UNIT I.

INDUSTRIAL PUMPS

Overview

In this unit, you will learn the basic principles, process and technical definitions of
pumps. You will be able to understand how a pump works, identify different pumps
classifications, identify parts and learn the construction of a pump.

Learning Objectives:

At the end of this unit, I am able to:

1. Solve for the total head in different situations.
2. Identify every parts of a pump.
3. Classify different pumps.
4. Solve for the appropriate pump capacity to be use in the system.
5. Select the proper pump and impeller to be use.
Setting Up

Name: ____________________________________________ Date: ___________________

Course/Year/Section: __________________________

Directions: Answer the following questions.

1. What is a pump?
2. What are the classification of pumps?
3. What is pump capacity?
4. What is the difference of Darcy and Morse’ formula in friction loss?
5. What are the basic parts of a pump?
Lesson Proper

Pumps
Pump is a machine used to add energy to a liquid in order to transfer the liquid from
one point to another point of higher energy level.

Classification of Pumps:
1. Centrifugal Pump – is a machine which the pumping action is accomplished by imparting
kinetic energy to the fluid by a high-speed revolving impeller with vanes and subsequently
converting this kinetic energy into pressure energy either by passing through a volute casing
or through diffuser vanes
2. Rotary Pump – is a positive displacement pump consisting of a fixed casing containing
gears, cams, screws, vanes, plungers or similar elements actuated by rotation of the drive
shaft.
3. Reciprocating Pump – is a positive displacement unit wherein the pumping action is
accomplished by the forward and backward movement of a piston or plunger inside a
cylinder usually provided with valves.
4. Deep Well Pump – is divided into plunger or reciprocating, turbine, ejector-centrifugal types
and air lifts.

Common Pump Assembly

1. Volume Flow Rate of liquid handled by the Pump (Q)
Volume flow rate is the volume of the liquid that passes through a given surface per
unit time. It is the product of the area and velocity of the liquid.
Q = AV
where: Q = volume flow rate (m3/s, ft3/s, Li/s, etc.)
V = velocity of the flow (m/s, ft/s, etc.)
A = area of the flow (m2, ft2, etc.)

2. Pressure Head (hp)

Pressure head is the height of the column of water of liquid necessary to develop a
specific pressure.
𝐏
𝐡𝐩 = 𝛄

where: P = pressure (Pa, lb/in2, etc.)

γ = specific weight (N/m3, lbf/ft3, etc.)
γwater = 9.81 kN/m3 = 62.4 lbf/ft3

3. Velocity Head (hv)

Velocity head is the square of the speed of flow of a liquid divided by twice the
acceleration of gravity. It is equal to the static pressure head corresponding to a pressure
equal to the kinetic energy of the liquid per unit volume.
𝐕𝟐
𝐡𝐯 = 𝟐𝐠

where: V = velocity (m/s, ft/s, etc.)

g = acceleration due to gravity (m/s2, ft/s2)
acceleration due to gravity on standard elevation = 9.81 m/s2, 32.2 ft/s2

4. Friction Head (hf)

Friction head is the head lost by the flow in a stream or conduit due to frictional
disturbances set up by the moving liquid and its containing conduit and by intermolecular
friction.
a. Using Darcy’s Equation
𝐟𝐋𝐕 𝟐
𝐡𝐟 = 𝟐𝐠𝐃
b. Using Morse Equation
𝟐𝐟𝐋𝐕 𝟐
𝐡𝐟 = 𝐠𝐃

where: L = total length (m, ft, in, etc.)

V = velocity (m/s, ft/s, etc.)
D = inside diameter (m, mm, in, ft, etc.)
g = 9.81 m/s2 = 32.2 ft/s2
f = coefficient of friction
Note: f should be taken from MORSE table if Morse Equation is to be used.

