INDUSTRIAL PLANT ENGINEERING

Module 3. Industrial Pumps

Objectives:

1. Discuss the various industrial pumps and its application.

2. Examine fundamental equations associated with pumps.
3. Solve problems applying related formula for pumps.

Contents:

Industrial pumps are essential devices used in various industries to transport liquids or slurries from one
location to another. They are critical components in sectors such as manufacturing, water treatment, oil and
gas, chemical processing, food and beverage, and more. Below is an overview of industrial pumps:

Classification of Industrial Pumps

A. DYNAMIC PRESSURE PUMPS – Energy is continuously added to increase the fluid velocities within the
machine.

Dynamic pressure pumps convert mechanical energy into kinetic energy using rotating impellers or other
mechanisms. This kinetic energy is then transformed into pressure energy as the fluid exits the pump. The main
process involves:

1. Acceleration of Fluid: A rotor (such as an impeller) increases the velocity of the fluid.

2. Conversion to Pressure: The kinetic energy is converted into pressure energy as the fluid passes
through the diffuser or volute casing.

Types of Dynamic Pressure Pumps

I. CENTRIFUGAL PUMPS are the most common type of dynamic pumps, used for transporting fluids by
converting rotational kinetic energy (imparted by a motor or engine) into hydraulic energy. These pumps are
widely used due to their simplicity, efficiency, and versatility across various industries).

The working principle of a centrifugal pump is based on the conversion of energy:

1. Fluid Entry: The fluid enters the pump through the suction port and reaches the center of the impeller
(called the eye of the impeller).
2. Impeller Action: The rotating impeller imparts kinetic energy to the fluid, increasing its velocity.
3. Volute/Discharge: The volute or diffuser converts the velocity energy into pressure energy, directing the
fluid to the discharge port.
Components of a Centrifugal Pump:
1. Impeller:
o The rotating component that transfers energy to the fluid.
o Types include open, semi-open, and closed impellers.
2. Casing:
o Encases the impeller and fluid, directing flow.
o Designs include volute or diffuser casings.
3. Suction Pipe:
o Connects the fluid source to the pump's suction side.
4. Discharge Pipe:
o Guides the pressurized fluid out of the pump.
5. Shaft:
o Transmits mechanical energy from the motor to the impeller.
6. Bearings:
o Support the shaft and reduce friction during rotation.
7. Seal or Gland:
o Prevents fluid leakage along the shaft.

Types of Centrifugal Pumps

1. Based on Flow Direction
• Radial Flow Pump:
o Fluid flows outward from the center (perpendicular to the shaft).
o Used for high-pressure, low-flow applications.
• Axial Flow Pump:
o Fluid flows parallel to the shaft.
o Suitable for high flow, low-pressure applications.
• Mixed Flow Pump:
o Combines radial and axial flows.
o Suitable for moderate flow and pressure.

2. Based on Number of Stages

• Single-Stage Pump:
o Contains one impeller.
o Used for low to medium head applications, such as water supply systems.
• Multi-Stage Pump:
o Contains two or more impellers in series to achieve high head.
o Common in applications like boiler feedwater systems.

3. Based on Shaft Orientation

• Horizontal Pump:
o Shaft is horizontally aligned.
o Easier to maintain and install in accessible locations.
• Vertical Pump:
o Shaft is vertically aligned.
o Takes up less floor space and is often used in deep wells.

4. Based on Casing Design

• Volute Pump:
o Features a spiral-shaped casing that reduces velocity and increases pressure.
o Common in general applications.
• Diffuser Pump:
o Has stationary vanes around the impeller to guide the fluid and recover pressure efficiently.
5. Based on Impeller Design
• Open Impeller:
o No side shrouds; suitable for handling solids or slurries.
• Semi-Open Impeller:
o One side has a shroud; balances efficiency and the ability to handle solids.
• Closed Impeller:
o Both sides are enclosed by shrouds; provides high efficiency for clean fluids.

6. Based on Special Features

• Self-Priming Pump:
o Can evacuate air and prime itself for operation.
o Ideal for situations with challenging suction conditions.
• Submersible Pump:
o Fully submerged in the fluid; no priming needed.
o Common in drainage and sewage systems.
• Magnetic Drive Pump:
o Uses magnetic coupling instead of a shaft seal.
o Suitable for hazardous or toxic fluids.

