Contents 4
3 Contents 4
Contacts
Sales and Administration
1420 Lakeview
Arlington Business Park
Theale, Reading
Berkshire RG7 4SA
Tel: +44 (0) 118 932 3123
Fax: +44 (0) 118 932 3302
Manufacturing Centre
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire GL16 8PS
Email: enquiries@spppumps.com
Tel: +44(0)1594 832701
Fax: +44(0)1594 836300
UK Service Centre Contact Directory
Western Service Centre
Tufthorn Avenue, Coleford
Gloucestershire
England GL16 8PJ
Email: enquiries@spppumps.com
Tel: +44 (0) 1594 832701
Fax: +44 (0) 1594 810043
North West Service Centre
Metrology House
Dukinfield Road
Hyde
England SK14 4PD
Email: enquiries@spppumps.com
Tel: +44 (0) 161 366 7309
Fax: +44 (0) 161 366 8849
2
Scottish Service Centre
137 Deerdykes View
Cumbernauld G68 9HN
Email: enquiries@spppumps.com
Tel: +44 (0) 1236 455035
Fax: +44 (0) 1236 455036
Southern Service Centre
Unit 1 Stanstead Road
Boyatt Wood Industrial Estate
Eastleigh, Hampshire
England SO50 4RZ
Email: enquiries@spppumps.com
Tel: +44 (0) 2380 616004
Fax: +44 (0) 2380 614522
Northern Ireland Service Centre
Unit 2 Oak Bank
Channel Commercial Park
Queens Road, Queens Island
Belfast
Northern Ireland
BT3 9DT
Email: enquiries@spppumps.com
Tel: +44 (0) 2890 469802
Fax: +44 (0) 2890 466152
For Service support outside
of office hours please call
+44 (0) 8443 759662
3 Contents 4
France
SPP Pumps
2 rue du Chateau d’eau
95450 US
France
Email: sppfrance@spppumps.com
Tel: +33 (0) 1 30 27 96 96
Fax: +33 (0) 1 34 66 07 33
North and South America
2905 Pacific Drive
Norcross
GA 30071 U.S.A.
Email: sales@spppumpsusa.com
Tel: +1(770) 409 3280
Fax: +1(770) 409 3290
www.spppumpsusa.com
South Africa
SPP Pumps (South Africa)
Cnr Horne St & Brine Ave
Chloorkop Ext 23
Kemptonpark
Gauteng
R.S.A 1619
Email: enquiries@spppumps.com
Tel: +27(0)11 393 7177 / 71792
Italy
SPP Italy
Via Watt, 13/A
20143 Milano
Email: italy@spppumps.com
Tel: +(0039) 02 58111782
Fax: +(0039) 02 58111782
Mobile: +(0039) 346 3204457
Middle East
SPP Pumps Limited (Middle East)
P O Box 61491, Jebel Ali
Dubai
United Arab Emirates
Email: enquiries@spppumps.com
Tel: +971 (0) 4 8838 733
Fax: +971 (0) 4 8838 735
Poland
Email: fire@spppumps.com
Asia
SPP Pumps Limited (Asia)
152 Beach Road
Gateway East #05 - 01 to 04
Singapore 189721
Email: asiapacific@spppumps.com
Tel: +(65) 6576 5725
Fax: +(65) 6576 5701
Netherlands
SPP Pumps Limited
Klerkenveld 7
NL-4704 SV
Roosendaal
The Netherlands
E-mail: gerrit_vruwink@spppumps.com
Tel: +31(0)165743053
3 Contents 4
3
Czech Republic
Email: czech_team@spppumps.com
Tel: +420 775 656 110
Russia
Email: russia@spppumps.com
Tel: +420 775 656 110
Parent Company
Kirloskar Brothers Limited
“YAMUNA”
Plot No 98
(3-17), Baner
411045 Pune
India
Tel: +91 20 2721 4444
www.kirloskarpumps.com
4
3 Contents 4
6
3 Contents 4
Useful Websites
USEFUL
WBSITES
Useful Websites
Trade Associations:
British Pump Manufacturers Association (BPMA)
www.bpma.org.uk
Construction Equipment Association (CEA)
www.coneq.org.uk
Fire Protection Association (FPA)
www.thefpa.co.uk
British Automatic Sprinkler Association
www.basa.org.uk
European Fire Sprinkler Network
www.eurosprinkler.org
Energy Industries Council
www.the-eic.com
Pump Centre
www.pumpcentre.com
Regulatory Authorities:
Factory Mutual (FM)
www.fmglobal.com
Underwriters Laboratories
www.ul.com
Loss Prevention Certification Board
www.brecertification.co.uk
National Fire Protection Association
www.nfpa.org
Pump Distributors Association
www.the-pda.com
Pumps-Directory
www.pumps-directory.com
3 Contents 4
5
CONTENTS
Introduction to SPP..................................8 -15
Manufacturing................................................... 9
Test Facility........................................................ 9
SPP Divisions................................................... 10
SPP International............................................. 15
Fire Protection and Approval Standards............ 16
Pump Specification & Operation...... 17 – 42
Data Required When Buying Pumps................. 19
Dimensions of Cast Iron Flanges to
BS EN 109221................................................. 21
Dimensions of Cast Iron Flanges to
ASME/ANSI B16.1............................................ 24
Dimensions of Steel Flanges to
ASME/ANSI B16.5............................................ 26
Pump Installation............................................. 28
Pump Operation............................................... 28
Faults and Remedial Action.............................. 29
Vibration Tolerance.......................................... 31
Condition Monitoring........................................ 33
Flow Estimation Methods................................. 34
Application Do’s and Don’ts............................. 39
Velocity Head Correction.................... 69 – 78
Electrical Design Data......................... 79 – 84
Average Efficiencies and Power Factors
of Electric Motors............................................. 80
Approximate Full Load Speeds (RPM)
of AC Motors.................................................... 82
Starting AC Motors........................................... 83
Whole Life Cost...................................... 85 – 90
Whole Life Cost Principles and Pump Design.... 86
Features of a Low Life-Cycle cost
centrifugal pumps............................................ 88
Energy...................................................... 91 – 94
Conversion Factors............................. 95 – 105
Conversion Factor Tables................................. 96.
Vacuum Technical Data.................................. 100.
Product / Application Charts........................... 101
Notes............................................................... 106
Hydraulic Design Data......................... 43 – 68
Pressure (bar) vs Head (m of Water)................. 44
Calculation of Head for Pump Selection............ 46
Autoprime Pumping Terms............................... 49
Friction Loss for Water
Hazen-Williams Formula, C=140)..................... 51
Resistance in Fittings....................................... 54
Quantities Passed by Pipes at
different Velocities........................................... 55
Recommended Maximum Flow
through Valves (l/s).......................................... 55
Water Discharged by Round Spray Holes in thin
walled Pipes Under Different Pressures............ 56
Net Positive Suction Head (NPSH)..................... 57
Maximum Suction Lift with Barometric Pressure
at Different Altitudes........................................ 59
Liquid Viscosity and its Effect on
Pump Performance.......................................... 60
Approximate Viscosity Conversion Schedule..... 62
Test Tolerances and Different Standards.......... 64
3 Contents 4
7
“For Where it Really Matters”
For more than 130 years SPP Pumps has been a leading manufacturer of
centrifugal pumps and associated systems. A global principal in design, supply
and servicing of pumps, pump packages and equipment for a wide range of
applications and industry sectors.
SPP pumps and systems are installed on all continents providing valuable high
integrity services for diverse industries, such as oil and gas production, water
and waste water treatment, power generation, construction, mines and for
large industrial plants.
Major applications include water treatment & supply, sewage & waste water
treatment, fire protection, and mobile pumps for rental sectors, for which
our low life cost and environmental considerations are fundamental design
priorities.
Assessed to
OHSAS 18001:2007
LPCB reg. no 111
8
3 Contents 4
MANUFACTURING
SPP requires the highest standards of manufacturing excellence from
its facilities around the world. This is crucial to the on-going growth and
development of the company. At the main manufacturing facility located in the
UK, SPP set the highest standards attainable in the industry for quality and
reliability.
SPP distinguishes its product split between pre-engineered standard products
and fully customised equipment engineered and packaged to order. The
extensive manufacturing and testing capabilities reflect this wide and diverse
product range.
To ensure efficient use of production resources, an ERP manufacturing
planning system is utilised. Assembly areas are segregated into the main
product groups; standard pumps, industrial fire pumps, contractors pumps
and engineered products. The machine shop is planned in cell layout with
individual cells specialising in types, or ranges of components. CNC machines
are linked by a DNC system allowing programming to be carried out on the
machine or offline.
Lean manufacturing principles ensure that SPP are always focused on
continuous improvement to support their ‘Right First Time’ philosophy.
Customers are always welcome to visit the facility, either during
manufacturing or when equipment is on test.
TEST FACILITY
Testing, including witness testing,
of all SPP’s range of pumps is
performed at SPP’s own extensive
in-house test facility. The main test
area has a 1.4 million litre test tank
with a depth of 6 metres. It can test
pressures up to 50 bar, flows up to
2000 l/s and powers up to 800kW
at 6.6kV, 400kW at 415V and 400kW
at 60Hz. Generators can be used for
higher powers or voltages.
3 Contents 4
9
WATER
Pumps for water supply, water/waste water treatment, industrial processes
and general pumping service.
SPP has an extensive range of products suitable for a variety of applications.
From end suction DIN24255 (EN 733:1995) through to vertical turbine, split
case and sewage pumps, SPP has reliable and well proven products to offer.
Lowest Life Cycle Cost Series
SPP’s recognises the increasing emphasis on whole life cost when
evaluating pumping schemes, for the twenty-first century. This has lead to
the development of their Lowest Life-Cycle Cost Series of split case, vertical
turbine, dry well sewage pumps and solides diverters.
FIRE
SPP is the world’s leading specialist manufacturer of quality fire protection
pump packages. Unrivalled experience in design and manufacture together
with advanced testing and accreditation ensures the utmost in equipment
reliability.
SPP fire pumps comply with the demanding requirements of the LPCB, FM and
UL approval standards and meet all the requirements of NFPA 20.
10
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OIL & GAS
SPP is a world leader in the design and manufacture of pumping equipment
for both onshore and offshore applications. In-house expertise ensures
compliance with all applicable specifications and regulations. SPP has also
established quality assurance and document control business systems allied
to the needs of the major oil and gas contractors and end users.
SPP is the packager as well as the pump manufacturer and takes full unit
responsibility for the complete scope of supply.
DEWATERING
The SPP Autoprime range is a proven, versatile and comprehensive
product range suitable for use in a variety of applications worldwide. The
Autoprime pumps are primarily sold to rental organisations, contractors,
utility companies, open cast mining companies and municipalities
providing a durable solution. Continual investment in market-led research
and development ensure that the products are designed to meet market
requirements and legislation, providing significant benefits and solutions to
owners and users alike.
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11
STANDARD PRODUCTS
The SPP standard pump product range has been expertly designed to enable
you to fit them to any of your existing DIN Standard Pump Applications. SPP’s
excellent modular pump design allows interchangeability across the range
and with the ability to use standard shaft motors, gives much more flexibility
in terms of maintenance, stock holding and material options. SPP Standard
pumps can also be used for a variety of new pump application needs.
INDUSTRY
This is the largest market sector spanning chemical, pharmaceutical, power
and general industry, including manufacturing processes such as foundries,
rolling mills, boiler houses and water reclamation.
The main pumping equipment is largely electrically driven such as:
• End suction / SH & SHL non clog along with current distribution offering
• KPD for chemical process
• Split case units
• RKB multistage
• Vertical turbines
12
3 Contents 4
TRANSFORMER OIL PUMPS
SPP’s transformer oil pump range is designed and manufactured to the
highest quality standards. SPP have been producing transformer oil pumps
for more than sixty years. Life expectancy in many cases has exceeded forty
years. Applications include oil circulation in the following: power transmission,
distribution and electric traction locomotive transformers.
ENERGY
Through the use of proven systems and techniques, the Energy Division offers
a complete energy saving package that can be applied equally to new projects
and existing installations. The new division offers the following services:
Energy Audits, Customer Training, Energy Management, Surveys/reports/
analysis and recommendations. By monitoring and/or analysing the actual
requirement of the installation and comparing this with the specifications of
the equipment installed, SPP can make recommendations that can reduce
running costs (eg: power requirements), minimise maintenance costs
(eg: parts/servicing and downtime) and improve plant reliability (eg: upgraded
material specifications).
3 Contents 4
13
Engineering services
At SPP we are committed to providing the very best in customer support.
We have built our reputation by providing a fast, cost effective service whilst
maintaining continually high standards of workmanship and quality. With
strategically located service centres in the UK and around the world, help is
never far away. Each service centre is fully equipped to offer a comprehensive
range of equipment repair and refurbishment techniques. Our support is
available 24 hours a day, and is only ever a phone call away.
SPP supports our customers around the globe through our extensive network
of field service engineers. SPP field service engineers have thousands of hours
of experience, backed by intensive product and applications training. Whatever
your technical support requirement, we can help you get the best performance
from our equipment in your application. Field service engineers can provide:
• Equipment installation and commissioning
• Preventative maintenance
• Equipment repair and upgrades
• Product training
On SPP and other manufacturers’ pumps.
SPP are proud to be a chosen partner by SKF Bearings in the UK. This has led
to all SPP service centres being the only UK approved SKF Certified Rebuilder
of pumps. SPP also works with SKF globally and is the first port of call for
SKF customers needing pump repairs and services.
14
3 Contents 4
SPP Locations
Approved Service Providers
SPP is a truly global company with the main R&D, manufacturing and
test facilities centrally located in the UK and local sites in the United
States, India, France, South Africa, Singapore, Dubai, Italy and Poland.
SPP INTERNATIONAL
3 Contents 4
15
FIRE PROTECTION APPROVAL STANDARDS
SPP has one of the widest ranges of approved and listed equipment in
the world complying with the demanding requirements of the UL and FM
approval standards and meeting all the requirements of NFPA 20. Along with
these approvals, SPP’s fire products are also approved for use in many other
markets such as Europe, The Far East, The Middle East and Africa. Although
many pump companies can offer equipment ‘designed to’ the various
locally applicable fire rules and regulations, only a very select few have had
their pumps subjected to the stringent performance and reliability tests of
specialist fire approval laboratories.
Being the first to achieve fire pump approval and listing by the internationally
recognised Loss Prevention Certification Board the company today has more
pumps approved by the LPCB than any other manufacturer.
16
3 Contents 4
PUMP SPECIFICATION
AND OPERATION
3 Contents 4
17
18
3 Contents 4
SECTION 1
Section 1
DATA REQUIRED WHEN buying PUMPS
Fundamentals
Number required.
Nature of service.
Whether continuous or intermittent.
PUMP SPECIFICATION AND OPERATION
Performance
Capacity (State whether total or per unit).
Total head or pressure to be developed.
Suction lift (including friction), inlet pressure or head, or NPSH available.
(State range of any variation in above items. Otherwise, send sketch or give
full details of lifts and pipe runs including lengths, bores, materials and class
of pipes and number and nature of bends, valves etc.).
Pumped Medium
Nature of liquid (if other than cold, clean water).
Values or ranges of actual pumping temperature with corresponding specific
gravities, viscosities (if greater than for water) and vapour pressures.
Any corrosive and/or abrasive properties.
Nature, proportion and maximum size of any solids content.
Driver
Nature of driver.
If driver to be supplied, give full specification.
If electric motor, state electricity supply details, any speed restriction.
Whether lining-up and connecting free issue driver required.
Details of starting equipment and/or other accessories required
system of control if automatic.
3 Contents 4
19
Other Data
If required to run in parallel with other units.
Is it to be self-priming with suction lift.
Pump type and arrangement.
Fixed or portable.
Horizontal or vertical shaft.
Whether close-coupled, dry well, wet well or borehole (if vertical).
Borehole diameter or any other space restrictions.
If baseplate and coupling required.
Constructional / material specification required.
Site conditions:
If altitude above 150m.
If ambient temperature above 30º C.
If to work outdoors.
Type of drive:
Direct or indirect (i.e. coupling, gearbox or V belt).
Direction of rotation (if restricted).
Official tests/inspection, packing and shipping requirements.
Tender receipt/material despatch date required.
Any other significant information.
Items printed in bold are minimum requirements for quotation of any standard
horizontal pump. All other items, so far as they apply, are necessary for the
correct execution of all orders and quotations other than standard horizontal
pumps.
20
3 Contents 4
SECTION 2
Section 2
DIMENSIONS OF CAST IRON FLANGES to BS en 1092
Pumps and Fittings
PUMP SPECIFICATION AND OPERATION
NOTE - All dimensions listed below are in millimetres
BS EN 1092 TABLE PN6
NOM.
DIA.
10
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
700
800
900
1000
FLANGE
RAISED FACE
BOLTS
DRILLING
NECK
D
b
d4
Fmax
DIA.
No
d2
k
d3
r
75
80
90
100
120
130
140
160
190
210
240
265
320
375
440
490
540
595
645
755
860
975
1075
1175
12
12
14
14
16
16
16
16
18
18
20
20
22
24
24
24
24
24
24
24
24
24
24
24
33
38
48
58
69
78
88
108
128
144
174
199
254
309
363
415
463
518
568
667
772
878
978
1078
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
5
5
5
5
5
M10
M10
M10
M10
M12
M12
M12
M12
M16
M16
M16
M16
M16
M16
M20
M20
M20
M20
M20
M24
M24
M27
M27
M27
4
4
4
4
4
4
4
4
4
4
8
8
8
12
12
12
16
16
20
20
24
24
24
28
11
11
11
11
14
14
14
14
19
19
19
19
19
19
23
23
23
23
23
28
28
31
31
31
50
55
65
75
90
100
110
130
150
170
200
225
280
335
395
445
495
550
600
705
810
920
1020
1120
20
26
34
44
54
64
74
94
110
130
160
182
238
284
342
392
442
494
544
642
746
850
950
1050
3
3
4
4
5
5
5
6
6
6
6
8
8
10
10
10
10
12
12
12
12
12
12
12
3 Contents 4
21
BS EN 1092 TABLE PN10
NOM.
