Pumps

05/04/2012
 Classification of Pumps
Continuous energy addition
Conversion of added energy
to increase in kinetic energy
(increase in velocity)
Conversion increased
velocity to increase in pressure
Periodic energy addition
Added energy forces
displacement of fluid in an
enclosed volume
Fluid displacement results in
direct increase in pressure
2
3
API 610 Centrifugal Pump
Classification

4
 Centrifugal Pump

Overhung Between Bearing Vertically Suspended Submersible Motor

5
 Flexible
Coupling

Overhung Pumps
Flexibly Coupled

Horizontal Vertical

Foot Mounted Centerline Mounted In-Line Bearing Frame

Flexible
Coupling

Thrust
Bearings

6
 Overhung Pumps
Rigidly Coupled

Vertical

Rigid Coupling In-Line

No thrust bearings!

7
 Overhung Pumps
Close Coupled

Horizontal Vertical High Speed Integral Gear

In-Line

8
 Overhung Pumps
Seal less

Magnetic Drive Canned Motor

9
 Between Bearing Pumps

1 & 2 Stage Multistage (more than 2 stages)

10
 Between Bearing Pumps
1 & 2 Stage

Axially Split Radially Split

11
 Between Bearing Pumps
Multistage

Radially Split Axially Split

Single Casing Double Casing

12
 Vertically Suspended Pumps

Single Casing Double Casing

13
 Vertically Suspended Pumps
Single Casing

Discharge Through Column Seperate Discharge

Diffuser Volute Tubular Casing Line Shaft Cantilever

(Axial / Mixed Flow)

14
 Vertically Suspended Pum ps
Double Casing

Diffuser Volute

15
Working of a Centrifugal Pump

Main Parts are –

Impeller
Volute casing

16
Working of a Centrifugal Pump
Impeller rotates exerting
centrifugal force on the liquid

Kinetic energy is created

Centrifugal force throws the liquid

out
Creating low pressure at the
suction eye
This forces new liquid into the
impeller inlet
Liquid thrown out of the impeller
is met with resistance to flow

17
Working of a Centrifugal Pump

The first resistance is created by

the volute
As the liquid moves in the volute
towards the outlet it slows down due
to increasing cross sectional area
As the liquid slows down its
velocity (kinetic energy) is
converted into pressure

18
Relation between Head and
Velocity
Head = pressure in terms of height of liquid
v2
Head (m) =
2xg

v = velocity at periphery of impeller (m/s)

g = Gravitational acceleration (m/s2)

NxD
v (m/s) =
2.748

N = Impeller RPM
D = Impeller diameter (mm)

19
 Working of a Centrifugal Pump
The impeller is offset in the volute to
create a close clearance between the
impeller and the volute at the cut water

The kinetic energy given to the liquid is

proportional to the velocity at the edge of
the impeller vane tip.
Faster the impeller rotates or bigger the
impeller is, higher will be the liquid velocity
at the vane tip.

A centrifugal pump neither creates pressure nor does it suck, it

only provides flow. Pressure is just an indication of the amount
of resistance to flow!
20
 Why Head is used to measure
the energy of a centrifugal pump?

30 m 2.4 kg/cm2 30 m 3 kg/cm2 30 m 3.6 kg/cm2

Kerosene Water Brine

Sp.gr. 0.8 Sp.gr. 1.0 Sp.gr. 1.2

21
 Why Head is used to measure
the energy of a centrifugal pump?
Pressure at any point in a liquid is caused by a vertical
column of liquid due to its weight.
Height of this column is called Static head and is
expressed in meters of liquid.
Head is a measurement of the height of a liquid column
that the pump could create from the kinetic energy
imparted to the liquid.
Pressure is dependent on the specific gravity of a liquid
but head is not.

A given pump with a given impeller diameter and speed will

raise a liquid to a certain height regardless of the weight of the
liquid!
22
Pressure – Head conversion

Pressure (kg/cm2) x 10
Head (m) =
Specific Gravity

23
 Various Heads
Static Suction Head (hs) Total Suction Head (Hs)

Static Discharge Head (hd) Total Discharge Head (Hd)

Total Differential Head (HT)

Friction Head (hf)

Vapour Pressure Head (hvp) Net Positive Suction Head

Required (NPSHr)
Pressure Head (hp)
Net Positive Suction Head
Velocity Head (hv) Available (NPSHa)

24
Exit Various Heads & Continue
Static Suction Head (hs): Vertical distance between the
pump centerline and the liquid surface in the suction tank.

Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

25
Next Back
Static Suction Head (hs): Vertical distance between the
pump centerline and the liquid surface in the suction tank.
Suction Lift (-hs): Liquid level is below pump center line.

Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

26
Next Back
Static Suction Head (hs): Vertical distance between the
pump centerline and the liquid surface in the suction tank.
Suction Head (+hs): Liquid level is above pump center
line.

Ps

Pd
Pvp
Vs
Vd
hd hs

Datum Level
Pump Center Line

27
Back
Static Discharge Head (hd): Vertical distance between
the pump centerline and the point of free discharge or
liquid surface in the discharge tank.

Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

28
Next
Static Discharge Head (hd) and Static Suction Head
(hs) change as the liquid flows.

29
Back
Friction Head (hf): Head required to overcome resistance
to flow in the pipe and fittings.
“ hf ” depends upon the size, condition and type of pipe &
fittings, flow rate and nature of liquid.
Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

30
Back
Vapour Pressure Head (hvp): is the vapour pressure
converted into head.
hvp increases with increase in temperature
hvp acts opposite to the surrounding pressure acting on
the liquid (atmospheric pressure)
Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp

Vs

31
Back
Pressure Head (hp): is the absolute pressure (Ps or Pd)
acting on the liquid in the suction or discharge tanks.
If tank is open to atmosphere, hp = atmospheric pressure
head.
Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

32
Back
Velocity Head (hv): refers to the energy of the liquid as a
result of its motion at some velocity.
It is the equivalent head in meters through which the liquid
would have to fall to acquire the same velocity.
“ hv ” is relatively small in high head systems and relatively
large in low head systems Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

33
Back
Total Suction Head (Hs) = Pressure head in suction
reservoir (hps) + static suction head (hs) + velocity head
at the pump suction flange (hvs) – friction head in the
suction line (hfs).
Hs = reading of the gauge on the suction flange converted
to meters of liquid.
Pd

Vd
Hs
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

34
Back
Total Discharge Head (Hd) = Pressure head in discharge
reservoir (hpd) + static discharge head (hd) + velocity
head at the pump discharge flange (hvd) + friction head in
the discharge line (hfd).
Hd = reading of the gauge on the discharge flange
converted to meters of liquid.
Pd

