DESIGN & SELECTION OF PUMPING

MACHINERY
 Classification of Pumps
The pumps can be classified on various aspects
but mainly it is on principle of operation
(1) Positive Displacement: a) Reciprocating
pumps (Piston / Plunger / Diaphragm Type) &
b) Rotary Pumps (Gear / Cam / Vanes / Screw)
(2) Rotodynamic or Dynamic Pressure (Velocity)
a) Centrifugal (Radial) Flow, b) Semi Axial or
Mixed Flow, c) Axial Flow or Propeller Pump, d)
Centripetal Action & e) Turbo blade pumps
(3) Impulse, (4) Buoyancy & (5) Miscellaneous.
 Principle of Operation of Rotodynamic
Pumps
• Pumping is the process of adding energy to the
fluid to move it from one point to another or
raising its pressure or to transfer it from a low
pressure region to high pressure region.
• They have impeller revolving in a casing at high
speed. Impeller is a circular disc with built in
passage for flow of fluid to convert kinetic
energy supplied by prime mover to pressure or
velocity energy for pumping the fluid
 Type of Casing
Casing is provided over the impeller to contain the
liquid coming out of the impeller & also to convert its
kinetic energy into pressure energy. They are volute,
vortex or diffuser type.
• Volute: Spiral shaped casing known as volute
chamber. Sectional area of flow of discharged water
gradually increases from its throat to the discharge
pipe. Restricted throat area leading to formation of
whirls as water gets choked near the neck portion.
• Vortex Chamber: Annular ring is provided to increase
throat area & to ensure laminar flow of discharged
water & to achieve higher efficiency.
Casing type Continued
 Type of Casing
• Double Volute: This type of casing is designed &
adopted to minimize radial thrusts.
• Diffuser or Turbine: Stationary diffuser ring is
provided around the impeller for flow guidance and
conversion of kinetic to pressure energy. Water after
leaving impeller passes through guide vanes with
gradual enlarged passages enabling reduction of
velocity & increase in pressure. Water diffuses out
into the annular ring formed by casing which may be
circular or spiral.
Guide vanes also change direction of water in
multistage bowl type VT pump from radial to axial, so
that water enters the next stage radially.
 Methods of Opening The Casing
Casing is provided in two separable halves to
facilitate opening of pump & exposing its internals eg
impeller, bearing etc. for repair & maintenance.
Splitting of the pump is vertical or horizontal.
• Radial (Vertical) Split: Casing is vertically divided in
two halves which are bolted together & provided
with tight water packing. Splitting may be at NDE
bearing side & on the coupling side. Draw back is
that entire pump has to be dismantled for repairs.
• Back Pull Out Design: Design allows removal of
stuffing box & bearing from the pump. This enables
dismantling of pump without disturbing suction &
delivery pipes. It takes care of draw back in above.
 Methods of Opening The Casing
• Axial (Horizontal) Split Casing: Casing of such pumps
is provided in two halves, splitting in horizontal
plane. Pump can be split open by removing the
upper half for easy access to internal parts without
affecting the suction & discharge pipe & pump
assembly. The lower half casing contain the suction
and delivery outlets.
• End suction has side suction & discharge from top
side while HSC CF pump has suction from side and
discharge too from side.
• Most commonly used pumps in major projects in
water sector are HSCF, V T and End Suction type.
 Function of Centrifugal Pump
CF pump receives energy from its prime mover &
imparts it to the water being pumped by centrifugal
force. This function is performed by impeller coupled
to the prime mover. The water is forced into impeller
by atmospheric pressure (by virtue of its being at
higher level) or other artificial pressure. When water
enters the vanes of rotating impeller it gets rotated
centrifugally by the impeller imparting it kinetic
energy enabling water to leave it at very high velocity
which is subsequently converted into pressure
energy by means of a totally enclosed volute casing
with gradually enlarged area (or by stationary
diffuser ring / vanes in case of VT pump).
Constructional Features of CF Pump
C F pump has essentially following major parts:
1) Impeller
2) Volute Chamber & / or Diffuser / Stationary Bowl
3) Shaft
4) Stuffing Box
5) Bearings
6) Coupling
7) Suction & Discharge Ends
Typical cross sectional sample views of single & two
stage HSCF pumps & axial / mix flow V T pumps are
given in the photos. (HSCF-1) (HSCF-2) (VT-A) (VT-M)
 Selection of Pumping Machinery
