WHAT IS MEANT BY PUMP

PRIMING???
Priming is a term used in pumps regarding
their ability to draw-in liquid at the suction/
intake line without having much difficulty (as in
using certain set-ups/ devices)
Centrifugal pumps are non-priming which is
why their suction lines necessitates the use of check
valves/ foot valves
Since there is a
continuous passageway
(even if not in operation)
of the liquid inside, no
liquid would be trapped
assuming that there is no
foot valve or that there is
damage on the foot
valve
While reciprocating
and rotary pumps due to
their internal make-up has
no continuous
passageway, that there
would only be if the pump
is actuated.
As such, liquid is
isolated thus not requiring
any foot valve for
isolation
In cases that pumps warrants such condition
(PRIMING) auxiliary priming instruments are
needed to discharge liquid properly and at the
soonest possible time.
TYPICAL AUXILIARY PRIMING METHODS:
Kinds of priming methods used in CPUMPS to
take care of priming which could use extra/
additional devices/ equipments.
APM A uses a
certain reservoir to help in
priming where the natural
effects of gravitation is
used.
APM B uses a by-
pass line coming from the
discharge line.
APM C uses an
auxiliary line to augment
those trapped in the foot/
check valve
APM D uses a
separate pump used
specifically to draw out air
from the casing
APM E uses an
ejector to draw in liquid
coming from the same
source into the casing
APM F uses a
priming tank where due to
its pressure conveys liquid
into the pump before being
diverted IN & OUT again
APM G & H uses
vacuum pumps that are
either controlled manually
or controlled automatically
for pump priming
MANUAL:
AUTOMATIC:
It is important to
note that such means of
APM also necessitates the
proper use of valves &
fittings
IS PRIMING REQUIRED ALL
THE TIME FOR CPUMPS???
YES
NO
YES.If for the first time, the C-PUMP is
to be operated
NO.If the C-PUMP has been previously
operated with the foot valve properly
working
or if the installed foot valve is
defective.
or If the C-PUMP has suction head
source or if the source is of the
flooded type
IN ALL POSSIBLE
CIRCUMSTANCES, ARE RO-
PUMPS & R-PUMPS SELF
PRIMING???
YES
NO
YES. for static lifts of only 28 ft
NO.If the static lift required is greater
than 28 ft
provided that there is no loss
pressure in the inside (no damage).
or If there is certain degree of abrasion
causing loss of pressure in the
inside
WHAT IS MEANT BY PUMP
CAVITATION???
Cavitation is a phenomena that is always
associated with CPUMPS (as well as certain VALVE
TYPES) in which there is formation of VAPOR
BUBBLES/ VAPOR POCKETS within the pump
casing
This cavitation causes a DECREASE IN
PUMP EFFICIENCY and worst PUMP FAILURE.
DETRIMENTAL EFFECTS
Cavitation begins as
the formation of vapor
bubbles at the impeller
eye due to low pressure
This formation is at the
point where the lowest
possible pressure of the
pump could be located
At the point just prior
to the liquid being acted
upon by the impeller
vanes
Cavitation begins as
the formation of vapor
bubbles at the impeller
eye due to low pressure
Rapid impeller
movement causes
compression of vapor
pockets to collapse
(IMPLOSION) sending
shockwaves inside the
casing translating into
vibration
VAPOR BUBBLE
FORMATION???
This vapor bubble formation is what we call
LIQUID VAPORIZATION where liquid vaporizes
into gas
??? ARE WE FOOLING EACH
OTHER AROUND???
Vaporization is synonymous to BOILING
which is characterized by application of HEAT
onto the substance (liquid)
CORRECT?????? INCORRECT??????
However BOILING/ VAPORIZATION OF LIQUID is not
only limited to such scenario
Water boils at 100
o
C or at 212
o
F at SEA
LEVEL or at locations slightly above.
REVIEW OF THERMODYNAMIC
CONCEPT:
FACT # 1:
At high altitude locations, boiling point of
water changes, in that they boil at a much
lower temperature.
