ASHRAEQATARORYXCHAPTER

TechnicalSeminar
UnderstandingPumps
Sizing,SelectionandApplications
Presentedby:AdonisLayyous
Date:Dec.10,2011

Part1 PumpTerminology
1.
2.
3.
4.
55.
6.

PumpFlowRate
P
PumpTotalHead
T lH d
HydraulicHPandBreakHP
SystemEfficiency/Power
Cavitation
NPSH

Part2 IntroductiontoPumps
1.
2.
3.
4.
5.
6.

PumpClassification
PumpTypes
PumpDNA
PumpApplications
UnderstandingPumpCurves
PumpSelections

Part3UnderstandingPackagedPumpStations
1.
2.

p
TraditionalSiteBuiltPumpStations
PackagedPumpStations

BriefDescription
Applications

3.

BenefitsofUsingPackagedPumpStations

4.

ConstantSpeedPumpStations

TotheOwner
TotheEngineer
TotheContractor
T h C

RealityofSystemDemand
T i lS t C
TypicalSystemComponents
t
SystemLimitations
EnergyConservationMethods

Part3UnderstandingPackagedPumpStations
5.

VariableSpeedSystems

TypicalSystemComponents
NormalSystemOperation
TruePowerofAffinityLaws
HowSystemSavesEnergy
P
PowerConsumptionComparison
C
ti C
i

Part4 PumpAccessories
1.
2.
3.
4.

MotorClassifications
MotorDesign
MotorApplication
Couplings,guards,gauges

Part1
PumpTerminology

P
PumpFlowRate
Fl
R t
Capacity Becauseliquidsareessentiallyincompressible,thereisadirect
relationshipbetweenthecapacityinapipeandthevelocityofflow.
Q=AxVORV=Q
A
Where
Q=capacityingpm
V=VelocityofflowinFt/Sec
A=AreaofpipeorconduitinSq.Ft.
PumpFlow Thepumpflowrateistypicallyacalculatedfigureofthetotal
demandofabuildingtakingintoconsiderationallofthefixtureunits.It
isexpressedasaunitofvolumeperincrementoftime.TheUSunitsis
GPM.OtherunitsofflowincludeLit/Sec,M3/Hr,IGPM.

P
PumpTotalHead
T t lH d
TotalDynamicSuctionLift (Hl) Isthestaticsuctionliftminusthevelocity
headatthepumpsuctionflangeplusthetotalfrictionheadinthesuction
line.
line
TotalDynamicSuctionHead(Hs) Isthestaticsuctionheadplusthevelocity
headatthepumpsuctionminusthetotalfrictionheadinthesuction
line.
TotalDynamicDischargeHead(Hd) Isthestaticdischargeheadplusthe
velocityheadatthepumpdischargeflangeplusthetotalfrictionheadin
thedischargeline.
TotalHeadorformerlyTDH(H) Isthetotaldynamicdischargeheadminusthe
totaldynamicsuctionheadorplusthetotaldynamicsuctionlift.
HorTDH=Hd+Hs(withasuctionlift)
HorTDH=Hd Hs(withasuctionhead)

P
PumpTotalHead
T t lH d
WithSuctionLift
TDH=Hd+Hs
(Hst+Hf)+(Hl+Hf)
WithSuctionHead
TDH=Hd Hs
(Hst+Hf)+(HsuHf)
Note:Keepinmindthatthefrictionheadincludesallfrictionlossesinpipesand
plusanyequipmentpressuredrop(P),suchasvalves,strainers, heat
exchangers,etc

P
PumpTotalHead
T t lH d

P
PumpTotalHead
T t lH d
Keepinmindthatfrictionlossesthroughpipesandfittingscanbeobtaineddirectly
fromtablesinseveralpublications,includingHIstandards.
f
bl i
l bli i
i l di HI
d d

H d li HP d B k HP
HydraulicHPandBreakHP
Horsepower=Workperformedinpumping
Theworkperformedinpumpingaliquiddependsontheweightoftheliquidbeing
handledinagiventimeagainstthetotalhead(infeetofliquid)ordifferential
h dl di i ti i tth t t lh d(i f t fli id) diff
ti l
pressure(inpsi)beingdevelopedanditsS.G..
SinceoneHPequals33,000ftlbperminute,thetheoreticalHP(usuallycalledthe
q
33
p
y
hydraulicHP)willequal:
HydHP=LbofLiquid/minxH(ft)
33,000
H
However,theengineeringcommunitytypicallyusepumpcapacityinGPMandthe
th
i
i
it t i ll

it i GPM dth
liquidS.G.ratherthantheactualweightoftheliquidpumped.Ifwedothisthe
hydraulicHPorpumpoutput(Whp)istheliquidHPdeliveredbythepump.Itis
definedbythefollowingformula:
Whp=Q(gpm)xH(ft)xS.G.
h
(
)
(f )
3960
Note: Theconstant3960isobtainedbydividingthenumberoffootpoundsforone
HP(33,000)bytheweightofonegallonofwater(8.33pounds).
(33,
) y
g
g
( 33 p
)