5. Total Head or Total Dynamic Head (H)

Total head to Total Dynamic head is the total energy developed by the pump
expressed in height of liquid. It is the algebraic sum of static head, pressure head, friction
head and velocity head.
Total head = Static head + Pressure head + Velocity head + Friction head
H = (Zd – Zs) + (hpd – hps) + (hvd – hvs) + (hfd + hfs)
𝐏𝐝 − 𝐏𝐬 𝐕𝐝𝟐 − 𝐕𝐬𝟐
H = (Zd – Zs) + + + (hfd + hfs)
𝛄 𝟐𝐠

where: Z is negative (-) if source is below the pump centerline.

Ps is negative (-) if pressure is vacuum.

Example:
A pump with a 400 mm diameter suction pipe and a 350 mm discharge pipe is to deliver
20,000 liters per minute of 15.6°C water. Calculate the pump head in meters if suction gauge
is 7.5 cm below pump centerline and reads 127 mmHg vacuum and discharge gage is 45 cm
above the pump centerline and reads 75 kPa.
Solution:
𝐿𝑖 1m3 1min m3
Q = 20,000 min (1000 Li) (60 sec) = 0.333 sec

m3
𝑄 0.333
sec
𝑉𝑠 = 𝜋𝑑2
= 𝜋(0.4 𝑚)2
= 2.65 𝑚/𝑠
4 4

m3
𝑄 0.333
sec
𝑉𝐷 = 𝜋𝑑2
= 𝜋(0.35 𝑚)2
= 3.46 𝑚/𝑠
4 4
 H = total dynamic head
Pd − Ps V2d − V2s
H = (Zd – Zs) + + + (hfd + hfs)
γ 2g

Pd − Ps V2d − V2s
H = (Zd – Zs) + + + (hfd + hfs)
γ 2g
101.325 kPa 2
75 𝑘𝑃𝑎−(−127mmHg x
760mmHg
) 3.462 − 2.65
H = [0.45m – (-0.075m)] + +
9.81 kN/m3 2(9.81)

H = 10.15 m

6. Hydraulic or Water Power (Pw)

Hydraulic or water power is the theoretical power necessary to raise a given volume
of liquid from a lower to a higher elevation.
Pw = γQH
where: Pw = hydraulic or water power (kW, hp, etc.)
Q = volume flow rate (m3/s, ft3/s, Li/s, etc.)
H = total dynamic head (m, ft, etc.)

Example:
From the example above, solve for the hydraulic or water power.
Pw = γQH
Pw = 9.81 kN/m3 (0.333 m3/s) (10.15 m)
Pw = 33.157 kN-m/s or kJ/s or kW
Pw = 33.157 kW (1 hp/0.746 kW) = 44.45 hp

7. Pump Efficiency (ep)

Pump efficiency is the ratio of the hydraulic power or water power to the brake
power.
𝐏𝐰
𝐞𝐩 = 𝐏𝐛

where: Pw = hydraulic or water power (kW, hp, etc.)

 Pb = brake power (kW, hp, etc.)

Example:
From the example above, solve for the brake power assuming your pump has a 70%
efficiency.
Pw
ep =
Pb
Pw
Pb =
ep

44.45 ℎ𝑝
Pb = = 63.5 hp
0.7

8. Motor Efficiency (em)

Motor efficiency is the ratio of the brake power to the input power.
𝐏𝐛
𝐞𝐦 = 𝐏𝐢

where: Pb = brake power (kW, hp, etc.)

Pi = input power (kW, hp, etc.)

Example:
From the example above, solve for the input electric power to the motor assuming your
electric motor has a 90% efficiency.
Pb
em =
Pi
Pb
Pi =
em
63.5 hp
Pi = = 70.55 hp
0.9
Pi = 70.55 hp (0.746 kW/1 hp) = 52.63 kW

9. Overall Efficiency (e)

Overall efficiency is the ratio of the hydraulic or water power to the input power.
 𝐏𝐰
𝐞= 𝐏𝐢

where: Pw = hydraulic or water power (kW, hp, etc.)

Pi = input power (kW, hp, etc.)

Example:
From the example above, solve for the overall efficiency of the system.
Pw
e=
Pi
33.157 kW
e= = 0.63 or 63%
52.63 kW

10. Specific Speed (Ns)

Specific speed is a number used to predict the performance of centrifugal pumps. It is

the speed at which a geometrically similar impeller of a pump would run to discharge 1 gpm
at 1 ft head.