Applications of Centrifugal Pumps

1. Water Supply Systems:
o Municipal water distribution, irrigation, and drinking water systems.
2. Industrial Processes:
o Used in chemical, petroleum, and food processing industries.
3. HVAC Systems:
o For circulating water in heating and cooling systems.
4. Sewage and Wastewater Treatment:
o Handles wastewater and slurries.
5. Power Plants:
o Boiler feedwater and cooling systems.
6. Marine Applications:
o Bilge and ballast pumping.
7. Mining:
o Dewatering and slurry transport.

II. PROPELLER PUMPS is a type of axial flow pump, which is part of the broader category of dynamic pressure
pumps. It is specifically designed to move large volumes of fluid at low pressures by imparting energy to the
fluid using a propeller-like impeller.

• The propeller-shaped impeller rotates, imparting axial momentum to the fluid.

 • Unlike centrifugal pumps, where the fluid is forced outward by centrifugal force, the flow in a propeller
pump is parallel to the pump shaft.
• The fluid gains velocity and kinetic energy, which is partially converted to pressure energy as it moves
through the pump casing.

Components of a propeller pump:

1. Propeller (Impeller):
o A set of blades shaped like a marine propeller.
o Can be fixed-pitch or adjustable-pitch (variable angles for flow control).
2. Casing:
o Houses the impeller and helps guide fluid flow.
o Designed to minimize turbulence and ensure smooth axial flow.
3. Guide Vanes (Diffuser):
o Stationary blades that straighten and stabilize the flow after it exits the impeller.
o Help recover pressure by converting velocity energy into pressure energy.
4. Shaft:
o Connects the impeller to the motor or turbine that drives the pump.

Characteristics
• Flow Direction: Axial (parallel to the shaft).
• Flow Rate: Very high (can handle hundreds of thousands of gallons per minute).
• Head (Pressure): Relatively low (typically up to 10 meters or 30 feet of head).
• Efficiency: High for low-head, high-flow applications.

Applications of propeller pumps:

1. Flood Control:
o Used in drainage and flood management systems due to their ability to handle large volumes of
water quickly.
2. Irrigation:
o Common in agricultural settings to move large quantities of water over short distances.
3. Cooling Systems:
o Found in industrial and power plant cooling systems where large water flow rates are required.
4. Sewage and Stormwater Management:
o Handles non-viscous fluids efficiently in large municipal systems.
5. Marine Applications:
o Utilized for ballast water transfer and other high-flow, low-pressure needs.

III. SPECIAL EFFECT PUMPS

Special effect pumps are designed for unique applications that require specific fluid behavior, often used in the
entertainment, theatrical, and movie production industries, or in other niche applications where unique fluid
flow characteristics are needed. These pumps are typically customized to create specific visual, tactile, or
performance effects that enhance the experience of an event or production.

Types of special effect pumps:

1. Fog Pumps are used in special effects for generating mist, fog, or smoke, often used in stage productions,
concerts, movies, and Halloween events. These pumps are designed to work in conjunction with fog machines,
which heat up a fluid (usually glycol or glycerin-based) to produce dense fog when released into the air.
Types of Fog Pumps:
• High-Pressure Fog Pumps:
o Structure: These pumps pressurize the fog fluid and push it into the fog machine where it is
vaporized and released as a dense mist.
o Applications: Large-scale productions, concert stages, and outdoor events.
• Low-Pressure Fog Pumps:
 o Structure: These pumps move the fluid through the system at lower pressures, ideal for smaller
systems or compact fog machines.
o Applications: Smaller events, home or DIY projects.
Applications:
• Theatrical fog and smoke effects.
• Concert lighting and visual effects.
• Haunted houses, theme parks, and film productions.

2. Water Jet Pumps (Water Shoots) are used for dramatic water effects in films, live performances, and
outdoor events. These pumps are designed to shoot water at high pressures, often creating geysers, fountains,
or water streams for visual effects.
Types of Water Jet Pumps:
• High-Pressure Water Jet Pumps:
o Structure: These pumps use high-pressure systems to force water through nozzles, creating
jets of water that can reach considerable heights.
o Applications: Action movies, water fountains, concerts with water shows, and water-based
special effects.
• Low-Pressure Water Jet Pumps:
o Structure: Designed for a more controlled flow of water, these pumps provide a softer stream of
water, often used for background effects.
o Applications: Water features for smaller shows, architectural displays, and film backgrounds.
Applications:
• Special effects for film and TV (water scenes, floods).
• Fountains and water displays in theme parks.
• Water-based special effects for concerts or stage performances.

