Mining Machinery

th
5 Semester, Mining Engineering Department
By
Dr. Umakanta Behera
Assistant Professor & Head
Department of Mining Engineering
Government College of Engineering, Keonjhar

MINE PUMP
INTRODUCTION
• Pump is a mechanical device used to drain out water from the mine to surface.
Why Pumping?
Pumping in mining is required for
• Dewatering of mine: mine water, Storm water, groundwater
• Hydraulic Backfilling: slurry
• Tailings disposal
• Dust suppression

How does a pump work?

❖ Pumps work by creating a vacuum or areas of low pressure in which ambient air
pressure forces the liquid. The difference in pressure creates suction. A liquid under
higher pressure will move to an area of 'lower pressure.
Type of pumps
❖ Centrifugal pump
❖ Reciprocating pump

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 CENTRIFUGAL PUMP
• It is filled with liquid and the impeller is rotated Rotation imparts energy to the liquid
causing it to exit the impellers vanes at a greater velocity than what it had at the time
of entering.
• This outward flow reduces the pressure at the impeller eye, allowing more liquid to
enter.
• The liquid that exits the impeller is collected in the casing (volute) where its velocity is
converted to pressure before it leaves the pump's discharge.

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 PARTS OF CENTRIFUGAL PUMP

The different parts of the centrifugal pump are listed below.

❖ Shaft
❖ Impeller
❖ Casing
❖ Suction Pipe
❖ Delivery Pipe

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Shaft
• It is a central part of the pump which is rotating with the impeller is connected.
• The shaft coupled to the prime mover to get the power.
• The shaft fits with the ball bearing.
Impeller
• It is consisting of a series of backward curved vanes.
• It is mounted to the shaft of an electric motor.
• An impeller is a rotating part of the centrifugal pump.
• It enclosed in a watertight casing.
Casing
• It is an airtight passage surrounding the impeller.
• It is designed in such a way that the kinetic energy of the water discharged at the outlet
is converted into pressure energy before the water leaves the casing and enters the
delivery pipe.
• The casing works as a cover to protect the system.
Suction Pipe with a Foot Valve and Strainer
• The suction pipe has two ends.
• One end is connected to the inlet of the pump and the other dips into the water in a
sump.
• A foot valve fits at the lower end of the suction pipe. The foot valve is the one-way type
of valve which only opens in an upward direction.
• A strainer is also fitted at the end of the suction pipe to prevent the entry of foreign
bodies into the suction pipe.
Delivery valve
• The delivery valve has two ends.
• One end is connected to the outlet of the pump and the other end delivers the water at
a required height.

TERMINOLOGY

Head - Head refers to the height at which a pump can raise a fluid.

Static Suction Head - The vertical distance between the centre line of a pump and the level
to which the liquid is pumped.

Delivery Head -the vertical distance between the centreline of a pump and the level to which
the liquid is discharged.

Vacuum- Defined as any pressure lower than atmospheric. Each pump creates a vacuum into
which fluids flow under atmospheric pressure.

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Volumetric Flow Rate-Flow rate/Capacity of a pump is the amount of liquid delivered by
the pump per unit of time (m3/h

Hydraulic Power: Power transferred by the pump to the liquid.

Why Centrifugal Pumps Need Priming?

• Centrifugal pumps do not create suction at the start without impeller filled with water.
Hence Priming required.
• Priming is the process in which the impeller of a centrifugal pump will get fully sub
merged in liquid without any air trap inside.
• This is especially required when there is a first start up. But it is advisable to start the
pump only after primping.

Cavitation
• It is the process in which bubbles are formed due to sufficient Pressure drop at the
suction of the pump.
• Cavitation occurs when the liquid in a pump turns to a vapor at low pressure.
• It occurs because there is not enough pressure at the suction end of the pump, or
insufficient Net Positive Suction Head available.
• When cavitation takes place, air bubbles are created at low pressure.