FACT # 2:
FACT # 3:
As such it would also be quicker to cook
foods.
FACT # 3:
MISCONCEPTION:
It takes quite a longer time to cook
foods***.
There are two ways to boil a liquid.
VAPOR PRESSURE &
CAVITATION:
1. Increase the temperature of the liquid while keeping
the surrounding pressure constant***
*** rate of vaporization could be enhanced by also increasing the
pressure surrounding/ accompanying such liquid (kettles &
pressure cookers)
2. Maintain the temperature while decreasing the
pressure***
SEA LEVEL..
t
1
t
2
t
3
t
4
100
o
C/
212
o
F
P = 1 atm
Temperature increases
VAPOR PRESSURE VS. TEMPERATURE:
SEA LEVEL..
P
2
P
3
t = 90
o
C
P = 1 atm
Pressure
decreases
HIGH ALTITUDE..
P = 70.14 kPA
P
1
VAPOR PRESSURE VS. TEMPERATURE:
To make the liquid BOIL or VAPORIZE, a
vacuum source is needed
TEMPERATURE CHANGE CORRESPONDS TO A
CHANGE IN VAPOR PRESSURE
AGAIN WHAT IS MEANT BY
PUMP CAVITATION???
A phenomena where there is formation of VAPOR
BUBBLES/ VAPOR POCKETS within the CPUMP casing
This happens because the pressure (region) inside
the pump falls below the vapor pressure (saturation
pressure) of the liquid
SATURATION
PRESSURE:
Necessary pressure for liquids to
start its boiling
Necessary pressure for gases to start
its condensation
As liquid enters the
pump casing, it encounters
a decrease in pressure
As such the vapor
pressure of the liquid is
now greater than the
inside pump pressure
The liquid now starts
to vaporize emitting liquid
vapors
This liquid vapor mixes
with the other portions of
liquid translating into
BUBBLE FORMATION
1. NOISE AND VIBRATION
WHAT ARE THE SIGNS/
SYMPTOMS OF CAVITATION
2. DROP IN PUMP CAPACITY & EFFICIENCY
3. IMPELLER VANE CORROSION & PITTING
1. NOISE AND VIBRATION:
Low level cavitation in pumps are inaudible but
higher levels produce varying distinctive sounds.
And these maybe either any of the following:

1. Crackling or sizzling
2. Small steel object rapidly striking against a metal
3. Hissing, rushing, swishing, or a static like sound
similar to radio or television static.
4. Suction Cavitation can produce loud knocking,
hammering, or crackling sounds, that are distinctive
from discharge recirculation cavitation.

This noise is actually the sound produced as the
vapor bubbles collapses as they are hit by the high
speed impeller or as in the case of the hissing/
static television sound as there is no liquid sucked
by the pump
Vibration on the other hand takes place as the
vanes hit void/ empty space (collapsed vapor
bubble portion) whose empty space is suddenly
taken by the surrounding liquid
COULD THE SOUND OF
CAVITATION BE
DISTINGUISHED FROM
OTHERS???
Experienced persons may be able to diagnose
cavitation by its unique sound qualities. Cavity collapse has
specific sound qualities that distinguish cavitation from
sounds made by entrained gas bubbles, and also from the
sound of failed bearings and other machinery noises.

1. A TRAINED EAR is capable of distinguishing IF or IF
NOT.

2. Such sounds can start and stop quickly in response
to changes in flow rate.


3. Such sounds exhibit precise repeatability, the noise
is always the same under identical conditions.
.


SUPPOSEDLY THAT
ENTRAINED BUBBLES TOOK
THE PLACE OF VAPOR
BUBBLES, HOW ARE THEY
DISTINGUISHED???
Entrained gas bubbles moving through a
pump or valve, make a softer and lower frequency
sound than cavitation because of the immense
difference in energy levels...