3. Air Cannon Pumps (Compressed Air Pumps) or compressed air pumps are used to create dramatic bursts
of air that can blow debris, confetti, or special effects fluids (like colored liquids) into the air for theatrical and
entertainment purposes. They are commonly used in fireworks displays, concerts, and live shows.
Types of Air Cannon Pumps:
• Static Air Cannons:
o Structure: These air pumps are fixed in place and used to release bursts of air to propel special
effects materials.
o Applications: Confetti cannons, pyrotechnic displays, and smoke effects.
• Mobile Air Cannons:
o Structure: These pumps are portable and can be directed at various angles for dynamic air
blasts.
o Applications: Event marketing (e.g., confetti blasts), crowd engagement during shows.
Applications:
• Propelling confetti, balloons, or snow in theatrical performances.
• Stage pyrotechnics and fireworks displays.
• Special effects for concerts and festivals.

4. Electromagnetic pumps are pumps that utilize electromagnetic forces to move electrically conductive
liquids, such as molten metals, electrolytes, or certain high-temperature fluids. These pumps do not use
moving mechanical parts, making them ideal for environments where contamination, wear, or high
temperatures may pose problems for traditional mechanical pumps.
The core operating principle behind electromagnetic pumps is the Lorentz force, which occurs when an
electrically conductive fluid is exposed to a magnetic field. The interaction between the fluid's electric current
and the magnetic field generates a force that moves the fluid.
- Magnetic Field: A magnetic field is generated using either electromagnets or permanent magnets
around the fluid path.
 - Electric Current: An electric current is passed through the conductive fluid, which could be a liquid
metal or an electrolyte.
- Lorentz Force: The electric current and the magnetic field interact to produce a force perpendicular to
both, which propels the fluid in a desired direction.
This method of pumping does not involve any moving parts, reducing mechanical wear and increasing
reliability.

Types of Electromagnetic Pumps

1. Liquid Metal Pumps
These are used primarily to move molten metals like aluminum, sodium, or lead, which are electrically
conductive. They are ideal for high-temperature applications, such as in metal casting and processing, where
traditional mechanical pumps would suffer from wear or could be contaminated by the molten metal.
Applications:
o Metal Foundries: Moving molten metals during casting processes.
o Nuclear Reactors: Circulating liquid metals like sodium as coolants.
o Metallurgical Plants: Pouring or transporting molten metal in metal processing industries.
2. Magnetohydrodynamic (MHD) Pumps
MHD pumps use both electric and magnetic fields to move ionized liquids or gases (plasma). This is a type of
electromagnetic pump typically used in scientific research or advanced energy systems. The design of MHD
pumps allows them to operate at very high temperatures and in environments that might otherwise be
hazardous for mechanical pumps.
Applications:
o Nuclear Power Plants: Circulating liquid metals for cooling reactors.
o Energy Conversion Systems: Used in MHD generators to generate electricity.
o Spacecraft Propulsion Systems: In experimental applications where high temperatures and
non-traditional propellants are involved.
3. Electrohydrodynamic (EHD) Pumps
Electrohydrodynamic pumps, also called ion pumps, use electric fields to induce movement of fluids, relying
on the interaction between charged particles and the fluid. EHD pumps are typically used for smaller-scale
applications, such as moving liquids in microfluidic devices or for cooling purposes.
Applications:
o Microfluidics: Circulating small amounts of fluids in lab-on-a-chip devices or analytical
systems.
o Cooling Systems: Cooling of electronic components or microelectronics.
o Biomedical Applications: Used for controlled fluid flow in medical devices like drug delivery
systems.

Applications of Electromagnetic Pumps

1. Metallurgical Industries:
 o Electromagnetic pumps are extensively used in metal casting and processing, particularly when
handling molten metals such as aluminum, lead, and zinc. Their ability to pump high-
temperature liquids without contamination makes them ideal for these environments.
2. Nuclear Energy:
o In nuclear reactors, electromagnetic pumps are used to circulate coolants like liquid sodium,
which must remain at high temperatures while being pumped. Their ability to work in extreme
heat and without mechanical components is vital in these systems.
3. Space Exploration:
o Electromagnetic pumps are also studied for use in propulsion systems and cooling
mechanisms in spacecraft. Their capacity to handle high temperatures and operate in vacuum
environments makes them useful in space applications.
4. Microfluidic Systems:
o These pumps are widely used in lab-on-a-chip devices for controlling the flow of fluids in small-
scale systems, such as for medical diagnostics or research.
5. Fuel Cells:
o Electromagnetic pumps are used in certain types of fuel cells where they pump electrolytes or
other conductive fluids to maintain the cell's operation.
6. Energy Conversion:
o Electromagnetic pumps are integral to magnetohydrodynamic generators, which convert heat
into electricity without using moving parts. These systems are still in research but hold promise
for future power generation.