H d li HP d B k HP
HydraulicHPandBreakHP
BreakHPorpumpinputHP(Bhp)istheactualHPdeliveredtothepumpshaft.It
isexpressedbythefollowingformula:
Bhp=Q(gpm)xH(ft)xS.G.
3960xPumpEff.
ThebreakHPorinputtoapumpisgreaterthanhydraulicHPoroutputduethe
mechanicalandhydrauliclossesdevelopedinsidethepump.Therefore,
th
thepumpefficiencyistheratioofthesetwovalues:
ffi i
i th ti fth t l
PumpEff.=output =Whp
i
inputBhp
tBh

S t
SystemEfficiency
Effi i
InputHPisthegeneraltermusedtoindicatethepowerrequiredatthecontrol
panel.ItisthepumpBhpdividedbythemotorefficiency.Itisexpressed
inthefollowingformula:
i h f ll i f
l
ElectricalHPInputtoMotor=Bhp
orKW Input=Bhpx0.746
M
MotorEff.MotorEff.
Eff M
Eff
FieldEfficiencyorOverallEfficiency=WaterHP orPumpEff.XMotorEff.
BHP
OverallPlantEfficiency* =Whp
I
InputHP
HP
*Overallplantefficiencyissometimesreferredtoaswiretowaterefficiency.

C it ti
Cavitation
Cavitationisaphenomenonofvaporbubblescollapsingastheygofrom
lowpressuretohighpressureregioninsidethepump.Thesebubbles
areformedwhenliquidenterstheimpellereyeandencountersa
suddendecreaseinpressure,whichinturncausesanincreaseinthe
liquidtemperature.Ifthevaporpressurefallsbelowthe
correspondingliquidtemperature,pocketsofvaporwillbecreated.
di li id

k f
illb
d
Topreventcavitation,donotselectpumps:
1.
Onthelefthandsideofthecurve(lessthan20%offlowatBEP).
2. Ontherighthandsideofthecurve(nomorethan85%ofthe
maximumflowattheendofthecurve).
)
3. NPSHashouldalwaysbelargerthanNPSHr.
4. Speedshigherthanthemanufacturersrecommendation.

NPSH
TheNetPositiveSuctionHeadisthetotalsuctionheadinfeetofliquid
beingpumpedlesstheabsolutevaporpressure(infeet)oftheliquid
beingpumped,lessthefrictionlosses.NPSHhastwovaluesthatmust
b i
d l th f i ti l
NPSHh t l th t
t
alwaysbeconsidered:NPSHrandNPSHa.
NPSHr=Netpositivesuctionheadrequired
NPSHr
Netpositivesuctionheadrequired bythepump.Itisafunctionof
bythepump Itisafunctionof
thepumpdesign.Itisacalculatedfigurebythepumpmanufacturer
typicallyshownonthepumpcurve.

NPSHa=Netpositivesuctionheadavailable isafunctionofthesystem.In
p
practicalterms,itistheenergyavailableattheimpellereye.Itisa
,
gy
p
y
calculatedfigureforanysystembasedonthefollowingformula:

NPSH
NPSHa=HaHvp Hf/+Hstwhere
Ha=Absolutepressure(infeet)onthesurfaceoftheliquidsupplylevel.In
caseofanopentank,thisisusuallybarometricpressureatsealevel.In
aclosedtank,itistheabsolutepressure.Atsealevel,itis14.5psi.
l d k i i h b l
A l l i i
i
Hvp=Theheadinfeetcorrespondingtothevaporpressureoftheliquidat
thepumpedtemperature.Inanopentank,thisvalueisalwayszero.
H t St ti h i hti f t fth f li idl lf
Hst=Staticheightinfeetofthefreeliquidlevelfromthesupplysource.
th
l

Thevalueisaplusiftheliquidisabovethepumpandaminusifitis
belowthepump.
Hf=Allsuctionlinelosses(infeet)includingfrictionlossesinpipes
Hf=Allsuctionlinelosses(infeet)includingfrictionlossesinpipes,
fittingsandequipment.
Note:NPSHamustalwaysbegreaterthanNPSHrbyatleast1m.

NPSH E
NPSHExamples
l
Example1:waterat68F,Hst=10Ft,Ha=33.96,Hf=2.92Ft
Hvp=0.783Ft
Ha=14.696psiax2.31=33.96Ftabs.
Hf=frictionthroughsuctionpipe=2.92Ft
Hvp=vaporpressureofwaterat68F=0.339psiax2.31=0.783Ftabs.
NPSHa=33.96 0.783 10 2.92=20.26Ft
SuctionLift=10+2.92=12.92
Thi h ldb dd d h di h
Thisshouldbeaddedtothedischarge
Headtoobtaintotalhead.

NPSH E
NPSHExamples
l
Example2:waterat68F,Hst=10Ft,Ha=33.96,Hf=2.92Ft
Hvp=0.783Ft
Ha=14.696psiax2.31=33.96Ftabs.
Hf=frictionthroughsuctionpipe=2.92Ft
Hvp=vaporpressureofwaterat68F=0.339psiax2.31=0.783Ftabs.
NPSHa=33.96 0.783+10 2.92=40.26Ft
SuctionHead=10 2.92=7.08Ft
Thi h ldb b
Thisshouldbesubtractedfromthe
df
h
DischargeHeadtoobtainTotalHead.

