Advanced Pump

Theory
Ezz Mamdouh – Sr. Sales Development Manager
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

History of Pumping systems

Pumping systems are as old as 7000B.C.

History of Pumping systems

Archimedean Screw –200 B.C

SaqiaWater Wheel –150 B.C –By Egyptians

Pumps nowadays

• Most common
• Versatile
• Reliable
• Simple construction
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

centrifugal pumps principle

 The centrifugal pump creates an increase in pressure by transferring mechanical energy

from the motor to the fluid through the rotating impeller.

 The fluid flows from the inlet to the impeller center and out along its blades.

 The centrifugal force hereby increases the fluid velocity and consequently
the kinetic energy is transformed to pressure.
Construction of a centrifugal pumps
Coupling Types

• Long Coupled

Pump and motor are connected through an external coupling.

Coupling can be standard or spacer type.

• Close Coupled

Pump casing is bolted to the Motor.

Pumps and motor either share one shaft or are connected

through Rigid Coupling inside the pump housing.
Construction of a centrifugal pumps
Construction of a centrifugal pumps
Other pump designs

Centrifugal Dosing pump

wastewater
(Not a centrifugal pump)
pump
Reference European Standards

End suction ( EN 733 ) Dimensions and rated performance, EN733 (10 bar).
Pumps with flange dimensions up to and including DN150 are marked PN16
End suction( ISO 2858 ) Dimensions and rated performance, ISO2858 (16 bar).
Pumps in stainless steel are marked PN25
ISO 5199 Common design guidelines
Suction and discharge flange, EN1092-2 ( 10 and 16 bar )
Motors are totally enclosed fan -cooled, designed, manufactured and tested according to
IEC60034-1 and IEC6007211/EN50347.
The mechanical shaft seal is according to EN12756
All pumps are statically balanced according to ISO1940 class 6.3.
Impellers are hydraulically balanced.
The steel base frame of the NK range is in accordance with EN2366/ISO3361
Pump curve tol. According to ISO 9906:2012 Grade 3B (Other grades also provided)
Construction of a centrifugal pump – Types of
Shaft Seal
Construction of a centrifugal pump – Types of
Shaft Seal
Construction of a centrifugal pump – Types of
Shaft Seal
Construction of a centrifugal pump – Types of
Shaft Seal

Mechanical Shaft Seal

Construction of a centrifugal pumps – Impeller
Types
Impeller design according to flow directions
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

Steady and Uniform flow in pipes

v1 Pipe diameter, D1 = D2 v2

1 2
(t2 )
v ( t1 )
1 =v ( t1 )
2 =v (t2 )
1 =v 2

Steady flow in a pipe of constant diameter

is at the same time uniform.

1. The time step, ∆t = t2 – t1, is assumed sufficiently small.

2. The mass density of water, ρ(kg/m3), is constant.
3. The pipe is made of rigid material (no deformations).
27
Mass Conservation Law (The Continuity
Equation)

Mass m (kg) can neither be created nor destroyed; any mass that
enters a system must either accumulate in that system or leave it

Qinp t1 V1 Qout

After ∆t... ∆V
∆V Qinp = Qout ±
t2 ∆t
Qinp Qout
V2
Mass Conservation Law (The Continuity
Equation)
j
Q3 ∑ Qi − Qn = 0
i=1

Q1 Node ‘n’

Qn

Q2 Q1+ Q2 = Q3+ Qn
A1V1 = A2V2
Mass Conservation Law (The Continuity
Equation)

V1 V2

A1V1 = A2V2
Energy Conservation law (The Energy equation)

1 2

E1 = E2 ± ∆E
Energy E (J) can neither be created nor
destroyed; rather, it transforms from one form
to another.
Potential Energy

Volume V (m3) under pressure p (N/m2),

positioned at elevation Z (m), possesses
the potential energy: V
Epot = mgH
m = Mass (kg)
g = Gravity (m/s2)
Epot = Potential energy (J, kWh, mwc)
Z

or per unit weight: Epot = H = Z

Reference level
Kinetic Energy

The kinetic energy is generated mv2

by the mass (volume) motion: Ekin =
2
2
v
or per unit weight: Ekin =
2g

35
The Bernoulli Equation

1 2
E1 = E2 ± ∆E becomes:

p1 v 2
p2 v 2
Z1 + + 1
= Z2 + + ± ∆E
2
ρg 2 g ρg 2 g
Steady state flow ?
Incompressible fluid
Frictionless
Steady state flow
Incompressible fluid
Frictionless
Hydraulic and Energy Lines

E1
v 2
1 H1 E2
2g v 22 H2
p1 2g
ρg p2
v ρg

1 2
Z1 Z2

Reference level
Static Vs. Total pressure
Hydraulic grade line as a pressure indication
E1,H1
v 12 v 22
= ≈0
2g 2g

Negative pressure!
E2,H2
p1 p2 = p = 0
= atm
Z1 ρg ρg

Reference level Z2
Pressure buffer
More buffer, more reliability (but also
H1 more water losses)!

hf H2
p1
ρg p2
ρg

1 v 2
Z1 Z2

Reference level
Hydraulic Gradient 1/2

S1 ∆E1

L Q1
Hydraulic Gradient 2/2

S2

L
Q2
∆E Flow rate in pipes under pressure
S= is related to the hydraulic gradient
L (not to the slope of the pipe)!

44
System characteristics – Single pipe

p Hdyn = ∆ H
H st = min ± ∆ Z
ρg

64
Gravity system – Regular supply

pend
∆Z = H d yn + H st = ∆ H +
ρg
Pump Curve – Working Points
Pumped Systems – Regular Operation

hreq = H + H = ∆H +
pmin ± ∆Z
p dyn st
ρg
Pump Curve – Working Points
 Test your knowledge

Question Y/N

Flow Direction is from B to A


Flow velocity in the pipe equals 0 m/s 
Head in Cross Section A is higher than head in B

The flow rate in the pipe is constant alongside its
length 
The pressure in cross section A equals pa/ρg = 35 mwc.