Also, according to Wikipedia, “Specific speed is an index used to predict desired pump
or turbine performance, i.e. it predicts the general shape of the pump’s impeller. It is this
impeller’s ‘shape’ that predicts its flow and head characteristics so that the designer can then
select a pump or turbine most appropriate for a particular application”.

𝐍√𝐐
𝐍𝐬 = 𝐡
( )𝟑/𝟒
𝐧

where: Ns = specific speed, must be in rpm

N = rotational speed, must be in rpm
Q = discharge, must be in gpm
H = head, must be in ft
n = number of stages
Radial flow pump: Often referred to as a volute or diffuser pump, this is the most popular
and common style of centrifugal pump in use today. The direction of fluid flow through the
impeller is 90° normal to the shaft. Simply stated, this means the flow enters the impeller
parallel to the pump shaft through an entrance opening called the impeller eye. More simply,
the eye travels through the impeller and is then discharged from the impeller at a
perpendicular right angle, or 90°, from the pump shaft.
Axial flow pump: This is more commonly referred to as a propeller pump. Flow through the
impeller is routed straight through the impeller, or at an angle of 180° normal to the shaft.
The pump’s primary use is in high capacity and low head applications, such as high-volume
fluid transfer for dewatering, stormwater pumping, and tailwater recovery systems.
Mixed flow pump: The mixed flow impeller is a compromise of design between the radial
and axial flow impeller where the flow through the impeller is oriented at an angle between
90° and 180° normal to the pump shaft. This impeller combines the design characteristics of
the two other impellers in order to achieve a system both efficient and capable of delivering
a high output of flow and head. This style of impeller is commonly used for applications in
vertical turbine and submersible pumps.

Example No. 1:
A centrifugal pump is powered by a direct drive induction motor is needed to discharge 150
gpm against a total head of 180 ft when turning at fully loaded speed of 3500 rpm. Solve for
the specific speed and choose which type of pump should be selected?

N√Q
Ns = h
( )3/4
n

3500 rpm√150 gpm

Ns = = 872.27 rpm
(180 ft)3/4
Example No. 2:
It is desired to deliver 5 gpm at a head of 640 ft in a single stage pump having a specific speed
not to exceed 40 rpm. If the speed is not to exceed 1352 rpm, how many stages are required?

N√Q
Ns = h
( )3/4
n

1352 rpm√5 gpm

40 𝑟𝑝𝑚 = 640 ft 3/4
( )
n

n = 2 stages

For Similar Pumps

𝐍𝟏 √𝐐𝟏 𝐍𝟐 √𝐐𝟐 𝐐𝟏 𝐐𝟐
a. 𝟑/𝟒 = 𝟑/𝟒 b. =
𝐇𝟏 𝐇𝟐 𝐍𝟏 𝐃𝟑𝟏 𝐍𝟐 𝐃𝟑𝟐

Pump Laws
a. Variation in impeller speed
If the impeller diameter is constant
𝐐𝟏 𝐍𝟏 𝐇𝟏 𝐍 𝟐 𝐏𝟏 𝐍 𝟑
= = ( 𝟏) = ( 𝟏)
𝐐𝟐 𝐍𝟐 𝐇𝟐 𝐍𝟐 𝐏𝟐 𝐍𝟐

a. Variation in impeller diameter

If the impeller speed is constant
𝐐𝟏 𝐃 𝟑 𝐇𝟏 𝐃 𝟐 𝐏𝟏 𝐃 𝟓
= (𝐃𝟏 ) = (𝐃𝟏 ) = (𝐃𝟏 )
𝐐𝟐 𝟐 𝐇𝟐 𝟐 𝐏𝟐 𝟐

Example No. 1:

A pump operating at 1750 rpm delivering 500 gal/min against a total head of 150 ft changes
in the piping system have increased the total head to 360 ft. At what rpm should the pump be
operated to achieve this new head at the same efficiency?