DIA.
FLANGE
D
RAISED FACE
b
d4
Fmx
BOLTS
DIA.
No
DRILLING
d2
k
NECK
d3
r
246
298
348
408
456
502
559
658
772
876
976
1080
1292
1496
1712
1910
2120
2320
8
10
10
10
10
12
12
12
12
12
12
12
12
12
12
15
15
20
NOTE: FOR NOMINAL SIZES 10 - 150 USE PN16 TABLE
200
250
300
350
400
450
500
600
700
800
900
1000
1200
1400
1600
1800
2000
2200
340
395
445
505
565
615
670
780
895
1015
1115
1230
1455
1675
1915
2115
2325
2550
26
28
28
30
32
32
34
36
40
44
46
50
56
62
68
70
74
78
266
319
370
429
480
530
582
682
794
901
1001
1112
1328
1530
1750
1950
2150
-
3
3
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5
-
M20
M20
M20
M20
M24
M24
M24
M27
M27
M30
M30
M33
M36
M39
M45
M45
M45
M52
8
12
12
16
16
20
20
20
24
24
28
28
32
36
40
44
48
52
23
23
23
23
28
28
28
31
31
34
34
37
41
44
50
50
50
56
295
350
400
460
515
565
620
725
840
950
1050
1160
1380
1590
1820
2020
2230
2440
BS EN 1092 TABLE PN16
NOM.
DIA.
10
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
700
800
22
FLANGE
RAISED FACE
BOLTS
DRILLING
NECK
D
b
d4
Fmx
DIA.
No
d2
k
d3
r
90
95
105
115
140
150
165
185
200
220
250
285
340
405
460
520
580
640
715
840
910
1025
14
14
16
16
18
18
20
20
22
24
26
26
30
32
32
36
38
40
42
48
54
58
41
46
56
65
76
84
99
118
132
156
186
211
266
319
370
429
480
548
609
720
794
901
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
5
5
5
M12
M12
M12
M12
M16
M16
M16
M16
M16
M16
M16
M20
M20
M24
M24
M24
M27
M27
M30
M33
M33
M36
4
4
4
4
4
4
4
4
8
8
8
8
12
12
12
16
16
20
20
20
24
24
14
14
14
14
19
19
19
19
19
19
19
23
23
28
28
28
31
31
34
37
37
41
60
65
75
85
100
110
125
145
160
180
210
240
295
355
410
470
525
585
650
770
840
950
28
32
40
50
60
70
84
104
120
140
170
190
246
296
350
410
458
516
576
690
760
862
3
3
4
4
5
5
5
6
6
6
6
8
8
10
10
10
10
12
12
12
12
12
3 Contents 4
NOM.
DIA.
RAISED FACE
BOLTS
DRILLING
NECK
D
b
d4
Fmx
DIA.
No
d2
k
d3
r
90
95
105
115
140
150
165
185
200
235
270
300
360
425
485
555
620
670
730
845
960
1085
16
16
18
18
20
20
22
24
26
28
30
34
34
36
40
44
48
50
52
56
56
56
41
46
56
65
76
84
99
118
132
156
186
211
274
330
389
448
403
548
609
720
820
928
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
5
5
5
M12
M12
M12
M12
M16
M16
M16
M16
M16
M20
M24
M24
M24
M27
M27
M30
M33
M33
M33
M36
M39
M45
4
4
4
4
4
4
4
8
8
8
8
8
12
12
16
16
16
20
20
20
24
24
14
14
14
14
19
19
19
19
19
23
28
28
28
31
31
34
37
37
37
41
44
50
60
65
75
85
100
110
125
145
160
190
220
250
310
370
430
490
550
600
660
770
875
990
28
32
40
50
60
70
84
104
120
142
162
192
252
304
364
418
472
520
580
684
780
882
3
3
4
4
5
5
5
6
6
6
6
8
8
10
10
10
10
12
12
12
12
12
PUMP SPECIFICATION AND OPERATION
10
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
700
800
FLANGE
SECTION 2
BS EN 1092 TABLE PN25
BS EN 1092 TABLE PN40
NOM.
DIA.
10
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
FLANGE
RAISED FACE
BOLTS
DRILLING
NECK
D
b
d4
Fmx
DIA.
No
d2
k
d3
r
90
95
105
115
140
150
165
185
200
235
270
300
375
450
515
580
660
685
755
16
16
18
18
20
20
22
24
26
28
30
34
40
46
50
54
62
62
62
41
46
56
65
76
84
99
118
132
156
186
211
284
345
409
465
535
560
615
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
M12
M12
M12
M12
M16
M16
M16
M16
M16
M20
M24
M24
M27
M30
M30
M33
M36
M36
M39
4
4
4
4
4
4
4
8
8
8
8
8
12
12
16
16
16
20
20
14
14
14
14
19
19
19
19
19
23
28
28
31
34
34
37
41
41
44
60
65
75
85
100
110
125
145
160
190
220
250
320
385
450
510
585
610
670
28
32
40
50
60
70
84
104
120
142
162
192
254
312
378
432
498
522
576
3
3
4
4
5
5
5
6
6
6
6
8
8
10
10
10
10
12
12
3 Contents 4
23
BS EN 1092 TABLE PN63
NOM.
DIA.
40
50
65
80
100
125
150
200
250
300
350
400
200
250
300
350
400
FLANGE
RAISED FACE
BOLTS
DRILLING
b
d4
Fmx
DIA.
No
d2
k
d3
r
170
180
205
215
250
295
345
415
470
530
600
670
360
425
485
555
620
28
28
28
31
33
37
39
46
50
57
61
65
34
36
40
44
48
84
99
118
132
156
184
211
284
345
409
465
535
274
330
389
448
403
3
3
3
3
3
3
3
3
3
4
4
4
3
3
4
4
4
M20
M20
M20
M20
M24
M27
M30
M33
M33
M33
M36
M39
M24
M27
M27
M30
M33
4
4
8
8
8
8
8
12
12
16
16
16
12
12
16
16
16
23
23
23
23
28
31
34
37
37
37
41
44
28
31
31
34
37
125
135
160
170
200
240
280
345
400
460
525
585
310
370
430
490
550
77
87
112
122
142
174
208
267
322
382
438
490
252
304
364
418
472
5
5
6
6
6
6
8
8
10
10
10
10
8
10
10
10
10
DIMENSIONS OF CAST IRON FLANGES to ASME/ANSI B16.1
ASME/ANSI B16.1 – 125lb – RATING – CAST IRON
250lb – RATING – CAST IRON
NOTE - All dimensions listed below are in inches
24
NECK
D
3 Contents 4
NOM.
DIA.
BOLTS
DRILLING
b
DIA.
No
d2
k
4.25
4.62
5.00
6.00
7.00
7.50
8.50
9.00
10.00
11.00
13.50
16.00
19.00
21.00
23.50
25.00
27.50
32.00
38.75
0.44
0.50
0.56
0.62
0.69
0.75
0.81
0.94
0.94
1.00
1.12
1.19
1.25
1.38
1.44
1.56
1.69
1.88
2.12
0.50
0.50
0.50
0.62
0.62
0.62
0.62
0.62
0.75
0.75
0.75
0.88
0.88
1.00
1.00
1.12
1.12
1.25
1.25
4
4
4
4
4
4
8
8
8
8
8
12
12
12
16
16
20
20
28
0.62
0.62
0.62
0.75
0.75
0.75
0.75
0.75
0.88
0.88
0.88
1.00
1.00
1.12
1.12
1.25
1.25
1.38
1.38
3.12
3.50
3.88
4.75
5.50
6.00
7.00
7.50
8.50
9.50
11.75
14.25
17.00
18.75
21.25
22.75
25.00
29.50
36.00
SPOTFACE
DIAMETER
1.00
1.00
1.00
1.25
1.25
1.25
1.25
1.25
1.50
1.50
1.50
1.62
1.62
1.88
1.88
2.12
2.12
2.25
2.25
HUB
d3
r
1.94
2.31
2.56
3.06
3.56
4.25
4.81
5.31
6.44
7.56
9.69
11.94
14.06
15.38
17.50
19.62
21.75
26.00
-
0.12
0.12
0.12
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.38
0.38
0.38
PUMP SPECIFICATION AND OPERATION
1
1 1/4
1 1/2
2
2 1/2
3
3 1/2
4
5
6
8
10
12
14
16
18
20
24
30
FLANGE
D
SECTION 2
ASME/ANSI B16.1 – 125lb RATING – CAST IRON
ASME/ANSI B16.1 – 250lb RATING – CAST IRON
NOM.
DIA.
1
1 1/4
1 1/2
2
2 1/2
3
3 1/2
4
5
6
8
10
12
14
16
18
20
24
30
FLANGE
BOLTS
DRILLING
D
b
DIA.
No
d2
k
4.88
5.25
6.12
6.50
7.50
8.25
9.00
10.00
11.00
12.50
15.00
17.50
20.50
23.00
25.50
28.00
30.50
36.00
43.00
0.69
0.75
0.81
0.88
1.00
1.12
1.19
1.25
1.38
1.44
1.62
1.88
2.00
2.12
2.25
2.38
2.50
2.75
3.00
0.62
0.62
0.75
0.62
0.75
0.75
0.75
0.75
0.75
0.75
0.88
1.00
1.12
1.12
1.25
1.25
1.25
1.50
1.75
4
4
4
8
8
8
8
8
8
12
12
16
16
20
20
24
24
24
28
0.75
0.75
0.88
0.75
0.88
0.88
0.88
0.88
0.88
0.88
1.00
1.12
1.25
1.25
1.38
1.38
1.38
1.62
2.00
3.50
3.88
4.50
5.00
5.88
6.62
7.25
7.88
9.25
10.62
13.00
15.25
17.75
20.25
22.50
24.75
27.00
32.00
39.25
3 Contents 4
SPOTFACE
DIAMETER
1.25
1.25
1.50
1.25
1.50
1.50
1.50
1.50
1.50
1.50
1.63
1.88
2.13
2.13
2.25
2.25
2.25
2.75
34.00
HUB
d3
r
2.06
2.50
2.75
3.31
3.94
4.62
5.25
5.75
7.00
8.12
10.25
12.62
14.75
16.25
18.38
20.75
23.00
27.25
34.00
0.13
0.13
0.13
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.38
0.38
0.38
25
DIMENSIONS OF STEEL FLANGES TO ASME/ANSI B16.5
ASME/ANSI B16.5 – 150lb – RATING - STEEL
– 300lb – RATING - STEEL
NOTE - All dimensions listed below are in inches
ASME/ANSI B16.5 – 150lb RATING - STEEL
NOM.
DIA.
1/2
3/4
1
1 1/4
1 1/2
2
2 1/2
3
3 1/2
4
5
6
8
10
12
14
16
18
20
24
26
FLANGE
RAISED FACE
BOLTS
DRILLING
D
b
d4
Fmax
No
DIA.
d2
k
3.50
3.88
4.25
4.62
5.00
6.00
7.00
7.50
8.50
9.00
10.00
11.00
13.50
16.00
19.00
21.00
23.50
25.00
27.50
32.00
0.44
0.50
0.56
0.62
0.69
0.75
0.88
0.94
0.94
0.94
0.94
1.00
1.12
1.19
1.25
1.38
1.44
1.56
1.69
1.88
2.00
2.50
2.88
3.62
4.12
5.00
5.50
6.19
7.31
8.50
10.62
12.75
15.00
16.25
18.50
21.00
23.00
27.25
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
4
4
4
4
4
4
4
4
8
8
8
8
8
12
12
12
16
16
20
20
1/2
1/2
1/2
1/2
1/2
5/8
5/8
5/8
5/8
5/8
3/4
3/4
3/4
7/8
7/8
1
1
1 1/8
1 1/8
1 1/4
0.62
0.62
0.62
0.62
0.62
0.75
0.75
0.75
0.75
0.75
0.88
0.88
0.88
1.00
1.00
1.12
1.12
1.25
1.25
1.38
2.38
2.75
3.12
3.50
3.88
4.75
5.50
6.00
7.00
7.50
8.50
9.50
11.75
14.25
17.00
18.75
21.25
22.75
25.00
29.50
3 Contents 4
SPOTFACE
DIAMETER
1.00
1.00
1.00
1.00
1.00
1.25
1.25
1.25
1.25
1.25
1.50
1.50
1.50
1.62
1.62
1.88
1.88
2.12
2.12
2.25
HUB
d3
r
1.19
1.50
1.94
2.31
2.56
3.06
3.56
4.25
4.81
5.31
6.44
7.56
9.69
12.00
14.38
15.75
18.00
19.88
22.00
26.12
0.12
0.12
0.12
0.12
0.12
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.38
0.38
NOM.
DIA.
D
b
RAISED FACE
d4
Fmax
No
BOLTS
DIA.
DRILLING
d2
k
SPOTFACE
DIAMETER
d3
HUB
r
3.75
4.62
4.88
5.25
6.12
6.50
7.50
8.25
9.00
10.00
11.00
12.50
15.00
17.50
20.50
23.00
25.50
28.00
30.50
36.00
0.56
0.62
0.69
0.75
0.81
0.88
1.00
1.12
1.19
1.25
1.38
1.44
1.62
1.88
2.00
2.12
2.25
2.38
2.50
2.75
1.38
1.69
2.00
2.50
2.88
3.62
4.12
5.00
5.50
6.19
7.31
8.50
10.62
12.75
15.00
16.25
18.50
21.00
23.00
27.25
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
1/16
4
4
4
4
4
8
8
8
8
8
8
12
12
16
16
20
20
24
24
24
1/2
5/8
5/8
5/8
3/4
5/8
3/4
3/4
3/4
3/4
3/4
3/4
7/8
1
1 1/8
1 1/8
1 1/4
1 1/4
1 1/4
1 1/2
0.62
0.75
0.75
0.75
0.88
0.75
0.88
0.88
0.88
0.88
0.88
0.88
1.00
1.12
1.25
1.25
1.38
1.38
1.38
1.62
2.62
3.25
3.50
3.88
4.50
5.00
5.88
6.62
7.25
7.88
9.25
10.62
13.00
15.25
17.75
20.25
22.50
24.75
27.00
32.00
1.00
1.25
1.25
1.25
1.50
1.25
1.50
1.50
1.50
1.50
1.50
1.50
1.62
1.88
2.12
2.12
2.25
2.25
2.25
2.75
1.50
1.88
2.12
2.50
2.75
3.31
3.94
4.62
5.25
5.75
7.00
8.12
10.25
12.62
14.75
16.75
19.00
21.00
23.12
27.62
0.12
0.12
0.12
0.12
0.12
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.38
0.38
*NOTE:
The standard for Ductile Iron flanges is ASME/ANSI B16.42 150lb and 300lb rating.
They are dimensionally the same as ASME/ANSI B16.5 including the raised face.
The standard for Copper Alloy flanges is ASME/ANSI B16.24 150lb and 300lb rating.
They are dimensionally the same as ASME/ANSI B16.5 except they are FLAT FACE.
3 Contents 4
27
PUMP SPECIFICATION AND OPERATION
1/2
3/4
1
1 1/4
1 1/2
2
2 1/2
3
3 1/2
4
5
6
8
10
12
14
16
18
20
24
FLANGE
SECTION 2
ASME/ANSI B16.5 – 300lb RATING - STEEL
Section 3
PUMP INSTALLATION
Fixed pumps must be securely anchored to firm foundations. Pumps must be
accurately levelled with shafts, coupling faces and flange faces truly horizontal
or vertical (as appropriate). The pump and driver shafts should be truly in
line in all senses and checks and requisite adjustments should be made by
means of wedges and shims both in initial setting-up and after grouting in and
tightening down.
Foreign matter must be prevented from ingress to liquid openings, bearings,
etc., and external pipe-bores ensured clean before connecting. Pipework
must be brought up to pump orifices, and independently supported, so as
not to impose any weight or strain on the pump when connected. Make sure
at all stages that the pump will turn freely. For fuller particulars see specific
instructions as supplied with pumps.
Section 4
PUMP OPERATION
SPP’s Field service engineers can provide a full commissioning service for a
wide range of pumps. Contact your local SPP office for details
• Check all guards are fitted correctly before starting the pump
• Make sure pump will turn freely
• Check driver and pump rotations agree, with driver uncoupled
• Make sure bearings are adequately charged with clean lubricant
• Check stuffing boxes are packed and correctly adjusted
• Make sure any external lubricating, cooling, sealing, etc., services and
connections are turned on and operative
• Make sure pump is effectively primed before starting up
• Check that pump runs without undue overheating, noise or vibration:
otherwise refer to detailed operating instructions for possible defects and
rectify accordingly
• On no account must a pump be allowed to continue running unprimed, or
with a closed discharge valve
• On no account should a pump be regulated by closing a valve on the
suction side
28
3 Contents 4
SECTION 3/4/5
section 5
Faults and remedial action
Potential Fault or Defect:
No liquid delivered.
Insufficient liquid delivered.
Liquid delivered at low pressure.
Loss of liquid after starting.
PUMP SPECIFICATION AND OPERATION
Excessive vibration.
Motor runs hotter than normal.
Excessive noise from pump cavitation.
Pump bearings run hotter than normal.
PROBABLE CAUSES
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Pump not primed.
Speed too low.
Speed too high.
Air leak in suction pipework.
Air leak in mechanical seal.
Air or gas in liquid.
Discharge head too high (above rating).
Suction lift too high.
Not enough head for hot liquid.
Inlet pipe not submerged enough.
Viscosity of liquid greater than rating.
Liquid density higher than rating.
Insufficient nett inlet head.
Impeller blocked.
Wrong direction of rotation.
Excessive impeller clearance.
Damaged impeller.