NPSH E
NPSHExamples
l
Example3:waterat212F,Hst=10Ft,Ha=35.38,Hf=2.92Ft
Inthiscase,wehaveavaporpressuretoconsider.Vaporpressure
ofwaterinfeetat212Fis(14.96psix144/59.81=35.38
NPSHa=35.38 35.38+10 2.92=7.08Ft
InthiscaseatmosphericpressuredoesnotaddtoNPSHasince
Itisrequiredtokeepthewaterinliquid
phase.
SuctionHead=10
S
i H d 2.92=7.08Ft
8F
Thisshouldbesubtractedfromthe
DischargeheadtoobtainTotalHead.

NPSH E
NPSHExamples
l
Example4:waterat350F,Hst=10Ft,Hvp=348.67Ft,Hf=2.92Ft
Inthiscase,wehaveavaporpressuretoconsider.Vaporpressure
ofwaterinfeetat350Fis(134.6psiax2.31/0.89)=348.67
NPSHa=348.67 348.67+10 2.92=7.08Ft
SuctionHead
Assumethegaugepressurereadingis
119psig=(119x2.31/0.89)=308.8Ft
SuctionHead=308.8+102.92=315.8Ft
Thi i b b
Thisistobesubtractedfromthedisch.
df
h di h
HeadtoobtainTotalHead.Itisimportant
tonotethatwhiletheSuctionHeadis
35
315.8Ft,theNPSHaisstillonly7.08Ft
,
y7

Part2
IntroductiontoPumps

PumpClassifications
P
Cl ifi ti
CentrifugalPumps
CentrifugalPumpsutilizecentrifugalforcetotransferliquid
C t if
lP
tili t if
lf
t t
f li id
frompointAtopointB.Theamountofheadthatapump
candeliverislimitedtotheimpellerdiameter.UOM=
H d(f t t B )
Head(feet,meters,Bar)

PositiveDisplacement
PDPumpsworkagainstsystemresistance.Theydelivera
certainvolumeperrevolutionagainstvariablesystem
pressure.Thedischargemustalwayshaveareliefvalve.
Th di h

l
h li f l
UOM=Pressure(PSI,Bar)

P
PumpClassifications
Cl ifi ti
ExamplesofPumpTypes
CentrifugalPumps
Endsuction,splitcase,VMS,Verticalturbine,Inline,
Submersiblesewage,selfpriming,horizontalmultistage,
g
p
g
g
etc

PositiveDisplacement
P
i i Di l
Gear,vane,piston,airoperateddiaphragm,rotarylobe,
peristaltic,screw,progressingcavity,metering,etc

P
PumpTypes
T
EndSuctionPumps
Alsoknownasradiallysplitcasepumps.Twobasictypes:
Alsoknownasradiallysplitcasepumps Twobasictypes:
Closecoupled
Framemounted
Closecoupledpumpsaresonamedbecausethepumppartsaremounted
directlyonthemotorshaft.Becauseofthat,thereisalimitonthesize
ofthesepumps.Theyaremainlyusedinareaswherespacecomesata
f h
Th i l di
h

premium.Theyaretypicallyselectedforsmallflowlowhead
applications.

P
PumpTypes
T

P
PumpTypes
T
EndSuctionPumps
Framemountedpumpshavethesameliquidendasaclosecoupledpump
withtheadditionofabearingframe.Theyareavailableinlargersizes
withhigherflowsandheads.Mostmanufacturersofferpumpswith
backpulloutdesigntofacilitatemaintenance.

P
PumpTypes
T

P
PumpTypes
T
HorizontalSplitCasePumps
Thesepumpsarealsoknownasaxiallysplitcasepumps.Theyare
commonlyreferredtoasinbetweenbearingdesign.Theyaremainly
usedforlargeflowandrelativelylargeheadapplications.These
pumpsarethebesthorizontalpumpsavailableinthemarketoffering
longtroublefreelife.Theyarealsoveryeasytomaintain.

P
PumpTypes
T

P
PumpTypes
T
VerticalMultistagePumps
Thesepumpsaremainlyusedforlowflowhighheadapplicationsorwhere
spacesavingisapriority.ThestampedSSpumpsarethemost
commontypeofpumpsoldinthemarketplace.However,thisdesign
isnotveryruggedasthesepumpstendtobethrowawaypumps.Cast
pumpsarepreferredastheyhavealongerlifeandcanbeeasily
repaired.

P
PumpTypes
T

P
PumpTypes
T
VerticalTurbinePumps
Thesepumpsaremainlyusedformediumandhighflowathighhead
applications.Theyarethebestdesignedmostflexibleverticalpump
availableinthemarket.Theyaremadefromvarietyofmaterialsand
configurationstosuitalmostanyapplication.
Avariationofthispumpisthesubmersiblewellpump.Thispumphasthe
samebowlassemblyasalineshaftpump,butusesasubmersible
b l
bl li h f
b
b
ibl
motorasthedriver.

P
PumpTypes
T

P
PumpTypes
T

P
PumpTypes
T

P
PumpTypes
T
SubmersibleSewagePumps
Thesepumpsaremainlyusedtopumpwastewaterwheretheyhavetopass
solids.Theyareavailableinavarietyofdesignstosuitmany
applications.Theyareusuallyinstalledwithaquickdisconnect
couplingtofacilitatemaintenance.Theyareavailableindifferent
materialsofconstructiontosuitvariousapplications.

