Pump

Training
By:
Noor Alam
Table Of Contents
1. Pump – Definition is a device that moves fluids by converting
mechanical energy into hydraulic energy, creating a pressure
difference for fluid flow.
2. Types of Pumps
• Centrifugal Pumps
• PD Pumps
• Jet Pumps
• Electromagnetic Pumps
• Hydraulic Pumps
3. Application & Selection Criteria – Performance Curves
4. Design and Calculations –
5. Non-destructive Testing (NDT)
6. Factory Acceptance Test (FAT)
7. Auxiliary Components
8. Piping for Pumps
9. Pump Operation
10. Case Study
Function of Pump
A pump is used to increase the total energy content of a liquid
in the form of pressure increase.
A pumps converts

Mechanical Power into Hydraulic

Power
Pumps are used to perform one of the following jobs:

• Move liquids from low level to high level

• Move liquids from low pressure location to high pressure location
• Hydraulic Systems
• To increase the flow rate of a liquid

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Pump Drives
The driver of pump could be
1. Electric motor.
2. Gas or diesel internal combustion engine.
3. Steam turbine.
4. Gas turbine.
5. Air Operated.
6. Hand operated.
Small pumps may be operated by hand or foot, by air
pressure or another fluid pressure, or an electromagnet.
Pressure and Head
• Pressure is dependent on the (specific gravity) of the liquid
• Head is totally independent of (specific gravity) of the liquid

H=115 H=115 H=115

ft ft ft

60 50 35
psi psi psi

S.G.- 1.2 S.G.- 1.0 S.G.- 0.7

Types of Pumps
PD CENTRIFUGAL
OTHERS
PUMPS PUMPS

Reciprocat Plung Axial Jet

ing er Flow Pumps
Pisto
Rotar n Radial Electromagne
y Flow tic
Gear
Diaphrag Mixed Hydro
m Lobe Flow Pumps

Screw

Vane
Centrifugal Pump
• Centrifugal pumps are mechanical devices used to transport
fluids by converting rotational kinetic energy from an impeller into
hydrodynamic energy. They are widely used for moving liquids in Casing

industries like water supply, chemical processing, and irrigation Shaf

Impelle t
due to their efficiency and simplicity. r

Key Features: Inlet

• Simple Design: Minimal moving parts, making them easy to
maintain and operate.
• Versatility: Suitable for a wide range of liquids and
applications across industries. Bearin
g
• High Flow Rates: Efficient at handling large volumes of Cross-section diagram Transfer pump
RO230109
liquid with steady flow.

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Working Principle of Centrifugal Pump

1 2 3 4 5

Fluid Entry Rotating Impeller Centrifugal Force Energy Conversion Discharge

Fluid enters The impeller, a The impeller's The fluid flows The high-pressure
through suction rotating disc with rotation generates around volute at fluid then exits into
inlet into the eye of blades, spins centrifugal force, high velocity and as the discharge line
impeller, under the rapidly within the pushing the fluid the cross section of of the pump.
influence of suction pump's casing. outwards at high volute increases
head. velocity. velocity turn into
pressure.

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Working
Classification of Centrifugal
Pumps
Centrifugal
Pumps

Orientatio
Stages Impeller Flow
n

Single Multi- Horizont Vertica

Stage Stage al l

Enclos
Open Axial Radial
ed
Partiall
y
Open/s Mixed
emi
close
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Classification-Stages of Pumps
• Single-Stage Impeller

A single-stage centrifugal pump has one impeller and is best suited

for low-pressure applications where a high flow rate is needed. It is
simple in design, cost-effective, and widely used in industries like
water supply and HVAC systems.

• Multi-Stage Impeller

A multi-stage centrifugal pump consists of multiple impellers

arranged in series within the pump casing. Each impeller increases
the pressure of the fluid, making it ideal for high-pressure
applications like boiler feed, high-rise water supply, and industrial
processes.