Rotor binding.
Defects in motor.
Voltage and/or frequency lower than rating.
Lubricating grease or dirty oil or contaminated.
Foundation not rigid.
Misalignment of pump and driver.
Bearing worn.
Rotor out of balance.
Shaft bent.
Impeller too small.
SPP’s service division can carry out fault identification and rectification on a wide range of pumps. Contact your local SPP office
for details
3 Contents 4
29
CAUSE
REMEDIAL ACTION
Pump not primed.
Fill pump and suction pipe completely with fluid.
Check that the motor is correctly connected and receiving the full supply
Speed too low.
voltage also confirm that the supply frequency is correct.
Speed too high.
Check the motor voltage.
Air leak in suction pipework.
Check each flange for suction draught, rectify as necessary.
Check all joints, plugs and flushing lines, if fitted. Note that prolonged
Air leak in mechanical seal.
running with air in the mechanical seal will result in damage and failure
of the seal.
It may be possible to increase the pump performance to provide
Air or gas in liquid.
adequate pumping.
Discharge head too high (above Check that valves are fully open and for pipe friction losses. An increase
rating).
in pipe diameter may reduce the discharge pressure.
Check for obstruction of pump inlet and for inlet pipe friction losses.
Suction lift too high.
Measure the static lift, if above rating, raise the liquid level or lower
the pump.
Not enough head for hot liquid. Reduce the positive suction head by raising the liquid level.
Inlet pipe not submerged
If the pump inlet cannot be lowered, provide a baffle to smother the inlet
enough.
vortex and prevent air entering with the liquid.
Viscosity of liquid greater than
Refer to SPP Pumps Ltd for guidance to increase the size or power of
rating.
the motor or engine.
Liquid density higher than
Refer to SPP Pumps Ltd for guidance to increase the size or power of
rating.
the motor or engine.
Increase the positive suction head by lowering the pump or raising the
Insufficient nett inlet head.
liquid level.
Impeller blocked.
Dismantle the pump and clean the impeller.
Wrong direction of rotation.
Check driver rotation with the direction arrow on the pump casing.
Excessive impeller clearance.
Replace the impeller when clearance exceeds the maximum adjustment.
Rotor binding.
Check for shaft deflection, check and replace bearings if necessary.
Ensure that motor is adequately ventilated. Refer to manufacturers’
Defects in motor.
instructions.
Voltage and/or frequency lower If voltage and frequency are lower than the motor rating, arrange for
than rating.
provision of correct supply.
Lubricating grease or oil dirty
Dismantle the pump, clean the bearings, reassemble the pump and fill
or contaminated.
with new grease or oil.
Ensure that the foundation bolts are tight, check that foundations match
Foundation not rigid.
SPP Pumps Ltd recommendations.
Misalignment of pump and
Realign the pump and driver as specified.
driver.
Remove the bearings, clean and inspect for damage and wear, replace
Bearings worn.
as necessary.
Rotor out of balance.
Check impeller for damage, replace as necessary.
Shaft bent.
Check shaft run-out and replace if necessary.
Impeller too small.
Refer to SPP Pumps Ltd for options to fit a larger impeller.
SPP’s service division can carry out fault identification and rectification on a wide range of pumps.
Contact your local SPP office for details
30
3 Contents 4
VIBRATION TOLERANCE
In every pump there are dynamic forces of hydraulic or mechanical origin that
will inevitably lead to a certain level of vibration. To maintain the integrity of
the pump unit and associated equipment the level of vibration must be kept
within certain limits.
SECTION 6
Section 6
Acceptance Criteria
PUMP SPECIFICATION AND OPERATION
The following table defines the maximum allowable level of vibration
measured in mm/s RMS overall velocity during a factory acceptance test.
It should be noted that the factory acceptance test is not necessarily an
accurate representation of the vibration on site, when the unit is grouted in
with permanent pipe supports etc.
Application / Class
Class 1
Class 2
Class 3
3.0
4.7
7.1
3.9
5.6
9.0
Not applicable
9.0
13.0
Continuous operation over the preferred
operating range
Continuous operation over the allowable
operating range
Intermittent operation over the allowable
operaing range
Pump Classes
Class 1 pumps will only include those that have been designed in full
accordance with A.P.I. 610, for use in critical applications. None of the
standard ranges of SPP fall into this class and pumps that meet it are only
available on an engineered to order basis.
Class 2 pumps will include all SPP general purpose industrial designs apart
from those specifically identified as class 3 below.
Class 3 pumps shall include any pumps with less than three impeller vanes,
split case pumps of the “through bore” type and any unit driven by a diesel
engine of four or more cylinders. (Refer to SPP Engineering for units driven by
engines of three or less cylinders).
3 Contents 4
31
Method
Vibration measurements will be made on the pump bearing housings, as close
as is practical to the bearing positions.
For each bearing position two measurements will be taken perpendicular to
the pump rotation axis. In addition an axial measurement will be taken at the
thrust bearing position.
The measurements will be of velocity, overall RMS values, in mm/s.
In order to reliably achieve the stated acceptance limits the pump must
be rigidly restrained, aligned to the driver within the coupling makers
recommendations, operating without cavitation or air entrainment. Pipe work
must be arranged to provide straight uniform flow into the pump and be
connected and anchored so as avoid strains and resonance.
SPP’s field service engineers can undertake vibration analysis. Contact your
local SPP office for details
32
3 Contents 4
CONDITION MONITORING
Early diagnosis of potential equipment failure
can result in considerable repair cost savings
and crucially a reduction in unplanned downtime.
Monitoring of pump energy consumption and
system efficiency will bring visibility to pump
wear, operating efficiency and highlight any
system irregularities. All of these factors will
help minimise energy consumption and reduce
operating costs.
The SPP condition monitoring systems can provide
this level of security by detecting, analysing and
evaluating key equipment performance. These
include the following:
• Performance/Efficiency degradation
• Bearing vibration levels
• Bearing element damage
• Bearing operating temperatures
• Driver alignment condition
• Residual unbalance
• Cavitation
The system provides considerable flexibility in the display and use of
the diagnostic output. The options include web based user configurable
dashboard for live and trend data, automatic notification of alerts by text or
email and local download of data to PC for detailed evaluation.
3 Contents 4
33
PUMP SPECIFICATION AND OPERATION
In order to minimise the ownership costs of capital
equipment, it is critical for the user to monitor and
maintain the equipment once installed. Failure to
do so will impact both on the mechanical integrity
and economic performance of the installed
equipment.
SECTION 7
Section 7
Section 8
Flow Estimation Methods
Many pumping systems are fitted with permanently installed flowmeters
which enable a reasonably accurate measurement of system flow to be
obtained. Where permanent flowmeters are not installed, it is often possible
to use external clamp-on meters, insertion meters or thermodynamic testing
equipment to determine system flow. However, it is not always practical to
use these devices – either for financial reasons or system layout constraints
– and where this is the case, alternative indirect methods need to be used for
estimating system flow.
There are a number of methods available to enable an estimation of flow to be
made in the field. Each of these methods requires some form of knowledge of
the system or the pump, and all have inherent inaccuracies of varying degrees.
However, in the absence of any more accurate flow measuring apparatus,
these can be the only alternatives available.
There are four main indirect methods of determining pump flow in the field:
• Pressure method
• Power method
• Drop test
• Suction pressure measurement
The Pressure and Power methods require the use of the pump curve, whilst the
drop test requires sump geometry and level details.
Pressure MEASUREMENT
This is the more accurate and simplest of the four methods, requiring suction
and delivery pressure gauge readings, a copy of the pump performance curve
at the correct operational speed and knowledge of the impeller diameter.
Determine the differential head across the pump by subtracting the suction
head from the discharge head. Then use the pump performance curve to
obtain the pump flow at the measured head and impeller diameter.
For example, if the suction head is measured as 3m and the discharge head
as 63m, the pump differential head is 60m. Using the pump manufacturers
original test curve for the pump, the flow can be estimated as 150 l/s.
34
3 Contents 4
SECTION 8
Where existing installed site gauges are used, it should be remembered that
their accuracy may be far from ideal.
Remember that the pump Q/H curve is based on differential head, normally
pumping water with an SG of 1. If the site liquid being pumped has an SG
other than 1, SG correction should be applied to the site pressure readings to
match the performance curve being used.
Power Measurement
Power meters are rarely available on site, but amps (I) and volts (V) are
commonly displayed at the control panel. These readings can be used to
calculate power, although this also requires motor efficiency and power factor
data - which will need to be estimated if motor manufacturers information is
not available.
Power (kW) = (1.732 x I x V x eff x pf)/1000
Using this equation, the pump power can be calculated and from this, the flow
can be read off the pump curve.
3 Contents 4
35
PUMP SPECIFICATION AND OPERATION
Over time, a pump’s Flow/Head curve will change as wear occurs within the
pump. Therefore, the accuracy of this method will tend to reduce as the pump
gets older. However, this will remain a more accurate method than the others
detailed below.
For example, if the
current is read as 165A,
the voltage as 400V and
motor efficiency and pf
from manufacturers’
data are 95% and
0.92 respectively,
the calculated power
becomes:
Power = (1.732 x 400 x
165 x 0.95 x 0.92)/1000
= 100kW
Reading across the power scale on the pump manufacturers curve, the flow at
this absorbed power can be obtained – 150 l/s in this example.
As mentioned above, a pump’s Flow/Head curve and efficiency curve will
change as wear occurs within the pump. This will affect the pump’s power
curve and therefore, as with the pressure measurement method, accuracy will
tend to reduce as the pump gets older.
It should also be remembered that the installed instruments from which
readings are taken may themselves be inaccurate, as it is unlikely that they
will not have been calibrated to any significant accuracy since their original
installation.
As an alternative to the above calculation, taking a simple current ratio (actual
current/full load current) and applying it to the motor rated power can give
a reasonable estimation of the motor output power. In the above example,
assuming a 132kW motor with a full load current of 230A, this method would
result in a duty power of (165/230)*132 = 95kW, and a resultant flow of around
135 l/s.
36
3 Contents 4
SECTION 8
Although the power method can be used very effectively in situations where
a quick approximate on site estimate is required, it should not be applied to
high specific speed pumps such as vertical turbine or mixed flow pumps,
whose power curves can follow significantly different rules.
Drop Test
This is the least accurate method, and requires knowledge of sump
dimensions and levels. It is often used on sewage pump installations, where
sump emptying occurs over a relatively short period of time.
PUMP SPECIFICATION AND OPERATION
In this method, the time taken for a pump to lower the sump level over a
known depth is recorded. The volume of liquid pumped is then calculated
based on the sump level change and the sump area, and is divided by the
time taken to arrive at a volume flow rate.
For example, if a sump has dimensions of 4m x 3m, and the level is reduced
by 1m over a time period of 10 minutes, the average pump flow is
(4 x 3 x 1)/10 = 1.2 m3/min, or 72 m3/h
This method has a number of inherent inaccuracies:
• During the drop test, it is likely that flow will continue to enter the sump.
This will affect the result – the extent of the effect will depend upon the
rate of inflow in proportion to the outflow.
• The sump may not have a uniform section, making volume calculation
less accurate.
• As the level is lowered, the total head on the pump changes which
will affect the pump output. Any resultant calculation will only give an
average flow over the range of heads.
• Measurement of pumped depth may be difficult if there is no installed
measuring equipment.
SUCTION PRESSURE MEASUREMENT
In most pumping stations, it is possible to obtain a pressure reading on the
suction side of the pumps. The velocity and friction head components of this
reading can be used to estimate the flow. To use this method, it is necessary
to know the pressure drop on the pump suction (static suction pressure operational suction pressure), the type and number of pipe fittings up to
the pressure measurement point and fittings diameter. An estimation of the
fittings friction (K) factor is also required.
3 Contents 4
37
Convert the suction pressure drop (P in kPA) into a head drop (Zd in meters)
using the equation:
Zd = P x 0.102
sg
(note that this Zd calculation will change depending on your site measured units)
Obtain a total K factor for the suction fittings up to the measurement point.
Assuming there are no significant straight pipe losses in the suction, the
following equation can then be used to determine the flow velocity:
Zd = V2 x (1+K)
2g
Once the velocity is known, the flow rate can be calculated using the suction
diameter. This method can be adapted to suit a wide variety of suction and pump
configuration and the available locations for pressure measurement.
Although there are potential inaccuracies in determining K factors and internal
diameters, careful use of this method can allow the velocity to be estimated to
within a few percent.
Conclusion
There is no single simple and accurate method of determining flow in systems
where installed meters are not present, or where the use of alternative
temporary flow metering equipment cannot be fitted. Instead there are a number
of methods that can be utilised to obtain an approximate pumping rate, which in
many cases may be sufficient for the purposes required.
All these methods have limitations and inherent inaccuracies. Where these
methods need to be employed, it is worthwhile applying at least two methods to
get comparative results.
38
3 Contents 4
SECTION 9
Section 9
Application Do’s and Don’ts
Suction & Delivery Piping
Ensure that bolt grouting or chemical anchors are allowed to dry thoroughly
before connecting any pipework.
Note that fire pumpsets have regulatory requirements for piping and these
must be strictly observed. Refer to the appropriate standard for details.
PUMP SPECIFICATION AND OPERATION
Both suction and discharge piping should be supported independently and
close to the pump so that no strain is transmitted to the pump when the
flange bolts are tightened. Use pipe hangers or other supports at intervals
necessary to provide support. When expansion joints are used in the piping
system, they must be installed beyond the piping supports closest to the
pump.
Install piping as straight as possible, avoiding unnecessary bends. Where
necessary, use 45º or long sweep 90º bends to decrease friction losses.
Eccentric Reducer on a Split Case
Pump
Typical End Suction Pump Piping
Installation
3 Contents 4
39
Make sure that all piping joints are airtight. Where reducers are used, eccentric
or ‘flat top’ reducers are to be fitted in suction lines and concentric or straight
taper reducers in discharge lines. The length of eccentric reducers should be
about four times the pump suction diameter. Undulations in the pipe runs are
also to be avoided. Failure to comply with this may cause the formation of air
pockets in the pipework and thus prevent the correct operation of the pump
and measuring equipment.
The suction pipe should be as short and direct as possible, and should be
flushed clean before connecting to the pump. For suction lift applications, it is
advisable to use a foot valve. Horizontal suction lines must have a gradual rise
to the pump. If the pumped fluid is likely to contain foreign matter then a filter
or coarse strainer should be fitted to prevent ingress to the pump.
The discharge pipe is usually preceded by a non-return valve or check valve
and a discharge gate valve. The check valve is to maintain system pressure in
case of stoppage or failure of the driver. The discharge valve is used to prevent
back flow when shutting down the pump for maintenance.
Coupling alignment
Periodical checks of shaft alignments should be undertaken and if necessary
adjusted accordingly. In order to maintain the warranty status of your SPP
pump it is recommended to take out an SPP preventative maintenance
contract. SPP’s field service engineers have extensive experience in pump and
coupling alignment. Refer to the pump and coupling
instruction manuals for details of shaft alignment
procedures and tolerances or proceed generally thus:
a) Lateral Alignment
Mount a dial gauge on the motor shaft or coupling
with the gauge running on the outer-machined
diameter of the pump coupling. Turn the motor shaft
and note the total indicator reading.
b) Angular Alignment
Mount a dial gauge on the motor shaft or coupling
to run on a face of the pump coupling as near to the
outside diameter as possible. Turn the motor shaft and note the total indicator
reading at top & bottom and each side.
40
3 Contents 4
SECTION 9
c) Confirm Lateral Alignment
Mount the dial gauge on the pump shaft or
coupling with the gauge running on the machined
outer diameter of the motor coupling. Turn the
pump shaft and note the total indicator reading.
d) Adjustment
Note:
Shaft alignment must be checked again after the final positioning of the pump
unit and connection to pipework as this may have disturbed the pump or
driver mounting positions.
Engine Driven Pumps
Air is required for combustion and cooling purposes, with air and radiator
cooled engines in particular needing large volumes of air for cooling. Inlet
and outlet apertures, suitably sized and positioned to prevent air recirculation,
must be provided in the pump house structure. It is recommended that a low
level vent be matched by a high level vent in the opposite wall.
Exhaust runs should be as short as possible. Small bore pipe and/or excessive
length will cause backpressure on the engine, reducing engine performance
and therefore pump output.
Engine driven fire pumps should not be left unattended whilst undertaking
weekly test runs. The run-to-crash design of fire pump engines makes it
essential to that they are commissioned by experienced personnel to avoid
permanent damage. SPP offers fixed price fire pump commissioning services
Pre-commissioning Check
If SPP Pumps Ltd is contracted to carry out the commissioning, the following
check list shows items to be completed before the commissioning engineer
arrives.
SPP commissioning SERVICES
SPP use qualified engineers to maintain approved systems, warranty and
approved parts.
3 Contents 4
41
PUMP SPECIFICATION AND OPERATION
The motor must be shimmed and re-positioned to align the shafts to the
coupling manufacturer’s specifications.
Check List
1
Installation:
•Mounting plinths comply with instructions for size, construction
and location
•The baseplate has been accurately levelled and adequately supported.
This prevents distortion and makes achievable the final shaft alignment
to within manufacturers specification
•The fixing bolts are grouted as instructed and tightened to the
required torque
•The shaft alignment has been checked and set to within the stated
tolerances.
42
2
Suction and delivery pipework is adequately supported and NEGLIGIBLE
forces are transmitted to the pump casing.
3
Where applicable, all drain, minimum flow, and test pipelines are fitted,
together with valves gauges and flow meters.
4
The diesel engine exhaust has been fitted in line with recommendations.
5
The engine fuel tank is filled with sufficient fuel.
6
Batteries are filled and charged in accordance with the manufacturer’s
instructions.
7
All wiring to controls and to remote alarm panels is completed in line with
appropriate regulations & power supplies are connected.
8
The area is clear of all builders’ material and rubbish to allow access to
the pumps.