B. POSITIVE DISPLACEMENT PUMPS

Positive displacement (PD) pumps are a type of pump that moves fluid by trapping a fixed amount of fluid and
forcing (displacing) that trapped fluid into the discharge pipe. Unlike centrifugal pumps, which use kinetic
energy to move fluid, positive displacement pumps move a consistent volume of fluid regardless of pressure.
They are highly effective for applications where accurate and consistent flow is required, especially in
situations with high viscosity fluids or when handling solids.

The basic working principle of positive displacement pumps is to trap a fixed amount of fluid in a chamber and
then force it into the discharge pipe. This is accomplished through mechanical means such as pistons,
diaphragms, or gears. The fluid volume displaced per cycle is constant, regardless of the resistance (pressure)
in the discharge pipe.

Types of Positive Displacement Pumps

I. RECIPROCATING PUMPS
Reciprocating pumps are a type of positive displacement pump that use a back-and-forth (reciprocating)
motion to displace fluid. They are widely used for high-pressure, low to moderate flow applications. These
pumps can handle a variety of fluids, including those with higher viscosities or containing solids.
Types:
1. Piston Pumps are a type of reciprocating pump where a piston moves within a cylinder, alternately drawing
in and expelling fluid. The piston is typically connected to a crankshaft or motor that provides the reciprocating
motion.
Types of Piston Pumps according to piston sides:
• Single-Acting Piston Pumps: there is only one suction and one delivery pipe and the liquid is filled
only on one side of the piston, it is called a single-acting reciprocating pump.
o Structure: The piston moves in a single direction to both draw in and discharge fluid.
o Advantages: Simple design, relatively low maintenance.
o Applications: Water, oil, and chemical transfer at high pressure.
• Double-Acting Piston Pumps: A double-acting reciprocating pump has two suction and two delivery
pipes, Liquid is receiving on both sides of the piston in the cylinder and is delivered into the respective
delivery pipes.
o Structure: The piston displaces fluid on both the forward and return strokes.
o Advantages: Provides higher flow rates, smoother operation.
o Applications: Hydraulic systems, high-pressure cleaning, and oil drilling.
• Duplex Pumps: Two pistons.
• Triplex Pumps: Three pistons.
Types of Piston Pumps according to number of cylinder:

• Single- cylinder pump: A single-cylinder pump can be either single or double acting
• Double cylinder pump (or two throw pump): A double cylinder or two throw pump consist of two
cylinders connected to the same shaft.
• Triple cylinder pump (three throw pump): A triple-cylinder pump or three throw pump has three
cylinders, the cranks of which are set at 120° to one another. Each cylinder is provided with its own
suction pipe delivery pipe and piston.
• There can be four-cylinder and five-cylinder pumps also, the cranks of which are arranged accordingly.

2. Diaphragm Pumps use a flexible diaphragm that moves back and forth within a chamber, creating suction
and pushing fluid through the pump. The diaphragm separates the fluid from the moving parts, making these
pumps particularly suitable for hazardous or corrosive liquids.

Types of Diaphragm Pumps:

• Mechanical Diaphragm Pumps:
o Structure: The diaphragm is actuated by a mechanical link to a motor or crankshaft.
o Advantages: Capable of handling both liquids and gases, self-priming.
o Applications: Chemical dosing, water treatment, and food processing.
• Air-Operated Diaphragm Pumps (AODD):
o Structure: The diaphragm is moved by compressed air acting on one side of the diaphragm.
o Advantages: Self-priming, suitable for hazardous or explosive environments.
o Applications: Handling slurries, wastewater, and viscous fluids.

3. Plunger Pumps are similar to piston pumps but use a plunger (a solid, smooth rod) that moves back and
forth inside a cylinder to move the fluid. Plunger pumps are typically used for high-pressure applications, where
the fluid is forced through a small discharge opening.
Types of Plunger Pumps:
• Single-Acting Plunger Pumps:
o Structure: The plunger moves in one direction only to draw fluid in and then expel it.
o Advantages: Simpler design and operation.
o Applications: High-pressure cleaning, oil pumping, and fluid metering.
• Double-Acting Plunger Pumps:
o Structure: The plunger displaces fluid on both the forward and return strokes.
o Advantages: Higher flow rates and smoother operation.
o Applications: High-pressure systems like water jetting and boiler feedwater pumps.
• Duplex Pumps: Two plungers.
• Triplex Pumps: Three plungers.