Following parameters and specific details are essential
for selection of appropriate pumping machinery:
1) Design Data / Load: (a) Discharge Flow Rate / Capacity
(Q), (b) Total Head (H), (c) Speed of rotation n & (d) NPSH
2) Properties of Fluid: Specific Gravity, pH value,
Impurities, Viscosity, Temperature etc.
3) Type of Source: Method of pumping & suitability of
pump depends on type of source i e reservoir, canal,
sump, intake well etc.
4) Availability of Driving Power & Prime Mover
5) Site (Application & Place of Installation) & Operating
Conditions
6) Regulations, Specifications & Local Laws & Codes
 Fixation of Critical Parameters
Discharge: Before the required capacity of a pump can
be specified, the flow requirement (total water to be
pumped) of the system to be served must be calculated.
• Requirement of water shall be assessed by considering
present population & arriving @ intermediate or
ultimate stage demand by appropriate population
forecasting models.
• Per capita requirement whether rural, semi urban or
urban areas are to be served 70 / 100 / 140 LPCD.
• Filtration (Treatment) & Distribution Losses as specified
in GOI manuals shall also be taken into account.
• Hours of pumping shall be taken as per prevailing
technical guidelines of GWSSB or actual need. Continued
 Discharge (Flow Rate or Capacity)
Thus total requirement of water to be pumped for the
system to be served shall be finalised.
Discharge (Q): It is the volume of water pumped out in
unit time. It is measured in litres / second or m3 / hr.
There is direct relationship between the rate of flow of
water & the pipe diameter
Thus Q = V X A or V = Q / A where,
Q = Quantity in m3/s (l/s x 3.6 = m3/hr)
A = Area of pipe in square meters
V = Velocity of water in m/s
Flow velocity in pipe when discharge is given
V = (1273.20 x LPS) / d2 where V is in m/s & d = diameter
of pipe in mm.
 Head
Definition: A column of water in a vertical pipe exerts a
certain pressure (force per unit area) on a horizontal
surface at the bottom, this pressure is expressed in kg/
cm2 or meters of liquid column (mlc). The height of
liquid column is known as Head.
A square container with 1 m sides is filled with water to
the height of 1 m, containing one cubic meter of water
weighing 1000 kg, hence at the bottom it exerts a
pressure of 1000 kg / 10000 cm2 or 0.1 kg/cm2. One m
of water column will exert a pressure of 0.1 kg/cm2 at
the base. Head is always measured in terms of mlc as CF
pump with given speed & impeller dia. will deliver any
liquid to the same height irrespective of its sp. gravity.
Pressure is α to sp. gr. of the liquid. Continued
 Head
1) Static Suction Lift (hss): This exists when the source of
liquid is below the pump datum, and attracts – ve sign.
2) Static Suction Head (hss): This exists when the source of
liquid is above the pump datum, also called flooded
suction and attracts + ve sign. (Figure-1) (Figure-2)
3) Static Discharge Head (hsd): This is the vertical distance
in meter from pump datum to the highest delivery point.
To find out static head, subtract static suction lift or head
from static discharge head. This subtraction is Algebraic
& not Arithmetic. Vacuum is a negative pressure & hence
equation for pump working with suction lift equation for
static head = hsd – (– hss) = hsd +hss while the same for
pump with suction head = hsd – hss. Continued
 Head
• Figures attached give pictorial view & define terms for
head. Note that in both installations for calculation of
total head only exit velocity head (Vd2/2g) is considered.
• Total head for pump with suction lift: H = hsd + hss + hfs
+ hfd + Vd2/2g
• Total head for pump with suction head shall be: hd = hsd
- hss + hfs + hfd + Vd2/2g. Key is as follows.
hd = Total delivery head in meters
hsd = Static delivery head in meters (from pump datum
to highest delivery point)
hfs & hfd = Friction losses in suction & delivery pipes &
fittings
Vd2/2g = Velocity head at exit point Continued
 Selection Criteria
Now depending on the type of source viz canal / intake
well / sump; availability of space; type & availability &
electric power; particular application of pump whether
its for bulk line distribution - rising main pumping / ESR
filling or direct distribution to beneficiaries; working &
standby pump configuration etc. factors shall determine
the type of CF pump to be selected including its
rotational speed, attainable efficiency (prediction based
on HIS) and required capacity of prime mover i e motor
& its efficiency considering operating i e rated total
head.