3 Contents 4
HyDRAULIC
DESIGN DATA
3 Contents 4
43
44
71.38
81.58
91.77
20
203.94
8.00
9.00
10
101.97
40.79
4.00
7.00
30.59
3.00
61.18
20.39
2.00
6.00
10.19
1.00
50.99
0.00
0.00
5.00
0
bar
3 Contents 4
305.91
30
92.97
82.60
72.40
62.20
52.00
41.81
31.61
21.41
11.22
1.02
0.1
407.88
40
93.81
83.62
73.42
63.22
53.02
42.83
32.63
22.43
12.24
2.04
0.2
509.85
50
94.83
84.64
74.44
64.24
54.04
43.85
33.65
23.45
13.26
3.06
0.3
611.82
60
95.85
85.65
75.46
65.26
55.06
44.87
34.67
24.47
14.28
4.08
0.4
713.79
70
96.87
86.67
76.48
66.28
56.08
45.89
35.69
25.49
15.30
5.10
0.5
815.76
80
97.89
87.69
77.50
67.30
57.10
46.91
36.71
26.51
16.32
6.12
0.6
917.73
90
98.91
88.71
78.52
68.32
58.12
47.93
37.73
27.53
17.33
7.14
0.7
1019.70
100
99.93
89.73
79.54
69.34
59.14
48.95
38.75
28.55
18.35
8.16
0.8
metres
bar
100.95
90.75
80.56
70.36
60.16
49.97
39.77
29.57
19.37
9.18
0.9
Section 10
PRESSURE (bar) vs HEAD (m of water)
SECTION 10
Example
Find the metres head of water (1.0 s.g.) equivalent of 54.76 bar
50.00
bar
= 509.85m
Select ‘4 bar’ line in first column and
read along to figure under 0.7 in
top line, hence:
4.70
bar
= 47.93m
For 0.06 bar, read under 0.6 top line:
hence 6.12m dividing both figures by 10:
0.06
bar
= 0.612m
54.76
bar
= 558.392m
Thus by addition
Note:
For liquids with specific gravities differing from 1.0, answer must be divided by
actual specific gravity to obtain head in metres of liquid.
3 Contents 4
45
Hydraulic design Data
From bottom two lines:
Section 11
CALCULATION OF HEAD FOR PUMP SELECTION
To fulfill a pumping duty a pump must develop sufficient head and meet the
suction conditions. The total head of a system must take into account the
difference in liquid levels at inlet and outlet, friction in the pipes, surface
pressure (or in some cases vacuum) on inlet and outlet and the velocity of
the fluid at discharge. The following diagram and example explains how to
calculate the system head taking all these factors into account.
System head = total discharge head total suction head
H = hd – hs
The total discharge head is made from
four separate heads:
hd = hsd + hpd + hfd + hvd
• hd = total discharge head
• hsd = discharge static head
• hpd = discharge surface pressure head
• hfd = discharge friction head
• hvd = discharge velocity head
46
3 Contents 4
SECTION 11
The total suction head consists of four separate heads
hs = hss + hps - hfs - hvs
• hs = total suction head
• hss = suction static head
• hps = suction surface pressure head
• hfs = suction friction head
Hydraulic design Data
• hvs = suction velocity head
Example
Calculate the total head of the
following pump system.
The total friction through suction
pipes and fittings is equivalent
to 1m head and through delivery
pipes and fittings is equivalent to
10m head.
The header tank and discharge
pipe is open to atmosphere at sea
level.
The suction velocity head is 0.1m
and the discharge velocity head
is 0.5m
Pumped fluid is cold clean water.
3 Contents 4
47
First we calculate the total delivery head, hsd and hss – from the diagram we
can see that the discharge static head is 40m and the suction static head is
5m hpd –
0.014
= meters of liquid
specific gravity
pressure at sea level is approx. 760mm Hg, specific gravity of cold clean water
is 1, so 760 x 0.014/1 = 10.6m
millimeters of mercury x
so hpd is 10.6m, the header tank is also open to atmosphere so hps is also
10.6m
hd = hsd + hpd + hfd + hvd
= 40 + 10.6 + 10 + 0.5
= 61.1 m
hs = hss + hps - hfs - hvs
= 5 + 10.6 - 1 - 0.1
= 14.5 m
Total system head H = hd – hs
= 61.1 – 14.5
= 46.6 m
Note:
Gauge readings need correcting for height of gauge mounting. For this purpose
it is important that pressure gauges should be full of liquid. Where a vacuum
gauge is used for a suction lift, the gauge pipe should be left empty and
correction made from the point of connection, not from the gauge itself.
48
3 Contents 4
SECTION 11
Autoprime Pumping Terms
Head
“Total Head from all Causes” is the combination of both “Total Suction Head
and “Total Discharge Head”.
When static heights are kept to a minimum and pipework of the correct size
for the pump is used, performance will be maintained and running costs
minimised.
Hydraulic design Data
Suction head will be affected by changes in liquid viscosity and specific
gravity and in the vapour pressure resulting from increased liquid
temperature.
Net Positive Suction Head (NPSH)
NPSHr: minimum liquid head (pressure) required by the pump at the impeller
to pump the liquid, this is determined by the pump design. NPSHa: minimum
liquid head (pressure) available from the atmosphere to deliver the liquid to
the impeller for pumping.
Example:
NPSHa (Available)
10.5 m
less Static Lift
3.0 m
Friction & Vapour Loss
1.5 m
NPSHr (Required)
2.0 m
Therefore leaving for Suction Lift
4.0 m
3 Contents 4
49
Typical Suction Lift Configuration
Discharge
Hose
Friction
AUTOPRIME
Static
Delivery
Head
Static
Suction
Lift
Suction
Hose
Friction
50
3 Contents 4
Total
Discharge
Head
TOTAL
HEAD
FROM
ALL
CAUSES
SECTION 12
Section 12
FRICTION LOSS FOR WATER (m/100m) IN SMOOTH AND NEW
UNCOATED STEEL PIPES (HAZEN-WILLIAMS FORMULA, C=140)
NB Figures assume actual bores exactly equal to nominal bores. See following
notes regarding corrections for actual bores of commercial pipes differing from
nominal bores.
0.1
0.2
0.5
1
1.5
2
3
4
5
6
7
8
9
10
12
14
16
18
20
25
30
35
40
45
50
60
70
80
90
100
120
140
160
180
200
Bore
20(3/4)
0.83
3.0
16.4
65(2½)
0.4
0.68
1.45
2.5
3.8
5.2
6.9
8.9
11.1
13.4
175(7)
0.20
0.26
0.32
0.39
0.59
0.83
1.10
1.41
1.76
2.1
3.0
4.0
5.1
6.3
25(1)
0.28
1.0
5.5
20.0
80(3)
0.25
0.53
0.90
1.36
1.9
2.5
3.2
4.0
4.9
6.9
9.1
11.7
200(8)
0.20
0.31
0.43
0.58
0.74
0.92
1.11
1.56
2.1
2.7
3.3
4.0
5.6
7.5
32(1 3/4)
0.30
1.66
6.0
12.7
21.6
100(4)
0.30
0.46
0.64
0.84
1.10
1.36
1.66
2.3
3.1
4.0
4.9
6.0
9.0
225(9)
0.32
0.42
0.52
0.63
0.88
1.17
1.50
1.87
2.3
3.2
4.2
5.4
6.7
40(1 1/2)
0.56
2.0
4.3
7.3
15.5
26.4
125(5)
0.22
0.29
0.37
0.46
0.55
0.78
1.04
1.33
1.65
2.0
3.0
4.3
5.7
7.3
250(10)
0.38
0.53
0.70
0.90
1.12
1.36
1.90
2.5
3.2
4.0
50(2)
0.68
1.45
2.5
5.2
8.9
13.4
18.8
150(6)
0.15
0.19
0.23
0.32
0.43
0.55
0.68
0.83
1.25
1.76
2.3
3.0
3.7
4.5
6.3
300(12)
0.37
0.46
0.56
0.78
1.04
1.33
1.65
8.2
4.9
2.0
Hydraulic design Data
l/s
Nominal and actual bores of pipes in mm width with nominal inch equivalents.
3 Contents 4
51
For other types of pipe, multiply foregoing figures as below, for pipes in smooth
and new condition.
Galvanised iron
1.33
Uncoated cast iron
1.23
Coated cast iron, wrought iron, coated steel
1.07
Coated spun iron
1.04
Smooth pipe (lead, brass, copper, stainless steel, glass, plastic)
0.88
Friction losses are affected to an even greater degree by deviations of actual
bore from the standard dimensions represented in the foregoing table.
To correct for actual bore, multiply also by
(D/d)4.87 Where D = Standard (nominal) bore.
d = Actual internal diameter.
Multiplying factors for grey iron pipes to BS 4622 (both sand mould cast and
spun): ductile iron pipes to BS 4772: and uPVC pipes to BS 3505 taking into
account the corrections both for type of pipe and for actual bore, are as follows
on the next page.
52
3 Contents 4
32
40
-
Class 3 (spun)
Class 4 (spun)
0.75
0.64
-
Class K9
Class K12
Class D
Class E
for galvanised
medium; also X 1.24
0.90
0.66
0.75
Class C
Steel Tubes, BS 1387
-
Class B
uPVC, BS 3505:
50
-
-
-
-
(2)
65
-
-
-
-
(2½)
80
1.18
0.99
0.91
0.84
(3)
1.21
1.04
0.97
0.90
(4)
100
-
-
-
-
(5)
125
1.16
1.04
0.99
0.93
(6)
150
-
-
-
-
(7)
175
0.84
0.75
0.64
0.57
-
-
-
0.85
0.91
0.78
0.68
-
-
-
1.06
1.12
0.96
0.83
0.78
0.82
0.73
0.87
0.97
0.84
0.72
0.65
0.88
0.97
0.92
1.06
0.92
0.79
0.68
-
-
0.93
1.07
0.92
0.79
0.68
0.85
0.77
-
1.13
0.98
0.84
0.73
-
-
For sand mould cast pipes multiply by 1.03: also for uncoated bore pipes by 1.15
-
Ductile Iron, BS 4722:
-
(1½)
Class 2 (spun)
(1¼)
Class 1 (spun)
0.79
(in)
Hydraulic design Data
Grey Iron, BS 4622:
25
(1)
20
(¾)
Nominal bore mm
-
1.10
0.97
0.85
0.74
0.86
0.78
1.14
1.04
1.00
0.95
(8)
200
-
1.16
1.03
0.88
0.77
-
-
-
-
-
-
(9)
225
250
-
1.12
0.98
0.86
0.75
0.87
0.80
1.13
1.04
1.00
0.96
(10)
300
-
1.19
1.04
0.90
0.80
0.84
0.78
1.12
1.04
1.00
0.97
(12)
SECTION 12
3 Contents 4
53
Section 13
RESISTANCE IN FITTINGS
As in straight pipe, having length of following multiples of pipe diameter:
Flush sharp-edged entry
22
Slightly rounded entry
11
Flush bellmouth entry
4
Sharp entry projecting into liquid
36
Bellmouth entry projecting into liquid
9
Footvalve with strainer
113
Round elbow
45
Short radius bend
34
Medium radius bend
18
Close return bend
Tee: 100
straight through
11
side outlet, sharp angled
54
side outlet, radiused (swept tee)
22
Branch piece, straight through
7
Branch piece, flow to branch
45
Branch piece, flow from branch
22
Sluice (gate) valve
7
Reflux (back pressure, non-return) valve
45
Angle valve
225
Globe valve
450
Bellmouth outlet
9
Sudden enlargement
45
Taper, divergence angle above 60º
45
Taper, divergence angle 15º - 60º
22
Taper increaser or reduced with less than 15º divergence angle: Equivalent to pipe of mean
diameter.
Flap
0.06m Head
Note:
Multiplying factor for type and class of pipe to be applied to above equivalent
lengths for pipe fittings (elbows, bends, tees etc) but not to those for valves.
54
3 Contents 4
SECTION 13/14/15
Section 14
QUANTITIES PASSED BY PIPES AT DIFFERENT VELOCITIES
Actual bore of pipe, mm
Velocity
of flow,
m/s
50
80
100
125
150
1
1.96
5.03
7.85
12.27
1.5
2.95
7.54
11.78
2
3.93
10.05
15.71
2.5
4.91
12.57
175
200
225
250
300
17.67
24.1
31.4
39.7
49.1
70.7
18.41
26.51
36.1
47.1
59.6
73.6
106.1
24.54
35.34
48.1
62.8
79.5
98.2
141.4
19.64
30.68
44.18
60.1
78.5
99.4
122.7
176.7
l/s
5.89
15.08
23.56
36.82
53.02
72.2
94.3
119.3
147.3
212.1
6.87
17.59
27.49
42.95
61.85
84.2
110
139.2
171.8
247.4
4
7.85
20.11
31.42
49.09
70.69
96.2
125.7
159.0
196.4
282.8
5
9.82
25.13
39.27
61.36
88.36
120.3
157.1
198.8
245.4
353.4
Hydraulic design Data
3
3.5
Section 15
RECOMMENDED MAXIMUM FLOW THROUGH VALVES (l/s)
Size of Valve, mm
50
65
80
100
125
150
175
200
250
300
2.2
4.0
6.0
12.0
20.0
30.0
40.0
55.0
90.0
130.0
110.0 160.0
Foot valve with
strainer
Back pressure valve
3.0
5.0
8.0
15.0
25.0
37.5
50.0
70.0
Sluice valve
5.5
10.0
15.0
25.0
40.0
60.0
80.0
100.0 160.0 220.0
3 Contents 4
55
56
10.2
15.3
20.4
1.0
1.5
2.0
30.6
35.7
40.8
51.0
61.2
3.0
3.5
4.0
5.0
6.0
25.5
5.1
0.5
2.5
Head
(m water)
Pressure
(bar)
3 Contents 4
0.150
0.136
0.122
0.114
0.106
0.096
0.086
0.075
0.061
0.043
3
0.266
0.243
0.218
0.204
0.188
0.172
0.154
0.133
0.109
0.077
4
0.416
0.380
0.340
0.318
0.294
0.269
0.240
0.208
0.170
0.120
5
0.600
0.546
0.489
0.458
0.424
0.387
0.346
0.300
0.245
0.173
l/s per hole
6
Size of hole (mm)
1.065
0.972
0.870
0.814
0.754
0.688
0.615
0.532
0.435
0.307
8
1.67
1.52
1.36
1.27
1.18
1.07
0.96
0.83
0.68
0.48
10
2.40
2.19
1.96
1.83
1.70
1.55
1.38
1.20
0.98
0.69
12
Section 16
QUANTITIES OF WATER DISCHARGED BY ROUND SPRAY HOLES IN THIN
WALLED PIPES UNDER DIFFERENT PRESSURES
SECTION 16/17
Section 17
NET POSITIVE SUCTION HEAD (NPSH)
For a pump to fulfil a particular duty it must first be able to get the required
quantity in. For example, a pump may work satisfactorily when installed at a
given height above the liquid level on the suction side, but no longer do so if
it is placed higher, even though the total head remains unaltered in view of a
corresponding reduction in the height of lift on the delivery side.
Hydraulic design Data
The criteria for this is termed NPSH, which has two aspects, the NPSH the
installation and operating conditions provide (NPSH available) and the NPSH
needed to get stable flow into the pump impeller (NPSH required). The
installation conditions and pump selection must be reconciled so that the
NPSH required does not exceed the NPSH available.
Fluid not being sensibly cohesive, it cannot be towed. To be made to flow, it
must be pressed from behind. There must, therefore, be either an extraneous
pressure on the liquid and/or a head of the liquid itself, which is sufficient to
cover losses as far as the pump inlet and then overcome pump inlet losses
and create the requisite velocity into the impeller vanes.
The pressure available behind a liquid for creating movement is the absolute
pressure on the liquid free surface, less the liquid’s own pressure to move in
the opposite direction, i.e. to evaporate into the spaces above the free surface
– this is called vapour pressure. The head available at the pump inlet for
getting the flow into the pump impeller is therefore:• Absolute pressure on liquid free surface
Ha
• Plus height of liquid free surface above pump impeller
+ hs
• Less liquid vapour pressure
- hv
• Less losses between liquid free surface and pump inlet
- hl
(All expressed in metres head of the liquid).
3 Contents 4
57
Note:
+hs becomes negative if the liquid free surface is below the pump impeller.
Care must be taken to state NPSH available taking all these factors into
account, even though in particular cases the two may equalise each other, e.g.
with a liquid at boiling point hv equals Ha and they thus cancel each other out.
Otherwise confusion may arise through statement of NPSH, which is plainly
inconsistent with the circumstances, e.g. a figure being quoted as NPSH when
head over suction hs is meant.
The velocity required at inlet to the impeller vanes is a function of flow
quantity, area at vane inlets and velocity induced by impeller rotation.
Consequently the NPSH required varies with pump type and size, and increases
with both capacity and speed.
To maintain NPSH required within given limits, the permissible speed reduces
approximately as the square root of capacity increases.
The increased vapour pressure of warm water often affects suction as
indicated by the following table.
Negative figures represent minimum requirement of head of liquid above
impeller eye.
Temp of water oC
40
50
60
70
75
80
85
90
95
100
Suction limit (m)
6.25
5.75
4.75
3.25
2.5
1.5
0.25
-1
-2
-3
Note:
The above figures are intentionally conservative in order to cover varying
suction capabilities of different pumps. Better values may be obtainable
especially when the normal capacity of the pump is above the output required,
but to allow investigation, full details should be submitted, and the possibility
of the temperature being underestimated should not be overlooked.
