EBOOK - Pump Characteristics and Applications 2nd Edition (Michael Volk)
16 thg 7, 2018 | 13:15

EBOOK - Pump Characteristics and Applications 2nd Edition (Michael Volk)


EBOOK - Đặc điểm và ứng dụng của bơm (Michael Volk) - 548 Trang.

Thankfully, the laws of physics have not changed since the first edition of this book was written in 1996. Therefore, virtually everything about pump selection, sizing, system analysis, and other aspects of pump hydraulics remains unchanged from the first edition. There have, however, been a number of innovations in the world of pumps, which are introduced in this second edition. This edition also expands the material on many components of typical pump installations that were only briefly covered in the first edition, if at all.


CONTENTS:

1 Introduction to Pumps ..............................................1
I. What Is a Pump?............................................................ 1
II. Why Increase a Liquid’s Pressure?............................... 2
III. Pressure and Head......................................................... 3
IV. Classification of Pumps.................................................. 5
A. Principle of Energy Addition ................................... 5
1. Kinetic ................................................................. 5
2. Positive Displacement ........................................ 5
B.How Energy Addition Is Accomplished .................. 7
C.Geometry Used ......................................................... 7
V.How Centrifugal Pumps Work ...................................... 7
VI. Positive Displacement Pumps ..................................... 14
A. General .................................................................... 14
B.When to Choose a P.D. Pump................................ 15
C.Major Types of P.D. Pumps.................................... 22
1. Sliding Vane Pump ........................................... 24
2. Sinusoidal Rotor Pump .................................... 25
3. Flexible Impeller Pump ................................... 25
4. Flexible Tube (Peristaltic) Pump..................... 26
5. Progressing Cavity Pump ................................ 27
6. External Gear Pump ........................................ 29
7. Internal Gear Pump ......................................... 33
8. Rotary Lobe Pump............................................ 33
9. Circumferential Piston and Bi-Wing
Lobe Pumps....................................................... 35
10. Multiple-Screw Pump....................................... 36
11. Piston Pump...................................................... 38
12. Plunger Pump ................................................... 40
13. Diaphragm Pump ............................................. 41
14. Miniature Positive Displacement Pumps ....... 47
2 Hydraulics, Selection, and Curves .......................51
I. Overview ....................................................................... 51
II. Pump Capacity ............................................................. 54
III. Head .............................................................................. 54
A. Static Head ............................................................. 56
B. Friction Head.......................................................... 58
C.Pressure Head ........................................................ 66
D. Velocity Head .......................................................... 70
IV. Performance Curve....................................................... 71
V.Horsepower and Efficiency .......................................... 80
A. Hydraulic Losses .................................................... 82
B. Volumetric Losses................................................... 82
C.Mechanical Losses .................................................. 83
D.Disk Friction Losses............................................... 83
VI. NPSH and Cavitation .................................................. 89
A. Cavitation and NPSH Defined .............................. 89
1. NPSHa............................................................... 98
2. NPSHr................................................................ 99
B.Calculating NPSHa
: Examples ............................ 101
C.Remedies for Cavitation ...................................... 102
D.More NPSHaExamples........................................ 106
E. Safe Margin NPSHa vs. NPSHr........................... 109
F. NPSH for Reciprocating Pumps.......................... 114
VII. Specific Speed and Suction Specific Speed............... 116
VIII. Affinity Laws .............................................................. 122
IX. System Head Curves.................................................. 127
X. Parallel Operation ...................................................... 139
XI. Series Operation......................................................... 146
XII. Oversizing Pumps ...................................................... 152
XIII. Pump Speed Selection................................................ 155
A. Suction Specific Speed ......................................... 156
B.Shape of Pump Performance Curves .................. 156
C.Maximum Attainable Efficiency.......................... 157
D.Speeds Offered by Manufacturers....................... 158
E. Prior Experience ................................................... 159
3 Special Hydraulic Considerations......................161
I. Overview ..................................................................... 161
II. Viscosity ...................................................................... 162
III. Software to Size Pumps and Systems ...................... 185
A. General .................................................................. 185
B. Value of Piping Design Software......................... 186
C.Evaluating Fluid Flow Software ......................... 186
D.Building the System Model ................................. 187
1. Copy Command............................................... 189
2. Customize Symbols......................................... 190
3. CAD Drawing Features.................................. 190
4. Naming Items ................................................. 190
5. Displaying Results.......................................... 190
6. The Look of the Piping Schematic ................ 191
E. Calculating the System Operation...................... 191
1. Sizing Pipe Lines............................................ 192
2. Calculating Speed........................................... 192
3. Showing Problem Areas ................................. 192
4. Equipment Selection ...................................... 192
5. Alternate System Operational Modes........... 193
F. Communicating the Results ................................ 193
1. Viewing Results within the Program............ 193