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 OPERATIONAL DIFFICULTIES IN CENTRIFUGAL PUMP
(1) Pump fails to pump the liquid
Cause Remedy
Improper priming, due to leakage in foot Repair or replace the foot valve; prime
valve or incomplete filling properly
Head greater than equal to design head Reduce the head or change the pump
Clogging of impeller vanes, suction pipe, Clean the suspected part
or strainer
Suction lift is very high Reduce the height of the pump above the
sump
Speed ≤ design speed Connect another prime mover of higher
speed
Direction of rotation of impeller is wrong Change the direction

(2) Pump does not provide the required quantity

Cause Remedy
Leakage of air through suction pipe joints Check & stop the leakage
or through gland packing
Damage to some parts of the pump by Replace the damaged parts
wear and tear
Clogging of impeller passages Clean the impeller
❖ Gland is a mechanical seal that is tightened to create a secure, leak-free seal.
(3) Pump has poor efficiency
Cause Remedy
Higher than design speed Reduce the speed
Low head & higher discharge Reduce discharge by throttling
Impeller touching the casing or improper Carry the necessary repair
shaft alignment
❖ Throttling is a way to control the flow rate by changing the system's resistance.
This is done by opening or closing a valve in the pump's discharge line.

Selection of Pumps:
Selection of pump is based on the specific speed for the pump. The specific speed is
calculated from the values of discharge (Q) head (H) and speed (N)

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 MULTISTAGE CENTRIFUGAL PUMP
• A multistage centrifugal pump consists of two or more identical impellers mounted on
the same shaft or on different shafts.
• To produce the heads higher than that of using single impeller keeping the discharge
constant. This is achieved by Series arrangement of pumps
• To discharge the large quantity of fluid keeping the head constant. This is achieved by
parallel arrangement of pumps.
Series Arrangement of Pumps
• The discharge from first impeller having high pressure is fed to second impeller through
guided passage.
• The pressure at the outlet of second impeller will be more than the pressure at the outlet
of first impeller.
• If the greater number of impellers are mounted on the same shaft in series arrangement,
then the pressure will be increases further.
• For each stage, the head developed will be Hm hence for number of stages (n)
total head developed will be given by Htotal = n x Hm

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 Parallel Arrangement of Pumps

• To obtain a high discharge at relatively small head number of impellers are mounted in
parallel arrangement.
• The pumps are arranged such that each of these pumps is working separately to lift the
liquid from common sump and deliver it to the common delivery pipe
• In this arrangement the head remains constant and the discharge of each pump gets
added to give large quantity of liquid at the outlet
Q total = Q1 + Q2+……+Qn
Advantages of Centrifugal Pump

1. Centrifugal pumps are relatively simple in design and easy to operate, which makes
them a popular choice for many industrial applications.
2. They are capable of handling high flow rates, making them ideal for moving large
volumes of fluid.
3. These pumps have few moving parts, which means they require less maintenance
compared to other types of pumps.
4. Centrifugal pumps are generally efficient at converting input power into the fluid flow,
making them energy-efficient.

Disadvantages of Centrifugal Pump

1. Centrifugal pumps have a limited suction lift, which means they cannot lift fluid from
depths greater than a few meters.
2. They are not capable of generating high pressure.
3. These pumps are sensitive to changes in fluid properties such as viscosity and
temperature, which can affect their performance.

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 4. Centrifugal pumps can experience cavitation when operating at high flow rates, which
can damage the impeller and decrease performance.
5. These pumps can be more expensive compared to other types of pumps, especially
when used in applications that require high flow rates or pressure.

RECIPROCATING PUMP
Reciprocating pumps are different from Centrifugal pumps on basis of its working, features,
applications etc. The main difference is that Impellers are used in Centrifugal pumps whereas
in reciprocating pumps piston is used to move the liquid. Centrifugal pumps continuously
discharge the liquid, unlike reciprocating pumps. They are used for high viscous fluid and are
lighter in weight, less expensive as compared to reciprocating pumps.
The key components used in reciprocating pumps are
Piston
All these parts have the basic functionality of moving the liquid inside the cylinder. The
piston is a lubricated sliding shaft that moves inside the cylinder and pushes the liquid in a
forward and backward motion, creating a cavity and a high-volume pressure at the outlet.
Crank and Connecting rod:
Crank is a circular disk attached to the motor and used to transfer the rotary motion of
the motor to the piston. Piston, in turn, moves in a reciprocating motion with help of a
connecting rod.
Suction pipe:
Liquid flows from this pipe into the cylinder. One side of the pipe is immersed in the
liquid and the other end is connected to the cylinder.
Delivery pipe:
This can be understood as an outlet pipe. One end is connected to the cylinder while
the other is towards the discharge/Outlet.
Suction and Delivery valve:
It adjusts the rate of the flow of liquid at the suction and discharge points.