58
3 Contents 4
SECTION 18/19
Section 18
MAXIMUM SUCTION LIFT WITH BAROMETRIC PRESSURE AT
DIFFERENT ALTITUDES
Barometric pressure
Practical
maximum suction
lift of pumps (m)
mm Hg
Sea level
1.013
760
10,33
500
0.954
716
9.73
6.5
6
1000
0.899
674
9.16
5.5
1500
0.846
634
8.62
5
2000
0.796
597
8.12
4.5
Hydraulic design Data
bar
Equivalent
head of
water (m)
Altitude (m)
Section 19
THERMOMETER SCALES
Temperature Conversion Formulae:o
F = (oC x 9/5) + 32 oC = (oF – 32) x 5/9
Comparison values in oF and oC Scales of temperature
o
F
o
-40
-31
-22
-4
5
14
23
32
41
50
59
68
77
86
95
104
-40
-35
-30
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
C
o
F
113
122
131
140
149
158
167
176
185
194
203
212
230
248
266
284
o
C
45
50
55
60
65
70
75
80
85
90
95
100
110
120
130
140
o
F
302
320
338
356
374
392
410
428
446
464
482
500
518
536
554
572
o
C
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
3 Contents 4
59
Section 20
LIQUID VISCOSITY AND ITS EFFECTS ON PUMP PERFORMANCE
Viscosity is the property of reluctance of a liquid to flow, i.e. the opposite of fluidity.
It involves units of force, length and time and can be expressed as ‘absolute’
in regard to the internal forces in the liquid, or as ‘kinematic’ relating these
forces to the liquid specific gravity. The most widely used unit of absolute
viscosity is the poise (100 centipoises). However, in all considerations of liquid
flow and pump performance the operative factor is the kinematic viscosity, the
corresponding unit being the stokes (100 centistokes).
stokes (centistokes) =
Poises (centipoises)
specific gravity
Common viscometers (Redwood, Saybold, Engler, etc) give readings having
arbitrary relationship to fundamental units. Conversion figures are given in the
schedule overleaf. These are approximate only as they may vary slightly with
temperature and other factors, and are not universally agreed on, but they are
sufficiently accurate for the purposes under consideration.
The only values of interest to the pump engineer are kinematic viscosity at
actual pumping temperatures. Viscosities are frequently quoted at standard
reference temperatures, commonly 100ºF (37.8ºC) or 60ºC (140ºF). If either of
these does not correspond with the actual pumping temperature, the viscosity
at the latter must be obtained from product data or estimated from general
viscosity/temperature curves.
The performance of a centrifugal pump when handling a viscous liquid depends
not only on the viscosity of the liquid but also its relative size and on whether the
pump is of low or high specific speed design. The smaller the required pumping
duty, the lower the viscosity for which centrifugal pumps are appropriate. For
these reasons it is necessary that all enquiries for pumps to handle viscous
liquids should be submitted to the pump maker for individual consideration.
In the last column of the schedule, indications have been given of the
approximate minimum practical size of centrifugal pump corresponding to
each viscosity. In general, for greater viscosities exceeding 25 stokes, pumps
of a positive displacement type should be used.
60
3 Contents 4
SECTION 20
Centrifugal Pump Affinity Laws
The affinity laws can be used to show the effect of either speeding up or slowing
down the rotational speed of the impeller and also how changing impeller
diameter will alter the performance of a pump. The affinity laws state that:
Pump capacity increases in proportion with impeller rotational speed.
Q N
∝
Pump head increases in proportion to the square of rotational speed.
H N2
Hydraulic design Data
∝
Pump power increases in proportion to the cube of rotational speed.
P N3
∝
Where Q = Capacity, H = Head, P = Power and N= Rotational speed
This allows the change in performance to be predicted as a result of
changing the pump speed.
Q2 = Q1 N2 N1
H2 = H1 N2 N12
P2 = P1 N2 N13
Where the subscript 1 indicates original condition and the subscript 2 indicates the revised condition.
Increasing either impeller diameter or rotational speed will have the same
proportional effect on impeller peripheral speed. This means the same can
be applied for changing impeller diameter.
Q2 = Q1 D2 D1
H2 = H1 D2 D12
P2 = P1 D2 D13
Where D = Impeller diameter
The affinity laws are proven to work more effectively for some types of
pumps as opposed to others and the accuracy of them is dependent on the
pump’s hydraulic design. Because of this fact and that there may be other
limiting factors (eg. casing or seal pressure rating, bearing life, etc), it is
strongly advised the pump manufacturer be consulted before any changes
are undertaken.
3 Contents 4
61
62
1
2
3
4
5
6
7
8
9
10
20
30
40
50
60
70
80
90
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Kinematic Kinematic
Viscosity
Viscosity
Stokes
Centistokes
3 Contents 4
364
324
284
244
203
163
123
85.0
51.7
48.8
46.0
43.2
40.5
37.9
35.3
33.0
30.9
29.0
Redwood
No 1
Seconds
416
370
323
277
231
186
141
97.5
58.6
55.4
52.0
48.7
45.5
42.3
39.1
36.2
33.5
31.0
Saybolt
Universal
Seconds
606
559
473
406
340
274
209
147
93.9
89.3
84.7
80.1
75.9
71.3
67.2
62.6
57.5
51.3
Engler
Seconds
11.8
10.5
9.21
7.90
6.61
5.33
4.07
2.87
1.83
1.74
1.65
1.56
1.48
1.39
1.31
1.22
1.12
1.00
36
32
28
24
20
16
12
9
-
-
-
-
-
-
-
-
-
-
44.0
39.5
35.0
30.5
26.0
22.2
18.5
15.0
-
-
-
-
-
-
-
-
-
-
68.9
77.5
88.6
103
124
153
207
310
620
689
775
886
1033
1240
1550
2067
3100
6200
Redwood Saybolt
Engler
Barbey
Admiralty
Furol
Degrees
Fluidity
Seconds Seconds
50-65
50-65
50-65
40-50
40-50
32-40
25-32
20-25
No
reasonable
limitation
Minimum Size
Centrifugal
Pump (mm)
APPROXIMATE VISCOSITY CONVERSION SCHEDULE
100
200
300
400
500
600
700
800
900
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
1
2
3
4
5
6
7
8
9
10
0
30
40
50
60
70
80
90
100
40500
36450
32400
28350
24300
20250
16200
12150
8100
4050
3645
3240
2835
2430
2025
1620
1215
810
405
Redwood
No 1
Seconds
46200
41580
36960
32340
27720
23100
18480
13860
9240
4620
4158
3696
3234
2772
2310
1848
1386
924
462
Saybolt
Universal
Seconds
67700
60600
53900
47300
40600
33800
27000
20300
13500
6770
6060
5390
4730
4060
3580
2700
2030
1350
677
Engler
Seconds
1316
1180
1050
921
789
658
526
395
263
132
118
105
92.1
78.9
65.8
52.6
39.5
26.3
13.2
4050
3645
3240
2835
2430
2025
1620
1215
810
405
365
324
284
243
203
162
122
81
41
4700
4230
3760
3290
2820
2350
1880
1410
940
470
423
376
329
282
235
188
141
94.7
48.5
1.03
1.24
1.55
2.07
3.10
6.2
6.9
7.8
8.9
10.3
12.4
15.5
20.7
31.0
62.0
Redwood Saybolt
Engler
Barbey
Admiralty
Furol
Degrees
Fluidity
Seconds Seconds
Hydraulic design Data
Kinematic Kinematic
Viscosity
Viscosity
Stokes
Centistokes
Positive
displacement
pump required
400-450
300-350
250-300
250-300
200-250
200-250
175-200
150-175
125-150
80-100
50-80
Minimum Size
Centrifugal
Pump (mm)
SECTION 20
3 Contents 4
63
Section 21
TEST TOLERANCES AND DIFFERENT STANDARDS
API 610 11th Edition
The following tolerances shall apply: • Test speed shall be within ± 3.0% of rated speed shown on pump
datasheet, at duty point.
• Rated differential head at duty - 0m to 75m ±3%
75m to 300m - ±3%
Over 300m - ±3%
• Rated differential head shutoff - 0m to 75m - ±10%
75m to 300m - ±8%
Over 300m - ±5%
• Rated Power at duty -
+4% (Cumulative tolerances are not acceptable)
• Rated NPSH at duty -
+0%
• Efficiency is not a rating value.
Note:
= If a rising head flow curve is specified, the negative tolerance specified here
shall be allowed only if the test curve still shows a rising characteristic.
British Standards – (Class C)
The following tolerances shall apply at duty flow rate: • Rate of flow
± 3.5%
• Pump Total head
± 3.5%
• Pump Input power
± 3.5%
• Pump Efficiency
± 5.0%
64
3 Contents 4
SECTION 21
Hydraulic Institute Test Standards
In making tests under this standard no minus tolerance or margin shall be
allowed with respect to capacity, total head or efficiency at the rated or
specified conditions.
The following tolerances shall apply:
• At rated head +10% of rated capacity
Hydraulic design Data
OR
• At rated capacity +5% of rated head under 500 feet
+3 % of rated head 500 feet and over
Conformity with only one of the above tolerances is required. It should be
noted that there might be an increase in horsepower at the rated condition
when complying to plus tolerances for head or capacity.
For a fire pump the following tolerances from NFPA 20 shall also apply:
• At 150% of rated capacity, head will range from minimum of 65% to
maximum of just below rated head.
• Shutoff head will range from minimum of 101% to maximum of 140% of
rated head.
Exception
If available suction supplies do not permit the flowing of 150% of rated
capacity, the fire pump shall be operated at maximum allowable discharge
to determine if it is acceptable. This reduced capacity shall not constitute an
unacceptable test.
3 Contents 4
65
ISO 9906:2012 (grade 1) Table 10
The following tolerances shall apply at duty flow rate: •
•
•
•
Rate of flow
Pump Total head
Pump Efficiency
Speed of rotation
± 4.5 %
±3%
-3%
±1%
ISO 9906:2012 (grade 2) Table 10
The following tolerances shall apply at duty flow rate: • Rate of flow ±8%
• Pump Total head
± 5.5 %
• Pump Efficiency
-5%
• Speed of rotation
±1%
ISO 9906:2012 (grade 2) Annex A.1 – Pumps produced in series.
The following tolerances shall apply at duty flow rate: • Rate of flow
±9%
• Pump Total head
±7%
• Pump Input Power
+9%
• Driver Input Power
+9%
• Pump Efficiency
-7%
ISO 9906:2012 (grade 2) Annex A.2 – Pumps with a driver power
input less than 10 kW
The following tolerances shall apply at duty flow rate: • Rate of flow
± 10 %
• Pump Total head
±8%
66
3 Contents 4
SECTION 21
Loss Prevention Council (LPC)
The following tolerances shall apply: • Rate of flow
±0%
• Pump total head
+5 %
• Pump input power
within duty rating and/or driver rating + 10%
The following tolerances shall apply: • At rated head +10% of rated capacity
OR
• At rated capacity +5% of rated head under 500 feet
• At 150% of rated capacity, the pump will develop not less than 65% of
rated head.
• The maximum net pressure for a fire pump shall not exceed 140% of rated
head.
Note:
No minus tolerance or margin shall be allowed with respect to capacity, total
head or efficiency at the rated or specified conditions.
3 Contents 4
67
Hydraulic design Data
Underwrites Laboratories (UL)
68
3 Contents 4
Velocity HEAD
CORRECTION
3 Contents 4
69
SECTION 22 Tables of Velocity Head Correction (Bar)
Flow (Litres/Minute)
Di
Dd
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
50
80
0.305
0.369
0.440
0.516
0.598
0.687
0.782
0.882
0.989
1.102
65
80
0.071
0.086
0.102
0.120
0.139
0.160
0.182
0.206
0.231
0.257
80
100
0.032
0.039
0.047
0.055
0.064
0.073
0.083
0.094
0.105
0.117
80
150
0.051
0.061
0.073
0.085
0.099
0.114
0.129
0.146
0.164
0.182
100
125
0.013
0.016
0.019
0.022
0.026
0.030
0.034
0.038
0.043
0.048
100
150
0.018
0.022
0.026
0.031
0.035
0.041
0.046
0.052
0.059
0.065
100
200
0.021
0.026
0.030
0.036
0.041
0.047
0.054
0.061
0.068
0.076
100
250
0.022
0.027
0.032
0.037
0.043
0.049
0.056
0.063
0.071
0.079
125
150
0.005
0.006
0.007
0.008
0.009
0.011
0.012
0.014
0.015
0.017
125
200
0.008
0.009
0.011
0.013
0.015
0.018
0.020
0.023
0.025
0.028
125
250
0.009
0.010
0.012
0.015
0.017
0.019
0.022
0.025
0.028
0.031
150
175
0.002
0.002
0.003
0.003
0.004
0.005
0.005
0.006
0.007
0.007
150
200
0.003
0.004
0.004
0.005
0.006
0.007
0.008
0.009
0.010
0.011
150
250
0.004
0.005
0.006
0.007
0.008
0.009
0.010
0.011
0.013
0.014
150
300
0.004
0.005
0.006
0.007
0.008
0.009
0.011
0.012
0.014
0.015
175
200
0.001
0.001
0.001
0.002
0.002
0.002
0.003
0.003
0.003
0.004
200
225
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.002
0.002
0.002
200
250
0.001
0.001
0.001
0.001
0.002
0.002
0.002
0.002
0.003
0.003
200
300
0.001
0.001
0.002
0.002
0.002
0.003
0.003
0.003
0.004
0.004
250
300
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.001
0.001
0.001
300
350
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
350
400
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Di - Smaller diameter (mm)
Dd - Larger diameter (mm)
Gauge pressure variations, where the flow is from :the smaller diameter to the larger diameter, then VAR. is POS(+) or,
the larger diameter to the smaller diameter, then VAR. is NEG(-)
70
3 Contents 4
SECTION 22
Flow (Litres/Minute)
Di
Dd
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
50
80
1.2211
1.3463
1.4776
1.6149
1.7584
1.9080
2.0637
2.2255
2.3934
2.5674
80
0.2847
0.3138
0.3444
0.3765
0.4099
0.4448
0.4811
0.5188
0.5579
0.5985
100 0.1298
0.1431
0.1571
0.1717
0.1869
0.2028
0.2194
0.2366
0.2544
0.2729
80
150 0.2021
0.2228
0.2445
0.2673
0.2910
0.3158
0.3415
0.3683
0.3961
0.4249
100 125 0.0532
0.0586
0.0643
0.0703
0.0766
0.0831
0.0899
0.0969
0.1042
0.1118
100 150 0.0723
0.0797
0.0874
0.0956
0.1041
0.1129
0.1221
0.1317
0.1417
0.1520
100 200 0.0844
0.0931
0.1022
0.1117
0.1216
0.1319
0.1427
0.1539
0.1655
0.1775
100 250 0.0878
0.0968
0.1062
0.1161
0.1264
0.1371
0.1483
0.1599
0.1720
0.1845
125 150 0.0191
0.0211
0.0231
0.0253
0.0275
0.0298
0.0323
0.0348
0.0374
0.0402
125 200 0.0313
0.0345
0.0378
0.0413
0.0450
0.0488
0.0528
0.0570
0.0613
0.0657
125 250 0.0346
0.0381
0.0418
0.0457
0.0498
0.0540
0.0584
0.0630
0.0678
0.0727
150 175 0.0082
0.0090
0.0099
0.0108
0.0118
0.0128
0.0138
0.0149
0.0160
0.0172
150 200 0.0122
0.0134
0.0147
0.0161
0.0175
0.0190
0.0206
0.0222
0.0238
0.0256
150 250 0.0155
0.0171
0.0187
0.0205
0.0223
0.0242
0.0262
0.0282
0.0303
0.0326
150 300 0.0167
0.0184
0.0202
0.0221
0.0240
0.0261
0.0282
0.0304
0.0327
0.0351
175 200 0.0040
0.0044
0.0048
0.0053
0.0057
0.0062
0.0067
0.0072
0.0078
0.0084
200 225 0.0021
0.0023
0.0026
0.0028
0.0030
0.0033
0.0036
0.0039
0.0041
0.0044
200 250 0.0033
0.0037
0.0040
0.0044
0.0048
0.0052
0.0056
0.0061
0.0065
0.0070
200 300 0.0045
0.0050
0.0055
0.0060
0.0065
0.0071
0.0076
0.0082
0.0089
0.0095
250 300 0.0012
0.0013
0.0014
0.0016
0.0017
0.0019
0.0020
0.0022
0.0023
0.0025
300 350 0.0005
0.0006
0.0006
0.0007
0.0007
0.0008
0.0009
0.0009
0.0010
0.0011
350 400 0.0002
0.0003
0.0003
0.0003
0.0004
0.0004
0.0004
0.0005
0.0005
0.0005
3 Contents 4
VELOCITY HEAD CORRECTION
65
80
71
Flow (Litres/Minute)
Di
Dd
3000
50
80
2.7475 2.9338 3.1261 3.3245 3.5291 3.7397 3.9564 4.1793 4.4083 4.6433
3100
3200
3300
3400
3500
3600
3700
3800
3900
65
80
0.6405 0.6839 0.7287 0.7750 0.8227 0.8718 0.9223 0.9742 1.0276 1.0824
80
100 0.2921 0.3119 0.3323 0.3534 0.3752 0.3976 0.4206 0.4443 0.4686 0.4936
80