2. Incorporating User-Defined Limits ............... 194
3. Selecting the Results to Display ................... 194
4. Plotting the Piping Schematic....................... 194
5. Exporting the Results .................................... 194
6. Sharing Results with Others......................... 195
7. Sharing Results Using a Viewer Program ... 195
G.Conclusion............................................................. 195
H. List of Software Vendors...................................... 196
IV. Piping Layout ............................................................. 196
V.Sump Design............................................................... 200
VI. Field Testing ............................................................... 203
A. General .................................................................. 203
B.Measuring Flow.................................................... 205
1. Magnetic Flowmeter....................................... 205
2. Mass Flowmeter ............................................. 205
3. Nozzle .............................................................. 205
4. Orifice Plate .................................................... 206
5. Paddle Wheel .................................................. 206
6. Pitot Tube........................................................ 206
7. Segmental Wedge............................................ 207
8. Turbine Meter................................................. 207
9. Ultrasonic Flowmeter..................................... 207
10. Venturi............................................................. 208
11. Volumetric Measurement............................... 208
12. Vortex Flowmeter ........................................... 208
C.Measuring TH....................................................... 209
D.Measuring Power.................................................. 211
E. Measuring NPSH ................................................. 212
4 Centrifugal Pump Types and Applications......213
I. Overview ..................................................................... 213
II. Impellers ..................................................................... 215
A. Open vs. Closed Impellers ................................... 215
B.Single vs. Double Suction .................................... 223
C.Suction Specific Speed ......................................... 225
D.Axial Thrust and Thrust Balancing.................... 227
E. Filing Impeller Vane Tips .................................... 230
F. Solids Handling Impellers ................................... 232
III. End Suction Pumps.................................................... 233
A. Close-Coupled Pumps........................................... 233
B. Frame-Mounted Pumps ....................................... 237
IV. Inline Pumps .............................................................. 240
V.Self-Priming Centrifugal Pumps............................... 242
VI. Split Case Double Suction Pumps ............................ 245
VII. Multi-Stage Pumps .................................................... 250
A. General .................................................................. 250
B.Axially Split Case Pumps .................................... 250
C.Radially Split Case Pumps.................................. 254
VIII. Vertical Column Pumps ............................................. 256
IX. Submersible Pumps.................................................... 260
X. Slurry Pumps.............................................................. 264
© 2005 by Taylor & Francis Group, LLC
Contents xxv
XI. Vertical Turbine Pumps............................................. 268
XII. Axial Flow Pumps ...................................................... 277
XIII. Regenerative Turbine Pumps.................................... 278
XIV. Pump Specifications and Standards ......................... 279
A. General .................................................................. 279
1. Liquid Properties............................................ 280
2. Hydraulic Conditions ..................................... 280
3. Installation Details......................................... 281
B.ANSI ...................................................................... 282
C.API......................................................................... 284
D.ISO......................................................................... 286
XV. Couplings .................................................................... 287
XVI. Electric Motors ........................................................... 291
A. Glossary of Frequently Occurring Motor
Terms..................................................................... 294
1. Amps................................................................ 294
2. Code Letter ..................................................... 295
3. Design Letter .................................................. 295
4. Efficiency ......................................................... 296
5. Frame Size ...................................................... 296
6. Frequency........................................................ 296
7. Full Load Speed.............................................. 297
8. High Inertial Load.......................................... 297
9. Insulation Class.............................................. 297
10. Load Types ...................................................... 297
11. Phase ............................................................... 298
12. Poles................................................................. 298
13. Power Factor ................................................... 298
14. Service Factor ................................................. 298
15. Slip................................................................... 299
16. Synchronous Speed......................................... 299
17. Temperature.................................................... 299
18. Time Rating .................................................... 300
19. Voltage ............................................................. 300
B.Motor Enclosures.................................................. 300
1. Open Drip Proof.............................................. 300
2. Totally Enclosed Fan Cooled.......................... 301
3. Totally Enclosed Air Over.............................. 301
4. Totally Enclosed Non-Ventilated ................... 301
5. Hazardous Location........................................ 302
C.Service Factor ....................................................... 302
D.Insulation Classes ................................................ 303
E. Motor Frame Size................................................. 303
1. Historical Perspective..................................... 303
2. Rerating and Temperature ............................ 307
