERTICAL AXIAL FLOW

FRAME MOUNTED AXIALLY SPLIT-CASE

VERTICAL TURBINE PUMP

Easy inspection without disturbing suction & delivery piping and

Heavier than end suction- due to large split flange

STANDARD HORIZONTAL SPLIT-CASE PUMP

SPLIT CASE PRODUCT VARIANTS

Water Supply Pump High Head Mine Drainage Pump

Bottom Suction Water Supply Pump

Side Suction Top

C/L Mounted, Compact

CASING(TOP & BOTTOM)

BEARING HOUSING IMPELLER ACCESSORIES

BEARING BRACKET SHAFT STUFFING BOX SEAL

CASING WEAR RINGS SHAFT SLEEVE SEAL FLUSHING LINE

SHAFT SLEEVE NUTS LUBRICATING /

BEARING (INNER RACE)

BEARING LOCK NUT

IMPELLER TO DEVELOP DYNAMIC HEAD

SINGLE SUCTION DOUBLE SUCTION

TO CONVERT KINETIC ENERGY INTO PRESSURE ENERGY WITH

TO PROTECT THE ROTATING IMPELLER FROM RUBBING WITH

IMPELLER NUT TO LOCK THE IMPELLER IN ITS PROPER AXIAL POSITION

SHAFT TRNSMITS TORQUE TO THE IMPELLER FROM THE DRIVER

TO ENHANCE THE STIFFNESS OF THE ROTATING ELEMENT

TO FASTEN THE SLEEVES TO THE SHAFT

CAUSES PRESSURE BREAKDOWN AS THE LIQUID THROTTLES

ACTS AS ADDITIONAL HYDRODYNAMIC BEARING SUPPORT FOR THE

PRESSES THE OUTSIDE RING AGAINST STUFFING BOX BORE

TO ACCOMODATE THE STATIONARY SEAT OF MECHANICAL SEAL AND TO

TO CIRCULATE OR DISTRIBUTE THE COOLING WATER TO THE PACKING RINGS

BEARING HOUSING HOLDS THE BEARINGS

BEARING PROVIDES SUPPORT FOR THE ROTATING ELEMENT

BEARING BRACKET SUPPORTS THE WHOLE BEARING ASSEMBLY

KEY IMPELLER KEY TRANSMITS THE TORQUE FROM

SECTIONAL VIEWS OF IMPELLERS SHOWN BELOW

CLOSED IMPELLER SEMI-OPEN IMPELLER PARTIAL SHROUDED OPEN IMPELLER

IMPELLERS FOR BOILER FEED

SINGLE SUCTION IMPELLER DOUBLE SUCTION IMPELLER

RADIAL VANE IMPELLER MIXED FLOW IMPELLER PROPELLER

IMPELLER BETWEEN BEARINGS

VERTICAL SHAFT PUMP

HORIZONTAL SHAFT PUMP

RESTRICTED FLOOR SPACE

SCALE MODEL OF A THREE STAGE PUMP

Essentially a High Pump having two or more Impellers Mounted