150 0.4547 0.4855 0.5174 0.5502 0.5840 0.6189 0.6548 0.6917 0.7295 0.7684
100 125 0.1196 0.1277 0.1361 0.1448 0.1537 0.1628 0.1723 0.1820 0.1920 0.2022
100 150 0.1626 0.1736 0.1850 0.1968 0.2089 0.2213 0.2342 0.2474 0.2609 0.2748
100 200 0.1900 0.2029 0.2162 0.2299 0.2440 0.2586 0.2736 0.2890 0.3048 0.3211
100 250 0.1975 0.2108 0.2247 0.2389 0.2536 0.2688 0.2843 0.3003 0.3168 0.3337
125 150 0.0430 0.0459 0.0489 0.0520 0.0552 0.0585 0.0619 0.0654 0.0689 0.0726
125 200 0.0703 0.0751 0.0800 0.0851 0.0903 0.0957 0.1013 0.1070 0.1129 0.1189
125 250 0.0778 0.0831 0.0885 0.0942 0.0999 0.1059 0.1121 0.1184 0.1248 0.1315
150 175 0.0184 0.0197 0.0210 0.0223 0.0237 0.0251 0.0265 0.0280 0.0296 0.0311
150 200 0.0274 0.0292 0.0311 0.0331 0.0351 0.0372 0.0394 0.0416 0.0439 0.0462
150 250 0.0348 0.0372 0.0396 0.0422 0.0448 0.0474 0.0502 0.0530 0.0559 0.0589
150 300 0.0375 0.0401 0.0427 0.0454 0.0482 0.0511 0.0540 0.0571 0.0602 0.0634
175 200 0.0089 0.0095 0.0102 0.0108 0.0115 0.0122 0.0129 0.0136 0.0143 0.0151
200 225 0.0048 0.0051 0.0054 0.0058 0.0061 0.0065 0.0069 0.0072 0.0076 0.0080
200 250 0.0075 0.0080 0.0085 0.0090 0.0096 0.0102 0.0108 0.0114 0.0120 0.0126
200 300 0.0102 0.0109 0.0116 0.0123 0.0131 0.0138 0.0146 0.0155 0.0163 0.0172
250 300 0.0027 0.0029 0.0031 0.0032 0.0034 0.0037 0.0039 0.0041 0.0043 0.0045
300 350 0.0012 0.0012 0.0013 0.0014 0.0015 0.0016 0.0017 0.0018 0.0018 0.0019
350 400 0.0006 0.0006 0.0006 0.0007 0.0007 0.0008 0.0008 0.0009 0.0009 0.0009
Di - Smaller diameter (mm)
Dd - Larger diameter (mm)
Gauge pressure variations, where the flow is from :the smaller diameter to the larger diameter, then VAR. is POS(+) or,
the larger diameter to the smaller diameter, then VAR. is NEG(-)
72
3 Contents 4
SECTION 22
Flow (Litres/Minute)
Di
Dd
4000
50
80
4.8845 5.1318 5.3852 5.6447 5.9102 6.1820 6.4598 6.7437 7.0337 7.3298
4100
4200
4300
4400
4500
4600
4700
4800
4900
65
80
1.1386 1.1963 1.2553 1.3158 1.3777 1.4411 1.5058 1.5720 1.6396 1.7086
80
100
0.5193 0.5456 0.5725 0.6001 0.6283 0.6572 0.6867 0.7169 0.7477 0.7792
150
0.8084 0.8493 0.8912 0.9342 0.9781 1.0231 1.0691 1.1160 1.1640 1.2130
125
0.2127 0.2235 0.2345 0.2458 0.2574 0.2692 0.2813 0.2936 0.3063 0.3192
100
150
0.2891 0.3037 0.3187 0.3341 0.3498 0.3659 0.3823 0.3991 0.4163 0.4338
100
200
0.3377 0.3548 0.3724 0.3903 0.4087 0.4274 0.4467 0.4663 0.4863 0.5068
100
250
0.3510 0.3688 0.3870 0.4057 0.4247 0.4443 0.4642 0.4846 0.5055 0.5268
125
150
0.0764 0.0803 0.0842 0.0883 0.0924 0.0967 0.1010 0.1055 0.1100 0.1146
125
200
0.1250 0.1314 0.1379 0.1445 0.1513 0.1583 0.1654 0.1726 0.1801 0.1876
125
250
0.1383 0.1453 0.1525 0.1599 0.1674 0.1751 0.1830 0.1910 0.1992 0.2076
150
175
0.0327 0.0344 0.0361 0.0378 0.0396 0.0414 0.0433 0.0452 0.0472 0.0491
150
200
0.0486 0.0511 0.0536 0.0562 0.0589 0.0616 0.0643 0.0672 0.0700 0.0730
150
250
0.0619 0.0651 0.0683 0.0716 0.0749 0.0784 0.0819 0.0855 0.0892 0.0929
150
300
0.0667 0.0701 0.0736 0.0771 0.0807 0.0844 0.0882 0.0921 0.0961 0.1001
175
200
0.0159 0.0167 0.0175 0.0184 0.0192 0.0201 0.0210 0.0219 0.0229 0.0239
200
225
0.0085 0.0089 0.0093 0.0098 0.0102 0.0107 0.0112 0.0117 0.0122 0.0127
200
250
0.0133 0.0140 0.0147 0.0154 0.0161 0.0168 0.0176 0.0184 0.0191 0.0199
200
300
0.0181 0.0190 0.0199 0.0209 0.0219 0.0229 0.0239 0.0249 0.0260 0.0271
250
300
0.0048 0.0050 0.0053 0.0055 0.0058 0.0060 0.0063 0.0066 0.0069 0.0072
300
350
0.0020 0.0022 0.0023 0.0024 0.0025 0.0026 0.0027 0.0028 0.0029 0.0031
350
400
0.0010 0.0010 0.0011 0.0011 0.0012 0.0013 0.0013 0.0014 0.0014 0.0015
3 Contents 4
VELOCITY HEAD CORRECTION
80
100
73
Flow (Litres/Minute)
Di
Dd
5000
50
80
7.6320 7.9404 8.2548 8.5754 8.9020 9.2348 9.5736 9.9186 10.2697 10.6268
5100
5200
5300
5400
5500
5600
5700
5800
5900
65
80
1.7791 1.8510 1.9243 1.9990 2.0751 2.1527 2.2317 2.3121 2.3940
2.4772
80
100
0.8114 0.8441 0.8776 0.9116 0.9464 0.9817 1.0178 1.0544 1.0918
1.1297
80
150
1.2631 1.3141 1.3661 1.4192 1.4732 1.5283 1.5844 1.6415 1.6996
1.7587
100
125
0.3323 0.3458 0.3595 0.3734 0.3876 0.4021 0.4169 0.4319 0.4472
0.4627
100
150
0.4517 0.4700 0.4886 0.5075 0.5269 0.5466 0.5666 0.5870 0.6078
0.6290
100
200
0.5277 0.5490 0.5708 0.5929 0.6155 0.6385 0.6620 0.6858 0.7101
0.7348
100
250
0.5485 0.5706 0.5932 0.6163 0.6398 0.6637 0.6880 0.7128 0.7380
0.7637
125
150
0.1194 0.1242 0.1291 0.1341 0.1392 0.1444 0.1497 0.1551 0.1606
0.1662
125
200
0.1954 0.2033 0.2113 0.2195 0.2279 0.2364 0.2451 0.2539 0.2629
0.2720
125
250
0.2162 0.2249 0.2338 0.2429 0.2521 0.2615 0.2711 0.2809 0.2909
0.3010
150
175
0.0512 0.0532 0.0553 0.0575 0.0597 0.0619 0.0642 0.0665 0.0689
0.0713
150
200
0.0760 0.0791 0.0822 0.0854 0.0887 0.0920 0.0953 0.0988 0.1023
0.1058
150
250
0.0968 0.1007 0.1047 0.1087 0.1129 0.1171 0.1214 0.1258 0.1302
0.1348
150
300
0.1042 0.1085 0.1127 0.1171 0.1216 0.1261 0.1308 0.1355 0.1403
0.1451
175
200
0.0248 0.0258 0.0269 0.0279 0.0290 0.0301 0.0312 0.0323 0.0334
0.0346
200
225
0.0132 0.0138 0.0143 0.0149 0.0154 0.0160 0.0166 0.0172 0.0178
0.0184
200
250
0.0208 0.0216 0.0225 0.0233 0.0242 0.0251 0.0261 0.0270 0.0279
0.0289
200
300
0.0282 0.0294 0.0305 0.0317 0.0329 0.0342 0.0354 0.0367 0.0380
0.0393
250
300
0.0075 0.0078 0.0081 0.0084 0.0087 0.0090 0.0094 0.0097 0.0100
0.0104
300
350
0.0032 0.0033 0.0035 0.0036 0.0037 0.0039 0.0040 0.0042 0.0043
0.0045
350
400
0.0016 0.0016 0.0017 0.0017 0.0018 0.0019 0.0019 0.0020 0.0021
0.0022
Di - Smaller diameter (mm)
Dd - Larger diameter (mm)
Gauge pressure variations, where the flow is from :the smaller diameter to the larger diameter, then VAR. is POS(+) or,
the larger diameter to the smaller diameter, then VAR. is NEG(-)
74
3 Contents 4
SECTION 22
Flow (Litres/Minute)
Dd
6000
80
10.9901 11.3595 11.7350 12.1166 12.5043 12.8981 13.2981 13.7041 14.1162 14.5345
6100
6200
6300
6400
6500
65
80
2.5619 2.6480 2.7355 2.8245 2.9149 3.0067 3.0999 3.1946 3.2906
3.3881
80
100 1.1684 1.2076 1.2475 1.2881 1.3293 1.3712 1.4137 1.4569 1.5007
1.5451
80
150 1.8188 1.8799 1.9421 2.0052 2.0694 2.1346 2.2008 2.2680 2.3362
2.4054
100 125 0.4786 0.4946 0.5110 0.5276 0.5445 0.5616 0.5791 0.5967 0.6147
0.6329
100 150 0.6505 0.6723 0.6945 0.7171 0.7401 0.7634 0.7870 0.8111 0.8355
0.8602
100 200 0.7599 0.7854 0.8114 0.8378 0.8646 0.8918 0.9195 0.9476 0.9761
1.0050
100 250 0.7898 0.8164 0.8433 0.8708 0.8986 0.9269 0.9557 0.9849 1.0145
1.0445
125 150 0.1719 0.1777 0.1835 0.1895 0.1956 0.2017 0.2080 0.2143 0.2208
0.2273
125 200 0.2813 0.2908 0.3004 0.3102 0.3201 0.3302 0.3404 0.3508 0.3614
0.3721
125 250 0.3113 0.3217 0.3324 0.3432 0.3541 0.3653 0.3766 0.3881 0.3998
0.4116
150 175 0.0737 0.0762 0.0787 0.0812 0.0838 0.0865 0.0892 0.0919 0.0946
0.0975
150 200 0.1095 0.1131 0.1169 0.1207 0.1245 0.1285 0.1324 0.1365 0.1406
0.1447
150 250 0.1394 0.1440 0.1488 0.1536 0.1586 0.1636 0.1686 0.1738 0.1790
0.1843
150 300 0.1501 0.1551 0.1603 0.1655 0.1708 0.1762 0.1816 0.1872 0.1928
0.1985
175 200 0.0358 0.0370 0.0382 0.0394 0.0407 0.0420 0.0433 0.0446 0.0459
0.0473
200 225 0.0190 0.0197 0.0203 0.0210 0.0217 0.0223 0.0230 0.0237 0.0244
0.0252
200 250 0.0299 0.0309 0.0319 0.0330 0.0340 0.0351 0.0362 0.0373 0.0384
0.0396
200 300 0.0407 0.0420 0.0434 0.0448 0.0463 0.0477 0.0492 0.0507 0.0522
0.0538
250 300 0.0107 0.0111 0.0115 0.0118 0.0122 0.0126 0.0130 0.0134 0.0138
0.0142
300 350 0.0046 0.0048 0.0049 0.0051 0.0052 0.0054 0.0056 0.0057 0.0059
0.0061
350 400 0.0022 0.0023 0.0024 0.0025 0.0025 0.0026 0.0027 0.0028 0.0029
0.0030
3 Contents 4
6600
6700
6800
6900
VELOCITY HEAD CORRECTION
Di
50
75
Flow (Litres/Minute)
Di
Dd
7000
50
80
14.9588 15.3892 15.8258 16.2685 16.7172 17.1721 17.6331 18.1001 18.5733 19.0526
7100
7200
7300
7400
7500
7600
7700
7800
65
80
3.4870 3.5874 3.6891 3.7923 3.8969 4.0030 4.1104 4.2193 4.3296
4.4413
80
100 1.5903 1.6360 1.6824 1.7295 1.7772 1.8256 1.8746 1.9242 1.9745
2.0255
80
150 2.4756 2.5468 2.6191 2.6923 2.7666 2.8419 2.9182 2.9955 3.0738
3.1531
100 125 0.6514 0.6701 0.6891 0.7084 0.7279 0.7477 0.7678 0.7882 0.8088
0.8296
100 150 0.8853 0.9108 0.9367 0.9629 0.9894 1.0163 1.0436 1.0713 1.0993
1.1276
100 200 1.0343 1.0641 1.0943 1.1249 1.1559 1.1874 1.2192 1.2515 1.2842
1.3174
100 250 1.0750 1.1060 1.1373 1.1691 1.2014 1.2341 1.2672 1.3008 1.3348
1.3692
125 150 0.2340 0.2407 0.2475 0.2545 0.2615 0.2686 0.2758 0.2831 0.2905
0.2980
125 200 0.3829 0.3940 0.4051 0.4165 0.4280 0.4396 0.4514 0.4634 0.4755
0.4877
125 250 0.4237 0.4358 0.4482 0.4607 0.4735 0.4863 0.4994 0.5126 0.5260
0.5396
150 175 0.1003 0.1032 0.1061 0.1091 0.1121 0.1151 0.1182 0.1214 0.1245
0.1277
150 200 0.1490 0.1533 0.1576 0.1620 0.1665 0.1710 0.1756 0.1803 0.1850
0.1897
150 250 0.1897 0.1951 0.2007 0.2063 0.2120 0.2178 0.2236 0.2295 0.2355
0.2416
150 300 0.2043 0.2102 0.2162 0.2222 0.2283 0.2345 0.2408 0.2472 0.2537
0.2602
175 200 0.0487 0.0501 0.0515 0.0529 0.0544 0.0559 0.0574 0.0589 0.0604
0.0620
200 225 0.0259 0.0267 0.0274 0.0282 0.0290 0.0297 0.0305 0.0313 0.0322
0.0330
200 250 0.0407 0.0419 0.0431 0.0443 0.0455 0.0467 0.0480 0.0493 0.0505
0.0519
200 300 0.0553 0.0569 0.0585 0.0602 0.0618 0.0635 0.0652 0.0670 0.0687
0.0705
250 300 0.0146 0.0150 0.0155 0.0159 0.0163 0.0168 0.0172 0.0177 0.0182
0.0186
300 350 0.0063 0.0064 0.0066 0.0068 0.0070 0.0072 0.0074 0.0076 0.0078
0.0080
350 400 0.0030 0.0031 0.0032 0.0033 0.0034 0.0035 0.0036 0.0037 0.0038
0.0039
Di - Smaller diameter (mm)
Dd - Larger diameter (mm)
Gauge pressure variations, where the flow is from :the smaller diameter to the larger diameter, then VAR. is POS(+) or,
the larger diameter to the smaller diameter, then VAR. is NEG(-)
76
3 Contents 4
7900
SECTION 22
Flow (Litres/Minute)
Dd
8000
80
19.5380 20.0295 20.5271 21.0308 21.5407 22.0566 22.5786 23.1068 23.6410 24.1813
8100
8200
8300
8400
8500
65
80
4.5545 4.6691 4.7851 4.9025 5.0213 5.1416 5.2633 5.3864 5.5109
5.6369
80
100 2.0771 2.1293 2.1822 2.2358 2.2900 2.3448 2.4003 2.4565 2.5133
2.5707
80
150 3.2334 3.3148 3.3971 3.4805 3.5649 3.6502 3.7366 3.8240 3.9125
4.0019
100 125 0.8508 0.8722 0.8938 0.9158 0.9380 0.9604 0.9832 1.0062 1.0294
1.0530
100 150 1.1564 1.1855 1.2149 1.2447 1.2749 1.3054 1.3363 1.3676 1.3992
1.4312
100 200 1.3509 1.3849 1.4193 1.4542 1.4894 1.5251 1.5612 1.5977 1.6346
1.6720
100 250 1.4041 1.4394 1.4752 1.5114 1.5480 1.5851 1.6226 1.6606 1.6990
1.7378
125 150 0.3056 0.3133 0.3211 0.3289 0.3369 0.3450 0.3532 0.3614 0.3698
0.3782
125 200 0.5002 0.5128 0.5255 0.5384 0.5514 0.5646 0.5780 0.5915 0.6052
0.6190
125 250 0.5533 0.5673 0.5814 0.5956 0.6101 0.6247 0.6395 0.6544 0.6695
0.6849
150 175 0.1310 0.1343 0.1376 0.1410 0.1444 0.1479 0.1514 0.1549 0.1585
0.1621
150 200 0.1946 0.1995 0.2044 0.2094 0.2145 0.2197 0.2249 0.2301 0.2354
0.2408
150 250 0.2478 0.2540 0.2603 0.2667 0.2731 0.2797 0.2863 0.2930 0.2998
0.3066
150 300 0.2669 0.2736 0.2804 0.2872 0.2942 0.3013 0.3084 0.3156 0.3229
0.3303
175 200 0.0636 0.0652 0.0668 0.0684 0.0701 0.0718 0.0735 0.0752 0.0769
0.0787
200 225 0.0338 0.0347 0.0356 0.0364 0.0373 0.0382 0.0391 0.0400 0.0409
0.0419
200 250 0.0532 0.0545 0.0559 0.0572 0.0586 0.0600 0.0614 0.0629 0.0643
0.0658
200 300 0.0723 0.0741 0.0759 0.0778 0.0797 0.0816 0.0835 0.0855 0.0874
0.0894
250 300 0.0191 0.0196 0.0201 0.0206 0.0211 0.0216 0.0221 0.0226 0.0231
0.0236
300 350 0.0082 0.0084 0.0086 0.0088 0.0090 0.0092 0.0095 0.0097 0.0099
0.0101
350 400 0.0040 0.0041 0.0042 0.0043 0.0044 0.0045 0.0046 0.0047 0.0048
0.0049
3 Contents 4
8600
8700
8800
8900
VELOCITY HEAD CORRECTION
Di
50
77
Di
Dd
9000
50
80
24.7278 25.2804 25.8390 26.4038 26.9747 27.5517 28.1347 28.7239 29.3192 29.9206
9100
9200
9300
9400
9500
9600
9700
9800
65
80
5.7643 5.8931 6.0233 6.1550 6.2881 6.4226 6.5585 6.6958 6.8346
6.9748
80
100 2.6288 2.6875 2.7469 2.8070 2.8677 2.9290 2.9910 3.0536 3.1169
3.1808
80
150 4.0923 4.1838 4.2762 4.3697 4.4642 4.5597 4.6562 4.7537 4.8522
4.9517
100 125 1.0768 1.1008 1.1251 1.1497 1.1746 1.1997 1.2251 1.2508 1.2767
1.3029
100 150 1.4635 1.4962 1.5293 1.5627 1.5965 1.6307 1.6652 1.7000 1.7353
1.7709
100 200 1.7098 1.7480 1.7866 1.8257 1.8651 1.9050 1.9454 1.9861 2.0273
2.0688
100 250 1.7771 1.8168 1.8569 1.8975 1.9386 1.9800 2.0219 2.0643 2.1071
2.1503
125 150 0.3868 0.3954 0.4041 0.4130 0.4219 0.4309 0.4401 0.4493 0.4586
0.4680
125 200 0.6330 0.6472 0.6615 0.6759 0.6906 0.7053 0.7202 0.7353 0.7506
0.7660
125 250 0.7003 0.7160 0.7318 0.7478 0.7640 0.7803 0.7968 0.8135 0.8304
0.8474
150 175 0.1658 0.1695 0.1732 0.1770 0.1809 0.1847 0.1886 0.1926 0.1966
0.2006
150 200 0.2463 0.2518 0.2573 0.2630 0.2686 0.2744 0.2802 0.2861 0.2920
0.2980
150 250 0.3136 0.3206 0.3277 0.3348 0.3421 0.3494 0.3568 0.3642 0.3718
0.3794
150 300 0.3377 0.3453 0.3529 0.3606 0.3684 0.3763 0.3843 0.3923 0.4004
0.4087
175 200 0.0805 0.0823 0.0841 0.0859 0.0878 0.0897 0.0916 0.0935 0.0954
0.0974
200 225 0.0428 0.0438 0.0447 0.0457 0.0467 0.0477 0.0487 0.0497 0.0508
0.0518
200 250 0.0673 0.0688 0.0703 0.0719 0.0734 0.0750 0.0766 0.0782 0.0798
0.0814
200 300 0.0915 0.0935 0.0956 0.0977 0.0998 0.1019 0.1041 0.1063 0.1085
0.1107
250 300 0.0242 0.0247 0.0253 0.0258 0.0264 0.0269 0.0275 0.0281 0.0287
0.0292
300 350 0.0104 0.0106 0.0108 0.0111 0.0113 0.0115 0.0118 0.0120 0.0123
0.0125
350 400 0.0050 0.0051 0.0053 0.0054 0.0055 0.0056 0.0057 0.0058 0.0060
0.0061
Di - Smaller diameter (mm)
Dd - Larger diameter (mm)
Gauge pressure variations, where the flow is from :the smaller diameter to the larger diameter, then VAR. is POS(+) or,
the larger diameter to the smaller diameter, then VAR. is NEG(-)
78
3 Contents 4
9900
VELOCITY HEAD CORRECTION
Flow (Litres/Minute)
ELECTRICAL
DESIGN DATA
3 Contents 4
79
Section 23
AVERAGE EFFICIENCIES AND POWER FACTORS OF ELECTRIC MOTORS
Efficiency %
Typical PF
kW
2 Pole
4 Pole
6 Pole
Full load
¾ load
½ load
0.75
77.4
79.6
79.6
0.75
0.69
0.56
1.1
79.6
81.4
78.1
0.77
0.71
0.59
1.5
81.3
82.8
79.8
0.77
0.71
0.59
3
84.5
85.5
83.3
0.82
0.77
0.67
5.5
87
87.7
86
0.82
0.77
0.67
7.5
81.1
88.7
87.2
0.84
0.8
0.71
11
89.4
89.8
88.7
0.84
0.8
0.71
18.5
90.9
91.2
90.4
0.84
0.8
0.71
22
91.3
91.6
90.9
0.84
0.8
0.71
30
92
93.2
91.7
0.84
0.8
0.71
37
92.5
92.7
92.2
0.86
0.83
0.75
45
92.9
93.1
92.7
0.86
0.83
0.75
55
93.2
93.5
93.1
0.86
0.83
0.75
75
93.8
94
93.7
0.86
0.83
0.75
90
94
94.2
94
0.86
0.83
0.75
110
94.3
94.5
94.3
0.86
0.83
0.75
132
94.6
94.7
94.6
0.87
0.84
0.76
Note:
Power factors are of importance where the current is charged on a kVA
basis. The power factors of motors may be improved by the use of a suitable
condenser. To find the output kw of motors when Current, Efficiency and Power
Factor (PF) are known.