Vd
hd
Hd
Datum Level
Pump Center Line
Ps hs

Pvp
Vs

35
Back
Total Differential Head (HT) = Total Discharge Head (Hd) -
Total Suction Head (Hs)

Pd

Vd
Hs
hd
Hd
Datum Level
Pump Center Line
Ps hs

Pvp
Vs

36
Back
 Net Positive Suction Head
Before we jump to the term NPSH, we shall
understand

Parts of a Pump

Flow through Pump Inlet

Cavitation

37
 Parts of a Centrifugal Pump
Discharge Flange
(outlet)
Bearing Bracket
Pump
Vent Plug
Casing
Bearing
Cover
Suction
Flange Shaft
(Inlet)
Bearing Bracket
Support
Pump Feet
(support) Mechanical Seal
/ Gland Packing
38
 Parts of a Centrifugal Pump
Heating/ Cooling Jacket
Seal Flushing Pipe
Outlet(Discharge)
Bearing Bracket Lantern
Discharge Flange
Bearing Bracket
Pump Casing
Radial Bearing
Casing Wear Ring
Thrust Bearing

Bearing Cover
Impeller

Inlet (Suction)

Suction Flange Oil Seal

Impeller nut Shaft Oil Chamber
Casing Cover Splash Ring Bearing
Bottom Feet Mechanical Seal Bracket
Key Support
Casing Drain Connection Shaft Protection Sleeve 39
Impeller Nomenclature
Front Shroud Back Shroud

Vane
Outer Hub

Vane Suction Edge

Suction
Impeller Eye Shaft Eye
Diameter

Inner Hub

Back Vane

Vane Discharge
Edge

40
 Liquid moves through
Flow Through Pump Inlet decreasing cross-section
area (as in a Venturi).
Liquid velocity increases
as its pressure decreases not
only due to Venturi effect but
also frictional loss.
At the point of minimum
cross-section (impeller eye)
velocity is max and pressure
is min.
Pressure drops down
further due to shock &
turbulence as the liquid
strikes the edges of impeller
vanes.
Results in creation of low
pressure around the impeller
eye and beginning of impeller
vanes.

41
If the pressure drops below the vapour pressure of the liquid at the
operating temperature, the liquid will vaporize.

42
43
 Formation of Bubbles inside the liquid
New bubbles continue to form and older ones grow in size
Bubbles get carried by liquid at high velocity from impeller eye towards
impeller exit
Bubbles eventually reach the regions of high pressure within the impeller
The pressure outside of the bubble exceeds that inside of the bubble
Hundreds of bubbles collapse by bursting inwards (implosion, not
explosion!)
When bubbles collapse surrounding liquid rushes to fill the void forming a
liquid microjet
Creates highly localised hammering effect, pitting the impeller
An audible shock wave emanates outward from the point of collapse

Bubble Collapse pressures greater than 1GPa (10,000 bar) have been reported!
Life cycle of a bubble has been estimated to be in the order of 0.003 seconds!

44
 This dynamic process of formation of bubbles
inside the liquid, their growth and subsequent
collapse is called CAVITATION.
Cavitation can be of two types
Vaporous: due to vaporisation of the liquid
Gaseous: due to formation of gas bubbles in a liquid
containing dissolved gas
Cavitation - Heart Attack of the Pump
Obstruction to flow
Impair performance – reduce capacity and head
Abnormal noise and vibrations
Damage impeller and other sensitive components
A Centrifugal pump can handle air in the range of 1/2 % by volume. Cavitation
begins if this value is increased to 6%. 45
Impeller Cavitation Regions

46
Cavitation Pitting

47
 NPSH
Pumps can only pump liquid, not vapours
1 cu. ft. of water at room temperature becomes 1700 cu. ft.
of vapour at the same temperature ! Hence, to pump a liquid
effectively, it must be kept always in liquid form

Rise in temperature and fall in pressure induces

vaporisation
The pump always needs to have a sufficient amount of
suction head present to prevent vaporisation at the lowest
pressure point in the pump

NPSH as a measure to prevent vaporisation

The NET POSITIVE SUCTION HEAD is the total head at
the suction flange of the pump less the vapour pressure
converted to fluid column height of the liquid
48
 NPSH
NPSHr - Net Positive Suction Head Required
NPSHr is a function of the pump design
NPSHr is determined based on actual pump test by pump
manufacturer.
NPSHr is the positive head in meters absolute required at
the pump suction to overcome the pressure drop in the pump
and maintain the majority of the liquid above its vapour
pressure.
“Net” refers to the actual pressure head at the pump
suction flange and not the static suction head.
NPSHr increases as capacity increases
NPSHr is independent of liquid specific gravity

49
 NPSH
NPSHa - Net Positive Suction Head Available
NPSHa is a function of the system design
NPSHa is calculated based on the system or process
conditions
NPSHa is the total suction head corrected to the centerline
of the first stage impeller less the vapour pressure head.
“Net” refers to the actual pressure head at the pump
suction flange and not the static suction head.
NPSHa is independent of liquid specific gravity

50
NPSHa = Pressure head in suction reservoir (hpi) + static
suction head (hs) + velocity head at the pump suction
flange (hvi) – friction head in the suction line (hfi) – vapour
pressure head at the max. pumping temperature (hvp)

Pd

Vd
hd

Datum Level
Pump Center Line
Ps hs

Pvp
Vs

51
Back
 Capacity
Flow rate with which liquid is moved by the pump
Measured in m3/hr or GPM or LPM
Capacity depends on
Liquid characteristics – density, viscosity
Pump size, inlet & outlet sections
Impeller size
Impeller rotational speed RPM
Size & shape of cavities between vanes
Pump suction & discharge temperature and pressure
conditions

52
 Power and Efficiency
Brake Kilo Watt (BKW)
• Mechanical power delivered to the pump shaft
Q = Capacity, m3/hr
Q  H  Specific Gravity
BKW  H = Total Differential Head, m
367  η
h = Efficiency, %

Hydraulic Kilo Watt (WKW)

• Liquid power delivered by the pump
Q = Capacity, m3/hr
Q  H  Specific Gravity
WKW  H = Total Differential Head, m
367

W KW
Pump Efficiency (h)  BKW = WKW + Mechanical Losses
BKW + Hydraulic Losses
53
 Pump Performance Curve
Shutoff Head Point Best Efficiency Point
70 14
Run Out Point

Pump Input (BKW) / NPSHr (m)

60 12
Head (m) / Efficiency (%)

50 10

40 8

30 6

20 4

10 2

0 0
0 10 20 30 40 50
Capacity (m3/hr) 54
Radial Thrust

Radial Force acting

on Impeller = Flow
(=constant) x Area
(=varying)

55
 Radial Thrust
The exact points at which the forces will be generated is
determined by the Specific Speed (shape) of the impeller.
Francis vane impellers (the most popular shape) deflect at
approximately 60 and 240 degrees measured from the cutwater, in
the direction of shaft rotation.
Radial vane impellers deflect at close to 90 and 270 degrees.
Axial flow impellers deflect close to 180 and zero degrees from
the cut water

56
 Pump Performance Curve & Radial Thrust
Shutoff Head Point Best Efficiency Point
70 14
Preferred operating
range
60 12
Head (m) / Efficiency (%)