P
PumpTypes
T

P
PumpDNA
DNA
Pumpsaremadeupofseveralcomponentswitheachofthesecomponents
havingaspecificfunction:

Casing
Casingwearring
Impeller
Shaft
Sh f l
Shaftsleeve
Mechanicalsealorpacking
Bearings
Bearinghousing

P
PumpApplications
A li ti
PumpsareusedwheneveryouneedtotransferanyliquidfrompointAtoa
higherpointB.Pumpsarethesecondmostcommonlyusedrotating
equipmentaftermotors.Theyareusedonthousandsofapplications.
Belowisalistofcommonapplications:

C
CentrifugalPumps
if
lP
HVAC condenserwater,chilledwater,coolingtowermakeup
Plumbing
g Hotwater,drainage,condensatereturn,boilerfeed,fuelfeed
,
g ,
,
,
GeneralService Coolingtower,booster,rawwaterintake,plantservice
water,firefighting,filterfeed
Industrial hundredsofprocessapplicationsinsidetheplant
Industrial
Wastewater grinder,liftstations,sewagetransfer
TurfIrrigation golfcourses,parks,cropirrigation

P
PumpApplication
A li ti
PositiveDisplacementPumps
PDPumpsareusedtopumpviscousfluids.Thereforemostoftheir
applicationsareinindustrialandfoodsectors.
FoodIndustry
PharmaceuticalPlants
W
WastewaterTreatmentPlants
T
Pl
Pulp&Paper
PetrochemicalPlants

U d t di P
UnderstandingPumpCurves
C
Whatinformationistypicallyfoundonapumpcurve:

Flowandhead

Efficiency

NPSHr

BHP
Arethereotherthingsthatwecanlearnfromapumpcurve?

U d t di P
UnderstandingPumpCurves
C

U d t di P
UnderstandingPumpCurves
C

S t
SystemCurve
C
Asystemcurverepresentstheheadrequiredtomovefluidthroughthe
systematvariousflowrates.
Intheabsenceofcontrolfeatures,thesystemwillalwaysoperateatthe
intersectionofthesystemcurveandthepumpcurve.Theheadin
atypicalsystemismadeupoftwocomponents:

Static
Friction

S t
SystemCurve
C

R
RequiredPumpData
i dP
D t
The first step in selecting a pump for a particular application is to
decide what type of pump to use. The following selection criteria
need to be considered:
1.
Application
2.
Space requirements
4. Life Expectancy
3.
Power source
5. Budget
After deciding on what type of pump to use, we can begin the
selection process. For any application, the following information
must be known to properly select a pump:
1
1.
Flow (GPM or L/S
L/S, M3/Hr)
7.
7 Materials of
construction
2.
TDH (FT, M, KPa)
8. Motor data
3.
Fluid name and temperature
4.
Pump
p speed
p
5.
S.G. and viscosity
6.
Horizontal or vertical installation

I
ImproperPumpSelection
P
S l ti
WARNING

P
ProperPumpSelection
P
S l ti
Example 1: Water Transfer application
Select an end suction frame mounted pump to
deliver 56M3/Hr of clean water at 42M TDH.
Maximum allowable speed is 3000RPM.
NPSHa=6M. Water temperature 150 F.
Suction source: above ground tank
Look at the curves on the next slide. Which pump
would you select? Why?

P
ProperPumpSelection
P
S l ti

P
ProperPumpSelection
P
S l ti
Select Pump Model F825A, because it is higher in efficiency, is
closer to BEP and will require a smaller size motor
motor.
BHP = 56 (4.4) X 42 (3.28) X 1.0 = 11.47
3960 X 0.747

or 8.56kw

Max. non-overloading power = 14.23hp or 10.62 kw

Motor size = 15hp (11.2kw), 2900RPM
NPSHr = 3.46 M less than NPSHa = 6M

P
ProperPumpSelection
P
S l ti
Example 2: Water Booster Application
Select a horizontal split case pump to deliver 2000GPM of clean
water at 350FT Head. Maximum allowable speed is
1500RPM. NPSHa=24Ft. Water temperature 150 F. Suction
pressure is 20psi
First thing we need to do is determine the pump TDH. We have
20psi of positive suction pressure aiding the pump
pump. 20psi x
2.31 = 46.2Ft
So, pump head = 350 46 = 304Ft
Select pump to deliver 2000GPM at 304Ft

Whatotherthingscanwelearnfromreadingpump
curves?????

Theshapeofthepumpcurve(flatorsteep)isimportant
forcertainapplications
Wecanvisuallyseehowthepumpcurveinteractswith
thesystemcurve
Diagnosepumpproblemsinthefield
Seehowflow/headchangesonVFDapplications
Determinetheshutoffpressurewhichisimportantfor
componentselectionandsystemdiagnosis

Part3
UnderstandingPackagedPump
g
g
p
Stations

1.
2.
3.

4.

TraditionalSiteBuiltPumpStations
PackagedPumpStations

BriefDescription
Applications

BenefitsofUsingPackagedPumpStations

TotheOwner
TotheEngineer
TotheContractor

ConstantSpeedPumpStations

RealityofSystemDemand
yp
y
C p
TypicalSystemComponents
SystemLimitations
EnergyConservationMethods

5.