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Classification-Impeller Type
• Pumps are also classified based on the construction of the impellers and are
shown as follows:

• Open type impeller pumps are suitable for handling fluids with solids or debris, like
wastewater, while enclosed impellers are preferred for clean liquids or applications requiring

minimal leakage and high pressure.

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Classification-Orientation
• Horizontal Pumps
Horizontal pumps have their shaft positioned horizontally, making
them easy to maintain and install in areas with ample floor space.
They are commonly used for high-flow and moderate-pressure
applications, such as water supply and industrial processing.
Horizontal
Pump

• Vertical Pumps
Vertical pumps have their shaft positioned vertically, often designed to
fit in compact spaces or handle fluids from deep wells or reservoirs.
They are ideal for applications requiring high head and where floor
space is limited, such as in water treatment plants or cooling towers.

Vertical Pump

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Classification- Flow

• Axial flow pumps have higher flow rates while radial flow pumps generate
higher pressure
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Components of Centrifugal
Pump
• Casing encloses the impeller and directs the fluid
toward discharge nozzle.
• Impeller is the rotating component which transfers
mechanical energy of shaft into hydrodynamic energy
of fluid
• Bearing includes rolling element to support the shaft
and ensure smooth rotation.
• Coupling connects the pump shaft to the motor shaft.
Close coupling, rigid, split and flexible coupling
depending on alignment and vibration needs.

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Components of Centrifugal
Pump
• Seal System
• All pumps developed pressure to pump the liquid.

• The pressurized liquid must be contained by a seal to prevent

leakage around the drive shaft.
• There are many types of seals that are used in different
types of pump. E.g.
• Wearing ring
Mechanical Seal cross-section for
• Packing Mechanical transfer pump (RO203109)
Seal
• Mechanical seal

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Components of Centrifugal
Pump

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 Codes and Standards for Pumps
• API 610 is a commonly used standard for centrifugal pumps Petrochemical and Oil & Gas
industry.

• ANSI/ASME B73.1 defines specifications for horizontal end-suction centrifugal pumps for
chemical processes. Focuses on dimensions, tolerances, and performance.

• AWWA E101 provides guidelines for centrifugal pumps used in water supply, including
maintenance, operation, and testing.

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NFPA (National Fire Protection Association)
• NFPA20-Standard for the Installation of Stationary Pumps for Fire Protection
IEEE (Institute of Electrical & Electronics Engineers)
• IEEE 1017-Recommended Practice for Field Testing Electric Submersible Pump Cable
• IEEE 1018-Recommended Practice for Specifying Electric Submersible Pump Cable ‐ Ethylene‐Propylene Rubber Insulation
• IEEE 1019-Recommended Practice for Specifying Electric Submersible Pump Cable ‐ Polypropylene Insulation
Air Conditioning Heating & Refrigeration Institute.
• AHRI210/240-Performance Rating of Unitary Air‐Conditioning & Air‐Source Heat Pump Equipment
• AHRI 340/360 I P-Performance Rating of Commercial and Industrial Unitary Air‐conditioning and Heat Pump Equipment
• AHRI 551/591 SI - Performance Rating of Water‐chilling and Heat Pump Water‐heating Packages Using the Vapor Compression Cycl
API (American Petroleum Institute)
• API 11 AR-Care And Use Of Subsurface Pumps
• API 11 S-Operation, Maintenance And Troubleshooting Of Electric Submersible Pump Installations
• API 11 S1-Electrical Submersible Pump Teardown Report
• API 11S2- Electric Submersible Pump Testing
• API 11 S3-Electric Submersible Pump Installations
• API 11 S4-Sizing And Selection Of Electric Submersible Pump Installations
• API 11 S6-Testing of Electric Submersible Pump Cable Systems
• API 11 S7-Application and Testing of Electric Submersible Pump Seal Chamber Sections
• API 11 S8- Electric Submersible Pump System Vibrations
• API 674 - Positive Displacement Pumps ‐ Reciprocatin
• API 675 - Positive Displacement Pumps ‐ Controlled Volume
• API 676 - Positive Displacement Pumps‐Rotary
• API 681 - Liquid Ring Vacuum Pumps and Compressors for Petroleum, Chemical, and Gas Industries Services
• API 682 - Pumps—Shaft Sealing Systems for Centrifugal And Rotary Pumps
• API 685 - Sealless Centrifugal Pumps for Petroleum, Petrochemical and Gas Industry Process Service
ASME (American Society of Mechanical Engineers)
• ASME B73.1 – Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process
• ASME B73.2 - Specification for Vertical In‐line Centrifugal Pumps for Chemical Process
ISO (International Organisation for Standardization)
Positive Displacement Pumps
They make fluid move by trapping a fixed amount and forcing
(displacing) that trapped volume into the discharge pipe.