Run Out Point

50 10

Radial Thrust
40 8

30 6

20 4
Allowable operating
range
10 2

0 0
0 10 20 30 40 50
Min. Continuous Capacity (m3/hr)
Stable Flow 57
Single Volute Vs Double Volute

58
 Effect of Impeller Diameter
70 70

60 60

50 50

Efficiency (%)
Head (m)

40 40

30 30

20 20

10 10

0 0
0 10 20 30 40 50
Capacity (m3/hr) 59
Pump Performance Curve

60
 Typical H-Q with Iso-Efficiency Curves
Iso-Efficiency Curves
Head

Capacity 61
 System Resistance Curve
Total System Head = Static System Head + Dynamic System Head
= ( Discharge Static Head - + ( Discharge Velocity Head
Suction Static Head) + - Suction Velocity Head +
(Discharge Pressure Head - Discharge Friction Head +
Suction Pressure Head ) Suction Friction Head )
= ( hd – hs ) + ( hps – hpd ) + ( hvd - hvs ) + ( hfd + hfs )

= ( hd – hs ) + ( Pd – Ps ) + ( Vd2 – Vs2 ) + ( hfd + hfs )

rxg 2xg

hs = -ve, if suction lift Pd

hs = +ve, if suction head Vd
suffix “s” = suction
hd
suffix “d” = discharge
r = density, kg/m3 Datum Level
Pump Center Line
g = gravitational constant, m/s2 hs
Ps
hf = z x V2 , (zloss coeff. )
2xg
Pvp
Vs 62
 System Resistance Curve
70

60

50
Dynamic
Head (m)

40 System
Head
30

20
Static
10 System
Head
0
0 10 20 30 40 50
Capacity (m3/hr) 63
 Operating Point
Best Efficiency Point
70
Operating Point
60
Head (m) / Efficiency (%)

50

40 Dynamic
System
30 Head

20
Static
10 System
Head
0
0 10 20 30 40 50
Capacity (m3/hr) 64
 Specific Speed (Ns)
Specific speed (Ns) is a non-dimensional design index
Ns, is the speed in RPM at which a geometrically similar impeller would
operate if it were of such a size as to deliver 1 m3/hr against 1 m head.
Ns, is primarily used to describe the geometry (shape) of a pump
impeller N Q
Ns  3  4index to predict certain pump characteristics
Ns, is used asΗan

N = The speed of the pump in revolutions per minute (rpm.)

Q = Capacity in LPM at the best efficiency point
H = The total head per stage in meters at the best efficiency point

65
 Specific Speed (Ns)
As the specific speed increases, the ratio of the impeller outlet
diameter, D2, to the inlet or eye diameter, Di, decreases. This ratio
becomes 1.0 for a true axial flow impeller
Values of Specific Speed, Ns

66
Impeller Types Based on Flow

Radial Flow Impeller Mixed Flow Impeller

Axial Flow Impeller 67

 Impeller Types Based on Flow
Head Develoved Centrifugal Axial
by Force Force
Low Flow High Flow
Flow Vs Head
High Head Low Head
Nature of H-Q Lesser Steep More Steep
Curve (More Flatter)
Increases Decreases
Power Input
with flow with Flow
Lower Higher
Specific Speed
Specific Speed Specific Speed

Radial Flow Impeller Axial Flow Impeller Mixed Flow Impeller

68
Typical Performance of a Radial Impeller

69
Typical Performance of a Mixed Impeller

70
Typical Performance of a Axial Impeller

71
 Affinity Laws
Effect of Speed on Pump Performance
System Resistance
Keeping Impeller
Curve
diameter D constant

B1
H1 N2
B2 Q2 = x Q1
H2 N1 N1
B3
H3 N2
N2 2
N3 H2 = x H1
N1
Head H

N2 3
P2 = x P1
N - Speed N1
B - Operating Point

Q3 Q2 Q1
Capacity Q
72
 Affinity Laws
Effect of Impeller Diameter on Pump Performance
System Resistance
Keeping Speed N
Curve
constant

B1
H1 D2
B2 Q2 = x Q1
H2 D1 D1
B3
H3 D2
D2 2
D3 H2 = x H1
D1
Head H

D2 3
P2 = x P1
N – Speed (constant) D1
B - Operating Point

Q3 Q2 Q1
Capacity Q
73
 Effect of Viscosity on Pump Performance

HW
BW QZ = fQ x QW
HZ
BZ HZ = fH x QH
Head H

h Z = fh x Q W
D1
fQ – Capacity Correction Factor
Power P

D2
fQ – Head Correction Factor
D3
fh– Efficiency Correction Factor
Efficiency

B – Operating Point
W – Water
Z – Viscous Liquid
Capacity Q QZ QW

74
Viscosity Correction
Chart
- use for viscosity greater than
or equal to 4.0 cst
- not to use for gels, slurries,
paper stock (non Newtonian
liquids)
- use for pumps with
conventional hydraulic design, in
normal operating range, open or
closed impellers
- not to use for axial, mixed flow
or special hydraulic design
- do not extrapolate

75
 Effect of Valve Closing on the
Operating Point
System Resistance
Curve
B4
B3 Q-H Curve
B2
B1
Head H

B - Operating Point

Capacity Q
76
 Characteristics of
Performance Curve

Drooping Curve (unstable)

DH

Flat Curve
Head H

DQ DQ
Steep Curve

Capacity Q B - Operating Point

77
Parallel Operation

Two or more pumps operating in

parallel
Common method for meeting
variable capacity requirement
Pumps with unstable
characteristics may be troublesome
unless operation only on the steep
portion
No pump should be operated at
flows less than pump minimum flow

78
 Parallel Operation
50
System Head
45 Curve
40
H1= H2 35

30
Head H

Combined
25 Pump 1
20
Pump 2
15
Q2
10
Q1
5 Q1+ Q2
0
0 10 20 30 40 50 60 70
Capacity Q 79
Series Operation

Two or more pumps operating in

series
Common method for meeting
variable head requirement

80
 Series Operation
90
System
80 Head Curve
70

60
Combined
Head H

50
Pump 1
40

30

H1 + H2
20 Pump 2
H2 H1
10

0
0 10 20 30 40 50
Capacity Q 81
 Types of Impellers

Closed Radial Flow Impeller Closed Mixed Flow Double Entry Impeller

Closed Mixed Flow Impeller Open Mixed Flow Impeller

Open Mixed Flow Impeller Axial Flow Entry Impeller 82

 Types of Impellers (Non-Clog)

Closed One Vane Impeller Closed Two Vane Impeller Closed Three Vane Impeller

Open One Vane Impeller Open Two Vane Impeller Open Three Vane Impeller
Used for liquids containing solids
More free passage
83
Types of Impellers (Special)

Free Flow Impeller

84
 Types of Impellers
(based on the no. of inlets)

Single Double
Suction Suction
85
 Axial Thrust
(Single Suction Impeller)
Discharge
Pressure Discharge
Pressure