II. ROTARY PUMPS

Rotary pumps displace fluid by trapping it between rotating elements and then forcing it into the discharge
pipe.
Types:
1. Gear Pumps are one of the most widely used rotary pumps. They work by meshing gears together to move
the fluid. The gear teeth create a cavity that traps fluid and moves it through the pump as the gears rotate.
Types of Gear Pumps:
• Internal Gear Pumps:
o Structure: Consist of a smaller inner gear and a larger outer gear. The inner gear rotates inside
the outer gear, and the fluid is trapped between the gear teeth.
o Advantages: Efficient, compact design, handles high-viscosity fluids, and can be self-priming.
o Applications: Lubricating oils, hydraulic systems, chemical transfer.
• External Gear Pumps:
o Structure: Two gears mesh externally, trapping and displacing fluid between the teeth.
o Advantages: Simple, reliable, and easy to maintain.
o Applications: Fuel transfer, lubricating oil pumps, industrial applications.
• Gear Pump with Crescent:
o Structure: Incorporates a crescent-shaped divider inside the pump to separate the inlet and
discharge cavities, ensuring smooth fluid flow.
o Advantages: Reduced pulsation, increased efficiency.
o Applications: Food processing, industrial liquids, adhesives.

2. Screw Pumps use one or more screws that rotate inside a cylinder to move the fluid. The rotation of the
screws creates a continuous, non-pulsating flow. The trapped fluid moves along the length of the screw and is
discharged at the end.

Types of Screw Pumps:

• Single-Screw Pumps:
o Structure: A single screw rotates inside a cylindrical casing, displacing fluid along the shaft.
o Advantages: Suitable for high-viscosity fluids, self-priming, and generates a smooth flow.
o Applications: Used for handling slurries, oils, and pastes.
• Twin-Screw Pumps:
o Structure: Two intermeshing screws rotate in a cylindrical casing, moving fluid in a continuous
flow.
o Advantages: Higher efficiency, ideal for clean and dirty fluids, minimal pulsation.
o Applications: Handling oil, food processing, pumping chemicals.
• Triple-Screw Pumps:
o Structure: Three screws rotate within the casing, providing higher efficiency and reduced
pulsation compared to twin-screw pumps.
o Advantages: Very efficient, suitable for high-pressure applications, handles clean and viscous
fluids.
o Applications: Fuel transfer, oil industry, lubricating fluids.

3. Vane Pumps consist of a rotor with multiple vanes that slide in and out of slots. As the rotor turns, the vanes
create chambers that trap and displace fluid. The flow is smooth and continuous, and the vane pump can
handle both clean and slightly dirty fluids.
Types of Vane Pumps:
• Fixed Displacement Vane Pumps:
 o Structure: The displacement is fixed, meaning the pump delivers a constant volume of fluid per
revolution.
o Advantages: Simple, compact, and reliable for low-pressure applications.
o Applications: Lubrication systems, fuel transfer, water circulation.
• Variable Displacement Vane Pumps:
o Structure: The displacement can be varied by adjusting the angle of the rotor or vanes. These
pumps can provide variable flow rates based on system needs.
o Advantages: Higher flexibility, ideal for systems where flow needs to change frequently.
o Applications: Hydraulic systems, power steering systems, automotive applications.

4. Lobe Pumps are similar to gear pumps but use two or more lobes (rotating elements) instead of gears. These
lobes intermesh to move fluid through the pump. Lobe pumps have a more gentle action than gear pumps and
are capable of handling fluids with suspended solids.

Types of Lobe Pumps:

• Single Lobe Pumps:
o Structure: One lobe rotates within a casing, trapping and displacing fluid.
o Advantages: Simple and efficient for low to moderate flow rates.
o Applications: Slurries, food processing, pharmaceutical industries.
• Twin Lobe Pumps:
o Structure: Two intermeshing lobes rotate in the casing, trapping and moving fluid.
o Advantages: Smooth, continuous flow, and ideal for liquids with solids.
o Applications: Dairy, food processing, chemical transfer.
• Multi-Lobe Pumps:
o Structure: Multiple lobes provide smooth flow, reducing pulsation and allowing for higher flow
rates.
o Advantages: High efficiency, low pulsation, and can handle both low and high-viscosity fluids.
o Applications: Industrial sludge, wastewater treatment, and heavy-duty applications.
5. Peristaltic Pumps are a type of rotary pump where a rotor with rollers or shoes compresses a tube, forcing
fluid through the tube. They are particularly useful for transferring sensitive fluids or those that need to be
isolated from the pump mechanism (e.g., for sanitary applications).
Applications:
• Handling chemicals, slurries, and sensitive liquids.
• Pharmaceutical, food and beverage, and water treatment.