VariableSpeedSystems

TypicalSystemComponents
NormalSystemOperation
TruePowerofAffinityLaws
H S t S
HowSystemSavesEnergy
E
PowerConsumptionComparison

1 T diti
1.TraditionalSiteBuiltPumpStations
l Sit B ilt P
St ti

Thechallengeofprojectmanagement.
Mustissuepurchaseordersforallequipment.
Contractorresponsibleforintegrationofall
equipment.
i
Anydelaytoanycomponentwillaffecttheproject
timeline.
timeline
Lastminutefailureofequipment.
Fingerpointingwhenequipmentfails
Fingerpointingwhenequipmentfails.
Differentwarrantyfordifferentequipment.

2 P k dP
2.PackagedPumpStations
St ti
p
BriefDescription
Apackagedpumpstationincludesallthe
p
g p p
componentsofatraditionalsitebuiltstation.
Thisincludespumps,valves,pipes,controlsand
instrumentationallmountedononeskidand
testedasacompletestationbeforeitleavesthe
factory.
factor

2 P k dP
2.PackagedPumpStations
St ti
Applications
Packagedpumpstationsareusedonalotof
applications.
Plumbing
l bi
HVAC
Firefighting
Fi fi hti
Industrial
Irrigation
Municipal

3 B
3.BenefitsofUsingPackagedPumpStations
fit f U i P k d P
St ti

ToEngineer
Assistancewithsystemdesign,specreview
Designoptimizationbetweenmechanicaland
electricalcomponents
2Dor3Dlayoutdrawings
Highestpossiblesystemefficiency
g
p
y
y
Completesystemtestingtodesigncriteria
Singlesourceresponsibility
Completesupportfromdesigntostartup
l
f
d
Integrationofotherequipmentonpumpskid

3 B
3.BenefitsofUsingPackagedPumpStations
fit f U i P k d P
St ti
ToContractor

Completeunitresponsibilitybysystem
manufacturer
Completepretestedsystem nosurprisesatsite
Minimalinstallationtime minimizesfieldlabor
Minimalinstallationtime
costs
OneP/Oforentiresystem
Onewarrantyforentiresystem
f
Timelyprojectcompletion

3 B
3.BenefitsofUsingPackagedPumpStations
fit f U i P k d P
St ti
ToOwner

Completeunitresponsibilitybysystem
manufacturer
Completepretestedsystem nosurprisesatsite
Onewarrantyforentiresystem
y
y
Timelyprojectcompletion
Highestpossiblesystemefficiency lowest
operatingcost
ti t
Minimizefloorspaceinmechanicalroom

4 C t tS
4.ConstantSpeedPackagedPumpStations
dP k dP
St ti
TypicalSystemComponents
Pumps endsuction,VMS,Inline,splitcase,VTP
Motors ODPorTEFC
IsolatingValves Butterfly,Ball,Gate
PRVwithbuiltincheckvalve
Instrumentation
Instrumentation Pressuregauge,pressureswitch,
Pressuregauge pressureswitch
pressuretransmitter,flowmeter,etc
ControlPanel Housesallelectricalcomponents
p
Piping branchpipingandheaders
Skid

C t tS
ConstantSpeedPackagedPumpStations
dP k dP
St ti

4 C t tS
4.ConstantSpeedPackagedPumpStations
dP k dP
St ti
y
y
RealityofSystemDemand
80/20%Rule
Generallyspeaking,80%ofthetimethesystemdemand
y p
g
y
flowisat20%orlessofthedesignflowcapacity.

4 C t tS
4.ConstantSpeedPackagedPumpStations
dP k dP
St ti
SystemOperation
Thesystemusesamechanicalmeanstoreducethe
dischargepressure.Inthesesystems,thepump
g p
y
,
p p
operatesat100%ofthedesignmotorspeedallthe
time.Sincethepumpimpellerdiameterandspeed
areconstant,thesystemrequireshydraulically
y
q
y
y
controlledmechanicalforcestoholdbackpump
pressureregardlessofwhereitisoperatingalongits
performancecurvetomaintainaconstant
downstreampressure.

4 C t tS
4.ConstantSpeedPackagedPumpStations
dP k dP
St ti
SystemOperation
ThePRVisthemechanicaldevicethatregulatesthe
pressure.ThejobofthePRVistoadjustits
pressuredroptomatchtheoverpumped
pressureoftheconstantspeedpumpatagiven
pointonitsdemandcurve ThePRVwouldbe
pointonitsdemandcurve.ThePRVwouldbe
throttlednearlyclosed80%ofthetimeforcing
thevalvetoaddsignificantfrictionhead,whichis
dissipatedasheatloss.
dissipatedasheatloss

4 C t tS
4.ConstantSpeedPackagedPumpStations
dP k dP
St ti

4 C t tS
4.ConstantSpeedPackagedPumpStations
dP k dP
St ti
g
EnergyConservationMethods

1.
2.
3.