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Piston is a primary component of a reciprocating pump. This works inside a chamber which
defines the ultimate pump volume. A connecting rod is attached to a motor crank on one end
and the piston. A suction pipe allows fluid to be drawn into the chamber, while a delivery pipe
allows fluid to be discharged. Inlet and outlet valves check the flow of fluid into and out of the
chamber.
At a high level, the actions of a reciprocating pump can be divided into two phases:

❖ Suction phase: The piston is pulled back which increases chamber volume and
thereby creates a vacuum. This process opens the inlet valve and closes the
outlet valve. Vacuum acting on the chamber pulls fluid through the inlet.
❖ Compression phase: After the piston has reached its maximum displacement
it is then pushed back into the chamber. The inlet valve is closed and the outlet
valve is opened. Fluid is then discharged under pressure through the outlet.

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There are several benefits of selecting a reciprocating pump:

• It can deliver the required flow rate very precisely

• It gives a continuous rate of discharge
• It can deliver fluid at very high pressure
• No pricing is needed
What should be considered when choosing a reciprocating pump?
Some common considerations:
• Flow rate and pressure
• Temperature
• Viscosity
• Composition of the fluid being pumped
Factors that determine the efficiency of a Reciprocating Pump

• Brake Horsepower (BHP): How much is the actual power requirement at the input
shaft to achieve a desired pressure and flow.
• Capacity: It can be defined as the total volume of liquid/flow delivered per unit of
time.
• Slips: Slip is the capacity loss as a fraction or percentage of the suction capacity.
• Mechanical efficiency: Working at full load pressure and speed is 90% to 95%
depending on the size, speed, and construction.
• Pressure: Mainly, the suction and the discharge pressure in a pump.
• Displacement: it is the calculated capacity of the pump with no-slip losses.

Advantages of Reciprocating Pumps

• High Pressure, Low Flow Applications: Reciprocating pumps are generally designed
to pump in low flow, high head applications.
• Proven, Common Technology: Reciprocating pumps are one of the oldest, most
proven pump types.
• Durability: Reciprocating pumps are used in some of the most abrasive and corrosive
applications.
• Efficiency: Reciprocating pumps operate at high a higher efficiency compared to
other pump designs. In most cases, at any setpoint, reciprocating pumps operate
around 90%.

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Disadvantages of Reciprocating Pumps

• High Maintenance / Short Life: The main disadvantage of a reciprocating pump is

high maintenance and short life. There are many parts in the pump works, all constantly
changing directions. Unless careful maintenance takes place, the lifespan of the pump
is greatly reduced. While pumps such as centrifugal pumps can last 15 to 20 years with
little maintenance, a reciprocating pump requires higher levels of attention and
rebuilding several times within the same time frame. The cost of a reciprocating pump
rebuild is usually inexpensive which still makes them cost-competitive compared to
longer-lasting, higher-priced pump designs.
• Pulsations: A characteristic of reciprocating pumps is the production of pressure
pulsations through the pump inlet and outlets.