• Theoretically can produce the same flow at a given

speed (RPM) no matter what the discharge
pressure.
• Called “constant flow machines”
• Must not operate against a closed valve on the
discharge side of the pump, it has no shutoff head
like centrifugal pumps
• A relief valve on the discharge side of the positive
displacement pump is therefore necessary
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Reciprocating Pump
A reciprocating pump is a type of positive displacement pump that uses a
back-and-forth (reciprocating) motion of a piston, plunger, or diaphragm to move a
fixed volume of fluid through the pump with each cycle. This motion creates a
suction and discharge effect, enabling the pump to handle fluids efficiently, even at
high pressures.
Key Features:
• Positive Displacement: Delivers a fixed volume of fluid
per stroke.

• High-Pressure Capability: Can generate high

pressures, making it ideal for demanding applications.

• Precise Flow Control: Suitable for applications requiring

accuracy.

• Handles Viscous Fluids: Can pump thicker or abrasive

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
fluids effectively.
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Piston Pump
A piston pump is a type of positive displacement
pump that uses a reciprocating piston to move fluids. It is
designed to create a high-pressure flow by drawing in and
expelling liquid through a cylinder with the movement of
the piston.
Key Features:
• High-Pressure Capability: Can generate pressures up-to 10,000 psi or more,
making it suitable for demanding applications.

• Versatility: Works with a wide range of fluids, including water, oils, chemicals,
and even abrasive or viscous materials.

• Adjustable Flow Rate: Flow can be controlled by adjusting the speed of the
piston movement.

• Reversible Operation: Can pump fluids in both directions if designed for

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
bidirectional Pumps
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Key Components of a Piston Pump

1. Piston: A cylindrical component that moves back

and forth within a cylinder to create suction and

discharge.

2. Cylinder: The chamber in which the piston

operates.

3. Valves:

• Suction Valve: Allows fluid to enter the

cylinder during suction stroke.

PD Pumps Centrifugal Selection Piping for • Discharge

Pump Valve:Case
Allows fluidCalculations
to exit during
&
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the discharge stroke.
Operating Principle of a Piston Pump
1. Suction Stroke:

• The piston or plunger moves away from the

pump chamber, creating a vacuum.

• This vacuum draws fluid into the chamber

through a one-way suction valve.

2. Discharge Stroke:

• The piston or plunger moves toward the chamber,

compressing the fluid.

• The compressed fluid exits through a one-way

discharge valve.

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Operating Principle of a Piston Pump

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Adv./Disadv. Of Piston Pump
Advantages Disadvantages
1. High Pressure Capability 1. High Maintenance
Piston pumps contain seals, rings, and
valves that experience wear and tear,
Upto 10,000 psi or more
requiring regular maintenance and
replacement.
2. Versatility 2. Limited Abrasive Fluid Handling
Can handle a variety of fluids, including Not ideal for highly abrasive or corrosive
clean, viscous, or mildly abrasive liquids, fluids, as these can accelerate wear on the
and even some gases. piston and seals.
3. Precise Flow Control 3. Pulsating Flow
The reciprocating motion creates
They deliver a fixed volume of fluid with pulsations in the fluid flow, which may
each stroke, allowing accurate dosing and require additional components (e.g.,
consistent flow. pulsation dampeners) to smooth the
output.
4. Reversible Flow 4. Noise and Vibration
The mechanical movement of the piston
Can pump fluid in both directions if
can produce significant noise and
designed for bidirectional operation,
vibration, which may require damping
PD Pumps offering flexibility in certain
Centrifugal applications.
Selection Piping for Pump Case Calculations &
measures.
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Single/Double Acting Piston/Plunger Pump
All reciprocating pumps can be either single acting or double
acting.
Feature Single-Acting Pump Double-Acting Pump