Sound from entrained gasses changes slowly
to variations in flow rate, whereas, cavitation
sounds appear and disappear quickly in response
to small changes in flow rate, and sounds caused
by cavitation have precise repeatability
2. DROP IN CAPACITY & EFFICIENCY
With formation of vapor bubbles taking away certain
spaces/ volumes, it would translate into a dip of its
rated capacity (discharge)
A dip in its capacity (discharge) means that there is
less work/ lesser output given-off by the pump as
supposed to its rated capacity thereby resulting into a
decrease in its efficiency
3. IMPELLER VANE CORROSION & PITTING
As the vapor bubbles collapses, the surrounding
liquid rushes into that collapsed void space ACTING LIKE
A CHISEL CUTTING AWAY AT A METAL resulting in a
PITTING like manner, that of SLOWLY CHIPPING AWAY
at the impeller vanes and at certain inner portions of
the CPUMP casing
That as bubble formation and collapse ensue,
oxygen is liberated resulting into oxidation of the
invlolved parts
IMPELLER VANE CAVITATION PICTURES:
Suction cavitation
specifically damaging the
suction side of the vane and
outer vane surfaces
Such cavitation damage
would only mean that large
cavities had formed even
before it had reached the
impeller, thus damage is before
the impeller
IMPELLER VANE CAVITATION PICTURES:
Severe discharge
recirculation cavitation
specifically damaging the vane
tips and outer ends of the front
and rear shrouds
Such cavitation damage
indicates that the cavities had
formed at the impeller portion
thus damage is after passage
CASING CAVITATION PICTURES:
CASING CAVITATION PICTURES:
IF IMPELLER IS AT THE
DISADVANTAGE, HOW
COULD THEY WITHSTAND
SUCH PHENOMENA???
There are a variety of ways/ means to offset
or at least minimize the destructive effects of such
phenomena and one of them is the proper
selection of the impeller/ casing material
Metals normally have this protective layer
(oxide layer) that protects them from corrosion
Cavitation however continuously degrades
such layer thereby further exposing them to
oxidation
From then on, cavitation & corrosion work
hand in hand to continuosly remove metal from
the casing & impeller
These would
eventually lead to a wear and
tear on the part of impeller &
casing, leading to this
probable condition
No known material can withstand such
phenomena but proper material selection can result
in longer casing/ impeller life, that is why pump
construction should be properly be analyzed
In instances where pumps are not subjected
to cavitation, or not predicted to be a problem,
materials such as CAST-IRON & BRONZE can with-
stand 20 or more years of service life
The Materials listed below are in the order of
their ability to withstand the undesirable effects of
Cavitation:
1. Cast iron -- least resistance
2. Leaded Bronze
3. Cast carbon steel
4. Manganese bronze
5. Monel
6. Stainless steel
7. Cast nickel aluminum bronze
8. Titanium
9. Cast Carburized 12% Chromium Stainless,
Chrome-manganese austenitic Stainless
10. Stellite -- highest resistance
Also an innovation in technology is used, in that
SPECIAL POLYMERIC REBUILDING & COATING
MATERIALS is used
A special blend of polymeric material that
reduces friction and improving its capability against
wear and tear
This is used not only
in impellers but also for the
casing. And is applied
specifically onto damaged
portions or portions prone
to damage
WHAT ARE THE POSSIBLE
REASONS FOR PUMP
CAVITATION???
Cavitation an undesired phenomena could be
caused by any or a combination of any of the following:
1. Suction lift or Suction heads are lower than the
manufacturers required parameters
2. Speed (PRIME MOVER) is higher than the
manufacturers required parameters
3. Improper recognition of VAPOR PRESSURE/
TEMPERATURE of liquid conveyed (too high)
4. Proper NPSHA (NET POSITIVE SUCTION HEAD
AVAILABLE which is the required head at the pump
inlet (suction) to prevent cavitation from forming
C-PUMP ADVANTAGES.