UseaJockeyPump forsmallloads
PressureSwitchSequencing
q
g 20/40/40%or
4 4
33/66/100%
BladderTank Leakloadsandpumpshort
p p
cycling

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
TypicalSystemComponents
Pumps
P
endsuction,VMS,Inline,splitcase,VTP
d
i VMS I li li
VTP
Motors ODPorTEFC
IsolatingValves
g
Butterfly,Ball,Gate
y
Silentcheckvalve
Instrumentation Pressuregauge,pressureswitch,
p
pressuretransmitter,flowmeter,etc
,
,
Variablefrequencydrives
ControlPanel Housesallelectricalcomponents
Piping
Piping branchpipingandheaders
Skid

V i bl S
VariableSpeedPackagedPumpStations
dP k dP
St ti

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
y
p
SystemOperation
Thissystemtypicallyusesavariablefrequencydrive
y
yp
y
q
y
tovarythespeedofthemotorwhichwillinturn
varythepumpspeed,therebychangingtheflow
andpressureofthepump.Takingthesignalfrom
d
f h
k
h
lf
apressureorflowtransmitter,theVFDrampsthe
speedofthemotorupordowntoconstantly meet
thebuildingdemand.

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
TheAffinityLaws
Withimpellerdiameterheldconstant:
Law#1:Q1 =N1
Q
Q2N2
Law#2:H1 =(N1)
H2(N2)
Law#3:Bhp1 =(N1)
Bhp2(N2)
WhereQ=capacity,H=head,N=speed

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
TruePowerofAffinityLaws
Law#1:Doublingthepumpspeedwillbasicallydoubletheflow.
Law#2:Thepumppressurechangestothesquareofthespeed.(i.e.When
p pp
g
q
p
(
thespeedisdoubled,theheadincreasesby4times)
Law#3:Thepumppowerconsumptionchangestothecubeofthespeed.
(i e Whenthespeedisdoubled thepowerconsumptionincreasesby
(i.e.Whenthespeedisdoubled,thepowerconsumptionincreasesby
8times)
Example:Assumea10%reductioninspeed,thisequatesto0.9=0.73.This
p
p
q
9
73
meansthatwithonly10%speedreduction,youcanachieve27%
reductioninpowerconsumption.Similarly,with20%speedreduction,
youcanachievealmost50%reductioninpowerconsumption.

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
HowVFDSystemSavesEnergy
1. PressureVariation#1:Whencalculatingplumbing
systemloads,FRICTIONLOSSESarecalculatedatthe
FULLsystemflowdemand
FULLsystemflowdemand.
2. PressureVariation#2:Whencalculatingsystem
pressuredemand,WORSTCASECONDITIONistaken
forsuctionpressure.
3. PressureVariation#3:Asthepumprisestowardshutoff
andawayfromsystemdesignpoint thepumppressure
andawayfromsystemdesignpoint,thepumppressure
generallyincreases.

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
PowerConsumption ConstantSpeed

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
PowerConsumption VariableSpeed

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
ReasonstoUseVFDSystems
1.
2.

3
3.

Electronicreductionofpressurereducesvalvenoise
duetovelocityacrossanearlyclosedPRVseat.
y
y
Bearingradialloadsaresignificantlyreducedsince
pumpreducesitsspeedasitapproachesshutoff.
Thesehydraulicloadscontributesignificantlytopre
Thesehydraulicloadscontributesignificantlytopre
maturebearingfailureduetoheat,stressand
vibration.
Avariablespeedsystemcanmorecloselyfollowthe
buildingloadprofile,applyingonlyasmuchenergy
asrequiredforanygivendutycondition.

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
ReasonstoUseVFDSystems
4.
5.
6.

HighmaintenancebladdertanksandPRVscanbe
eliminated.
PIDfirmwarecontrolineachdriveallowsamore
accuratemeansofpressurecontrolwhichisnot
subjecttotamperinginthefield.
VFDsoffersoftstartingcapabilities.Thisreduces
thermalandmechanicalstressesonwindingsand
couplings.
couplings

5 V i bl S
5.VariableSpeedPackagedPumpStations
dP k dP
St ti
WhereShouldweUseVFDSystems
1.
2.
3.
4.

Whenwehavevariablesystemdemand(eitherflow
orpressure)
p
)
Whenwehavevariablesuctionpressure
Whenenergysavingsisatapremium
Wh th illb f t d
Whentherewillbefuturedemandchanges
d h

P
ProperSystemSelection
S t
S l ti
SystemDesignRequirements
1.
2
2.
3.
4.
55.

Calculateflowandboostpressure
Understandwhataretheoverallselectioncriteriaforthe
system/equipment
Selectthetypeofpumpthatbestmeetsthehydraulicsas
wellasdesigncriteria
ll d i it i
Decideonnumberofpumpstouseandpumpsplit
Decideonhowthesystemwillinterfacewithother
y
equipment

P
ProperSystemSelection
S t
S l ti
WhatissystemBoostPressure?
Itisthedifferencebetweenthedesiredsystempressureand
suctionpressure.
p
Theattacheddatasheetwillhelpillustratethis.