After assessing the total demand of water i e flow rate
and total head we now come to prediction of efficiency
to assess the requirement of prime mover.
 Power Requirement & Efficiency of Pump
• The work performed by the pump is equal to the liquid
pumped (l/s) in unit time x total head (meters).
• Pump Output (WHP): Water Horse Power
• Pump Input (BHP): Brake Horse Power
• Pump Efficiency: η = (WHP/ BHP) x 100 OR
= (Pump Output / Pump Input) x 100
• WHP delivered by pump in kW= {Q(LPS) x H(m) x Sp. Gr.}/102
• Pump input (BHP) in kW = (WHP / Pump Efficiency) x 100
• The brake horse power is greater than hydraulic horse power
due to the mechanical & hydraulic losses incurred in the
pump.
• A pump’s power demand is α to the difference between the
inlet & outlet pressure & the flow rate.
 Efficiency Prediction of Pump & Factors Affecting It
• Hydraulic Institute Standards (HIS) notifies the guidelines for
efficiency prediction for rotodynamic (centrifugal & vertical)
pumps.
• Factors that play major influence on pump efficiency are:
Pump size, specific speed ns (Ns) & the type of pump selected
to meet the service conditions & surface roughness.
• Surface roughness of waterways depends on quality of
casting, castability of MOC, grinding & polishing & use of
specialty coatings.
• Internal clearances e g pump wear ring clearance which are
determined by design & galling properties of MOC.
• Mechanical losses e g bearings, mechanical shaft seals, gland
packing etc. Continued
 Efficiency Prediction of Pump & Factors Affecting It
• Pumpage: Viscosity of liquid & size of solids can reduce η.
• High suction specific speed results into drop of η of pumps.
• Trimming of impeller diameter also results in drop of η of
pump especially with suction specific sped.
• Methods used for hydraulic thrust balance may reduce η.
• For multistage VT (diffuser) type pumps, there will be a
difference between attainable bowl η & pump η due to
staging effect i e hydraulic losses at the inlet & discharge of
pump and hydraulic losses in the column pipes, discharge
elbow & bearings.
Optimum normally attainable η chart (fig 20.3 a), η reduction
due to specific speed (fig 20.3 b) & deviation from normally
attainable η (fig 20.3 e) are used for prediction of η.
 Specific Speed of Pump (Ns)
• The specific speed is a dimensionless index used to classify
pumps which is used in pump design calculations. The usual
way of evaluating the performance of a particular pump is to
state its specific speed (Ns).
• If we want to compare one pump with another, having similar
Q-H range and impeller geometry design, then the group of
figures like discharge, head, RPM etc. might not be very
illuminating therefore it would be better to use a single numeral
which would itself convey a general description of pump type.
• For this the term, “specific speed of pump’’(Ns) is used.
• Ns=3.65 N x Q0.5 / H0.75 (Metric system IS-5120)
where Q is in m3/s (Half total discharge in case of multistage
pump), H in meter (per stage for Multi stage pump) & N is
rotating speed (RPM) of pump.
 Suitability of Type of Pump
• The factors to be considered for choosing most suitable type of
pump e g centrifugal horizontal end suction, horizontal axial split
casing, horizontal multi stage or centrifugal vertical turbine are
suction (capacity to lift i e low 3.5 m, medium 6 m & high 8.5 m);
head range (low up to 10 m, medium 10 – 40 m & high above 40
m) & discharge range (low up to 30 lps, medium up to 500 lps &
high above 500 lps).
• End suction pumps are suitable up to high suction, medium head
range & medium discharge range.
• HSCF pumps (single stage) are suitable up to low suction, medium
head range & medium to high discharge range.
• HSCF pumps (multi stage) are suitable up to medium suction,
medium to high head range & low to medium discharge range.
• VT pumps are suitable for low to high head & discharge ranges.
They are used when suction lift is to be avoided.
Why Select Higher Efficiency of Pump?
Comparative formula for pumps with different η i e higher &
lower for two pumps with same discharge Q and Head H is
given below.
C = (η2 – η1)/ η1 x P x Z x S x 0.735 Where
C = The cost of power saved annually in Rs. due to better η of the
pump
η2 & η1 = Higher & lower η of two pumps (for same Q – H range)
P = Power input in HP to motor (relates to low η of pump)
Z = Running hours of pump annually
S = Electricity Tariff in Rs. / kWh
Thus pump with identical load conditions but with higher η
results in reduced power consumption & savings during its entire
life cycle ensuring pay back in terms of initial capital cost.