Suction
Pressure

Discharge
Discharge Pressure
Pressure

86
 Axial Thrust
(Double Suction Impeller)
Discharge Discharge
Pressure Pressure

Suction Suction
Pressure Pressure

Suction Suction
Pressure Pressure

Discharge Discharge
Pressure Pressure

87
 Axial Thrust
Discharge
Pressure Balanced
Forces

Un-Balanced
Forces

Un-Balanced
Forces

Balanced
Discharge Forces
Pressure

The Unbalanced Axial Thrust on an impeller is counterbalanced by Thrust Bearings88

 Axial Thrust
Methods to Reduce Unbalanced Axial Thrust

Back Vane

89
 Axial Thrust
Methods to Reduce Unbalanced Axial Thrust

Back Wearing Ring

Balancing Hole
Balancing Hole

90
 Axial Thrust
Methods to Reduce Unbalanced Axial Thrust
Counter Balancing Disc

Balancing Disc

Balancing Disc

91
 Axial Thrust
Methods to Reduce Unbalanced Axial Thrust
Balancing water line to the suction
Expansion chamber casing of the pump or to the
feedwater tank

Oil-lubricated
thrust bearing

Balancing Drum
(Single Piston)
Balancing Piston
92
 Axial Thrust
Methods to Reduce Unbalanced Axial Thrust

Expansion chamber Balancing water line to the

suction casing of the pump or to
the feedwater tank

Oil-lubricated
thrust bearing

Balancing Drum
(Double Piston) Balancing Double Piston
93
 Internal Recirculation
Recirculation is a flow reversal at
the suction and or discharge tips of
impeller vanes
Recirculation depends on impeller
design
Every impeller has a critical flow at
which recirculation occurs
Recirculation can cause noise,
vibration & cavitation
Pumps with Low NPSHR is more
susceptible to cavitation when
operating in the regions of
recirculation flows
Suction Specific Speed (NSS) is a
guide to predict how close the pump
is to be operated to the BEP to avoid
recirculation and thus cavitation

Suction Recirculation Discharge Recirculation

94
Suction Specific Speed (NSS)
Nss, is used as a non-dimensional index to predict cavitation due to
suction recirculation flow
N Q at BEP
Nss  3 4
NPSHat BEP

N = The speed of the pump in revolutions per minute (rpm.)

Q = Capacity in GPM (m3/s) at the best efficiency point of top
impeller
NPSH = The NPSH in feet (meters) at the best efficiency of
top impeller
Higher the NSS, the closer will be the beginning of recirculation to
the capacity at best efficiency
Guideline: NSS should not exceed 12,000 USGPM, ft, rpm (or 232
m3/s, m, rpm). Lower the NSS safer the pump against cavitation.
If the available NPSH is low enough to require a pump with NSS of
18,000 US units(348 metric units) then it is better to use an axial flow
impeller ahead of the centrifugal impeller.

95
Initial recirculation

*Typical h1/D2 ratios are as follows -

Double suction 0.35-0.50
Multistage 0.50-0.70

1. For water pumps rated at 2500 gpm

& 150 feet total head or less the min.
operating flows can be reduced to
50% of the suction recirculation values
shown for continuous operation & 25%
for intermittent operation

2. For hydrocarbons the min.

operating flows can be reduced to
60% of the suction recirculation values
shown for continuous operation & 25%
for intermittent operation.

96
 Diffuser
Impeller Impeller
Diffuser

Volute Casing without Volute Casing with

Diffuser Diffuser

97
 Diffuser

Comparison of Radial Forces acting on an impeller inside a volute

casing and inside a diffuser casing
98
 Diffuser
A diffuser consists of a number of vanes set around the
impeller
Flow from a diffuser is collected in a volute or circular casing
and discharged through the outlet pipe
A diffuser does the same function as the volute casing in
energy conversion
A diffuser converts vortex flow at the exit of an impeller into
a vortex-free flow with minimum loss
A diffuser reduces the unbalanced radial forces acting on an
impeller
Diffuser is used in high pressure multistage pumps, in
vertical turbine (axial flow) pumps and seldom applied to a
single stage radial flow pump.
99
 Common Suction & Discharge
Configurations

End Suction / Top Suction /

Top Discharge Top Discharge Side Suction /
Side Discharge

100
 Axially Split Casing Pump
Single Stage,
Double Suction,
Between Bearing,
Side Suction / Side Discharge

Multistage Stage,
Single Suction,
Between Bearing,
Side Suction / Side Discharge 101
Radially Split Casing Pump
Single Stage,
Single Suction,
Overhung,
End Suction /
Top Discharge

Multi Stage,
Ring Section,
Single Suction,
Between Bearing,
Top Suction / Top
Discharge
102
 Barrel Casing & Ring Section
Multi Stage,
Ring Section,
Single Suction,
Between Bearing,
Top Suction / Top Discharge

Barrel Casing

Multi Stage,
Double Casing,
Single Suction,
Between Bearing,
Top Suction / Top Discharge 103
Vertical (Can) Barrel Casing Pump

Thrust Bearing

Column Pipe

Guide Bearing
Line Shaft

Bowl Casing
Impeller
Pump Shaft

Barrel Casing
104
 End-Suction, Back Pull-out
Arrangement with Spacer Coupling
Discharge Pipe

Coupling with
Suction
Spacer
Pipe

105
 End-Suction, Back Pull-out
Arrangement with Spacer Coupling

Remove Spacer

106
 End-Suction, Back Pull-out
Arrangement with Spacer Coupling
Pump Suction &
Discharge nozzles
remain connected
to piping!

107
 End-Suction, Back Pull-out
Arrangement with Spacer Coupling

Back Pull-out
assembly lifted!

108
 End-Suction, Back Pull-out
Arrangement with Spacer Coupling

109
Advantage of a Double (Barrel)
Casing Pump
Discharge Suction
Barrel Pipe
Pipe Casing

Cartridge

Cartridge
Removal
Tools
110
 Pump Priming

Earth’s atmosphere is approx. 80,000 m above the earth, resting

on the earth with a weight equivalent to a layer of water 10 m deep
at sea level
The weight of water is approx. 8000 times that of air
111
 Pump Priming
Centrifugal pumps can pump air at their rated capacity, but only
at a pressure equivalent to the rated head of the pump.
Centrifugal pump can produce only 1/8000 of its rated water
pressure when handling air
In other words, for every 1m water that has to be raised to fill
the pump, the pump must produce a discharge head of approx.
8000 m, which is impossible!
Hence, it is necessary to fill the waterways in a pump with liquid
before starting it.
A centrifugal pump is said to be PRIMED when the waterways of
the pump is completely filled with liquid to be pumped.

112
Methods of Pump Priming

Foot Valve

113
Methods of Pump Priming

Priming Chamber

114
Methods of Pump Priming

To Vacuum
Pump

115
 Methods of Pump Priming

Self Priming Pump

116
 Inducer
Inducer is an axial flow impeller fitted ahead of the centrifugal
impeller to reduce the NPSH of the pump or to permit the pump
to operate at higher speeds.