3. Motor Frame Dimensions .............................. 307
4. Fractional Horsepower Motors ...................... 307
5. Integral Horsepower Motors.......................... 312
6. Frame Designation Variations....................... 312
F. Single Phase Motors............................................. 314
G.Motors Operating on Variable Frequency
Drives .................................................................... 319
H. NEMA Locked Rotor Code................................... 321
I. Amps, Watts, Power Factor, and Efficiency ........ 322
1. Introduction .................................................... 322
2. Power Factor ................................................... 322
3. Efficiency ......................................................... 323
4. Amperes........................................................... 325
5. Summary ......................................................... 325
5 Sealing Systems and Sealless Pumps ................327
I. Overview ..................................................................... 327
II. O-Rings........................................................................ 328
A. What Is an O-Ring?.............................................. 328
B.Basic Principals of the O-Ring Seal.................... 329
C.The Function of the O-Ring................................. 329
D.Static and Dynamic O-Ring Sealing
Applications .......................................................... 330
E. Other Common O-Ring Seal Configurations...... 330
F. Limitations of O-Ring Use................................... 333
III. Stuffing Box and Packing Assembly ......................... 333
A. Stuffing Box .......................................................... 334
B.Stuffing Box Bushing ........................................... 334
C. Packing Rings ....................................................... 335
D. Packing Gland....................................................... 336
E. Lantern Ring......................................................... 337
IV. Mechanical Seals ........................................................ 338
A. Mechanical Seal Advantages ............................... 338
1. Lower Mechanical Losses .............................. 338
2. Less Sleeve Wear ............................................ 338
3. Zero or Minimal Leakage............................... 338
4. Reduced Maintenance .................................... 339
5. Seal Higher Pressures.................................... 339
B.How Mechanical Seals Work ............................... 339
C.Types of Mechanical Seals................................... 343
1. Single, Inside Seals ........................................ 343
2. Single, Outside Seals...................................... 345
3. Single, Balanced Seals ................................... 346
4. Double Seals ................................................... 347
5. Tandem Seals.................................................. 349
6. Gas Lubricated Non-Contacting Seals.......... 351
V.Sealless Pumps........................................................... 352
A. General .................................................................. 352
B.Magnetic Drive Pumps ........................................ 354
1. Bearings in the Pumped Liquid .................... 357
2. Dry Running ................................................... 358
3. Inefficiency ...................................................... 358
4. Temperature.................................................... 358
5. Viscosity .......................................................... 359
C.Canned Motor Pumps .......................................... 359
1. Fewer Bearings ............................................... 360
2. More Compact................................................. 361
3. Double Containment ...................................... 361
4. Lower First Cost............................................. 361
6 Energy Conservation and Life-Cycle Costs .....363
I. Overview ..................................................................... 363
II. Choosing the Most Efficient Pump ........................... 364
III. Operating with Minimal Energy............................... 372
IV. Variable-Speed Pumping Systems ............................ 373
V.Pump Life-Cycle Costs............................................... 395
A. Improving Pump System Performance:
An Overlooked Opportunity?............................... 395
B.What Is Life-Cycle Cost? ..................................... 397
C.Why Should Organizations Care about
Life-Cycle Cost? .................................................... 397
D.Getting Started..................................................... 399
E. Life Cycle Cost Analysis ...................................... 399
1. Cic — Initial Investment Costs...................... 401
2. Cin
— Installation and Commissioning
(Start-up) Costs .............................................. 402
3. Ce— Energy Costs ......................................... 403
4. Co— Operation Costs..................................... 404
5. Cm— Maintenance and Repair Costs........... 404
6. Cs
— Downtime and Loss of Production
Costs ................................................................ 406
7. Cenv
— Environmental Costs, Including Disposal
of Parts and Contamination
from Pumped Liquid ...................................... 407
8. Cd
— Decommissioning/Disposal Costs,
Including Restoration of the Local
Environment ................................................... 407
F. Total Life-Cycle Costs .......................................... 408
G.Pumping System Design...................................... 408
H. Methods for Analyzing Existing Pumping
Systems ................................................................. 413
I. Example: Pumping System with a Problem
Control Valve ........................................................ 414
J. For More Information........................................... 419
1. About the Hydraulic Institute ....................... 419
2. About Europump ............................................ 419
3. About the U.S. Department of Energy’s
Office of Industrial Technologies ................... 421
7 Special Pump-Related Topics ..............................423
I. Overview ..................................................................... 423
II. Variable-Speed Systems............................................. 424
III. Sealless Pumps........................................................... 425
IV. Corrosion..................................................................... 426
1. Galvanic, or Two-Metal Corrosion................. 428
2. Uniform, or General Corrosion...................... 429
3. Pitting Corrosion ............................................ 430
4. ................................. 430