Solution:

H1 N 2
= (N1)
H2 2
150 1750 2
=( )
360 N2

N2 = 2711.09 rpm

Example No. 2:

The power output is 30 Hp to a centrifugal pump that is discharging 900 gpm and which
operates at 1800 rpm against a head of 120 ft, 220 V, 3 phase, 60 Hz. If this pump is modified
to operate 1200 rpm, assuming its efficiency remains constant, determine its discharge in
gpm, the theoretical head it imparts to the liquid and the power input to the pump.

Solution:

Solving for the discharge Q2:

Q1 N
= N1
Q2 2

900 1800
= 1200
Q2

Q2 = 600 gpm

Solving for the theoretical head H2:

H1 N 2
= (N1)
H2 2

120 1800 2
= (1200)
H2

H2 = 53.33 ft

Solving for the power input P2:

P1 N 3
= (N1)
P2 2

30 1800 3
= (1200)
P2

P2 = 8.89 Hp
For Reciprocating Pumps:
1. Piston Displacement (VD)
Piston Displacement is the volume which a piston in a cylinder displaces in a single
stroke, equal to the distance the piston travels times the internal cross-sectional area of the
cylinder.
a. Piston displacement if piston rod is neglected:
𝛑𝐃𝟐 𝐋𝐍
𝐕𝐃 = [ ]
𝟒

b. Piston displacement if piston rod is considered:

𝛑𝐃𝟐 𝐋𝐍 𝛑𝐋𝐍
𝐕𝐃 = [ ]+ [𝐃𝟐 − 𝐝𝟐 ]
𝟒 𝟒

where: d = piston rod diameter (mm, in, etc.)

D = diameter of piston (mm, in, etc.)
L = length of stroke (mm, in, etc.)
N = rotational speed (rpm, rps, etc.)

2. Actual Discharge (Q)

Q = AV
where: Q = volume flow rate (m3/s, ft3/s, Li/s, etc.)
V = velocity of the flow (m/s, ft/s, etc.)
A = area of the flow (m2, ft2, etc.)

3. Slip (S)
Slip is the difference between the piston displacement and the actual discharge.
S = VD – Q
4. Percent Slip (%S)
Percent slip is the ratio of the slip to the piston displacement.
𝐒 𝐕𝐃 −𝑸
%𝐒 = [𝐕 ] 𝑥𝟏𝟎𝟎% = [ ] 𝑥𝟏𝟎𝟎%
𝐃 𝐕𝐃

5. Volumetric Efficiency (ev)

Volumetric efficiency is the ratio of the actual discharge to the piston displacement.
 𝐐
𝐞𝐯 = 𝐕
𝐃

Example No. 1
A single cylinder reciprocating pump delivers a water at a rate of 20 Li/sec. The reciprocating
pump having a bore and stroke of 0.5 and 0.15 meters respectively reciprocate at a rate of 50
rpm. Calculate:
a. The volume displacement of the pump.
b. The Slip and the percent slip of the pump.
c. The volumetric efficiency of the pump.

Solution:
Solving for the volume displacement of the pump:
πD2 LN
VD = [ ]
4

π(0.5m)2 0.15m(50 rpm)

VD = [ ] x 1 cylinder
4

VD = 1.47 m3/min (1 min/60 sec) (1000 Li/1 m3)

VD = 24.5 Li/sec

Solving for the slip and the percent slip of the pump:

S = VD – Q
S = 24.5 Li/sec – 20 Li/sec
S = 4.5 Li/sec

S
%S = [V ] 𝑥100%
D

4.5
%S = [24.5] 𝑥100%

%S = 18.37%

Solving for the Volumetric Efficiency of the Pump:

 Q
ev = V
D

20
ev = 24.5

Ev = 0.8163 or 81.63%
References

(Capote & Mandawe, POWER PLANT ENGINEERING, 2007)

Assessing Learning

Activity 1

Name: ____________________________________________ Score: ___________________

Course/Year/Section: __________________________ Date: _____________________

Directions: Research, solve, and compile at least 10 problems in unit 1