Impeller

Inducer

Inducer
117
 Inducer
Inducer is mounted on the same shaft as that of the centrifugal impeller
and rotates at the same speed
Inducer increases the suction pressure of a conventional impeller
Although the efficiency of the inducer is low, it will not reduce the pump
overall efficiency significantly
Inducers have typically 2 but not more than 4 vanes

NPSH without
Inducer
NPSHr

NPSH with
Inducer

Capacity Q 118
Methods of Reducing Pump NPSH

Double Suction Arrangement

119
Methods of Reducing Pump NPSH

Impeller

Inducer Inducer Arrangement

120
Methods of Reducing Pump NPSH

Increase Impeller Eye Area

121
TYPICAL MATERIAL OF
CONSTRUCTION

122
TYPICAL MATERIAL OF
CONSTRUCTION

123
Torque – Speed Characteristics

124
 Bearing Bracket

Thrust
Radial Bearing Bearings

Shaft

Deflector
Oil Seal
Oil Seal

125
•REQUIREMENTS
Scope OF API 610
API 610 is a standard that covers the
minimum requirements for centrifugal pumps
for use in petroleum, heavy duty chemical and
gas industry services. It includes pumps
running in reverse as hydraulic power
recovery turbines.

• Why is API 610 Published?

API 610 has been written to ensure a
minimum standard for:
Safety
Reliability
Maintainability

• Pump Types Covered 126

API 610 covers all types of centrifugal pumps,
 FEATURES OF API 610
• Long Reliable Life
– API pumps must be designed and constructed for a
minimum service life of 20 years and at least 3
years of uninterrupted operation (clause 2.1.1). In
practice there are many API 610 pumps in industry
that have been operating for in excess of 40 years
and many oil refineries are now reporting MTBF
figures in excess of 7 years.

• Casing Design
– The pump pressure casings must be designed using
the stresses, welding and inspection practices given
in the pressure vessel code (2.2.1).
– Overhung pumps, between bearings radially split
pumps, multi-stage pumps and vertical double case
pumps are to be designed with a pressure rating
equal to the lesser of 4,000 kPa-g or an ANSI 300#127
flange rating (2.2.2).
 FEATURES
• External OF
Nozzle Forces andAPI 610
Moments
– API 610 lists the maximum forces and moments, which
the pump nozzles must be able to take, and still give
satisfactory performance. Case distortion and shaft
misalignment are considered when assessing
satisfactory performance (2.4.1).
– The pump must meet these requirements without any
bearing housing support (3.3.6).

• Rotors
– Default impeller design is closed and constructed as a
one piece casting. Except on vertical suspended
pumps, impellers must be keyed to the shaft and
secured by a cap screw or cap nut, which in turn must
have a positive mechanical locking method (2.5.1, 2.5.2,
2.5.3)
– Shaft runout is limited to 0.001 inch (2.5.6). 128
– Shaft stiffness must limit the deflection at the
 FEATURES OF API 610
• Mechanical Seals
– There is now an API standard for mechanical seals, API 682 (2.7).
– Both API 610 and API 682 specify seal chamber dimensions. These
dimensions help ensure an ideal environment for the mechanical
seal. External Nozzle Forces and Moments
• Vibration
– API 610 specifies maximum allowable vibration levels – nominally
3.0 mm/s RMS unfiltered, at the bearing housing (2.8.3).
• Balancing
– Single stage and two stage pumps: impellers dynamic balanced to
Grade G1.0 (2.8.4.1).
– Multi-stage pumps: impellers and major components balanced to
grade G1.0, rotors balanced to G2.5 (5.2.4.2)
• Bearings
– Minimum L10 design bearing life is 25,000 hours, at rated
conditions (table 2.7). In practice most API 610 pumps will have an
L10 bearing design life far in excess of this figure.
– Bearing housings must have constant level oilers fitted.
• Rotors
– Default impeller design is closed and constructed as a one piece
casting. Except on vertical suspended pumps, impellers must129be
keyed to the shaft and secured by a cap screw or cap nut, which in
turn must have a positive mechanical locking method (2.5.1, 2.5.2,
• Drivers
FEATURES OF API 610
– Driver power ratings must be at least equal to the following (table
3.1):
– Motor kW Percentage of Rated Pump Power <22 125% 22-55
115% >55 110%
• Baseplates
– Strict guidelines are given for baseplate design. These design
criteria ensure minimal misalignment of pump and driver shafts
(3.3.5).
– Baseplates must be single piece drain rim or drain pan design, to
ensure that any leakage is contained within the baseplate (3.3.1,
3.3.2).
– Pump and drive train components must have mounting pads, fully
machined flat and parallel. Values are specified for measuring
compliance (3.3.3).
• Inspections
– The manufacturer must keep quality records for at least 20 years
(4.2.1.1).
• Material Inspections
– The purchaser should specify which parts are to be subjected to
surface and subsurface examination, and the type of examination
required (i.e. magnetic particle, liquid penetrant, radiographic or
ultrasonic) (4.2.1.3). 130
– The standard lists the appropriate procedure and acceptance
 FEATURES OF API 610
• SUMMARY

– Heavy duty casing design

– Centerline supports
– Low shaft stiffness ratio
– Low shaft deflection at the seal faces
– Long design bearing life
– Low vibration levels
– High allowable forces and moments on nozzles
– Stringent testing requirements

131
Need to Seal a Pump

132
 Stuffing Box / Seal Chamber
Shaft Protection Sleeve

Impeller

Shaft

133
Need to Seal a Pump

Pump Environment
Wall

Shaft

Process
Fluid
Leakage

134
 Seal Types

Gland Packing Mechanical Seal

135
 Gland Packing
Stuffing Box
Gland

Shaft

Lantern Ring (Seal cage)

Shaft Sleeve
Packing

136
 Mechanical Seal

Stuffing Box
Secondary Sealing Element (Seal Chamber)

Mating
Ring

Shaft

Primary Ring Secondary Sealing Element

137
 Mechanical Seal
Principle Components

1. A rotating face (primary ring)

2. A stationary seat, (mating ring)

3. A secondary sealing element

4. A mechanical loading device to press face and

seat together, and

5. Auxiliary components

138
 Mechanical Seal
Primary Ring Mating Ring
Assembly
Snap Ring (Stationary)

O-Ring
O-Ring
Disk
Springs Mating Ring
Retainer
Set Screw

Seal Head
(Rotating)
Shaft

139
 Mechanical Seal
Process Fluid Acts as Lubricant Between Faces
Pump Housing
Gland

Process Fluid

Primary Ring Mating Ring

Invisible Leakage:
140
Fluid Evaporates Upon Reaching Atmosphere
 Mechanical Seal
Without Lubrication, Faces Run Dry And Overheat

Pump Housing
Gland
No Fluid Or Dry Running

Primary Ring Mating Ring

141
 Mechanical Seal
Heat Transfer
• Conduction
• Convection

142
 Mechanical Seal
Flushing
• Removes Heat
• Replenishes Cool Clean Lubricating Liquid
• Removes any solids
Injection

143
 Mechanical Seal
Single Seal Flushing By - Pass from Discharge
(API Plan 11)
Discharge
By- pass Line from
Pump Discharge
to Seal Gland
Flow

Suction
144
 Mechanical Seal
Balance Ratio

Balance ratio is used to control the face load.