 Motor & Its Efficiency
• Suitable prime mover i. e. properly rated motor is to be selected
considering full operational range of the pump & its efficiency to
compute BKW (BHP).
• Motor efficiency are affected by quality of MOC, quality of
workmanship, under loading / over loading operating condition &
quality of power supply.
• Reserve power margin must be kept as per CPHEEO manual, i e for
BKW required at operating point and multiplying factor to decide
drive rating. For example from 7.5 to 15 BKW range multiplying
factor is 1.2, from 15 to 75 it is 1.15 & above 75 BKW it is 1.1).
• Overall η of pump motor set = pump η x motor η and hence
higher motor η results in overall higher water to wire η.
• Better η of motor results in lesser life cycle cost of the pumping
system.
 Examples of Computation of Q, H & η
• Sample illustrative example of computing total
requirement of water, flow rate, static & frictional heads
etc. to determine individual parameters of pump i e Q
and H is given in excel format sheet annexed here.
• Sample illustrative example of computing attainable
efficiency of pump based on HIS, suction specific speed
with respect to nominal speed, correction factor wrt to
Ns based on HIS, minimum & maximum deviation from
normally attainable efficiency based on HIS, calculation
of WHP, BHP, reserve power margin of motor & final
selection of available standard rating of motor water is
given in excel format sheet annexed here. (Design data)
(HIS VT) (HIS HSCF)
THANKS
PUMP PERFORMANCE & ITS
CHARACTERISTICS
 Pump Performance Curves
• The pump performance curves are based on
data generated in a test rig using water as the
fluid also known as water performance curves.
• The characteristic curve of a CF pump provides
a graphic picture of relationships between
Head, BHP, Efficiency & NPSHR against
capacity.
• These are broadly 1) Q - H, 2) Q - P, 3) Q - η &
4) Q - NPSHR curves.
Pump Characteristic Curves
 ISO-Efficiency (Composite) Curve
Performance curve with different impeller diameter.
 Shut off Head & Cut-off Point Definition
• Shut off Head
When the discharge valve is completely closed,
then discharge is ZERO and this ZERO capacity the
pump develops maximum head. That is called
shut-off head.
• Cut-off point
As Q-H curve reaches maximum discharge (when
delivery valve is fully opened), the flow velocity in
the suction pipe may become so high that Q-H
curve will drop abruptly in the vertical downward
direction, the point where this drop occurs is
known as cut-off point.
 Types of Q vs. H Curves
• FLAT: Suits applications where total head has to
remain almost constant against wide variations in
discharge.
• STABLE (RISING): Head increases continuously as the
discharge goes on reducing up to shutoff head.
• STEEP (RISING): The application of steep curve is
where site has fluctuating varying static head.
• DROOPING: This is unstable curve. We get two
discharges at the same head. Shut-off head is lower
than at any point along the unstable zone. It offers
narrow operating range & hence is not suitable for
parallel operation.
 Capacity vs. Power Curve
• Non Overloading: The curve which rises to a
limited height in operating range near BEP and
then falls as the discharge increases.
• Overloading: The power increases continuously
with the increase in discharge in the operating
zone and beyond.
These are two main types of power curves of
which Flat power curve is related to mixed flow
type impeller while falling curve is associated
with axial type impeller.
 Impellers (Geometry)
• Types of Impellers & performance curves have a close
relation.
• Impeller Geometry: For each type basic dimensions of
impellers are different:
1) Ratio of impeller outside (outlet) diameter to eye (inlet)
diameter i. e. D 2 / D 1 and
2) Outlet width
• Further impeller vane outlet angle , inlet angle & outlet
finishing will also affect Q-H curves & NPSHR.
• Valve inlet angle is one of the parameters that decide
NPSHr of impeller design. Smaller angle lower NPSHr & vice
versa.
• Figure illustrates the relationship between pump
performance, impeller geometry & vane numbers.
Continue
 Impeller Types
• Radial Flow: Discharges fluid at right angle to the shaft axis.
It is for generally high head & low discharge pumps. Shut-
off head is more than at BEP. BHP increases gradually over
the flow range. Q-H curve is relatively flat. Ratio of D2 / D1
= 2 or more. Narrow width.
• Mixed Flow: The flow direction is partly axial and partly
radial hence flow is diagonal. It is for medium head & large
discharge pumps. Shutoff head is more by 1.5 times than at