Applications of Positive Displacement Pumps

1. Oil & Gas Industry:
o Used for transferring crude oil, lubricating oils, and other fluids.
o Gear pumps and diaphragm pumps are commonly used in these sectors.
2. Food and Beverage Industry:
o Moving viscous liquids like syrups, oils, milk, and juices.
o Often used for metering and accurate transfer of ingredients.
3. Pharmaceutical and Chemical Industries:
o Diaphragm pumps are especially useful for transferring corrosive chemicals or hazardous
materials.
4. Water Treatment:
o Used in dosing chemicals like chlorine, coagulants, and flocculants.
5. Hydraulic Systems:
o Piston and gear pumps are widely used for generating hydraulic pressure.
6. Lubrication Systems:
o PD pumps are used to ensure continuous lubrication in machinery, engines, and turbines.
7. Pumping Slurries:
o Common in mining, cement plants, and wastewater treatment for handling fluids with solids.
Other Important terms to consider:

Total dynamic head or dynamic head – is the sum of the pressure and velocity heads at a given section stated in
units of feet of the fluid flowing.

Total dynamic suction lift – is applied to pumps handling cold water and is the reading of a manometer or
vacuum gage (converted to feet of the fluid flowing).

Net positive suction head (NPSH) – is the difference between the absolute dynamic pressure of the liquid
measured at the centerline of a pump and the saturation pressure corresponding to the temperature of the
liquid at the same point, all expressed in terms of feet head of the fluid flowing. NPSH may also be defined as
the pressure at the pump suction flange, corrected to the pump centerline, that prevents vaporization of the
water.

Developed head (DH) – is the difference between the sum of the absolute pressure head and velocity head (or
absolute dynamic head) at the outlet of the pump and the sum of the absolute pressure head and velocity head
(or absolute dynamic head) at the inlet, both corrected to the centerline of the pump and expressed in feet
head of the fluid.

Static head – is the height of the surface of water above the gauge point.

Pressure head – is the static head plus gauge pressure on the water surface plus friction head.

Velocity head – is the head required to produce a flow of the water.

Suction lift – the vertical distance in feet (meters) from the liquid supply level to the pump center line with the
pump physically located above the liquid level supply.

Suction head - the vertical distance in feet (meters) from the liquid supply level to the pump center line with the
pump physically located below the liquid level supply.

Static discharge head – the vertical distance in feet (meters)between the pump center line and the point of free
discharge on the surface of the liquid in the discharge tank.

Total static head – the vertical distance in feet (meters) between the liquid level of the supply and the point of
free discharge on the surface of the liquid in the discharge tank.

Friction head - the head required to overcome the resistance to flow in the pipe and fittings.

Total dynamic suction lift – is the static suction lift plus the velocity head at the pump suction flange plus the
total friction head in the suction pipeline.

Total dynamic suction head - is the static suction head minus the velocity head at the pump suction flange
minus the total friction head in the suction pipeline.

Total dynamic discharge head – is the static discharge head plus the velocity head at the pump discharge flange
plus the total friction head in the discharge line.

Capacity – is the rate of flow of fluid measure per unit time, usually gallons per minute (gpm) or liters per minute
(lpm).

Centrifugal pump – a pump in which the pressure is developed principally by the action of centrifugal force.

End suction pump – a single suction pump having its suction nozzle on the opposite side of the casing from the
stuffing box and having the face of the suction nozzle perpendicular to the longitudinal axis of the shaft.

In Line pump – a centrifugal pump whose drive unit is supported by the pump having its suction and discharge
flanges on approximately the same center.

Horizontal pump – a pump with the shaft normally in a horizontal position.

Vertical shaft turbine pump – a centrifugal pump with one or more impellers discharging into one or more bowls
and a vertical educator or column pipe used to connect the bowls to the discharge head on which the pump
driver is mounted.

Horizontal split-case pump – a centrifugal pump characterized by a housing which is split parallel to the shaft.

Booster pump – is a pump that takes suction from a public service main or private use water system for the
purpose of increasing the effective water pressure.

Submersible pump – is a vertical turbine pump with the pump and motor closed coupled and designed to be
installed underground, as in the case of a deepwell pump.
Static water level – the level, with respect to the pump, of the body of water from which it takes suction when
the pump is not in operation.