Comparison of Centrifugal and Reciprocating Pumps

Properties Centrifugal Pumps Reciprocating Pumps
Operating principle Centrifugal force Reciprocating piston motion
Flow of liquid High Low
Pressure capability Lower pressure capability Higher pressure
capability
Efficiency of pumps Efficiency for high-flow rates Efficiency is low due to
is high reciprocation
Mechanism Less complex mechanism with Complex mechanism with
fewer moving parts pistons, valves, and other
moving parts
Maintenance Minimal maintenance, durable Requires more
maintenance
Handling of fluids Can handle several types of Can also handle different
fluids types of fluid preferably
with low viscosity
Cost Less installation and High initial cost
operational costs
Dirty water Can lift dirty water Cannot lift dirty water

Discharge pattern Continuous and smooth Fluctuating and pulsating

Handling ability Handles massive volumes of Handles small volumes of
liquid liquid
Application type Used for large discharge Meant for small discharge
through small heads at high heads
Installation Area Needs smaller area Needs a larger floor area

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 SLIP OF A RECIPROCATING PUMP
➢ Slip of a pump is defined as the difference between the theoretical discharge and actual
discharge of the pump.
➢ The actual discharge of a pump is less than the theoretical discharge due to leakage.
➢ The difference of the theoretical discharge and actual discharge is known as slip of the
pump.
Hence, mathematically.

NEGATIVE SLIP
➢ Slip is equal to the difference of theoretical discharge and actual discharge.
➢ If actual discharge is more than the theoretical discharge, the slip of the pump will
become -ve.
➢ In that case, the slip of the pump is known as negative slip.
➢ Negative slip occurs when delivery pipe is short, suction pipe is long and pump is
running at high speed.

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 SUBMERSIBLE PUMP
• A submersible pump (or electric submersible pump (ESP) is a device which has a
hermetically sealed motor close-coupled to the pump body.
• The whole assembly is submerged in the fluid to be pumped.
• A submersible pump is a pump that is able to be placed underwater and still carry out
its intended purpose.
• Some pumps may be designed to work while being fully submerged, whereas others
may be submerged or placed in a dry area.
• A submersible water pump pushes water to the surface, instead of sucking the water out
of the ground like above ground water pumps.

WORKING PRINCIPLE
➢ The submersible pumps used in ESP installations are multistage centrifugal pumps
operating in a vertical position.
➢ Although their constructional and operational features underwent a continuous
evolution over the years, their basic operational principle remained the same.
➢ Produced liquids, after being subjected to great centrifugal forces caused by the high
rotational speed of the impeller, lose their kinetic energy in the diffuser where a
conversion of kinetic to pressure energy takes place.
➢ The pump shaft is connected to the protector by a mechanical coupling at the bottom of
the pump.
➢ Well fluids enter the pump through an intake screen and are lifted by the pump stages.
➢ Other parts include the radial bearings (bushings) distributed along the length of the
shaft providing radial support to the pump shaft turning at high rotational speeds.

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➢ An optional thrust bearing takes up part of the axial forces arising in the pump but most
of those forces are absorbed by the protector’s thrust bearing.

APPLICATIONS
Submersible pumps are found in many applications:
➢ Single stage pumps are used for drainage, sewage pumping, general industrial pumping
and slurry pumping.
➢ They are also popular with aquarium filters.
➢ Multiple stage submersible pumps are typically lowered down a borehole and used for
water abstraction, water

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 EFFICIENCY:
➢ Compared to the ordinary pumps, the submersible pumps are more efficient as it pumps
liquid which is close to the pump.
➢ It therefore functions less than the ordinary pumps.
➢ As these pumps are placed inside the sumps, it can detect the level of water quite easily.
wells and in oil wells.

DISADVANTAGE
➢ The largest disadvantage of these pumps is that you put it in the water. This means it
will have a shorter life because it is sitting in and sucking up muck from your pond.
➢ It is also harder to clean and maintenance because it is sitting on the bottom of the pond.
➢ There is the chance the pump will become corroded and lose its seals, thus allowing
liquid to penetrate into the motor housing and causing substantial damage to the unit.

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 WATER HAMMER
• Water hammer occurs when the flowrate of fluid in the pipe changes rapidly.
• It is also known as “surge flow.”
• It can cause very high pressures in pipes, very high forces on pipe supports, and even
sudden reversals of flow.
• It can cause burst pipes, damaged supports and pipe racks, and leakage at joints, damage
of impeller.
common cause
❖ Pump trips and starts
❖ Valve closing or opening

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