5. Erosion Corrosion ........................................... 431
6. Stress Corrosion ............................................. 431
7. Crevice Corrosion ........................................... 432
8. Graphitization or Dezincification
Corrosion ......................................................... 432
V.Nonmetallic Pumps .................................................... 432
VI. Materials Used for O-Rings in Pumps ..................... 435
A. General .................................................................. 435
B.Eight Basic O-Ring Elastomers .......................... 437
1. Nitrile (Buna N) ............................................. 437
2. Neoprene ......................................................... 437
3. Ethylene Propylene ........................................ 438
4. Fluorocarbon (Viton) ...................................... 438
5. Butyl ................................................................ 439
6. Polyacrylate..................................................... 439
7. Silicone ............................................................ 439
8. Fluorosilicone .................................................. 440
VII. High-Speed Pumps..................................................... 441
VIII. Bearings and Bearing Lubrication ........................... 446
IX. Precision Alignment Techniques ............................... 447
X. Software to Size Pumps and Systems ...................... 449
8 Installation, Operation, and Maintenance .......451
I. Overview ..................................................................... 451
II. Installation, Alignment, and Start-Up ..................... 452
A. General .................................................................. 452
B.Installation Checklist........................................... 453
1. Tag and Lock Out ........................................... 453
2. Check Impeller Setting .................................. 453
3. Install Packing or Seal................................... 453
4. Mount Bedplate, Pump, and Motor............... 454
5. Check Rough Alignment ................................ 454
6. Place Grout in Bedplate................................. 454
7. Check Alignment ............................................ 456
8. Flush System Piping ...................................... 457
9. Connect Piping to Pump ................................ 457
10. Check Alignment ............................................ 459
11. Turn Pump by Hand ...................................... 459
12. Wire and Jog Motor........................................ 459
13. Connect Coupling ........................................... 459
14. Check Shaft Runout ....................................... 460
15. Check Valve and Vent Positions .................... 460
16. Check Lubrication/Cooling Systems.............. 460
17. Prime Pump if Necessary .............................. 460
18. Check Alignment ............................................ 461
19. Check System Components Downstream..... 461
20. Start and Run Pump...................................... 462
21. Stop Pump and Check Alignment ................. 462
22. Drill and Dowel Pump to Base...................... 462
23. Run Benchmark Tests .................................... 462
III. Operation .................................................................... 462
A. General .................................................................. 462
B.Minimum Flow ..................................................... 463
1. Temperature Rise ........................................... 464
2. Radial Bearing Loads..................................... 465
3. Axial Thrust .................................................... 465
4. Prerotation ...................................................... 465
5. Recirculation and Separation ........................ 466
6. Settling of Solids............................................. 468
7. Noise and Vibration........................................ 468
8. Power Savings, Motor Load ........................... 468
C. Ten Ways to Prevent Low Flow Damage
in Pumps ............................................................... 468
1. Continuous Bypass ......................................... 470
2. Multi-Component Control Valve System ...... 471
3. Variable Frequency Drive .............................. 472
4. Automatic Recirculation Valve ...................... 473
5. Relief Valve ..................................................... 473
6. Pressure Sensor .............................................. 475
7. Ammeter.......................................................... 475
8. Power Monitor ................................................ 475
9. Vibration Sensor ............................................. 476
10. Temperature Sensor ....................................... 476
IV. Maintenance ............................................................... 477
A. Regular Maintenance ........................................... 477
1. Lubrication...................................................... 477
2. Packing ............................................................ 478
3. Seals ................................................................ 479
B.Preventive Maintenance ...................................... 479
1. Regular Lubrication ....................................... 480
2. Rechecking Alignment.................................... 480
3. Rebalance Rotating Element ......................... 480
4. Monitoring Benchmarks................................. 480
C.Benchmarks .......................................................... 480
1. Hydraulic Performance .................................. 480
2. Temperature.................................................... 481
3. Vibration.......................................................... 482
V.Troubleshooting .......................................................... 489
VI. Repair.......................................................................... 489
A. General .................................................................. 489
B.Repair Tips............................................................ 492
1. Document the Disassembly ........................... 492
2. Analyze Disassembled Pump......................... 492
3. Bearing Replacement ..................................... 493
4. Wear Ring Replacement................................. 494
5. Guidelines for Fits and Clearances............... 495
6. Always Replace Consumables........................ 495
7. Balance Impellers and Couplings ................. 495
8. Check Runout of Assembled Pump ............... 496
9. Tag Lubrication Status .................................. 497
10. Cover Openings Prior to Shipment............... 497

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EBOOK - Đặc điểm và ứng dụng của bơm (Michael Volk) - 548 Trang.