Pumping water level – the level, with respect to the pump, of the body of water from which it takes suction when
the pump is in operation.

Draw-down – the vertical difference between the pumping water level and the static water level.

Centrifugal Pumps in Parallel and Series Operations.

a. Parallel pumps – performance is obtained by adding the capacities at the same head.
b. Series pumps – performance is obtained by adding the heads at the same capacity.
Cavitation – is a two-stage phenomenon consisting of the formation of vapor cavities resulting from low
pressure and their collapse as they move out of the low-pressure into higher pressure regions. The higher
pressure region causing the vapor cavity to collapse can be immediately following the formation of the vapor
cavity or some distance downstream from the impeller inlet, depending on the downstream pressure
conditions and the quantity of vapor formed.

Net positive suction head (NPSH) – is the term used by the pump industry for describing pump cavitation
characteristics. NPSH is defined as the pressure (head) in excess of the saturation pressure of the fluid being
pumped. NPSH is expressed as NPSH A (available) and NPSHR (required).

NPSHA is the NPSH available or existing at the pump installed in the system.

NPSHR is a performance characteristic of a pump and is established through closed loop or valve suppression
tests conducted by the pump manufacturer.

Causes of Cavitation:
a. Low suction pressure
b. Low atmospheric pressure
c. High liquid temperature
d. High velocity
e. Rough surfaces and edges
f. Sharp bends

Bad effects of Cavitation:

a. Drop in capacity and efficiency
b. Noise and vibration
c. Corrosion and pitting

TYPICAL PIPING INSTALLATION:

List of formulas for pumps:

1. The VOLUMETRIC FLOW RATE of liquid handled by a pump refers to the volume of liquid that passes through
the pump in a given time period. It's commonly expressed in units such as cubic meters per second (m³/s),
liters per minute (L/min), or gallons per minute (GPM).
2. Pressure head is a term used to describe the height of a column of fluid that corresponds to the pressure at
a particular point in a fluid system. It is a measure of the potential energy per unit weight of the fluid due to
pressure. Pressure head is an important concept in fluid mechanics and is used to understand the energy
distribution in a pumping system.

3. Velocity head represents the kinetic energy per unit weight of a fluid in motion. It is a measure of the energy
of the fluid due to its velocity, and it is often used in fluid dynamics and applications like pipe flow and pump
systems.

4. Friction head refers to the loss of energy due to the friction between the fluid and the walls of a pipe, duct, or
any other fluid-conveying system. This energy loss results in a drop in pressure along the length of the pipe,
which must be overcome by the pump or other driving forces.
 Darcy Friction Factor:

5. The Total Dynamic Head (TDH) is a critical parameter in pumping systems. It represents the total energy per
unit weight of fluid that a pump must supply to move the fluid through a system. TDH is the sum of all the
energy components required to transport the fluid, including static head, pressure head, velocity head, and
friction losses.

6. Hydraulic Power (or Water Power) refers to the power delivered by a flowing liquid, such as water, in a
hydraulic or pumping system. It represents the rate at which energy is transferred by the fluid. Hydraulic power
is a critical concept in fluid mechanics, especially in the design and operation of pumps, turbines, and
hydraulic machinery.
7. Brake power is the mechanical power required to drive the pump shaft. It accounts for the hydraulic power
plus losses in the pump due to inefficiencies.

8. Pump Efficiency is a measure of how effectively a pump converts the input power (mechanical or electrical
power supplied to the pump) into useful hydraulic power (power imparted to the fluid).

9. Motor efficiency (is the ratio of the mechanical output power (shaft power) to the electrical input power,
expressed as a percentage. It indicates how effectively a motor converts electrical energy into useful
mechanical work.

10. The overall efficiency of a pump is the product of its pump efficiency and motor efficiency. It represents
how effectively electrical power is converted into hydraulic power.

or

RECIPROCATING CHARACTERISTICS:
1. Piston displacement refers to the volume of fluid (or air) displaced by the piston as it moves through a
cylinder in a pump or engine. It is crucial for determining the flow rate, engine size, or pump capacity.
For reciprocating pumps (whether single-acting or double-acting), piston displacement is a key factor that
affects how much fluid is moved with each stroke.
Piston displacement
a. Piston rod neglected

b. Piston rod considered

where:
D = diameter of piston
d = piston rod diameter
L = piston displacement or length of stroke
N = revolutions per minute

2. Volumetric efficiency – is the ratio of actual volume to the piston displacement. The Volumetric efficiency
of a reciprocating pump is a measure of how effectively the pump fills its cylinder with fluid during the suction
(intake) stroke and empties it during the discharge stroke, compared to the theoretical maximum
displacement. It is the ratio of the actual discharge to the theoretical discharge.