Direct Current
kW
=
volts x amps x eff %
1000 x 100
Alternating Current Single phase –
kW
=
80
volts x amps x eff % x PF
1000 x 100
3 Contents 4
SECTION 23
Three phase –
kW
= volts x amps x eff % x PF x 1.73
1000 x 100
Kilowatt consumption of any motor
= Output kW x 100
eff %
ELECTRICAL DESIGN DATA
To find amperes to be carried by cable connections to a motor when output
kW, Volts, Efficiency and Power Factor (PF) are known.
Direct current
amps
= kW x 1000 x 100
volts x eff %
Alternating current
Single phase amps
= kW x 1000 x 100
volts x eff % x PF
Three phase, amps per phase
= kW x 1000 x 100
volts x eff % x PF x 1.73
3 Contents 4
81
Section 24
APPROXIMATE FULL LOAD SPEEDS (RPM) OF ALTERNATING
CURRENT MOTORS
Frequency
82
kW
No of poles
25
30
40
50
60
0.75
2 Pole
1430
1716
2288
2860
3432
to
4 Pole
720
864
1152
1440
1728
2.2
6 Pole
475
570
760
950
1140
3
2 Pole
1450
1740
2320
2900
3480
to
4 Pole
720
864
1152
1440
1728
7.5
6 Pole
480
576
768
960
1152
11
2 Pole
1472.5
1767
2356
2945
3534
to
4 Pole
730
876
1168
1460
1752
22
6 Pole
485
582
776
970
1164
30
2 Pole
1485
1782
2376
2970
3564
to
4 Pole
740
888
1184
1480
1776
75
6 Pole
495
594
792
990
1188
3 Contents 4
SECTION 24/25
Section 25
STARTING ALTERNATING CURRENT MOTORS
Squirrel Cage Motors
Starting torque
(approx) %
Full load torque
Starting current
(approx) %
Full load current
Direct
100% - 200%
350% - 700%
Star delta (3 phase)
33% - 66%
120% - 230%
Series parallel (2 phase)
25% - 50%
90% - 175%
Auto transformer
25% - 85%
90% - 300%
ELECTRICAL DESIGN DATA
Method of starting
The above figures apply to Squirrel Cage motors of normal design and other
types are available namely:
High torque Squirrel Cage machines will give approximately twice the above
starting torques with unrestricted currents.
Low current Squirrel Cage machines restrict the current but give a lower
starting torque than the high torque machines. These two types can now be
used in many cases where slipring machines would have been necessary in
the past.
Slipring machines (2- and 3-phase). All slipring machines must be started
by means of a rotor resistance starter. A starting torque of full load torque is
obtainable with a starting current of approximately 1 ¼ full load current, this
usually being sanctioned by supply authorities for any size of motor.
3 Contents 4
83
84
3 Contents 4
WHOLE
LIFE COST
3 Contents 4
85
Section 26
Whole Life Cost Principles and Pump Design
Whole life cost can be broken down into a number of key components:
• Initial Capital Cost
• Operating/Energy Costs
• Replacement/Wear Part Costs
• Maintenance & Repair Costs
• Disposal Costs.
Initial Capital Cost
Capital cost is the most visible cost and has historically been the primary
selection criterion for most items of capital equipment. Pump users are now
becoming increasingly aware of post installation costs and their impact on the
total cost of ownership. Lowest capital cost purchases rarely prove economic
in the longer term and given that the initial capital cost of a centrifugal pump,
inclusive of installation, typically equates to between 5%-20% of whole life
cost, placing more emphasis on post installation cost will clearly prove much
more economic.
Operating/Energy Costs
Energy costs can easily equate to as much as 90% of the whole life cost of a
pumping installation, dependant on installed power and equipment utilisation.
Analysis of operating costs, in terms of energy consumption, is relatively
straightforward, given that pump utilisation and demand profiles are
understood and predictable. The wire to water efficiency of existing or
proposed installations can be compared and the results projected over
the estimated lifetime of the installation. This should be a fundamental
component of any tender assessment process or existing asset review
procedure.
Less visible however, is an installations’ capacity to operate at or near
optimum efficiency throughout its operational life. A degree of degradation
in hydraulic performance is inevitable with time. This degradation in
performance is primarily a result of wear and erosion of internal clearances.
Wear rings limit fluid re-circulation between the high and low-pressure
86
3 Contents 4
SECTION 26
areas within a centrifugal pump. A combination of erosion from high velocity
fluid passing between the wear ring surfaces and mechanical wear, resultant
from shaft deflection, widens the clearances allowing an increase in internal
re-circulation. Significantly, highlighting the importance of optimum pump
selection, this process will be accelerated if the pump operates at a duty point
less than 70% or more than 115% of best efficiency flow. The resultant loss of
performance usually leads to the pump running for longer periods to deliver a
given quantity of fluid.
WHOLE LIFE COSTS
Erosion of hydraulic profiles and increases in the relative roughness of
surfaces in contact with the pumped fluid, will also significantly impact on
pump performance.
Replacement/Wear Part Costs
The replacement of major components within a pump, whether as a result
of wear, erosion or following a component failure is often a very significant
contributor to whole life costs. A replacement rotating assembly will typically
equate to 70% of the costs of a replacement pump. It is not uncommon for all
components forming the rotating assembly to require replacement within the
lifetime of an installation. The selection of a conservatively engineered pump,
manufactured from high-grade materials should negate this, substantially
reducing maintenance costs and increasing the mean time between failure
and major service outages. Parts supplied by the original pump manufacturers
are likely to provide the highest levels of compatibility and will include any
reliability modifications that have been developed since the original date of
manufacture. SPP’s parts division provides a comprehensive section of spares
for SPP and Crane pumps. We can also provide a wide range of re-engineered
parts for other manufacturers’ pumps.
Maintenance & Repair Costs
The cost of regular monitoring and preventative maintenance is a necessary
component of an installations’ whole life cost and historical evidence shows
that regular maintenance is a lower cost option than unplanned emergency
repairs. When calculating the cost of maintenance, installation downtime and
resultant loss of productivity should be considered. Savings associated with
increased mean time between failure and service outages will offset any
higher initial capital costs incurred when installing a well-engineered pump,
designed for ease of maintenance. SPP’s service division can provide a range
3 Contents 4
87
of field and service centre based preventative maintenance programmes
to support our customers’ production and shut-down schedules. These can
vary between simple annual or biannual site based maintenance through to
planned pump and valve swap-out programmes to support maximum plant
uptime.
A well-engineered installation should be so designed as to offer good bearing
and seal life and facilitate all but a major overhaul in-situ, without recourse to
disturb either pipework or prime movers.
Disposal Costs
Disposal costs are relatively minor. Use of higher grade materials may
enhance recycling value but this is minimal in the pumps whole life cost and
is normally ignored.
Features of a Low Life-cycle Cost Centrifugal Pump
The majority of pumps employed on utility type applications fall into one of
the following categories: Horizontal Split Casing, Vertical Suspended Bowl or
End Suction Pumps. Only the latter are regularly manufactured to recognised
international standards e.g. ISO 5199. The requirement for low life-cycle cost
pumps is generally applicable to pumps with branch sizes 150mm and above,
where power requirements are higher, so it is not usually relevant to the
majority of End Suction Pump applications.
The following key areas have been identified by pump end users and designers
in relation to low life-cycle cost applications.
Mechanical Design
A significant change has taken place over the last decade in that the switch from
soft packed glands to mechanical seals for shaft sealing on utility applications is
near universal. The benefits of this change however have not been fully realised,
as mechanical seal life is generally proportional to certain key aspects of pump
performance, not least shaft deflection, vibration levels and seal chamber
design. The vast majority of utility pumps available today have their design roots
in the packed gland era. In many instances this is leading to premature bearing
and seal failures, as many pump shafts are quite simply too flexible without the
support of numerous packing rings and neck bushes.
88
3 Contents 4
SECTION 26
WHOLE LIFE COSTS
This is arguably the most significant factor, influencing the mean time between
failures of utility pumps. Mechanical seals and bearings are intolerant of shaft
deflection and residual unbalance. Therefore it is suggested that a pump
designed for low life-cycle cost would have a shorter span between bearings
and an increased shaft diameter when compared to a similar pump designed
in the packed gland era. Specifically shafts should be so designed, as to limit
shaft deflection at the limits of the operating range of say, 50% - 115% of best
efficiency flow, to a maximum of 0.05mm at the seal faces. Bearings likewise
should be designed to provide a minimum L10 life of 50,000 hours at these
limits.
Hydraulic Design
With the aid of 3-Dimensional Computational Fluid Dynamics, pump
manufacturers are now able to produce hydraulic designs that achieve
the theoretical maximum efficiency for a given specific speed or impeller
geometry. The challenge is then to consistently replicate these designs in
material form. High quality manufacturing techniques and procedures are
therefore essential, particularly as pump casings and impellers (the most
dimensionally critical components of any centrifugal pump) tend to be
produced as castings. Only foundry techniques that ensure a high standard of
dimensional accuracy and surface finish should be employed in low life-cycle
cost pump production.
Efficiency Degradation
The maximum benefit of installing an energy efficient machine will only
be realised if performance levels can be maintained for long periods of
time between overhauls. Performance degradation is inevitable, however a
combination of good hydraulic and mechanical design can have a positive
impact in this area and prolong optimum efficiency for much longer periods
of time.
Hydraulic design considerations are:
• Maintenance of optimum clearances between the impeller outside
diameter and the volute cut-water, which will avoid vane pass cavitation.
• Optimisation of impeller geometry with satisfactory suction specific speed
values, this will limit internal re-circulation and facilitate a wide band of
operation (30%-115% of best efficiency flow).
3 Contents 4
89
• Application of internal hydrophobic coating (low electronic affinity)
in order to reduce the relative surface roughness value of the pump
casing; thus maintaining the relative surface roughness values at a more
constant level, unlike that of a bare metal casing, which will oxidise once
put into service immediately impacting on hydraulic performance.
Mechanical design considerations
• Minimisation of shaft deflection will ensure no contact between impeller
eye ring and sealing/wear rings surfaces, thus maintaining ‘as new’
clearances for longer periods.
• Often overlooked but highly important is wear ring design. A labyrinth
profile will help to provide a staged pressure drop across the wear ring,
rather than simply allowing high velocity fluid to flow across wear ring
faces rapidly eroding internal clearances.
• High-grade materials of construction for the pump impeller with good
erosion/corrosion properties will ensure that the relative roughness of
hydraulic surfaces remain reasonably smooth throughout.
Packaging the Pumpset
When packaging a low life-cycle cost pump with a suitable prime mover, it is
important to ensure that the same fundamental design principles be applied
to the prime mover, baseplate/mounting assembly.
The benefits of a superior hydraulic design and first class component quality
can easily be forfeited by coupling the highly efficient pump to a lower
efficiency driver. Likewise bearing and seal design lives will not be realised if
the pump and driver are connected via a flexible and inadequate baseplate or
mounting frame.
The mounting arrangement as well as being rigid should facilitate a high
degree of in-situ maintenance. Mechanical seals and bearings should be
accessible without recourse to disturb either driver alignment of connecting
pipework. This dictates the use of spacer type couplings, if drive end bearings
and seals are to be maintainable in-situ.
Only through the application of all these design and packaging principles will
the true benefits of Low Life-cycle Cost pumping be realised by the end user.
90
3 Contents 4
ENERGY
3 Contents 4
91
Section 27
SPP Energy – Energy Saving Services
Pumps are the single largest user of motive power in both industrial and
commercial applications in the UK, accounting for over 30% of total power
consumption within these sectors.
Pumps account for approximately 13% of the UK’s total annual electrical
consumption (BPMA Data) and energy consumption during operation has been
identified as the most significant impact of pumps on the environment.
In recent years, energy costs have become volatile with Oil, Gas and Coal
prices at record levels. With this in mind, SPP has identified the need to
operate pump systems more efficiently, and can realistically offer reductions
in energy consumption and running costs by 30 to 50%.
Saving Costs, Saving Energy, Saving the Environment
It is estimated that over 11 million motors with a total capacity of 90 GW
are installed in UK industry – which represents about 40% of the UK’s total
electricity consumption. With pumps contributing nearly a third of this
consumption, there is considerable scope to reduce carbon emissions by
improving pump system efficiency.
SPP Energy Division promotes the benefits of auditing complete pump
systems and producing recommendations to minimise the energy
consumption of pumps and their associated systems. SPP Energy Division
can also if required supply many of the solutions capable of realising these
savings coupled with ongoing monitoring to validate such savings and sustain
them through the lifetime of the installation.
92
3 Contents 4
SECTION 27
Savings through innovation
Through the use of proven systems and techniques, SPP Energy offers a
complete energy saving solution for pumping systems that can be applied
equally to new projects and existing installations.