Stroke Utilization Pumps fluid in one Pumps fluid during both

stroke only strokes
Flow Continuity Intermittent with More continuous and
pulsations smoother flow
Design Simpler, fewer More complex,
Complexity components additional valves
Efficiency Lower Higher due to dual
action
Applications Low-pressure, low-flow High-pressure, high-
systems flow systems

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 Plunger Pump
A plunger pump is a type of positive displacement pump
that uses a reciprocating plunger (or piston) to move fluids
through a pumping chamber. It is designed to handle high-
pressure applications and is commonly used for transferring
or metering fluids in industries like oil , chemical
processing, and water treatment for chemical injection.
Key Features:
• Positive Displacement: Delivers a fixed volume of fluid per stroke.

• External Seals: The plunger passes through a stationary seal, minimizing fluid leakage and allowing the pump to handle
high pressures effectively.

• High Pressure: Capable of generating extremely high pressures (often exceeding 10,000 psi), making it suitable for
demanding applications.

• High Efficiency: Operates with minimal energy loss, ensuring efficient fluid displacement, even under high-pressure
conditions.

• PD Pumps
Customizable Centrifugal
Flow Rates: Flow canSelection Piping for
be adjusted by altering Pump
the speed of the plunger or the Case Calculations
pump’s design, offering &
Pumps Criteria Pumps Issues Studies NDE
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Rotary dosing applications.
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Key Components of a Plunger Pump

1. Plunger/Piston: A reciprocating component that

creates pressure to draw in and discharge fluid on one or
Discharge Valve both sides of its stroke.

Suction Valve 2. Cylinder: The chamber in which the piston operates.

3. Packing: Sealing material around the plunger to prevent

leakage of fluid between the plunger and the cylinder. It
ensures efficient pumping by maintaining a tight seal
during operation.

Cylinder 4. Valves:

Plunger Packing • Suction Valve: Allows fluid to enter the cylinder

during suction stroke.

• Discharge Valve: Allows fluid to exit during the

Double-acting Plunger Pump
discharge stroke.
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Key Components of a Plunger Pump
1. Cross-rods: These are linkages that connect

plungers to the drive mechanism in a "cross" or

"X" configuration, ensuring synchronized motion

of the plungers during both strokes of the pump.

2. Ties: Ties are rods that stabilize and secure the

pump's plunger system, maintaining alignment

and preventing excessive flexing during operation.

Note: If cross rods and ties are used to connect the

plungers/pistons, the need for rod packing is

Double-acting Plunger Pump
eliminated.
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Operating Principle of a Double Acting
Piston/Plunger Pump 1. Forward Stroke (Suction and Discharge
Simultaneously):
• As the piston/plunger moves forward : On one side
of the cylinder, the suction valve (B) opens,
drawing fluid into the cylinder due to the vacuum
created.

• On the other side of the cylinder, the fluid already

in the chamber is compressed and pushed out
throughStroke
2. Backward the discharge valve
(Suction and(A).
Discharge
Reversed):
• As the plunger moves backward: The roles of the
chambers reverse. The side where suction occurred
during the forward stroke now compresses fluid,
forcing it out through the discharge valve.
• Simultaneously, the other side of the cylinder now
experiences suction, drawing in fluid through its
respective suction valve.
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Operating Principle of a Double Acting
Piston/Plunger Pump

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Adv./Disadv. Of Plunger Pump
Advantages Disadvantages
1. High Pressure Capability 1. High Initial Cost

