Pumps: Types, Working

Principles, and Inspection

Procedures
Explore the world of pumps. Learn about their types and principles. Discover
essential inspection procedures. This presentation offers comprehensive
insights into effective pump management.

by Sarath Chandran
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 Introduction to Pumps

Definition Importance Applications

Pumps are devices Pumps are vital across Pumps are essential
used to move fluids. industries. for fluid transfer.

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Types of Pumps
Centrifugal Pumps Positive Displacement Pumps Specialty Pumps

Use rotation to impart velocity. Displace fixed fluid volumes. Designed for unique applications.

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Centrifugal Pumps
1 Working Principle 2 Components
Kinetic energy transfer. Impeller, volute, shaft.

3 Performance Curves
Flow rate vs. head.

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 Positive Displacement Pumps

Working Principle
Fixed volume displacement.

Types
Piston, diaphragm, gear.

Applications
High viscosity fluids.

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 Pump Selection Criteria
Fluid Properties
Viscosity and density.

Flow Rate
Required output volume.

Head Requirements
System pressure needs.

Efficiency
Energy consumption.

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 Pump Installation and
Commissioning
1 Best Practices
Proper alignment.

2 Guidelines
Secure mounting.

3 Testing
Performance validation.

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Pump Operation and Maintenance

2 Monitoring

1
Operation

Maintenance
3

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Pump Inspection Procedures

1 Regular Checks

2 Troubleshooting

3 Documentation

Proper alignment.

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Overview of Pump Systems
• Types of Pumps:
❑ Centrifugal Pumps:
▪ Widely used in industrial and domestic settings.
▪ Work on the principle of centrifugal force to move fluid.
▪ Ideal for applications with low viscosity fluids.
❑ Positive Displacement Pumps:
▪ Transfer fluid by trapping a fixed amount and forcing it into the discharge pipe.
▪ Suitable for high-viscosity fluids and applications requiring precise flow control.
❑ Diaphragm Pumps:
▪ Operate using a flexible diaphragm to displace the fluid.
▪ Ideal for handling corrosive or abrasive fluids and applications requiring gentle pumping action.
❑ Gear Pumps:
▪ Consist of two or more gears that rotate to transfer fluid.
▪ Suitable for high-pressure applications and precise flow rate control.
❑ Peristaltic Pumps:
▪ Utilize a flexible tube and rollers to create a squeezing action, pushing fluid through the tube.
▪ Ideal for applications requiring contamination-free pumping and accurate dosing.

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Types of Pumps:
➢ Centrifugal Pumps:

➢ Positive Displacement Pumps:

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Types of Pumps:
➢ Diaphragm Pumps:

➢ Gear Pumps:

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Types of Pumps:
➢ Diaphragm Pumps:

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Inspection Techniques
• Visual Inspection:
▪ Assessing pump components for signs of wear, corrosion, or damage.
▪ Identifying leaks, loose connections, or abnormal conditions.
• Vibration Analysis:
▪ Monitoring pump vibrations to detect misalignment, imbalance, or bearing faults.
▪ Analyzing vibration patterns to predict potential failures and prevent downtime.
• Thermography:
▪ Using infrared imaging to detect overheating in pump components.
▪ Identifying areas of excessive friction, insulation failure, or electrical issues.
• Oil Analysis:
▪ Analyzing oil samples to assess lubrication effectiveness and detect contamination.
▪ Monitoring for signs of degradation, wear particles, or fluid breakdown.
• Performance Testing:
▪ Conducting operational tests to evaluate pump efficiency and performance.
▪ Measuring flow rates, pressure levels, and energy consumption to ensure optimal
operation.
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Visual Inspection
• External Condition(Check for corrosion, leaks, and signs of physical damage.)
• Pump Casing:(Inspect for cracks, erosion, and alignment issues).
• Impeller and Shaft (Look for wear, erosion, and misalignment.)
• Seals and Gaskets: (Ensure seals are intact and gaskets are properly seated)

Vibration Analysis
 Importance of Vibration Analysis
▪ Definition: Vibration analysis is a predictive maintenance technique used to
assess the condition of pumps by analyzing vibration patterns.
▪ Purpose: To identify potential faults, defects, or abnormalities in pump
machinery before they escalate into costly failures.
 Detecting Imbalance, Misalignment, and Bearing Wear
 Equipment Needed: Vibration Meter, Accelerometer

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Thermography
• Identifying Overheating Components
• Thermography, a non-destructive testing method, offers valuable insights
into pump performance and condition.
• By detecting temperature variations, thermography identifies potential
issues such as overheating, bearing failures, and insulation defects.
• Implementation of regular thermographic inspections enhances predictive
maintenance strategies and prolongs pump lifespan.