Annual C02 Savings Per 1% Efficiency Improvement
20000
18000
C02 Emissions Savings - kg
16000
14000
12000
10000
8000
20000 miles family car
6000
4000
Round the world flight
2000
0
0
50
100
150
200
250
300
350
400
450
500
550
System Power - kW
Energy Cost
Absorbed Power
Hours run per year
0.43
220
8750
kg C02/kWh
kW
hrs
C02 emissions
8277.5 kg C02
Savings per year
Annual Savings Per 1% Efficiency Improvement
3500
Annual saving £
3000
2500
2000
1500
1000
500
0
0
50
100
150
200
250
300
350
400
450
500
550
Power absorbed - kW
Energy Cost
Absorbed Power
Hours run per year
7 p/kWh
220 kW
8750 hrs
Saving per year
3 Contents 4
£1,347.50
93
ENERGY
It is clear that pump systems are heavy users of energy, especially large
pumps that run continuously. Such pumps are generally oversized and
operating far from their best efficiency points. They can suffer from poor pump
intake conditions and inefficient running regimes - all wasting considerable
amounts of energy. In order to save costs SPP Energy Division will undertake
site audits focused on complete pump systems, ultimately producing a detailed
report making recommendations for corrective action and clearly showing cost
savings, kW/Hr savings, payback time and CO2 reduction.
Services offered by SPP Energy include:
a. Site Survey/Audit (including equipment and operating regime)
b. Analysis by accredited engineers with Report (which will include
recomendations for efficiency improvements)
c. Solutions – eg:
•
Upgrade/ refurbish/replace pumps
•
Training
•
Operational recommendations
Computational Fluid Dynamics (CFD)
•
•
System Modelling
d. Sustained improvements through Lowest Life Cycle cost
e. Monitoring and Review
Intrusive measurement (Thermodynamic)
•
•
Individual parameter measurement (Non intrusive - Ultrasonic)
•
Permanent or temporary installations
•
Pump and system performance log
f. Pump Systems Management Contracts.
SPP Energy – Accreditation
The SPP Energy Team is certified and accredited in the use of Pump System
Analysis Testing (PSAT) and Competent Pump System Assessor (CPSA) –
working to globally recognised standards set within the Europe and the US.
The team also operates within guidelines set by:
•
Government Legislation
•
BPMA
•
Carbon Trust
•
ISO BS EN etc
•
Insurance assessors – such as Lloyds, Beauro Veritas,
LPC, CEMARS, Achillies etc.
www.sppenergy.com
94
3 Contents 4
CONVERSION
FACTORS
3 Contents 4
95
96
3 Contents 4
x
x
x
x
x
gals (Imp)
gals (Imp)
gals (US)
gals (US)
acre-inches
x
x
ft3
gal / min
x
ft3
x
x
in3
long tonne (Imp)
x
x
x
acres
miles2
lbs
x
yds2
x
100
x
ft2
bbls (oil)
1.028
x
in2
x
2.59
x
miles
x
0.4047
x
yards
ha-cm
0.836
x
feet
bbls (oil)
1.609
645.16
x
feet
0.2727
1016
0.4536
0.159
159
0.003785
3.785
0.004546
4.546
0.02832
28.32
16387
0.0929
0.9144
0.3048
304.8
0.0254
x
inches
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
m3 / h
kg
kg
m3
lit
m3
ha-cm
m3
lit
m3
lit
m3
lit
mm3
km2
ha
m2
m2
mm2
km
m
m
mm
m
mm
x
x
x
3.667
0.000984
2.2046
6.297
x
0.01
0.0063
x
x
0.973
x
264.2
x
220
0.2642
x
x
0.2200
35.31
0.0353
0.000061
0.3861
2.471
1.196
10.764
0.00155
0.6214
1.0936
3.281
0.00328
39.37
0.03937
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Number of
25.4
x
Number of
inches
Metric to Imperial
Imperial to Metric
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
gal / min
tonne (metric)
lbs
bbls
bbls
ha-cm x 100000 = lit
acre-inches
gals (US)
gals (US)
gals (Imp)
gals (Imp)
ft3
ft3
in3
miles2
acres
yds2
ft2
in2
miles
yards
feet
feet
inches
inches
Number of
Section 28
CONVERSION FACTORS
0.001333
10 / s.g.
x
x
x
x
ins Hg
torrs (mm Hg)
torrs (mm Hg)
kg / cm2
x
hp
0.7457
x
x
hp
x
Std atm
metric hp (CV, PS, PK, CF)
1.01325
x
kPa
0.98065
m liquid
0.9863
0.7355
0.10197 / s.g.
0.098065 x s.g.
x
x
kg / cm2
0.0136 / s.g.
0.03386
0.34537 / s.g.
0.02989 x s.g.
x
0.703 / s.g.
x
x
p.s.i.
0.0703
ins Hg
x
p.s.i.
0.06895
0.2778
17.00 / s.g.
0.2834 / s.g.
0.12653 / s.g.
1.04
0.04416
ft liquid
x
x
tons / min
p.s.i.
x
tonnes / h
m3 / hr
x
x
1000 lb / h
x
1000 bpd
0.472
x
x
cumins
barrels / h (bph)
28.32
x
cusecs
1.263
52.61
x
x
mgd
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
l/s
metric hp
kW
kW
bar
m
bar
bar
m.liquid
bar
m.liquid
bar
m.liquid
bar
m.liquid
kg / cm2
bar
l/s
l/s
l/s
l/s
l/s
l/s
l/s
l/s
l/s
x
0.792
x
x
x
x
x
x
x
x
x
x
x
x
x
1.0139
1.3596
1.341
0.9879
9.807 x s.g.
10.197 / s.g.
1.197
0.1
750
73.56 x s.g.
29.53
2.896 x s.g.
33.456 / s.g.
1.422 x s.g.
14.22
x
x
14.504
3.6
0.0588 x s.g.
3.528 x s.g.
7.903 x s.g.
0.5345
22.65
2.119
0.0353
0.0190
x
x
x
x
x
x
x
x
x
x
=
=
=
=
=
=
=
=
x s.g.
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
CONVERSION FACTORS
1000 gals / h
hp
metric hp
hp
Std atm
kPa
m liquid
kg / cm2
kg / cm2
torrs
torrs
ins Hg
ins Hg
ft liquid
p.s.i.
p.s.i.
p.s.i.
m3 / hr
tons / min
tonnes / h
1000 lb / h
1000 bpd
bph
cumins
cusecs
mgd
1000 gals / h
SECTION 28
3 Contents 4
97
Supplementary data and conversion factors
1 Imp gal
= 10 lb cold fresh water = 1.2 US gal
1 US gal
= 8.33 lb cold fresh water = 0.833 Imp gal
1 Cubic foot
= 6.23 Imp gal = 62.3 lb cold fresh water = 64 lb cold sea
water
1 (long) ton
= 2240 lbs = 224 Imp gal cold fresh water
1 (short) ton
= 2000 lbs = 240 US gal cold fresh water
1 barrel (bbl) oil
= 42 US gal = 35 Imp gal
1 acre-inch
= 22610 Imp gal
1 dm3
= 0.220 gals (Imp)
l/s
= (m3 / h) /3.6
Gallons per minute
(gpm)
= gallons per hour / 60
= million gallons per day (mgd) / 694.4
= US gpm / 1.2
= cubic feet per second (cusecs) x 374
= cubic feet per minute (cumins) x 6.23
Imperial gpm
= lbs per hour / 600 / specific gravity
= tons per min x 224 / specific gravity
= tons per hour x 3.74 / specific gravity
= barrels (oil) per hour (bph) x 0.583
= 1000’s barrels per day (bpd) x 24.3 x10-6
1 atmosphere
(British)
= 14.70 lbs / sq inch (psi) = 30 inches mercury (Hg) = 34
feet of water
= psi x 2.31 / specific gravity
Feet head
= ins Hg x 1.133 / specific gravity
1 Horsepower (hp)
= 33000 ft lbs per minute = 550 ft lbs per second
Flow velocity ‘v’ in
pipe v (ft / sec)
= 0.49 x gpm (Imp)
d2
d = pipe actual bore in inches
= atmosphere (British) x 34 / specific gravity
98
3 Contents 4
=
SECTION 28
Flow velocity ‘v’ in pipe
v (m / s)
1273.2 x l / s
d2
d = pipe actual bore in mm
=
Imp gpm x ft hd x s.g. =
US gpm x ft hd x s.g.
=
lmp gpm x psi
=
Imp gal / hour x psi
3300
CONVERSION FACTORS
‘Water’ horsepower (whp)
3960
1430
85800
Mechanical hp
=
whp x 100
efficiency %
fluid hp
= l / s x m x s.g. = l / s x kg / cm2 (metric) = l / s x m x s.g. = l / s x kg / cm2 (British)
75
7.5
76
7.6
fluid kW
= l / s x m x s.g.
101.97
Driver output kW
=
l / s x kg / cm2
=
l / s x bar
10.197
10
= fluid kW x 100 / E% (pump efficiency)
required
E (fraction)
= fluid kW
kW input to pump E% = fluid kW x 100
kW input to pump
3 Contents 4
99
Section 29
VACUUM TECHNICAL DATA
700
600
500
400
760
700
600
500
400
300
150
60
50
40
100
90
80
70
15
14
10
9
8
7
6
10
9
8
7
5
6
3
4
4
2
3
60
50
40
2
1.5
30
30
20
20
20
15
1
0.9
0.8
0.7
0.6
1
0.9
0.8
0.7
0.5
0.6
0.3
0.4
0.5
15
10
9
8
7
6
5
4
10
9
8
7
1.5
100
1033
1
0.9
0.8
0.7
0.6
0.5
0.4
0.2
4
0.15
0.1
0.09
0.08
0.07
0.06
3
5
10
0.3
0.2
0.15
%
0
10
20
30
40
15
0.4
50
60
20
21
22
23
24
0.10
0.09
0.08
0.07
80
25
0.06
27
28
95
0.04
0.03
0.02
90
91
92
93
94
0.05
29
29.1
29.2
29.3
29.4
cmHg mH2O
0
20
0
1
2
3
30
4
10
40
96
98
0.10
0.05
2
0.08
0.04
1.5
0.06
0.03
0.04
0.02
0.006
29.7
29.8
0.005
60
65
66
67
68
69
70
0.003
0.002
99
99.1
99.2
99.3
99.4
99.6
29.9
29.91
29.92
29.93
29.94
˚C
0.5
7
8
4
5
9
72
6
9.5
7
8
9
10
9.8
15
99.7
10.1
10.2
75.7
10.3
10.31
29.96
75.9
3 Contents 4
170
160
6
65
150
60
140
55
130
7
8
9
10
12
14
16
18
20
50
45
40
120
110
100
35
60
70
70
80
90
100
180
70
40
60
190
5
50
29.95
1
85
75
30
150
75.6
95
4
40
75.5
75.8
3
30
10
74
99.8
200
20
73
74.5
212
2
80
2
˚F
1.673 100
90
71
75
99.5
0.004
m 3/kg
50
29.6
0.01
0.009
0.008
0.007
m 3/kg
0.816
0.9
0.1
3
73.5
97
5
6
50
70
26
0.2
0.3
5
“Hg
0
29.5
6
3
2
Ata
Water saturation
temperature
psia
5
150
100
90
80
70
25
300
300
200
“Hg
30
Saturated water steam
volume of 1kg
Torr
Dry air volume of
1kg at 15˚C
mbar
1030
1000
900
800
Vacuum
Absolute pressure
Pressure and vacuum units conversions. Air and saturated water steam
specific volumes. Water saturation temperature.
30
25
20
90
80
70
60
80
90
100
15
10
50
150
5
40
200
0
32
250
3 Contents 4
End Suction
Vertical
Multi-Stage
Suspended
Bowl
Horizontally
Split
Horizontal, Vertical Open Shaft, Vertical Direct Mounted Electric Motor or
Horizontal Electric Motor or Engine Driven
Horizontal, Vertical Open Shaft, Vertical Direct Mounted
Electric Motor or Horizontal Electric Motor or Engine Driven.
Vertical Electric Motor or Engine Driven. Wet well or Dry well.
Vertical Electric Motor or Engine Driven.
Wet well or Dry well.
Horizontal DIN 24255 Electric Motor
or Engine Driven.
Horizontal Close Coupled Electric
Motor Driven.
Vertical Close Coupled Electric
Motor Driven.
200 mm to 1000 mm. Outputs up
to 4500 l/s.
Heads up to 275m.
150 to 700mm. Outputs to 2500l/s.
Heads up to 275m
100 mm to 600 mm. Outputs up
to 2500 l/s. Heads up to 300 m.
Pumping from depths up to 100 m.
200 to 1000mm. Outputs to
4500l/s. Heads up to 160m
32 mm to 150 mm. Outputs up to
140 l/s. Heads up to 105 m.
32 mm to 100 mm. Outputs up to
100 l/s. Heads up to 105 m.
40 mm to 100 mm. Outputs up to
60 l/s. Heads up to 65m.
LLC
Turbostream
GH, GL,
GR, GT
LLC
Unistream
Eurostream
Instream
Horizontal, Vertical Open Shaft, Vertical Direct Mounted Electric Motor or
Horizontal Electric Motor or Engine Driven. Hi res, vDin etc.
150 mm to 700 mm. Outputs to
2500 l/s. Heads up to 275m.
Hydrostream
Thrustream
Configurations
Discharge and Performance
SPP Model
CONVERSION FACTORS
Pump
Type
PRODUCT / APPLICATION CHARTS
SECTION 29/30
Section 30
101
102
3 Contents 4
Vertical Direct Mounted or Open Shaft Electric Motor Driven.
Vertical Direct Mounted or Vertical Open Shaft, Electric or
Engine Driven.
In-Line and Elbow Horizontal Integral Electric Motor Drive.
(Custom designs available).
Acoustic canopy on road tow or site trailer or skid type chassis
75 mm to 200 mm. Outputs to
100 l/s.
Heads up to 60 m.
200 mm to 1100 mm. Outputs up
to 4000 l/s.
Heads up to 100m.
50 mm to 250 mm. Outputs up
to 220 l/s.
Heads up to 30 m.
50 – 400mm. Outputs up to 700
l/s. Heads up to 160m
75 mm to 250 mm. Outputs up
to 250 l/s.
Heads up to 48 m. Up to 100 mm.
Outputs up to 20 l/s.
Aquastream
Freeway
Freeway LLC
Autoprime
Stereo /
Disintegrator
Solids Cutting
EQ/EV Solids
Diverter
Transformer Oil Pumps
Contractors Pumps
Dry Well Solids Handling
Packaged
Horizontal and Vertical Open Shaft. Electric Motor Drive.
Tank packages. Electric Motor Drive.
Horizontal or Vertical Electric Motor or Engine Driven.
200 mm to 650 mm. Outputs up
to 1800 l/s.
Heads up to 28 m.
Dry Well Solids Handling
Configurations
Discharge and Performance
SPP Model
Pump Type
•
•
•
•
Raw sludge
SECTION 30
Unscreened Sewage
•
Digested sludge
•
Activated sludge
•
Storm water
•
•
Screened sewage
•
•
•
•
•
•
Water intake
•
•
•
•
•
Boosting
•
•
Town water supply
•
Reservoir pumping
•
•
Ground water extraction
•
•
Unistream
•
•
Eurostream
Raw water lift
•
•
•
Freeway
Service water
•
•
CONVERSION FACTORS
Effluent
•
Sump pumping
•
Drainage
•
•
•
•
•
•
Hydrostream
LLC Split Case
Fountains
Thrustream
•
Fish farming
•
•
•
•
•
•
Sand filter washing
•
•
Swimming pools
•
•
Sprinkler irrigation
•
•
Flood irrigation
3 Contents 4
Turbine
LLC Vertical
Distintegrator
Diverter
Stereo
SPP Pump Type:
ENVIRONMENTAL
SERVICES:
Water Supply
Water Treatment
Sewage
Treatment
Drainage
Agriculture
Forestry
Contracting
APPLICATIONS
103
•
•
•
•
•
•
•
•
•
•
•
•
Ballast/deballast
•
•
•
Washdown
•
•
•
Utility/service water
•
Crude oil shipping
•
Injection water booster
•
•
Drilling water
•
•
•
Cooling water
•
•
Sea water lift
•
•
•
•
•
•
•
•
•
Transformer oil cooling
•
•
•
Bottle washing
•
•
•
Cargo handling
•
Pipeline boosting
•
Tank farm/fuel transfer
•
Spray point
•
•
Oil slops
•
•
•
•
Unistream
Eurostream
Process liquids
•
•
Moulding machine cooling
•
•
Bearing cooling
•
•
•
•
•
•
•
LLC Split Case
Hydrostream
•
Robot cooling
•
•
•
•
Process waste
•
Industrial stock
•
Paper stock
•
•
Raw juices
•
•
Fish farming
•
•
Thyristor cooling
104
Turbostream
Transformer Oil
Aquastream
Freeway
Turbine
Thrustream
3 Contents 4
LLC Vertical
SPP Pump Type:
INDUSTRIAL
SERVICES:
Power
Food
Paper
Sugar
Brweing
Motor
Process
Chemical
Steel
Platics
Onshore/Offshore
Oild Industry
APPLICATIONS
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Eurostream
Instream
•
•
Unistream
•
•
Sump pumping
•
•
•
•
Turbostream
Water supply
Thustream
•
Air washer circulation
•
•
Cooling tower circulation
•
Chilled water circulation
•
Cold water boosting
•
Boosted systems
•
•
Condensate return
•
Hot water circulation
•
•
•
•
•
Fire fighting marine
•
•
•
•
•
•
•
•
•
•
Fire fighting stationary
•
•
Fire jockey
CONVERSION FACTORS
Hose-reel systems
•
•
•
Fire monitor
•
•
Hydrant systems
•
Foam pumping
SECTION 30
Sprinkler systems
3 Contents 4
Multistream
Drive
Overhead Belt
SPP Pump Type:
Hospital services
Buliding services
Hazard protection
Fire protection
SERVICES
Offshore/onshore
MECHANICAL
FIRE AND
APPLICATIONS
105
Notes
106
3 Contents 4
Notes
3 Contents 4
107
Notes
108
3 Contents 4
3 Contents 4