Plunger pumps can achieve very high pressures,

often exceeding those of most other pump types.
More expensive to purchase and install compared
The pressure capability depends on the pump's
to other pump types, such as centrifugal pumps.
design, materials, and application. (mostly greater
than 10,000 psi)

2. Self Priming 2. Pulsating Flow

Can draw fluids from a lower level without
additional priming, making it versatile for various Might require dampeners in sensitive applications.
setups.
3. Precise Flow Control 3. Pulsating Flow
The reciprocating motion creates pulsations in the
They deliver a fixed volume of fluid with each
fluid flow, which may require additional
stroke, allowing accurate dosing and consistent
components (e.g., pulsation dampeners) to
flow.
smooth the output.
4. Efficient Energy Use 4. Noise and Vibration
Can generate noise and vibrations during
High efficiency in transferring mechanical energy
operation, which may require additional
into fluid movement.
Centrifugal Selection Calculations &
PD Pumps Piping for Pumpdampening measures.
Case
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 Diaphragm Pump
A diaphragm pump is a type of positive displacement
pump that uses a flexible diaphragm to move fluids. The
diaphragm is reciprocated mechanically or pneumatically,
creating alternating suction and discharge pressures to
pump the fluid.
Key Features:
• Leak-proof Operation: The diaphragm isolates the fluid from the pump's mechanical components, ensuring

zero leakage.

• Self-Priming: Can handle air in the system and operate without priming.

• Versatility: Works with viscous, abrasive, and corrosive fluids.

• Durable Construction: Diaphragms and wetted components can be made from materials resistant to
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
specific chemicals or abrasion.
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Key Components of a Diaphragm Pump
1. Diaphragm: A flexible membrane (usually made
of rubber, Teflon, or elastomer) that moves to
create pressure and suction.
2. Valves:
• Suction valve: The inlet where the pump
draws fluid into the pumping chamber.
• Discharge Valve: The outlet through which
the pump expels the fluid under pressure.
3. Pump Liquid: The fluid being pumped. This fluid
is isolated from the hydraulic components by the
diaphragm.
4. Plunger: A reciprocating component driven by
the crankshaft or motor. The plunger pressurizes
the hydraulic fluid, which then moves the
diaphragm.
High Pressure Diaphragm Pump 5. Hydraulic Fluid: Transfers pressure from the
plunger to the diaphragm. It ensures smooth
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
Pumps Criteria Pumps
operation and
Issues
prevents wear on the diaphragm.
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Studies
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Operating Principle of a Diaphragm Pump
1. Suction Stroke:

• The plunger retracts, reducing the pressure

on the hydraulic fluid.

• This causes the diaphragm to move inward,

creating a vacuum in the pump chamber and
drawing in fluid through the suction valve.
2. Discharge Stroke:

• The plunger moves forward, pressurizing the

hydraulic fluid.

• The pressurized hydraulic fluid pushes the

diaphragm outward, expelling the pump liquid
through the discharge valve
High Pressure Diaphragm Pump
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Operating Principle of a Diaphragm Pump

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Sectional View of Double Diaphragm Pump
RO 230109 (CI Injection Pumps)