Thankfully, the laws of physics have not changed since the first edition of this book was written in 1996. Therefore, virtually everything about pump selection, sizing, system analysis, and other aspects of pump hydraulics remains unchanged from the first edition. There have, however, been a number of innovations in the world of pumps, which are introduced in this second edition. This edition also expands the material on many components of typical pump installations that were only briefly covered in the first edition, if at all.


CONTENTS:

1 Introduction to Pumps ..............................................1
I. What Is a Pump?............................................................ 1
II. Why Increase a Liquid’s Pressure?............................... 2
III. Pressure and Head......................................................... 3
IV. Classification of Pumps.................................................. 5
A. Principle of Energy Addition ................................... 5
1. Kinetic ................................................................. 5
2. Positive Displacement ........................................ 5
B.How Energy Addition Is Accomplished .................. 7
C.Geometry Used ......................................................... 7
V.How Centrifugal Pumps Work ...................................... 7
VI. Positive Displacement Pumps ..................................... 14
A. General .................................................................... 14
B.When to Choose a P.D. Pump................................ 15
C.Major Types of P.D. Pumps.................................... 22
1. Sliding Vane Pump ........................................... 24
2. Sinusoidal Rotor Pump .................................... 25
3. Flexible Impeller Pump ................................... 25
4. Flexible Tube (Peristaltic) Pump..................... 26
5. Progressing Cavity Pump ................................ 27
6. External Gear Pump ........................................ 29
7. Internal Gear Pump ......................................... 33
8. Rotary Lobe Pump............................................ 33
9. Circumferential Piston and Bi-Wing
Lobe Pumps....................................................... 35
10. Multiple-Screw Pump....................................... 36
11. Piston Pump...................................................... 38
12. Plunger Pump ................................................... 40
13. Diaphragm Pump ............................................. 41
14. Miniature Positive Displacement Pumps ....... 47
2 Hydraulics, Selection, and Curves .......................51
I. Overview ....................................................................... 51
II. Pump Capacity ............................................................. 54
III. Head .............................................................................. 54
A. Static Head ............................................................. 56
B. Friction Head.......................................................... 58
C.Pressure Head ........................................................ 66
D. Velocity Head .......................................................... 70
IV. Performance Curve....................................................... 71
V.Horsepower and Efficiency .......................................... 80
A. Hydraulic Losses .................................................... 82
B. Volumetric Losses................................................... 82
C.Mechanical Losses .................................................. 83
D.Disk Friction Losses............................................... 83
VI. NPSH and Cavitation .................................................. 89
A. Cavitation and NPSH Defined .............................. 89
1. NPSHa............................................................... 98
2. NPSHr................................................................ 99
B.Calculating NPSHa
: Examples ............................ 101
C.Remedies for Cavitation ...................................... 102
D.More NPSHaExamples........................................ 106
E. Safe Margin NPSHa vs. NPSHr........................... 109
F. NPSH for Reciprocating Pumps.......................... 114
VII. Specific Speed and Suction Specific Speed............... 116
VIII. Affinity Laws .............................................................. 122
IX. System Head Curves.................................................. 127
X. Parallel Operation ...................................................... 139
XI. Series Operation......................................................... 146
XII. Oversizing Pumps ...................................................... 152
XIII. Pump Speed Selection................................................ 155
A. Suction Specific Speed ......................................... 156
B.Shape of Pump Performance Curves .................. 156
C.Maximum Attainable Efficiency.......................... 157
D.Speeds Offered by Manufacturers....................... 158
E. Prior Experience ................................................... 159
3 Special Hydraulic Considerations......................161
I. Overview ..................................................................... 161
II. Viscosity ...................................................................... 162
III. Software to Size Pumps and Systems ...................... 185
A. General .................................................................. 185
B. Value of Piping Design Software......................... 186
C.Evaluating Fluid Flow Software ......................... 186
D.Building the System Model ................................. 187
1. Copy Command............................................... 189
2. Customize Symbols......................................... 190
3. CAD Drawing Features.................................. 190
4. Naming Items ................................................. 190
5. Displaying Results.......................................... 190
6. The Look of the Piping Schematic ................ 191
E. Calculating the System Operation...................... 191
1. Sizing Pipe Lines............................................ 192
2. Calculating Speed........................................... 192
3. Showing Problem Areas ................................. 192
4. Equipment Selection ...................................... 192
5. Alternate System Operational Modes........... 193
F. Communicating the Results ................................ 193
1. Viewing Results within the Program............ 193
2. Incorporating User-Defined Limits ............... 194
3. Selecting the Results to Display ................... 194