BEP. Power curve is fairly flat or increasing towards shutoff.
D2/D1<1.5. wider width .
• Axial Flow: Flow is parallel to shaft axis. This is for low head
very high discharge pumps. Head and power curves rise
sharply towards shutoff . Shutoff head is about three times
and BHP two times more than at BEP. D2/D1=1. No width.
Should not be run with closed discharge Valve for longer time.
Impeller Design Vs. Specific Speed
Specific Speed vs. Efficiency
 Affinity Laws
• These laws express the mathematical relationship
between several variables involved in pump
performance.
• These are derived from a dimensionless analysis of
three parameters that describe pump
performance: flow, total head & power.
• The analysis is based on the reduced impeller being
geometrically similar & operated at dynamically
similar conditions or equal specific speed.
• The affinity laws were developed using the law of
similitude which provide three basic relationships
viz. Flow, Total Head & Power vs. Diameter &
Speed. Continued
 Affinity Laws
For a given pump with a fixed diameter impeller Q is α to N,
H is α N2 and P is N3 (where efficiency remains almost
constant ie no appreciable change)
• Q1 / Q2 = N1 / N2
• H1 / H2 = (N1)2 / (N2)2
• P1 / P2 = (N1)3 / (N2)3
Where subscript 1 & 2 denote value before i. e. initial &
after change
Q is the Flow or Capacity, H the Total Head, N is Speed, D is
the Impeller Diameter & P is the Power.
For a given pump with a constant speed Q is α to D, H is α
D2 and P is D3 (where there are changes in efficiency
associated with changes in impeller diameter)
If the Speed is Fixed i. e. held constant these laws become:
Q 1 / Q 2 = (D1) / (D2) , H1/H2 = (D1)2 / (D2)2 and
P1 / P2 = (D1)3/ (D2)3
Continued
 Affinity Laws
• If the actual speed is more than the nominal than
power input as well as NPSHr will also be more, in
such a situation we can check for actual power
and NPSHr with the help of affinity formula and
ensure in respect of motor overloading and
cavitation.
• If the actual operating head is much lower than
rated head, pump will operate at excessive flow
resulting in overloading the motor. In such case
impeller diameter needs to be trimmed to suit
the operating conditions. However this will result
in reduction of the efficiency of the pump.
 Cavitation
• The lowest pressure point in a pump occurs at the
inlet of the pump impeller. If the pressure at any
point inside the pump drops below the vapour
pressure of liquid, then liquid may evaporate
generating small vapour bubbles i. e. the liquid
flashes i.e. changing from liquid to gaseous phase.
The vapour bubbles are carried along with the
stream through the impeller eye to regions where
the pressure within the impeller shroud rises due to
centrifugal force. In the higher pressure zone the
bubbles implode with tremendous shock and noise.
This phenomenon is called cavitations. Continued
 Cavitation
• To counter the situation of cavitation,
adequate suction head shall be provided so
that suction pressure at the impeller eye will
remain above the liquid vapour pressure.
Alternatively to reduce the discharge to bare
minimum and thus reduce the NPSHR. One
can reduce the speed and thus reducing the
discharge the NPSHR value will also get
reduced.
• Cavitation can occur at any point on the curve
if NPSHA is less than NPSHR.
 Net Positive Suction Head (NPSH)
• NPSH is the term applied to pump suction condition.
• Suction Head stands for absolute energy at the pump
suction flange in meters of liquid column (mlc) above
vapour pressure at pumping temperature. It is the
absolute energy in mlc available at the pump inlet
nozzle & corrected to pump datum less V. P. Of liquid.
• NPSHA: It is the characteristic of the System in which
the pump operates i. e. site condition. Factors to be
considered for NPSHA consideration:
1. Atmospheric pressure at site converted into mlc (Ha).
2. Absolute V. P. of liquid at pumping term in mlc (Hvp).
3. Friction losses in suction pipe in mlc (Hfs).
4. Suction lift or head in mlc (Hss).
5. Pressure head in closed suction vessel in mlc (Ps).
6. Sample calculation of NPSHa is given in the excel format
sheet. NPSH Calculation.xls
NPSHA (Available)
NPSH Graphical
 NPSHR (Required)
• NPSHR is defined as the positive head in metres
absolutely necessary at the impeller eye to
overcome the Internal Pressure Drop within the
impeller and maintain the pressure above its
vapour pressure and thus ensure stable flow
into the impeller. The pump designer decides
the NPSHR value of the pump model.
• It is the function of the impeller eye peripheral