Seal Body Diaphragm

Diaphragm
Ring

Or Seal
Screw Lip Seal Feeler Orm Seal
Group
Pilot Band Elastic Parallel
Pin

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Adv./Disadv. Of Diaphragm Pump
Advantages Disadvantages
1. Leak-free Operation 1. Pulsating Flow
The diaphragm acts as a barrier between the The reciprocating action of the diaphragm
pump liquid and the mechanical components, causes flow pulsations, which might require
ensuring there is no leakage of the fluid being pulsation dampeners for smoother flow in
pumped. certain applications.
2. Versatility 2. Limited Pressure Range
Capable of handling a wide range of fluids,
Typically operates at lower pressures
including:
compared to piston or plunger pumps, with
• Corrosive fluids: Acids, chemicals.
maximum pressures around 1,200 psi in most
• Abrasive fluids: Slurries, fluids with solids.
cases.
• Viscous fluids: Oils, adhesives, or sludges.
3. Self-Priming 3. Slower Flow Rates
Can self-prime even with air in the system, Cannot achieve as high a flow rate as
making it highly reliable for starting operation centrifugal or gear pumps of similar sizes,
without external priming assistance. limiting their use in high-flow applications.
4. Dry Running Capability 4. Higher Wear of Diaphragm
The diaphragm is subject to repeated
Can run dry without damage for short periods,
mechanical stress, which can cause wear or
making it suitable for applications where fluid
failure over time, especially with abrasive or
availability
Centrifugal might be inconsistent.
Selection Piping for Calculations &
PD Pumps high-pressure
Pump fluids.Case
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Comparison
Feature Piston Pump Plunger Pump Diaphragm
Pump
Design Piston moves in Plunger moves Flexible
cylinder in cylinder diaphragm
moves
Pressure Medium to high Very high (up to Low to medium
(upto 6000 psi) 20,000 psi)
Applications General-purpose, Heavy-duty, Slurries,
clean fluids high-pressure hazardous fluids
Maintenance Requires more Lower Low
maintenance maintenance maintenance
Advantages Efficient, High pressure Self-priming, can
compact, high capacity, handle solids
pressure durable
Disadvantage Prone to wear, Limited fluid Limited
s requires seals types, expensive pressure,
PD Pumps Centrifugal Selection Piping for Pump requires external Calculations &
Case
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 Rotary Pump
A rotary pump is a type of positive displacement pump
that uses the continuous rotation of gears, lobes, screws, or
vanes to transfer fluids. Unlike reciprocating pumps, which
rely on back-and-forth motion, rotary pumps operate with a
rotating mechanism that traps fluid and moves it from the
pump's inlet to its outlet.
Key Features:
• Sealed Cavities: The rotating components create sealed cavities that carry the fluid through the
pump.

• Continuous Flow: The fluid is moved in a smooth continuous flow without pulsation.

• Performance: Rotary pumps are capable of handling both low-viscosity liquids (like water) and
high-viscosity fluids.

• Self-Priming: Can handle suction lift applications.

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 Gear Pump
A gear pump is a type of rotary positive displacement
pump that uses meshing gears to pump fluid. The gears
trap fluid between their teeth and the pump casing,
transferring it from the inlet to the outlet as they rotate.
Gear pumps are known for their simple design, reliability,
and ability to handle high-viscosity fluids.

Key Features:
• Positive Displacement: Delivers a fixed volume of fluid per revolution, ensuring consistent and accurate flow.

• Rotary Mechanism: Operates using meshing gears to transfer fluid from the inlet to the outlet.

• Compact Design: Simple construction with minimal moving parts, making it reliable and easy to maintain.

• High Efficiency: Provides steady, non-pulsating flow, which is ideal for precision applications.

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Key Components of a Gear Pump
1. Casing: Encases and supports internal
components. Made from materials such as cast
iron, stainless steel or other alloys.

2. Gears: Commonly made of hardened steel,

bronze, or plastic. Can be external or internal.
Pressurizes fluid by trapping and sealing between
meshing gears.

3. Valves:

• Suction Port: Positioned at the inlet side of

the pump. Allows the fluid to enter the pump.

• Discharge Port: Outlet side of the pump.

Transfers pressurized fluid.
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Operating Principle of a Gear Pump
1. Suction: Gears rotate, creating a vacuum at the

suction port, drawing fluid into the pump.

2. Fluid Trapping: Fluid gets trapped between the

gear teeth and the pump casing.

3. Fluid Transfer: The rotating gears carry the

trapped fluid around the casing from the suction

side to the discharge side.

4. Discharge: At the discharge port, the gears re-

mesh, forcing the fluid out under pressure.