4. Plotting the Piping Schematic....................... 194
5. Exporting the Results .................................... 194
6. Sharing Results with Others......................... 195
7. Sharing Results Using a Viewer Program ... 195
G.Conclusion............................................................. 195
H. List of Software Vendors...................................... 196
IV. Piping Layout ............................................................. 196
V.Sump Design............................................................... 200
VI. Field Testing ............................................................... 203
A. General .................................................................. 203
B.Measuring Flow.................................................... 205
1. Magnetic Flowmeter....................................... 205
2. Mass Flowmeter ............................................. 205
3. Nozzle .............................................................. 205
4. Orifice Plate .................................................... 206
5. Paddle Wheel .................................................. 206
6. Pitot Tube........................................................ 206
7. Segmental Wedge............................................ 207
8. Turbine Meter................................................. 207
9. Ultrasonic Flowmeter..................................... 207
10. Venturi............................................................. 208
11. Volumetric Measurement............................... 208
12. Vortex Flowmeter ........................................... 208
C.Measuring TH....................................................... 209
D.Measuring Power.................................................. 211
E. Measuring NPSH ................................................. 212
4 Centrifugal Pump Types and Applications......213
I. Overview ..................................................................... 213
II. Impellers ..................................................................... 215
A. Open vs. Closed Impellers ................................... 215
B.Single vs. Double Suction .................................... 223
C.Suction Specific Speed ......................................... 225
D.Axial Thrust and Thrust Balancing.................... 227
E. Filing Impeller Vane Tips .................................... 230
F. Solids Handling Impellers ................................... 232
III. End Suction Pumps.................................................... 233
A. Close-Coupled Pumps........................................... 233
B. Frame-Mounted Pumps ....................................... 237
IV. Inline Pumps .............................................................. 240
V.Self-Priming Centrifugal Pumps............................... 242
VI. Split Case Double Suction Pumps ............................ 245
VII. Multi-Stage Pumps .................................................... 250
A. General .................................................................. 250
B.Axially Split Case Pumps .................................... 250
C.Radially Split Case Pumps.................................. 254
VIII. Vertical Column Pumps ............................................. 256
IX. Submersible Pumps.................................................... 260
X. Slurry Pumps.............................................................. 264
© 2005 by Taylor & Francis Group, LLC
Contents xxv
XI. Vertical Turbine Pumps............................................. 268
XII. Axial Flow Pumps ...................................................... 277
XIII. Regenerative Turbine Pumps.................................... 278
XIV. Pump Specifications and Standards ......................... 279
A. General .................................................................. 279
1. Liquid Properties............................................ 280
2. Hydraulic Conditions ..................................... 280
3. Installation Details......................................... 281
B.ANSI ...................................................................... 282
C.API......................................................................... 284
D.ISO......................................................................... 286
XV. Couplings .................................................................... 287
XVI. Electric Motors ........................................................... 291
A. Glossary of Frequently Occurring Motor
Terms..................................................................... 294
1. Amps................................................................ 294
2. Code Letter ..................................................... 295
3. Design Letter .................................................. 295
4. Efficiency ......................................................... 296
5. Frame Size ...................................................... 296
6. Frequency........................................................ 296
7. Full Load Speed.............................................. 297
8. High Inertial Load.......................................... 297
9. Insulation Class.............................................. 297
10. Load Types ...................................................... 297
11. Phase ............................................................... 298
12. Poles................................................................. 298
13. Power Factor ................................................... 298
14. Service Factor ................................................. 298
15. Slip................................................................... 299
16. Synchronous Speed......................................... 299
17. Temperature.................................................... 299
18. Time Rating .................................................... 300
19. Voltage ............................................................. 300
B.Motor Enclosures.................................................. 300
1. Open Drip Proof.............................................. 300
2. Totally Enclosed Fan Cooled.......................... 301
3. Totally Enclosed Air Over.............................. 301
4. Totally Enclosed Non-Ventilated ................... 301
5. Hazardous Location........................................ 302
C.Service Factor ....................................................... 302
D.Insulation Classes ................................................ 303
E. Motor Frame Size................................................. 303
1. Historical Perspective..................................... 303
2. Rerating and Temperature ............................ 307
3. Motor Frame Dimensions .............................. 307