Closing Force Opening Force

145
 Mechanical Seal
Balance Ratio

Balance ratio is the ratio of the closing area

to the opening area.

A A
o
c

Closing Area
Balance Ratio =
Opening Area
146
 Mechanical Seal
Balance Ratio
An Unbalanced Seal
Fc = p x Ac
P = Fc / Ao
= (p x Ac) / Ao

A A
c Fc o

147
 Mechanical Seal
Balance Ratio
A Balanced Seal

Ac Ao

148
 Mechanical Seal
Secondary Sealing Element
Pusher Seal

O-ring must
move axially
149
 Mechanical Seal
Secondary Sealing Element
Non Pusher Seal

Static O-ring

150
 Mechanical Seal
Secondary Sealing Element

Elastomeric Half Teflon Welded Metal

Bellows Convolution Bellows Bellows

V Rings U Cup Wedge Encapsulated O Ring

O Ring

151
 Mechanical Seal

Pusher vs. Non-Pusher

O-ring secondary seal Bellows secondary seal

must slide along shaft as expands to accommodate
seal face wears face wear. Bellows tail is
stationary against shaft

152
 Mechanical Seal
Multiple Seal Arrangements
Classical “Tandem”

Process seal Backup seal

Classical “Double”

Process seal Barrier fluid seal

153
 Mechanical Seal
Un-Pressurised Arrangement

Unpressurised
(Tandem)
Pressure

Process
Buffer Atmosphere

154
 Mechanical Seal
Pressurised Seal Arrangement

PRESSURISED
(double)

Barrier
Pressure

Process
Atmosphere

155
 Mechanical Seal
Categories of Mechanical Seal

– Pusher / Bellows

– Cartridge / Conventional

– Wet Seals / Gas seals

– Split / Whole

– Single / Double

156
 Mechanical Seal
Merits of Pusher & Non-Pusher Seals
PUSHER SEALS NON PUSHER SEALS
(NON BELLOWS) (BELLOWS)

• O ring seals • Metal Bellows

• Wedge seals • Rubber Bellows
• PTFE Bellows

• More material options • No ‘hang up’

• Higher Pressures • Better abrasive handling
• Easier to manufacture • More tolerant to
misalignments

157
 Mechanical Seal
Cartridge Seal

Metal
O-Ring Bellows

Elastomer
Bellows 158
 Mechanical Seal
Merits of Cartridge Seals & Conventional Seals

CARTRIDGE SEALS CONVENTIONAL

(COMPONENT)

• Easier to fit - reliable • Less expensive

• Factory set – reliable • Adaptable
• Less downtime in
replacement

159
 Mechanical Seal
Need for Flushing Plans & Sealing Systems
Pumped Liquid may be …
• Too hot
• Too cold
• Too viscous
Such a liquid if used for
• Prone to solidify or crystallise seal flushing may
• Abrasive damage the seal and
cause seal failure. Hence,
• Close to boiling point the need to condition the
• Contains dissolved gases liquid before being used
as a seal flushing liquid
• The liquid can not get to the seals
for satisfactory seal
• Dangerous liquid operation
• Sensitive liquid
160
 API PLANS
• Seals generate heat and require
lubrication while face sealing. These
systems are used to dissipate this
generated heat and cool the seal faces
thus extending the seal life

161
 Flushing Liquid

Fluid which is introduced into the seal

chamber on the process fluid side in close
proximity to the seal faces typically used
for cooling & lubricating the seal faces
 FLUSHING
 REMOVES HEAT GENERATED BETWEEN RUBBING FACES.
 PROVIDES LUBRICATION.

 INCREASES MARGIN BETWEEN VAPOUR PRESSURE AND STUFFING

BOX PRESSURE.

 KEEPS LIQUID INSIDE STUFFING BOX IN CONSTANT

CIRCULATION.
 IN CASE OF EXTERNAL FLUID FLUSHING - FLUSHING DOES
NOT ALLOW ABRASIVES TO REACH SEAL FACES.
Plan 01
 Plan 01

Integral (internal) re circulation is from discharge to

seal. A connection is made from an area behind the
impeller, near discharge to seal chamber. Recommended
for clean fluids.
Plan 01 (if possible to provide in the stuffing box) is
superior to Plan11 for the liquids, which may become
viscous or freeze at lower temperature. This minimizes
the risk of freezing of the fluids in the piping.
Disadvantage - No control on the flush flow rate.
Plan 02
 Plan 02

The stuffing box is dead-ended (with no circulation of fluid).

This plan is preferred plan for the clean and relatively cool
liquids having sufficient (at-least 1 kg/cm2) margin between
vapour pressure and stuffing box pressure.
Care should be taken to vent the stuffing box properly. One 5
mm diameter hole at the topmost position of the throat should
be provided for venting purpose.
Depending on the requirement cooling or heating is provided in
the stuffing box jacket.
For liquids at self ignition temperature API Plan 02 is not
recommended.
Plan 11
 Plan 11

A line with flow control orifice is connected from the

discharge side of the pump into the gland flush
connection. It is default seal flush plan.
Orifice must be sized properly.
Minimum orifice size recommended is 3 mm. For
larger pressure drop multiple orifice is recommended
instead of reducing the size of orifice.
Orifice
 Plan 13

Horizontal Pump
Orifice

From Seal

Suction
 Plan 13
Vertical Pump
From Seal

Orifice

Suction
 Plan 13

A line is connected from the gland, through a flow

control orifice, to the suction piping. It is standard
flush plan for vertical pumps where stuffing box
pressure is equal to discharge pressure.
Whenever stuffing box pressure is more than suction
pressure, API PLAN 13 is better than API PLAN 11.
In this plan liquid moves away from the seal face
instead of impinging on to it ( API Plan 11) and the
stuffing box pressure reduces making the seal more
comfortable.
Plan 14
MEDIA FROM DISCHARGE
TO SEAL CHAMBER THRU
ORIFICE.

MEDIA FROM SEAL CHAMBER

TO SUCTION THRU ORIFICE.
 Plan 14

It is combination of Plan 11 and Plan13. It is

mostly used for vertical pumps handling volatile
liquids. In Plan 13 because of throat bush,
pressure in the seal area may drop and liquid may
vaporise. Plan 11 provides cool fluid to the seal
area whereas Plan 13 provides complete venting in
the seal area.
Plan 21
 Plan 21

A line with orifice is connected from the discharge

side of the pump through a flow control orifice and
cooler into the seal chamber.
It provides cool flush to the seal. This plan is the
best for liquids at self ignition temperature. In the
event of seal leakage, cool liquid will continue to reach
seal faces as long as the pump is running ,ensuring
that hot liquid does not come out.
The disadvantage is that heat loss is more, also
cooling water requirement is high.
Plan 23
 Plan 23

In this plan process fluid is recirculated with the help of a pumping ring
in the seal chamber through a cooler and back in to the seal chamber.
A Plan 23 flushing system is most effective way of providing a cool
flush to the seal faces. In this arrangement fluid in seal chamber is
isolated from that in the impeller area of the pump by a throat bush.
Use of an internal circulating device to circulate the fluid through a
closed loop cooler allows the cooler to continuously cool a recirculated
stream rather than a continuous (hot) stream from discharge to seal
(Plan 21). The cooler is required to cool the liquid in the loop. Therefore
cooler size reduces drastically as compared to Plan 21 cooler. Also the
cooling water requirement is much less than Plan 21.
Coolers for API Plan 21 & 23
Air Fin Coolers

NATURAL
DRAUGHT
 Plan 23M
Modified API plan by ESSIL

Plan 23: Process liquid through coil & cooling liquid through shell.
Plan 23M: Process liquid through shell & cooling liquid through coil
 Plan 23M

It is shell and tube type heat exchanger.