velocity in m/s & suction velocity of liquid at
pump inlet in m/s.
• NPSHa must always be > NPSHr (at least 0.5 m).
• Vapour pressure of liquid is dependent of
temperature & will rise with increasing
temperature.
 Parallel pump operation
• Parallel operation means connecting two or
more pumps to common discharge header
outlet with necessary fittings like sluice /
butterfly and check valves. Additional pumps
are put to the service if demand increases
and vice versa. The working is absolutely
flexible, since this method increases
discharge at the same head.
Points to be observed before selecting
pump for parallel operation
1. Selecting identical pumps as far as possible
with stable Q-H characteristic (for equal load
on each pump. This also keeps the spare part
inventory to an economic level).
2. Pumps of dissimilar characteristics can
operate in parallel, if the system head does
not exceed the shut off head of any of the
pump at any capacity.
Pumps In Parallel Operation
THANKS
OPERATION & MAINTENANCE OF
PUMPING MACHINERY
 Operation of Pumping Machinery
• Pumping machinery & pumping station are critical components of
any water supply system. Pumps are subjected to normal wear &
tear as well as to erosion & corrosion due to nature of its
functioning i e pumping of water.
• Most failures in water supply system can be attributed to
failure of pumps & accessories etc. necessitating correct &
healthy operational practices, timely & periodical preventive
maintenance to prevent sudden break downs resulting in
interruptions in water supply.
• Proper recording of all parameters, inspections &
observations with follow up action, sufficient inventory of
fast moving spares & intensive monitoring at regular
intervals can take care of major O & M issues. Continued
 Operation of Pumping Machinery
Log book shall be maintained by making following entries accurately
1) Starting, run & closing time of all pumps over 24 hours duration
2) Voltage in all three phases & frequency
3) Current drawn by individual motor & all the motors if more than
one motor is in simultaneous operation.
4) Pressure gauge readings (individual & discharge header)
5) Vacuum gauge readings (If negative suction)
6) Motor winding temperature (of all motors in operation)
7) Bearing temperature of all pumps & motors in operation
8) Flow meter reading in every 24 hours duration
9) Level of water in intake well or sump
10) Power factor in every 24 hours duration
11) All events of power failure, trip/fault occurrence, pipe burst /
leakage occurred in PM and / or pumping system.
 Components of Pumping System
Water supply pumping system can be broadly classified in
following three groups:
1) Pumping Machinery: Pumps & mechanical & electrical
equipment like pumps, valves, suction-discharge pipe
manifold, vacuum pumps, induction motors, switchyard,
transformer, RMU, HV / LV switchgears, PLC system, cables
& all other associated mechanical & electrical accessories.
2) Ancillary Equipment: Material handling system e g EOT/
MCPB, Water hammer control device, Flow meter, Diesel
generating set etc.
3) Pumping Station (Head Works): Intake well / Sump / Canal
off-take, Pump house, screen & gate etc.
 Important Points of Operation of Pumps
Following points shall be observed while operating pumps.
• Priming of CF pumps before starting.
• Desirable for pump to operate at rated Q & H to obtain rated
η. However it should be operated within the recommended
range of H-Q so that η is not reduced substantially. Operation
near shut off H must be avoided to prevent recirculation within
the pump resulting in overheating water in the casing
consequently overheating the pump adversely affecting its
performance & η.
• Strict avoidance of dry running of pumps.
• Pumps used in WS are of low to medium Ns & hence they shall
be started with closed delivery valve so as to reduce starting
load on motor. While pumps with high Ns draw more power at
shut off & hence they should be started with open delivery
valve. Continued
 Important Points of Operation of Pumps
• Delivery valve should be operated gradually to avoid
sudden change in flow velocity which can cause water
hammer pressures. Gradual opening of valve to its
rated head also controls development of head within
its operating range. This is very important while
charging of pumping main initially or after shut down.
• When pumps are in parallel operation, they should
start & stop with a sufficient time lag between two
pumps to restrict abrupt change in flow velocity & to
restrict abnormal dip in voltage in incoming feeder.