4. Fractional Horsepower Motors ...................... 307
5. Integral Horsepower Motors.......................... 312
6. Frame Designation Variations....................... 312
F. Single Phase Motors............................................. 314
G.Motors Operating on Variable Frequency
Drives .................................................................... 319
H. NEMA Locked Rotor Code................................... 321
I. Amps, Watts, Power Factor, and Efficiency ........ 322
1. Introduction .................................................... 322
2. Power Factor ................................................... 322
3. Efficiency ......................................................... 323
4. Amperes........................................................... 325
5. Summary ......................................................... 325
5 Sealing Systems and Sealless Pumps ................327
I. Overview ..................................................................... 327
II. O-Rings........................................................................ 328
A. What Is an O-Ring?.............................................. 328
B.Basic Principals of the O-Ring Seal.................... 329
C.The Function of the O-Ring................................. 329
D.Static and Dynamic O-Ring Sealing
Applications .......................................................... 330
E. Other Common O-Ring Seal Configurations...... 330
F. Limitations of O-Ring Use................................... 333
III. Stuffing Box and Packing Assembly ......................... 333
A. Stuffing Box .......................................................... 334
B.Stuffing Box Bushing ........................................... 334
C. Packing Rings ....................................................... 335
D. Packing Gland....................................................... 336
E. Lantern Ring......................................................... 337
IV. Mechanical Seals ........................................................ 338
A. Mechanical Seal Advantages ............................... 338
1. Lower Mechanical Losses .............................. 338
2. Less Sleeve Wear ............................................ 338
3. Zero or Minimal Leakage............................... 338
4. Reduced Maintenance .................................... 339
5. Seal Higher Pressures.................................... 339
B.How Mechanical Seals Work ............................... 339
C.Types of Mechanical Seals................................... 343
1. Single, Inside Seals ........................................ 343
2. Single, Outside Seals...................................... 345
3. Single, Balanced Seals ................................... 346
4. Double Seals ................................................... 347
5. Tandem Seals.................................................. 349
6. Gas Lubricated Non-Contacting Seals.......... 351
V.Sealless Pumps........................................................... 352
A. General .................................................................. 352
B.Magnetic Drive Pumps ........................................ 354
1. Bearings in the Pumped Liquid .................... 357
2. Dry Running ................................................... 358
3. Inefficiency ...................................................... 358
4. Temperature.................................................... 358
5. Viscosity .......................................................... 359
C.Canned Motor Pumps .......................................... 359
1. Fewer Bearings ............................................... 360
2. More Compact................................................. 361
3. Double Containment ...................................... 361
4. Lower First Cost............................................. 361
6 Energy Conservation and Life-Cycle Costs .....363
I. Overview ..................................................................... 363
II. Choosing the Most Efficient Pump ........................... 364
III. Operating with Minimal Energy............................... 372
IV. Variable-Speed Pumping Systems ............................ 373
V.Pump Life-Cycle Costs............................................... 395
A. Improving Pump System Performance:
An Overlooked Opportunity?............................... 395
B.What Is Life-Cycle Cost? ..................................... 397
C.Why Should Organizations Care about
Life-Cycle Cost? .................................................... 397
D.Getting Started..................................................... 399
E. Life Cycle Cost Analysis ...................................... 399
1. Cic — Initial Investment Costs...................... 401
2. Cin
— Installation and Commissioning
(Start-up) Costs .............................................. 402
3. Ce— Energy Costs ......................................... 403
4. Co— Operation Costs..................................... 404
5. Cm— Maintenance and Repair Costs........... 404
6. Cs
— Downtime and Loss of Production
Costs ................................................................ 406
7. Cenv
— Environmental Costs, Including Disposal
of Parts and Contamination
from Pumped Liquid ...................................... 407
8. Cd
— Decommissioning/Disposal Costs,
Including Restoration of the Local
Environment ................................................... 407
F. Total Life-Cycle Costs .......................................... 408
G.Pumping System Design...................................... 408
H. Methods for Analyzing Existing Pumping
Systems ................................................................. 413
I. Example: Pumping System with a Problem
Control Valve ........................................................ 414
J. For More Information........................................... 419
1. About the Hydraulic Institute ....................... 419
2. About Europump ............................................ 419
3. About the U.S. Department of Energy’s
Office of Industrial Technologies ................... 421
7 Special Pump-Related Topics ..............................423
I. Overview ..................................................................... 423
II. Variable-Speed Systems............................................. 424
III. Sealless Pumps........................................................... 425
IV. Corrosion..................................................................... 426
1. Galvanic, or Two-Metal Corrosion................. 428
2. Uniform, or General Corrosion...................... 429
3. Pitting Corrosion ............................................ 430
4. ................................. 430