Advantages:

Vapour Lock : Plan 23 is not self venting

Friction loss: More in Plan 23
Heat transfer rate: The pot area is sufficient to carry away heat
generated by the seal and soaked heat. In majority of the cases if
proper thermal barrier is provided at the bottom of the throat bush
cooling water coil is not required.
 Plan 31
Solid Sp.Gravity should be at least 2 times media Sp. Gravity.
 Plan 31

Process liquid is recirculated through a cyclone separator to

the seal. Solid particles are centrifuged through cyclone
separator and sent back to suction. The Plan is specified for
services containing solids with a specific gravity at least
twice that of the process fluid.
Normally cyclone separators do not remove the solids
effectively and cause seal failure. Even if the efficiency of
cyclone separator is 92%.about 8% of the finer particles
reach to the seal faces. The finer particles can enter
between the seal faces and cause damage to the seal.
Cyclone Separator
Plan 32

PRESSURE STRAINER
GAUGE

EXTERNAL FLUSH
TO SEAL
ORIFICE
 Plan 32

Flushing product is brought from an external higher pressure

source to the seal.. This plan is excellent for liquid containing
solids/ abrasives. The flushing fluid mixes with the product.
Therefore it must be ensured that the flushing fluid is
compatible with the product. A close clearance throat bush
restricts the product to come to the seal area and also
increases the pressure margin.
Flushing fluid dilutes the product. Therefore unnecessarily
more liquid should not be circulated .
 Plan 41
Solid Sp.Gravity should be at least 2 times media Sp. Gravity.
 Plan 41

It is combination of Plan 21 and Plan 31. Process liquid is

recirculated through a cyclone separator and cooler to the
stuffing box. The plan is recommended for hot liquids
containing solids. Specific gravity of the solid particles should
be at least twice that of the process fluid. Solid particles are
centrifuged through cyclone separator and sent back to
suction.
If the process liquid is very dirty or is slurry, it may choke the
cooler.
 Plan 51

In this plan an external reservoir provides a dead ended

blanket for the fluid to the quench connection of the
gland.
Plan 52
 Barrier Fluid Properties

One of the most important properties of a good

buffer or barrier fluid is its viscosity.

A good buffer or barrier fluid should be a good

heat transfer fluid.

A good barrier or buffer fluid should not present

any potential danger whether equipment is running
or stationary.

The fluid must be compatible with the

metallurgy, elastomers and other materials
of the sealing system.
 Barrier Fluid Properties

The fluid should also be highly compatible with

the process pumpage being sealed.

Foaming risks are to be avoided.

Fluid stability must be ensured for a longer

maintenance cycle time.
 Plan 52

In this plan external reservoir provides buffer fluid for the outer seal
of an un-pressurized dual seal arrangement ( Arrangement 2). During
operation an internal pumping ring provides circulation. The reservoir
is connected to a vapour recovery system and is maintained at a
pressure less than the pressure in the seal chamber. It is normally
used for the applications where process fluid leakage to atmosphere
must be minimised and contained. Plan 52 works best with clean, non-
polymerising pure products that have vapour pressure more than the
buffer system pressure. Leakage of higher vapour pressure process
liquid into buffer system will flash in the seal pot and escape into the
vent system.
Leakage of the process fluid will mix with the buffer fluid and
contaminate the buffer fluid over a time. Therefore the buffer fluid
must be compatible with the process fluid.
Plan 53
 Plan 53

In this plan external pressurised barrier fluid reservoir provides fluid

for to the seal chamber. The Plan 53 is for double back to back seal
(Arrangement 3). During operation an internal pumping ring provides
circulation. It is normally used for the applications where process no
fluid leakage to atmosphere is permitted.
The barrier fluid must be pressurised to about 1.5 to 2 kg/cm2 above
the pump seal chamber pressure. Inner seal leakage (if any) will be
barrier fluid into the product and no process fluid will be allowed to
leak in to barrier fluid area.
Plan 53 is selected over Plan 52 for dirty, abrasive or polymerising
products which may either damage the seal faces or cause problem
with the buffer fluid system if Plan 52 was used.
Plan 53A
 Plan 53B

Pressurised barrier fluid circulation with bladder

accumulator. Cooler outside the reservoir.
 Plan 53C

Pressurised barrier fluid circulation with piston

accumulator. For Dynamic tracking of system pressure
Plan 54
 Plan 54

In Plan 54 cool clean product from an external source is supplied.

The supply pressure must be at-least 1.5 kg/cm2 greater than
the pump seal chamber pressure.
Plan 54 is used for the fluids where the process fluid is hot,
contaminated with solids or both.
In Plan 54 care should be taken of barrier fluid system. A
contaminated system may cause seal failure. A properly
engineered barrier fluid system is typically complex and
expensive. Where these systems are properly engineered they
provide most reliable system.
 QUENCHING
 KEEPS ATMOSPHERE AWAY
 TOXIC FLUIDS
 CRYSTALLIZING PRODUCTS
 CRYOGENIC APPLICATIONS
 HIGH FREEZING POINT FLUIDS
 HIGH TEMP. FLUIDS WHICH DECOMPOSE IN CONTACT WITH ATMOSPHERE
 FLUID HAVING TENDENCY TO BECOME VISCOUS IN CONTACT WITH
ATMOSPHERE

ADDITIONAL ADVANTAGES

 KEEPS AREA OUTSIDE SEALS CLEAN

 PROVIDES HEATING / COOLING TO SEAL FACES.
 Plan 61

Tapped and plugged connect for purchaser’s use.