3. Slip in a reciprocating pump refers to the difference between the theoretical discharge (volume the pump
should deliver) and the actual discharge (volume actually delivered). It accounts for losses such as leakage,
poor valve sealing, and the imperfect filling and emptying of the cylinder during each stroke.

Slip = Vd – Q

4. Actual discharge refers to the actual volume of fluid being delivered by the pump per unit of time, taking into
account various losses such as leakage, friction, air entrainment, and valve inefficiencies. It is always less than
or equal to the theoretical discharge, depending on the condition of the pump and the system.

Q=Av

5. Percent Slip is the ratio of the slip to the piston displacement.

Characteristics of Centrifugal Pumps:

1. Specific speed – is defined as the speed in revolutions per minute at which a geometrically similar impeller
would operate to develop 1 ft of head when displacing 1 gpm.

where:
Ns = specific speed, rpm
N = speed, rpm
Q = discharge, gpm
H = head, ft
2. Similar Pumps
a. b.

where D is the impeller diameter

3. The affinity laws are a set of mathematical relationships that describe how changes in the speed, size, or
other operating conditions of a pump, fan, or similar equipment affect its performance. These laws are
particularly useful for understanding how various parameters of a system scale when modifications such as
speed changes or size adjustments are made.

Sample Problems:
1. Water in the rural areas is often extracted from underground water source whose free surface is 60 m below
ground level. The water is to be raised 5 m above the ground by a pump. The diameter of the pipe is 10 cm at
the inlet and 15 cm at the exit. Neglecting any heat interaction with the surroundings and frictional heating
effects, what is the necessary power input to the pump for a steady flow of water at the rate of 15 liters/s in kw?
2. A double suction centrifugal pump delivers 70 ft3/sec of water at a head of 12 m and running at 1250 rpm.
What is the specific speed of the pump?

3. A certain pump is used to deliver 150 gpm of water having a density of 61.2 Ib/ft3. The suction and discharge
gage reads 4 in Hg vacuum and 25 psi, respectively. The discharge gage is 2 ft above the suction gage. What is
the brake power of the motor if pump efficiency is 75%?

4. A centrifugal pump is designed for 1800 rpm and head of 61 m. Determine the speed if impeller diameter is
reduced from 305 mm to 254 mm.
5. A single-acting reciprocating pump discharge 0.018 m3/s of water per second when running at 60 rpm. Stroke
length is 500 mm and the diameter of the piston is 220 mm. If the total lift is 15 m, determine:
a) Theoretical discharge of the pump
b) Slip and percentage slip of the pump
c) Co-efficient of discharge
d) Theoretical Power required for running the pump.

Practice Problems:
1. A three-throw reciprocating pump is delivering 0.1 m3/s of water against a head of 100 m. Diameter and
stroke length of the cylinder are 250 mm and 500 mm respectively. Friction losses amount to 1 m in the suction
pipe and 16 m in the delivery pipe. If the velocity of water in the delivery pipe is 1.4 m/s, pump efficiency 90%
and slip 2%, determine the pump speed and the input power supplied.

2. The suction pressure of a pump reads 2 in. of mercury vacuum and discharge pressure reads 130 psi is use to
deliver 100 gpm of water with specific volume of 0.0163 ft3/lb. Determine the pump work.

3. Water from a reservoir is pumped over a hill through a pipe 900 mm in diameter and a pressure of one kg/cm2
is maintained at the pipe discharge where the pipe is 85 m from the pump centerline. The pump has a positive
suction head of 5 m. Pumping rate of the pump at 1000 rpm is 1.5 m3/sec. Friction losses is equivalent to 3 m of
head loss. What amount of energy must be furnished by the pump in KW?

4. Determine the water horsepower and the mechanical efficiency of a centrifugal water pump which has an
input of 3.5 Hp if the pump has an 8 inches nominal size suction and 6 inches nominal size discharge if it
handles 150 gpm of water at 150°F. The suction line gage shows 4" Hg vacuum and the discharge gage shows
26 psi. The discharge gage is located 2 feet above the center of the discharge pipe line and the pump
inlet and discharge lines are at the same elevation.

5. A pump discharges 150 liters per second of water to a height of 75 meters. If the efficiency is 75% and the
speed of the pump is 1800 rpm, what is the torque in N-m to which the drive shaft is subjected?