5. Erosion Corrosion ........................................... 431
6. Stress Corrosion ............................................. 431
7. Crevice Corrosion ........................................... 432
8. Graphitization or Dezincification
Corrosion ......................................................... 432
V.Nonmetallic Pumps .................................................... 432
VI. Materials Used for O-Rings in Pumps ..................... 435
A. General .................................................................. 435
B.Eight Basic O-Ring Elastomers .......................... 437
1. Nitrile (Buna N) ............................................. 437
2. Neoprene ......................................................... 437
3. Ethylene Propylene ........................................ 438
4. Fluorocarbon (Viton) ...................................... 438
5. Butyl ................................................................ 439
6. Polyacrylate..................................................... 439
7. Silicone ............................................................ 439
8. Fluorosilicone .................................................. 440
VII. High-Speed Pumps..................................................... 441
VIII. Bearings and Bearing Lubrication ........................... 446
IX. Precision Alignment Techniques ............................... 447
X. Software to Size Pumps and Systems ...................... 449
8 Installation, Operation, and Maintenance .......451
I. Overview ..................................................................... 451
II. Installation, Alignment, and Start-Up ..................... 452
A. General .................................................................. 452
B.Installation Checklist........................................... 453
1. Tag and Lock Out ........................................... 453
2. Check Impeller Setting .................................. 453
3. Install Packing or Seal................................... 453
4. Mount Bedplate, Pump, and Motor............... 454
5. Check Rough Alignment ................................ 454
6. Place Grout in Bedplate................................. 454
7. Check Alignment ............................................ 456
8. Flush System Piping ...................................... 457
9. Connect Piping to Pump ................................ 457
10. Check Alignment ............................................ 459
11. Turn Pump by Hand ...................................... 459
12. Wire and Jog Motor........................................ 459
13. Connect Coupling ........................................... 459
14. Check Shaft Runout ....................................... 460
15. Check Valve and Vent Positions .................... 460
16. Check Lubrication/Cooling Systems.............. 460
17. Prime Pump if Necessary .............................. 460
18. Check Alignment ............................................ 461
19. Check System Components Downstream..... 461
20. Start and Run Pump...................................... 462
21. Stop Pump and Check Alignment ................. 462
22. Drill and Dowel Pump to Base...................... 462
23. Run Benchmark Tests .................................... 462
III. Operation .................................................................... 462
A. General .................................................................. 462
B.Minimum Flow ..................................................... 463
1. Temperature Rise ........................................... 464
2. Radial Bearing Loads..................................... 465
3. Axial Thrust .................................................... 465
4. Prerotation ...................................................... 465
5. Recirculation and Separation ........................ 466
6. Settling of Solids............................................. 468
7. Noise and Vibration........................................ 468
8. Power Savings, Motor Load ........................... 468
C. Ten Ways to Prevent Low Flow Damage
in Pumps ............................................................... 468
1. Continuous Bypass ......................................... 470
2. Multi-Component Control Valve System ...... 471
3. Variable Frequency Drive .............................. 472
4. Automatic Recirculation Valve ...................... 473
5. Relief Valve ..................................................... 473
6. Pressure Sensor .............................................. 475
7. Ammeter.......................................................... 475
8. Power Monitor ................................................ 475
9. Vibration Sensor ............................................. 476
10. Temperature Sensor ....................................... 476
IV. Maintenance ............................................................... 477
A. Regular Maintenance ........................................... 477
1. Lubrication...................................................... 477
2. Packing ............................................................ 478
3. Seals ................................................................ 479
B.Preventive Maintenance ...................................... 479
1. Regular Lubrication ....................................... 480
2. Rechecking Alignment.................................... 480
3. Rebalance Rotating Element ......................... 480
4. Monitoring Benchmarks................................. 480
C.Benchmarks .......................................................... 480
1. Hydraulic Performance .................................. 480
2. Temperature.................................................... 481
3. Vibration.......................................................... 482
V.Troubleshooting .......................................................... 489
VI. Repair.......................................................................... 489
A. General .................................................................. 489
B.Repair Tips............................................................ 492
1. Document the Disassembly ........................... 492
2. Analyze Disassembled Pump......................... 492
3. Bearing Replacement ..................................... 493
4. Wear Ring Replacement................................. 494
5. Guidelines for Fits and Clearances............... 495
6. Always Replace Consumables........................ 495
7. Balance Impellers and Couplings ................. 495
8. Check Runout of Assembled Pump ............... 496
9. Tag Lubrication Status .................................. 497
10. Cover Openings Prior to Shipment............... 497

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