Oil Analysis
 Purpose: (Monitor the condition of lubricating oil to detect contaminants, wear
particles, and degradation.)
 Parameters Analyzed: (Particle count, viscosity, water content, acidity, and metal
wear debris).
 Analysis Techniques: (Spectroscopy, ferrography, viscosity measurement, and water
content determination.)
 Interpretation: (Analyze trends and deviations to identify abnormal conditions and
schedule maintenance accordingly.)
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 Performance Testing
➢Flow Rate Measurement:
➢ Importance of accurately measuring the flow rate in pump systems.
➢ Methods such as volumetric flow meters, velocity-based flow meters, and
mass flow meters.

➢Pressure Testing:
➢ Significance of pressure testing in ensuring pump system integrity and safety.
➢ Common pressure testing techniques, including hydrostatic testing and
pneumatic testing.

➢Efficiency Assessment of Pumps:

➢ Evaluating pump efficiency to optimize performance and reduce energy
consumption.
➢ Factors affecting pump efficiency and methods for assessing efficiency, such
as pump performance curves and efficiency calculations.

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 Performance Testing
➢Performance Testing:
➢ With Job Motor or test motor for min one hour on offer pump & verify Q Vs Head, Q Vs
Efficiency, Q Vs Power at six different flow including Duty point, Min Safe flow & shut off.
➢ Efficiency example calculation of a Pumps
▪ While Witnessing a Performance test we have to note: Speed, flow, Suction Pressure, Delivery
Pressure, Voltage, Power, Frequency, …
1) Discharge l/s = 24.600 l/s
2) Bowl Head = Water level (WL) to ground level (GL) Distance + Delivery gauge reading +
Gauge Distance + velocity head correction factor + friction head loss
a) Water level (WL) to ground level (GL) Distance = Hs = Measure by Tape

= 0.340 m.
b) Delivery gauge reading = Reading by pressure transducer
Hd = 97.50m
c) Gauge Distance = Distance measured from ground level to
pressure transducer
Zd = 1.200 m

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Performance Testing
d) Velocity Head Correction (V^2/2g) = ( Discharge ^2 * Velocity head Correction
(V^2/2g) = (24.600^2 *0.0001632)
= 0.100 m
e) Friction head loss (Hf) = Discharge ^2 * friction head loss
Hf =
24.600^2*0.00025
= 0.150 m
Bowl total head (H) = 0.340+97.500+1.200+0.100+0.150
= 99.290 m
3) Speed (n) = Measured by tachometer
= 2970 RPM
4) Motor input (i/p) = (reading taken from KW from motor = 36.290KW
5) Bowl Input (i/p) = (motor i/p * motor efficiency in %) /100 – bearing loss
= (36.290 * motor efficiency in %) /100 – 0.400
= 33.430 KW

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Performance Testing
6) Bowl Output (o/p) = (Bowl head (H) – Discharge (Q) in l/s) /102.0
= (99.290 – 24.60) /102.0
= 23.950 KW
7) Bowl efficiency = (Bowl Output) *100 / (Bowl Input )
np = 23.950 * 100 / 33.430
= 71.64%

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 Duty point Curve
➢ The duty point of the application is the point on the
pump curve at which the pump operates. It is a
combination of flow rate and head for the
application. The flow rate is how fast the liquid is
being moved by the pump through the system.
➢ It represents the relationship between flow rate (Q)
and total head (H) generated by the pump.
➢ The curve is crucial for selecting the appropriate
pump for a specific application and ensuring optimal
performance.
➢ The duty point, marked on the curve, indicates the
operating condition where the pump delivers the
required flow rate against the corresponding head.
➢ Factors such as system resistance, fluid properties,
and operating conditions influence the positioning of
the duty point on the curve.
➢ Proper understanding of the duty point curve helps
in efficient pump selection, system design, and
performance optimization.

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1. Key Terms

• Pump
1
• Head By passvalv
lschargo valva

144 * P P u m p
H = - - - - Pump

- 6 2 . 4 * Sp.gr Coupling
box
motor

H: Head (ft)
P: Pressure (PSI) Drain valve
Suc11onvalve

Sp. gr: Specific

Gravity

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2. Introduction
What Pumps do?
Pumps are machines used to move liquid.

How They do it?

They convert mechanical energy into pressure in a flowing liquid.

Applications Industrial Processes Refrigeration Automobiles

Home Heating Systems Water Wells.