• Frequent starts & stoppages of pumps should be
avoided to minimize / eliminate overloading of motor,
starter, contactors etc. so as not to reduce the life of
equipment. Continued
 Important Points of Operation of Pumps
• The stuffing box should allow a drip of leakage of water to
ensure that no air is passing to the pump & gland is getting
adequate water for cooling & lubrication.
• By pass valves of all valves (SV/BFV/DPCV) if available, shall be
kept in closed condition while normal operation of pumps.
• Voltage during operation of pump-motor should be within ± 10%
of rated voltage. Similarly current drawn should be below the
rated current mentioned on the name plate of motor.
• Proper schedule of running of duty & standby pumps so as to not
to keep any pump idle for long period ensuring all pumps are in
ready to run condition. Unequal running shall also be ensured
that all pumps don’t require simultaneous overhauling.
• Undue vibration or excessive noise in pumps should be regularly
observed, if noticed, pump should be stooped to ascertain the
cause & take appropriate remedial measures.
 Extra Points of Operation of Pumps
• HSCF & VT pumps should be checked for correct rotation i e
clockwise or counterclockwise as per directional arrow shown in
casing or mentioned on name plate. As incorrect rotation will
reduce in discharge capacity of pump.
• Proper priming must be done if pump suction is negative.
• VT pump must also be primed properly & ensuring full opening of
air vent before starting of pump.
• Bowl assembly of VT pump must be completely submerged.
• Sufficient inventory of consumables like gland packing, grease,
transformer oil and other spares for two to three years operation
like bearings for pumps & motors, neck rings, sleeve-nuts, gland
ring, coupling bush – pin & nuts, relay, HRC & other fuses,
indication lamps for panels etc. should be maintained at pumping
station. It is advisable to have one rotating element (assembly)
per model of pump in case of pumps for five years of operation.
procured from OEM @ time of new purchase of pumps.
 Undesirable Operating Conditions for Pumps
• Operation @ higher and lower heads: Pump should neither be
operated at head higher than maximum recommended or head lower
than minimum recommended head. Both will result into greater radial
thrust on pump shaft leading to excessive unbalanced forces leading to
failure of pump shaft. It also results in reduction of pump efficiency in
both cases. Operation at higher head results into excessive recirculation
of water in the pump causing overheating of water as well as pump.
• Operation @ higher suction lift: If pump is operated on higher suction
lift than permissible value, pressure @ the impeller eye & suction side
falls below vapour pressure resulting in flashing of water into vapour.
These vapour bubbles during passage collapse resulting in cavitations in
the pump, pitting on suction side of impeller & casing & excessive
vibrations. Additionally it reduces discharge of the pump drastically
apart from mechanical damage. Operation of pump with clogged
strainer / foot valve may result in increasing high magnitude of friction
loss in strainer resulting in same cavitations condition. Periodical
cleaning particularly during monsoon must be carried out. Continued
 Undesirable Operating Conditions for Pumps
• Throttled operation: When pump is not operating on rated H &
Q due to difference in actual parameters @ site and rated duty
parameters, at times motor gets continuously overloaded. In
such cases mostly delivery valve is throttled to increase head
on pump so as to reduce power drawn from motor. Such
operation results in inefficient running as energy used in
pumping is wasted in throttling. It is preferable to reduce the
diameter of impeller by trimming suitably which will reduce
power drawn from motor. Another remedial measure is
installation of VFD or VVFD (variable voltage & variable
frequency drive).
• Operation with occurrence of Vortices: If vibration in the pump
continues abnormally even after taking all precautions vortex
may be the cause. All parameters necessary for vortex free
operation should be thoroughly checked.
 Major Checks Prior to Starting of Pumps
Following points should be checked before starting pump.
• Availability of power in three phases.
• Trip circuit is healthy.
• Check voltage in all three phases. It should be almost same &
within ± 10% range of rated voltage.
• Check stuffing box to ensure that its packed properly.
• Check whether pump is rotating freely.
• Check functioning of lubrication system specifically for oil