The uniform increase of the pipe diameter will
increase the flow velocity. 
If the inner pipe diameters Da = Db, the kinetic
energies in cross sections A and B are equal. 
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

Power consumption

P1 Power input from mains

= √ 3 V I cosϕ (3 phase motors)
= V I cosϕ (1 phase motors)

P2 Motor shaft output

P3 Pump input
P3=P2 incase of direct coupled pumps

P4 Pump output (hydraulic)

=QxHxρxg
 Efficiency

Motor efficiency (ηm) = P2 / P1

(ETA motor)

Pump efficiency(ηp) = Hydraulic output

(ETA pump) Power input
= P4 / P3

Total efficiency (ηgr) = P4/ P1

(ETA total) = η .η
m p
 Pump characteristic curves

Closed Valve → Open Valve

6
10,5kW
10
8- kW
400 V
50 hz

P1 Power input from mains

= √ 3 V I cosϕ (3 phase motors)
= V I cosϕ (1 phase motors)

25
19
14
9- m

50
25
75
0- l/s
Test report
 Tolerance of test
parameters

The standard test tolerance is ISO9906:2012 Grade 2B on LS pumps.

ISO9906:2012 Grade 1U; 1E; 1B are available on request.

AOP VS POR
AOP VS POR
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

Closed loop systems

Examples of closed loop systems:

• Domestic and commercial heating
circulation systems
• Primary and secondary chilled water
circulation systems
 Open loop systems

Examples of open loop systems:

• Water supply systems (water
transfer, pressure boosting,
irrigation, industrial)
• Wastewater systems
• Condenser water system in chilled
water application
Open loop system with negative geodetic lift

Two types of open loop systems exist:

• Open systems where the total required geodetic lift is positive. Positive geodetic lift is where the pump has to
work against gravity

• Open systems where the total required geodetic lift is negative. Negative geodetic lift is where the water
column height is pushing the water into the pump. A typical example is water boosting applications in
buildings from a tank.
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

 Adjusting pump performance

Throttle control Impeller trimming

Speed control
Throttle control
Impeller trimming
Speed control
Topics for this module

• History of Pumping systems?

• Centrifugal pumps characteristics

• Basics of Hydraulics

• Pump characteristic curves

• Pumping systems

• Adjusting pump performance

• Cavitation & NPSH

What is cavitation?

Cavitation occurs in a pump when the pressure

on the suction side of the impeller falls below
vapor pressure of the liquid.

Cavitation is harmful to the pump and results in:

• Noise & Vibrations (damage to bearings, seals etc.)
• Erosion / damage to impeller
• Reduced pump performance
Cavitation Sound ?
Absolute vs. Gauge pressure
Cavitation in details
Pressure development through a centrifugal
pump
 Cavitation & NPSH

Calculation of the risk of cavitation

No Risk of cavitation if NPSHA > NPSHR
NPSH – Net Positive Suction Head
Cavitation will occur if NPSHA < NPSHR

NPSHR indicates minimum inlet pressure required

by the pump for operation without cavitation.
Determined by test at factory and NPSHR curves published

NPSHA indicates NPSH available at site. Should be

determined at site based on site conditions.
NPSHR (Net Positive Suction Head Required)

NPSHR is published by the pump

manufacturer, based on testing the
pump on a test bed
 Calculation of NPSHA
NPSHA = Hb – Hf – Hv – Hs +/- h
Hb = atmospheric pressure at pump site
Hf = friction loss in suction pipe
Hv = vapor pressure of liquid (depends on liquid temperature)
Hs = safety factor (usually 0.5-1.0m)
h = max suction head. Add if positive head, subtract if suction lift.
 Physical properties for water
NPSHA T [C]
0
ρ [kg/m3] Hvapour [m]
1000 0,062
Hatm [m] NPSHav
10,332 10,3
(Net Positive Suction Head Available) 10
4 1000
999,7
0,083
0,125
10,332
10,335
10,2
10,2
20 998,2 0,239 10,351 10,1
• Hatm & Hvapour Varies 25 997,1 0,324 10,362 10,0
30 995,7 0,434 10,377 9,9
 Temperature 40 992,3 0,758 10,412 9,7
50 988,1 1,273 10,457 9,2
 Elevation 60 983,2 2,066 10,509 8,4
70 977,8 3,250 10,567 7,3
• 20 deg C to 40 deg C reduces NPSHa 0.4m 80 971,7 4,970 10,633 5,7
90 965,2 7,407 10,705 3,3
• Elevation: Hatm reduced approx. 1m head for every 1000m 100 958,2 10,783 10,783 0,0

• Stockholm vs. Mexico City ΔNPSHav=2.2m Altitude atmospheric

pressure variation
Altitude [m] Hatm [m]
0 10,347
250 10,049
500 9,758
750 9,474
1000 9,197
1250 8,926
1500 8,662
1750 8,404
NPSHre 2000 8,152
2250 7,906
f 2500 7,667
2750 7,433
3000 7,205
General case simplified (open or closed)

Suction pressure gauge right before suction flange

NPSHA (m) = (Px10 + 9) P (b)

Vaccuum Pressure
Gauge
 NPSHA
• Ensure sufficient tank level for opened systems.

• Minimize major & minor suction losses.

• Correct pipe sizing to ensure low velocity.

• Correct positioning of suction line fittings.

 NPSHR

• Correct pump selection (Designer).

• Avoid excessive flow pump running (Operator).

• Avoid air in water.

Thank you