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3. Classification
Vertical

Horizontal
Centrifugal
Dynamic Single-
Stage
Axial
Multi-Stage

Screw

External Gear

Pump
s
Internal
Rotar Gear
y Sliding Vane

Flexible Vane

Positive
Displacement Lope

Piston

Reciprocatin Plunger
g

Diaphrag
m
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3. Classification
Horizontal

Vertical
Centrifugal
Dynamic 1
Single-Stage I
Axial
Multi-Stage j

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3. Classification
Horizontal

Vertical
Centrifugal
Dynamic Single-Stage I
· - - - - - Axial
Multi-Stage I

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3. Classification
Horizontal

Vertical
Centrifugal
Dynamic Single-Stage
Axial
Multi-Stage I

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3. Classification
Horizontal

Vertical
Centrifugal
Dynamic Single-Stage I
· - - - - - Axial
Multi-Stage

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3. Classification
Horizontal

Vertical
Centrifugal
Dynamic ' Single-Stage I
Axial
Multi-Stage I

Thrust and
Radial Bearings
Propeller
Driver

Mechanical Seal Coupling

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3. Classification
Screw
Discharge
External Gear

Internal Gear
Idler Rotors
t
Rotary Power
Sliding Vane Rotor

Flexible Vane I
Positive
Displacement Lope

Piston
J t
Suction
Power Rotor
Interchangeable
Screws Timing Gears
Seals Coupling
Elastomer-lined Stator Bearings
Drive Shatt

Discharge M otor

Driver
Bearings

Cavity or Void Suction Idler Rotor

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3. Classification
Screw

External Gear

Internal Gear I
Rotary
SlidingVane I
Flexible Vane I
Positive
Displacement Lope

- - Piston I
- - - - - Suction -•1- Discharge
- - - ,
Plunger I
1
Diaphragm I

Idler Gear

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3. Classification
Screw
Flu
External Gear I
id
Internal Gear ou
Rotary
SlidingVane I t

Flexible Vane I
Positive
Displacement Lope
;'
Piston
t
Fluid
Reciprocating Plunger - _.,)
rn
Diaphragm

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 3. Classification
Screw

External Gear I
Internal Gear I
ROTOR
Rotary CAM RING
Sliding Vane

Flexible Vane I ECCENTRICITY

I Positive
Lope SHAFT
Displacement I
OUTLET
Piston

Plunger
INLET i=)
-- -
A SIDE LOAD IS EXERTED
ON BEARINGS BECAUSE
Diaphragm OFPRESSURE UNBALANCE

CASING

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3. Classification
Screw

External Gear I
Internal Gear I
Rotary
SlidingVane I
Flexible Vane
Positive
Displacement Lope

Piston

Plunger

Diaphrag

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3. Classification
Screw

External Gear I

Internal Gear I
Rotary
SlidingVane

Flexible Vane
Positive
Displacement Lope

Piston Suction Discharge

Reciprocating Plunger

Diaphragm

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3. Classification
Crank Pin Valves
Screw and
Main Connecting Rod
External Gear Bearings

Internal Gear I
Rotary Counter Weights
1 SlidingVane I
Piston
Flexible Vane I Foundation

Positive
Displacement I Lope
Discharge
Piston

Plunger t Packing
Diaphragm
DISCHARGE 1
R C'ltlNOER VALV£--+ I
\(1_
Check Valv_e . , . . .

•
I/ .,TON

3 - + "---- □-
' iulo sucnoo SIBOK£
RI
DISCHARGE STROKE
Suction
Piston Rings Packing Gland

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3. Classification
Screw

External Gear I
Internal Gear I Spring-Loaded Valve
Connecting Rod
Rotary Discharge
SlidingVane I
Flexible Vane I
Positive
Displacement Lope

Piston

ReciprocatinglrE,-----l
Plunger

Diaphragm
Suction

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3. Classification
Screw
Eccentric
External Gear I
Internal Gear I
Rotary
SlidingVane I
Flexible Vane I
Positive
Displacement Lope I Pumping Cavity - t : : _ . . . . ,
Piston j
Seat ....---+ - Discharge
Reciprocatingir.------l Plunger I .--.L .jjfl,N\Jw+- 1
1Fl -;; Valve
------
Diaphragm

Suction Spring
Valve

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 4. Basic Principles
Most Common Pump : Centrifugal Pump

Discharge

Open Impeller Semi-Open Impeller

Volute
Impeller

Wear Rings Vanes

Shaft Closed Impeller

. Gland Vanes
Pack1ng

• Wear Rings

Suction Eye - - 1
Shaft

Casing Suction Eye

El
Suction
Side View Front View

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4. Basic Principles

• Continuity Equation

A1V1 ==A2V2 ==
Constant ..&-H - - VOLUTE

• Bernoulli Equation
P1 vf P2
-y +2 g+ Z1 =-y + 2g+ Z2 + Hiosse
IMPELLER
vf s

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Conclusion: Pump
Management

1 2
Selection Installation
Choose the right pump. Install with precision.

3
Maintenance
Maintain for longevity.

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