Plan 62
 Plan 62

In Plan 62, a quench stream is brought from an external source on

atmospheric side of the seal faces.
The quench fluid can be clean water, steam or low pressure
Nitrogen.
Quenching is provided to keep atmosphere away. In following
conditions atmosphere must be kept away from the seal face.
 Plan 62

1) Toxic fluids
2) Crystallising products.
3) Cryogenic Application.
4) High Freezing point fluids.
5) High temp. Fluids, which decompose in contact with
atmosphere.
6) Fluid having tendency to become viscous in contact
with atmosphere.
Quenching fluid keeps area outside seals clean and provides
heating / cooling to seal faces
 Plan 62

Recommended flow rates:

Media: Water
Flow: 1 lpm
Pressure: 0.5 kg/cm2

Media: Steam
Flow: 1 m3/hr
Pressure: 0.5 kg/cm2
 Plans for dry containment seals
and single seals

Plan 71, 72, 74, 75 and 76 are for the dry

containment seal. Plan 71, 72 and 74 are similar to
Plan 51,52 and 54. Instead of liquid ,gas is provided
between the two seals. Plan 75 and 76 are for single
seal as well as for containment seals.The leakage
collection. Plan 75 is for non volatile liquids and Plan
76 is for volatile liquids.
 Plan 71

This is used in Tandem (Arrangement 2) un

pressurized dual seals, which utilize a dry
containment seal and where no buffer gas is
supplied but the provision to supply a buffer gas is
desired. Buffer gas may be needed to sweep inner
seal leakage away from the outer seal into a
connection system or to dilute the leakage, but it is
not specified.
Plan 72
 Plan 72

Plan 72 is used Tandem (Arrangement 2) un-pressurized

dual seals, which utilize a dry containment seal and
where buffer gas is supplied. The buffer gas can be used
to sweep inner seal leakage away from the outer seal to
a collection system and /or dilute the leakage so the
emissions from the containment seal are reduced.
Plan 74
 Plan 74

The system is used on dual pressurized seals (Arrangement 3),where

the barrier medium is a gas. They are the gas barrier equivalent to
the traditional plan 54 liquid barrier system. The most common
barrier gas is nitrogen The supply pressure to the to the seal is
typically at least 0.17 Mpa (1.7 bar) (25 ps) greater than the seal
chamber pressure. This results in small amount of gas leakage into the
pump, with most of the gas barrier leakage to atmosphere. This
arrangement should never be used where the barrier gas pressure can
be less than the sealed pressure If this were to happen the entire
barrier gas system could become contaminated with the pump fluid.
 Plan 74

Plan 74 systems are typically used in services which are not too hot
(within elastomer property limits) but which may contain toxic or
hazardous materials whose leakage cannot be tolerated. Because
they are pressurized dual seal systems, leakage to the system is
eliminated under normal conditions. Plan 74 may also be used to
obtain very high reliability, since solids or other materials which
may lead to premature seal failure cannot enter the seal faces.
Plan 75
 Plan 75

Systems are typically used on Arrangement 2, unpressurised dual

seals, which also utilize a dry containment seal and where the leakage
from the inner seal may condense. They may be used with a buffer
gas (Plan 72) and without a buffer gas (Plan 71)
If an unpressurised dual seal is installed, usually it is because leakage
of the pumped fluids to the atmosphere must be restricted more
than can be done with an arrangement 1 seal. Therefore a mean is
needed to collect the leakage and route it to a collection point. The
Plan 75 system is intended to perform this collection for pump fluids
that may form some liquid (condense) at ambient temperature
Plan 76
 Plan 76

System is typically used on arrangement 2, unpressurised dual seals,

which also utilize a dry containment seal and where leakage from the
inner seal will not condense. They may be used with a buffer gas (plan
72) or without a buffer gas (Plan 71).
If an unpressurised dual seal is installed, usually it is because if
leakage of the pumped fluid into the atmosphere must be restricted
more than can be done with an Arrangement 1 seal. Therefore a
means is needed to route the leakage to the collection point. The Plan
76 system is intended for services where no condensation of the
inner seal leakage or from the collection system will occur.
 PUMP VIBRATIONS

• BASIC SOURCES OF VIBRATION

– MECHNAICALLY INDUCED

– SYSTEM INDUCED

– OPERATION INDUCED

220
 PUMP VIBRATIONS
– MECHNAICALLY INDUCED
• BAD BEARINGS
• BENT SHAFT
• UNBALANCED ROTOR
• CHECK VALVE INSTALLED BACKWARDS
• MISALIGNMENT
• LOOSENESS
• SOFT FOOT
• MAXIMUM SIZE IMPELLER

221
 PUMP VIBRATIONS
– SYSTEM INDICED
• PARTIALLY / PLUGEGD STARINER
• CLOGGED IMPELELR OR SUCTION LINE
• INSTALLATION

– OPERATIONALLY INDICED
• CAVITATION
• FLOW
• SPEED
• INSUFFICIENT IMMERSION OF SUCTION
PIPE OR BELLMOUTH
222
 PUMP VIBRATIONS
– ACCEPTABLE LIMITS AS PER API 610

223
 PUMP VIBRATIONS
– API 610 REQUIREMENTS

224
PUMP VIBRATIONS

225
PUMP VIBRATIONS

226
 Trouble shooting

• Classification of Failure causes

• Common Problems in Centrifugal Pumps
• Specific Failure Cases
• Troubleshooting
• Modern methods of Troubleshooting
• Pump Troubleshooting Software
 Classification of Failure Causes

• Design Related

The problems related specifically to the design parameters of the pump which
are specified by the Process Engineer / Machinery Engineer / Vendor’s
Counterpart in the Pump Mechanical Datasheet.

• Operation Related

The problems related to the operation of the pump at site/shop due to reasons
dependent/independent of its design.
Common Failures in Centrifugal
pumps

• Insufficient Capacity / Insufficient Head

• Internal recirculation
• Cavitation
• Excessive Power Consumption
• Excessive Noise and Mechanical Vibrations
 Insufficient capacity
• The problem is in
a. The Pump
b. The Suction side
c. The Discharge side
Insufficient Head
• The problem is in
a. The Pump
b. The Suction side
c. The Discharge side
 Internal Recircultion

• Suction Recirculation
- Cause and Effect
• Discharge Recirculation
- Cause and Effect
 Cavitation

• What is Cavitation?
• Causes of Cavitation
- Vaporization
- Air Ingestion
- Internal Recirculation
- Flow Turbulence
- Vane Passing Syndrome
 Excessive Power Consumption

• Reasons could be due to

- use of oversized pump
- change in product
- increase in bearing loading
- starting procedure could be a problem
- too much axial thrust
 Excessive Noise and Mechanical
• Unbalance
Vibrations
• Critical Speed
• Resonance with natural Frequencies
• Misalignment
• Hydraulic Disturbances
• Cavitation
• Surging
• Water Hammer
• Other Reasons
 Troubleshooting
• Skill takes time to develop
• Pump may be a cause of a symptom
• Regulations may have additional safety precautions
• Make sure suction and discharge gages are available
• Verify pump speed
• Verify motor amps, voltage and power factor
• Make sure drivers are locked before doing any inspection
• Information gathering
– What is different from when it ran fine?
– When was the last maintenance work done? What was done?
– How do things look?
– Get the basics: inlet and discharge pressure, flow, speed, liquid, temperature,
viscosity, duty
• Noise?
 Troubleshooting

• Rotation
• Loss of suction
• Loss of developed head
• Wear
• Viscosity
• Pulsations, vibrations, noise
• Amps and power
• Hydraulics, mechanics, electrics
THANK YOU
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