ISO 9001

Part4
PumpAccessories

P
PumpAccessories
A
i
Couplings
Couplingsareusedtoconnectthedriver
shafttothepumpshaft.The
couplingwillallowforsomeslight
misalignment Therearevarious
misalignment.Therearevarious
typesofcouplings.Themost
commonbeingtheflexibleor
elastomericcoupling.
Othercouplingtypesinclude:

Gear
Di
Disc
Fluid

P
PumpAccessories
A
i
FlexibleCouplings
Flexibleorelastomericcouplingsare
usedonmostpumpapplications.
Therearetwogeneralcategories;
spacerandnon spacercouplings
spacerandnonspacercouplings.
Spacercouplingsalloweasier
disassemblyofpumpsandmotors
whenmaintenanceisrequired.
Thecouplingismadeupof2
components;theflangesand
elsatomericinsert.

E
ExamplesofShaftMisalignment
l fSh ftMi li
t
Torsionalmisalignment

Angularmisalignment

Parallelmisalignment

Axialmisalignment
g

P
PumpAccessories
A
i
PressureGauges
Pressuregaugescomeintwogeneralcategories:
Compoundgauges readvacuumaswellaspositivepressure.Theyare
typicallyusedonthesuctionsideofpumps.
yp
y
p p
Standardgauges comeinstandardincrementsanywherefrom30psito
5000psiandhigher.Thefacedisplaycanreadanypressureunit(psi,
b
bar,Kpa,etc)

)
Therearetwocommonsizesofgauges,2.5and4.5.Thecaseisusuallyair
filledorglycerinfilled Glycerinfilledgaugesaremorerobust They
filledorglycerinfilled.Glycerinfilledgaugesaremorerobust.They
aretypicallyusedinapplicationswherethereisalotofvibrationand
stress.

P
PumpAccessories
A
i
PressureGaugeExamples

INTRODUCTIONTO
MOTORS

M t Cl ifi ti
MotorClassifications
Therearemanydifferentwaystoclassifymotors.Themostcommonones
areby:

Installation horizontalorvertical.
Design synchronous,induction,capacitor
Design
synchronous induction capacitor
Enclosure ODP,TEFC,Xproof
Standards NEMA,IEC

M t D i
MotorDesign
Installation Horizontal
Themostcommonmotorsarehorizontalfootmounteddesign.Thereareseveral
typesoffereddistinguishedbytheirshaftextension.Thisisthemeansby
whichthemotorshaftiscoupledtothedrivenmachinery.Examplesinclude
Tframe,JM/JP,Cface.
Thesemotorscanbeinstalledverticallywithlittlemodification.

Installation Vertical
Thetwomostcommonverticalmotorsareverticalsolidshaft(VSS)andvertical
hollowshaft(VHS).VSSmotorshaveashaftextensionsimilartoahorizontal
motor.VHShaveahollowtubealongthecenterlineofthemotor.Thepump
h d h f ill h
headshaftwillgothroughthehollowcenterandissecuredatthetopofthe
h h h ll
di
d h f h
motorbyaspecialcoupling.Thesemotorsarespeciallydesignedtoabsorb
thehighthrustgeneratedbyverticalpumps.

M t D i
MotorDesign
Enclosure
g
p
Enclosuredefinesthemotorconstructionaccordingtoenvironmentalprotection
andmethodofcooling.Themostcommontypesare:
ODP(OpenDripProof) IP44
Th
Theconstructionoftheventilationopeningsallowsuccessfuloperationeven
t ti fth til ti
i ll
f l
ti

whendropsofliquidandsolidparticlesstrikeorentertheenclosureatany
anglefrom0to15degreesdownwardfromvertical.Mostcommonforindoor
use.
WP1(WeatherProtectedType1) Vertical
Thisclassificationistypicallyusedonverticalmotors.Ventilationpassages
aresoconstructedtominimizetheentranceofrain snoworairborne
aresoconstructedtominimizetheentranceofrain,snoworairborne
particlestotheelectricparts.

M t D i
MotorDesign
Enclosure
WPII(WeatherProtectedTypeII)
InadditiontotheenclosureinWPI,theventilatingpassagesatbothintake
anddischargearesoarrangedthathighvelocityairandairborneparticles
blownintothemotorbyhighwindscanbedischargedwithoutenteringthe
internalventilationpassagesleadingdirectlytotheelectricalparts.
TEFC(TotallyEnclosedFanCooled) IP54
Anenclosedmotorthatpreventsthefreeexchangeofairbetweentheinside
andoutsideofthemotor,butnotconsideredairtight.Coolingoccursviaa
fanintegralwiththemotorbutexternaltotheenclosingparts.Usedmostly
foroutdoorapplicationsandinlocationswhicharedirty dampandoily
foroutdoorapplicationsandinlocationswhicharedirty,dampandoily.

M t D i
MotorDesign
Enclosure
ExplosionProof ATEX
Atotallyenclosedmotordesignedtowithstandaninternalexplosionof
specifiedgasesorvaporsandnotallowtheinternalflameorexplosionto
escape Themotordegreeofprotectionisselectedbasedontheenvironment
escape.Themotordegreeofprotectionisselectedbasedontheenvironment
wherethemotorwilloperate.
SevereDuty
Atotallyenclosedmotorwithextraprotectiontoresistentryof
contaminants.Thismotoristypicallyusedinextradry,damporothernon
hazardousenvironments.