1. Ability to maintain a UNIFORM FLOW
2. Small space requirement
3. Low initial cost
4. As compared to R-PUMPS, it could handle solids
laden liquids without much difficulty but cannot
compare to that of ROTARY TYPES
5. Can handle/ convey large volume flow rates
6. Foundation is much lighter
7. Application of an E-MOTOR drive is possible
C-PUMP DISADVANTAGES.
1. Being a high speed machine, it is difficult to operate at
low speeds
2. Not suitable for HIGH HEAD (TDH) requirements
3. Not suitable at low flow rates
4. It must be PRIMED before it can deliver liquids
5. Being a high-speed machine, care is ncessary for the
proper alignment of shafts
6. Difficult to regulate with wide flunctuations in loads
7. Have a lower efficiency as compared to R-PUMPS
R-PUMP ADVANTAGES.
1. Able to start without priming
2. Have higher efficiencies as compared to CPUMPS in
that they have a constant efficiency with variations
in capacity and head
3. It can pump small volumes of liquid at a desired
head
R-PUMP DISADVANTAGES.
1. Greater floor space is required
2. Higher in initial cost
3. Costly design to construct in special alloys
4. Rubbing contact is too high, so reciprocating part is
difficult to seal against leakage
5. Pulsating flow
6. Not generally suitable for dirt or abrasive laden liquids
7. Most types need protection against over pressure and
over power due to its energy impartment
Centrifugal pumps being the most
commonly used type of pump because of its
versatility and adaptability of usage requires
an experienced personnel to properly maintain
its proper workability..
They operate
non-stop and their
set-up necessitates
the use of a back-up
line should one
falter
C-PUMP TROUBLE SHOOTING GUIDE.
1. PUMP DOES NOT DELIVER WATER/ LIQUID
-- No power in prime mover
-- Suction lift is too high or suction head is too low
-- Speed is too low
-- Actual TDH is higher than computed TDH
-- Pump seizure/ damage
-- Excessive amount of air or gas in liquid at the suction
line (source)
-- Improper use of foot valve/ damaged/ clogged foot
valve
-- End of suction line insufficiently/ not submerged
at all
-- Pump is not primed at all
C-PUMP TROUBLE SHOOTING GUIDE.
2. INSUFFICIENT CAPACITY DELIVERED
-- Pump is not primed properly
-- Insufficient margin between suction pressure & vapor
pressure
-- Excessive amount of air or gas in liquid at the suction
line (source)
-- Air leaks (seeping) into suction line
-- Air leaks into the pump thru the stuffing box
-- Improper use of foot valve/ damaged/ clogged foot
valve
-- Speed is too high
-- Seal gauge improperly located in stuffing box
preventing sealing liquid entering space to form a
SEAL
C-PUMP TROUBLE SHOOTING GUIDE.
2. INSUFFICIENT CAPACITY DELIVERED
-- Viscosity of liquid different different from
design criteria
-- Wearing rings are worn
-- Impeller damage
-- Foreign matter in the impeller
-- Casing gasket is defective allowing liquid leakage
-- Packing improperly installed
-- Incorrect type of packing for operating conditions
-- Actual TDH is equal to computed TDH
C-PUMP TROUBLE SHOOTING GUIDE.
3. PUMP LOSES PRIME AFTER STARTING
-- Pump is not primed properly
-- Seal gauge improperly located in stuffing box
preventing sealing liquid entering space to form a
SEAL
-- Excessive amount of air or gas in liquid at the suction
line (source)
-- Air leaks in suction line
-- Air leaks into the pump thru the stuffing box
-- End of suction line insufficiently/ not submerged
-- Improper use of foot valve/ damaged/ clogged foot
valve
C-PUMP TROUBLE SHOOTING GUIDE.
4. STUFFING BOX LEAKS PROFUSELY
-- Seal gauge improperly located in stuffing box
-- Worn bearing
-- Shaft misalignment
-- Packing improperly installed
-- Motor rotor imbalance
-- Incorrect type of packing for operating conditions
-- Bent shaft
-- Improper bearing installation
-- Machine foundation with CPUMP set-up not rigid
-- Impeller damage
C-PUMP TROUBLE SHOOTING GUIDE.