lubricated & clear water lubricated VT pumps & oil lubricated
bearings.
• Check over current setting if the pump is not operated for a
week or longer period.
• Before starting check water level in the sump / intake is above
minimum water level & inflow from the source or preceding
pumping station is adequate.
 Maintenance of Pumping Machinery
(1) Daily: Cleaning of pump, motor & accessories; Checking
stuffing box & gland; Checking of coupling bushes / rubber
spider.
(2) Monthly: Check free movement of gland of stuffing box;
Check gland packing & replace if necessary; Clean & apply oil
to gland bolts; Inspect mechanical seal for wear & replace if
necessary; Check condition of bearing oil & replace or top up
if necessary.
(3) Quarterly: Check alignment of pump & motor; Clean oil
lubricated bearings & replenish with fresh oil; In case of
grease lubricated bearings the same shall be replaced/
replenished to the correct quantity; tighten the foundation
bolts & holding down bolts of pump & motor mounting on
base plate; Check vibration level with instrument; Clean flow
indicator, other instruments & appurtenances. Continued
 Maintenance of Pumping Machinery
Critical inspection & maintenance of PM should be thoroughly performed
by Engineer or skilled trained operator annually.
• Clean & flush bearings with Kerosene to examine for flaws developed eg
corrosion, wear, scratches etc. check for end clay. Coat bearings with oil or
grease immediately after cleaning.
• Clean bearing housing & examine for flaws eg wear, grooving etc. Change
oil or grease.
• Examine shaft sleeves for wear or scour & necessary rectification.
• Check stuffing box, glands, lantern ring, mechanical seal, rectify if needed.
• Check clearances in wearing ring. It should be within limits as
recommended by OEM as excessive clearance reduces Q & η of pump.
• Check impeller hubs & vane tips for any pitting or erosion.
• Check interior of volute, casing & diffuser for pitting, erosion & rough
surface.
• All vital instruments eg gauges, meters available in pumping station.
• Check performance test of the pump for discharge, head & efficiency.
 Routine Observations of Irregularities in P. M.
Pump operator should be watchful & carefully observe any
irregularities while pumping & shall take appropriate remedial
action.
• Changes in sound of running pump & motor.
• Abrupt changes in bearing temperature.
• Oil leakage from bearings.
• Leakage from stuffing box or mechanical seal.
• Changes in voltage and current.
• Changes in vacuum gauge & pressure gauge readings.
• Sparks in leakage current in motor, starter, switchgears, cable
etc.
• Overheating of motor, starter, switchgear, cable etc.
• Keep proper recordings of all such observations for engineer.
 Trouble Shooting
• Diagnostic chart for centrifugal pumps troubles is
annexed herewith. It briefly describes problems &
possible causes. Diagnostic Chart Pump Troubles.pdf
• Trouble shooting chart prepared by a reputed
pump manufacturer is also annexed to study in
details & find out probable causes for failures.
Pump Trouble Shooting.pdf
• 10 different ways to damage CF pump again
prepared by a reputed pump manufacturer is also
annexed to study in details & find out probable
causes for failures.
THANKS
 








 
  














  

 

            
       


     



             
         




           
            


















 





 
   

   


  
 
  
  
  
 
  
  
  
  


  

 
 








 

 
 

 
 
 




 
              

      
























 


                 






              










                



 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

 
 









  




              






 

 

 

 

  


 

 

  
                


 

  



  


               


                


 





 

 


 


               



  


                


  



  
                




   

    

  


    

   

    

   




    

 

    

   
 


 
 



   

    

   
 


    

  


    

 


    

  


    

   
   
  



 




 
 
 











 







 
 



  
 



















 
 
 


 
 

 


 
 

 



 
 


 


              


                



                 











                    




        


 










  



                 











    
     
     
 

 
 


         


          


 



                








                 



                


 











  
 
 
   
 
  
   
   
  
 
  
   
 
  
   
  
   
 
  
   
  
   
   
   
   
   
 
   

   

 

 

 


 


 

 
 

   

  
  







  

 

  

 
  