M t D i
MotorDesign
Insulation
Insulationisusuallyclassifiedbymaximumallowableoperatingtemperaturesas
definedperU.L.Itisthecombinationofambienttemperatureplus
temperaturerise.
ClassA 105C(221F)
ClassB 130C(266F)
ClassF 155C(311F)
55
3
ClassH 180C(356F)
Note:StandardmotordesigninUSAusesclassFinsulationwith40C
Ambienttemperature.
Ambienttemperature

M t D i
MotorDesign
Speed
Itisimportanttodistinguishbetweensynchronousspeed,nominalspeedand
actualfullloadspeed.
Synchronousspeed
S
nchronousspeed isthetheoreticalmaximumspeedatwhichaninductiontype
isthetheoreticalma imumspeedat hichaninduction t pe
motorcanoperate.Itiscalculatedbythefollowingformula.
Syn.RPM=PowersupplyHzx120
y
pp y
No.ofPoles
Nominalspeed isthespeedachievedbythemotorwhenoperatingunderratedHP
conditions Thiswillalwaysbelessthanthesynchronousspeedandwillvary
conditions.Thiswillalwaysbelessthanthesynchronousspeedandwillvary
dependingontheratingandcharacteristicsoftheparticularmotor.The
nominalspeediswhatisusuallyshownonthemotornameplate.

M t D i
MotorDesign
Speed
Theactualmotorspeed willbeclosetothenominalspeed.Itisuniquetothat
motordesign.
Example:a4polefractionalhorsepowermotorwillhaveasynchronousspeedof
E
ample a4 polefractionalhorsepo ermotor illha eas nchronousspeedof
1800RPM,anominalspeedshownonthenameplateof1725RPMandan
actualfullloadspeedrangingfrom1715to1745RPM.
Typicalsynchronousspeeds:
50HZ
60HZ
2pole3000rpm3600rpm
4 pole1500rpm1800rpm
4pole1500rpm1800rpm
6pole1000rpm1200rpm

M t D i
MotorDesign
ServiceFactor
Ameasureofthereservemarginbuiltintoamotor.Forexample,motorsratedat
1.15S.F.haveasafetymarginof15%.Theyareusedwhereunusualconditions
arelikelytooccur,likehighorlowvoltage,momentaryoverloads,etc
Note:Motorsaredesignedtooperatesuccessfullywherethevoltagevariationdoes
notexceed/+10%nominalvoltage,orwherefrequencydoesnotfluctuate
morethan/+5%.Thesumofvoltageandfrequencyvariationshouldnot
5
g
q
y
exceed10%.

M t D i
MotorDesign
MotorEfficiency
Motorefficiencyistheratiobetweentheshaftoutputpowerandtheelectricalinput
power.
IfpoweroutputismeasuredinWatt(W),efficiency
p
p
( ),
y canbeexpressedas:
p
m=Pout/Pin?
where
m=motorefficiency
Pout=shaftpowerout(Watt,W)
Pin electricpowerintothemotor(Watt,W)
Pin=electricpowerintothemotor(Watt,W)
Ifpoweroutputismeasuredinhorsepower(hp),efficiency canbeexpressedas:
m=Pout746/Pin
where
Pout shaftpowerout(horsepower,hp)
Pout=shaftpowerout(horsepower,hp)
Pin=electricpowerintothemotor(Watt,W)

Note:asof1/1/2011,allmotorsusedinUSAmustbepremiumefficiency.

M t D i
MotorDesign
Torque
Torqueistheturningeffectcausedbyaforceactingnormaltoaradiusataset
distancefromtheaxisofrotation.ItcanbeexpressedinLbFt(Lbataradius
of1FT).Thefullloadtorqueofamotoris:
Full LoadTorque 2 0 HP
FullLoadTorque=5250xHP
RPM
Thetorquedevelopedbyasynchronousinductionmotorsvarieswiththespeedas
themotoracceleratesfromzerotofullspeed.
p
LockedRotororStartingTorque isthetorquethemotordevelopswhenitstarts
fromzerospeed.
PullupTorque istheminimumtorquedevelopedbyamotorwhenitrunsfrom
zerotofullloadspeed,beforeitreachesthebreakdowntorque.

M t D i
MotorDesign
Torque
BreakdownTorque isthehighesttorqueavailablebeforethetorque
decreaseswhenthemachinecontinuestoacceleratetotheworking
condition.
FullloadTorque isthetorquerequiredtoproducetheratedpowerofthe
electricalmotoratfullspeed

M t D i
MotorDesign

M t D i
MotorDesign

M t D i
MotorDesign
MotorAccessories
Athermostat,thermistororthermocouple aretemperaturesensingdevices
withexternalleadsthatareconnectedtothecontrolcircuitofthe
motorcontrollertolimittheframeorwindingtemperatureofthe
motor.
RTDsaretemperaturesensingdevicesthataretypicallyinstalledon
b i li i h
bearingstolimitthetemperatureofthemotor.
f h
SpaceHeaters areusedinareaswherethereishighhumiditytoprevent
condensationinsidethemotorwindings.
condensationinsidethemotorwindings

M t A li ti
MotorApplication
Toproperlyselectamotor,thefollowingmustbeeithercalculatedorgiven
bythedesignengineer:

Typeofmotor
Application
HPandRPM
Enclosure
Classofinsulation
Voltage,phaseandfrequency

Startingmethod
Ambienttemperature
Altitude(sitelocation)
Anyspecialaccessoriesforspecialconditions,likeheat,moisture,etc