4. STUFFING BOX LEAKS PROFUSELY
-- Dirt or grit in bypass line wearing/ scoring the
shaft/ shaft sleeve
-- Excessive thrust due to sudden surge in electricty
-- Lack of grease/ oil lubrication in oil chamber causing
bearing overheating
-- Dirt or grit in bypass line contaminating the
packing material
-- Water seeping into oil chamber
-- Bypass line to seal gauge not working
C-PUMP TROUBLE SHOOTING GUIDE.
5. PACKING HAS A SHORT LIFE THAN EXPECTED..
-- Seal gauge improperly located in stuffing box
-- Bent shaft
-- Improper bearing installation
-- Shaft misalignment
-- Machine foundation with CPUMP set-up not rigid
-- Worn bearing
-- Foreign matter in the impeller
-- Impeller damage
-- Packing improperly installed
-- Incorrect type of packing for operating conditions
C-PUMP TROUBLE SHOOTING GUIDE.
5. PACKING HAS A SHORT LIFE THAN EXPECTED..
-- Motor rotor imbalance
-- Gland is too tight
-- Bypass line to seal gauge not working
-- Dirt or grit in bypass line contaminating the
packing material
-- Excessive thrust due to sudden surge in electricty
-- Lack of grease/ oil lubrication in oil chamber causing
bearing overheating
-- Dirt accumulating in bearing
-- Water seeping into oil chamber
C-PUMP TROUBLE SHOOTING GUIDE.
6. PUMP VIBRATES OR IS TOO NOISY
-- Pump is not primed at all
-- Insufficient margin between suction pressure & vapor
pressure
-- Improper use of foot valve/ damaged/ clogged foot
valve
-- End of suction line insufficiently/ not submerged
-- Foreign matter in the impeller
-- Pump is not primed properly
-- Air leaks (seeping) into suction line
-- Air leaks into the pump thru the stuffing box
-- Shaft misalignment
-- Shaft is bent
C-PUMP TROUBLE SHOOTING GUIDE.
6. PUMP VIBRATES OR IS TOO NOISY
-- Worn bearing
-- Excessive thrust due to sudden surge in electricty
-- Motor rotor imbalance
-- Excessive grease/ oil lubrication in oil chamber
-- Lack of grease/ oil lubrication in oil chamber causing
bearing overheating
-- Shaft sleeve/ shaft worn at packing portion
-- Water seeping into oil chamber
-- Improper bearing installation
-- Machine foundation with CPUMP set-up not rigid
-- Impeller damage
-- Dirt accumulating in bearing
C-PUMP TROUBLE SHOOTING GUIDE.
7. BEARINGS HAVE SHORT LIFE
-- Machine foundation with CPUMP set-up not rigid
-- Excessive thrust due to sudden surge in electricty
-- Dirt accumulating in bearing
-- Water seeping into oil chamber
-- Lack of grease/ oil lubrication in oil chamber causing
bearing overheating
-- Shaft misalignment
-- Shaft is bent
-- Motor rotor imbalance
-- Improper bearing installation
-- Foreign matter in the impeller
-- Impeller damage
C-PUMP TROUBLE SHOOTING GUIDE.
8. PUMP OVERHEATS THEN SEIZES
-- Shaft is bent
-- Shaft misalignment
-- Pump is not primed at all
-- Worn bearing
-- Insufficient margin between suction pressure & vapor
pressure
-- Operation is at very low capacity
-- End of suction line insufficiently/ not submerged
at all
-- Foreign matter in the impeller
-- Improper bearing installation
C-PUMP TROUBLE SHOOTING GUIDE.
8. PUMP OVERHEATS THEN SEIZES
-- Motor rotor imbalance
-- Excessive thrust due to sudden surge in electricty
-- Dirt accumulating in bearing
-- Water seeping into oil chamber
-- Lack of grease/ oil lubrication in oil chamber causing
bearing overheating
-- Machine foundation with CPUMP set-up not rigid