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Types of Gear Pumps
Gear
Pumps

Position Type of
of Gears Gears

Externa
Internal Spur Herringbo
l
ne

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Types acc. To Position of Gears

External Gear Pump Internal Gear Pump

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Operating Principle of an External Gear Pump

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Operating Principle of an Internal Gear Pump

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Operating Principle of a Herringbone Gear Pump

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Adv./Disadv. Of Gear Pump
Advantages Disadvantages
1. Compact and Simple Design 1. Not Suitable for Abrasive Fluids
Tight clearances make them prone to
Minimal moving parts make gear
wear when pumping fluids with solids
pumps reliable and easy to maintain.
or abrasives.
2. Self-Priming 2. Limited Suction Lift:
Gear pumps can draw fluid into Although self-priming, the suction
themselves during startup, ideal for capacity is lower than other pump
suction lift applications. types like diaphragm pumps.
3. Close Tolerances Require
3. Handles High Viscosity Fluids
Maintenance
Excellent for pumping thick fluids like Worn or damaged parts can lead to
oils, syrups, and adhesives. reduced efficiency or leakage.
4. Steady and Non-Pulsating
4. Noise Levels
Flow:
Provides consistent and smooth fluid
Some gear pumps can be noisy,
delivery, suitable for precise
especially at high speeds or pressures.
applications.
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 Screw Pump
A screw pump is a type of positive displacement pump
that uses one or more screws (helical rotors) to move fluids
or solids along the pump's axis. The screws rotate within a
cylindrical housing, forming sealed cavities that transport
the fluid from the pump inlet to the outlet without
significant pulsation or turbulence.
Key Features:
• Smooth Flow: Provides a continuous, non-pulsating flow, making it ideal for applications requiring precision.

• Handles High Viscosities: Efficiently pumps viscous fluids, including oils, sludge, and other thick materials.

• High Pressure and Efficiency: Can operate under high pressure while maintaining efficiency.

• Minimal Noise and Vibration: Quiet operation due to smooth fluid movement.

• Axial Fluid Movement: The fluid moves axially (along the screw axis) with minimal shear, making it gentle on shear-sensitive
fluids.

• Low Maintenance:Centrifugal
PD Pumps The robust designSelection
and absence of valves or other complex
Piping for Pumpcomponents lead to reducedCalculations
Case maintenance &
Pumps Criteria Pumps Issues Studies NDE
requirements.
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Key Components of a Screw Pump
Discharge Port Drive Screw 1. Casing: The external housing that encloses the screws
and forms the flow pathway for the fluid.
2. Gears (Timing Gears): A set of external gears located
at one end of the screws.
3. Drive Screw: The main screw connected to the motor or
external drive system.
4. Idler Screw: The secondary screw that rotates in
synchronization with the drive screw.
5. Valves:
Gears • Suction Port: The inlet of the pump where fluid
Casing enters and flows into the chambers formed between
Idler Screw the screws and casing.
Suction Port
• Discharge Port: The outlet of the pump where the
fluid exits after being transported through the screw
chambers.

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Operating Principle of a Screw Pump
1. Suction:

• The rotation of the screws creates a low-pressure zone at the

suction port, drawing fluid into the pump.

• The screws start to trap the fluid in the cavities formed

between the screw threads and the casing.

2. Axial Fluid Transport:

• The fluid is trapped in sealed cavities between the screw

threads and the casing and moved axially along the screws.

3. Synchronization: Timing gears or intermeshing screws

ensure smooth, contact-free rotation for efficient operation.

4. Discharge: The fluid exits through the discharge port as a

steady, non-pulsating flow.
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Operating Principle of a Screw Pump

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Adv./Disadv. Of Screw Pump
Advantages Disadvantages
1. Smooth, Non-Pulsating Flow: 1. High Initial Cost
Ensures steady fluid transfer, ideal for More expensive than simpler pump
precision applications. designs like centrifugal pumps.
2. Handles High Viscosity Fluids: 2. Complex Design:
Precision manufacturing is required,
Excellent for thick, sticky, or abrasive
increasing costs and maintenance
liquids.
complexity.
3. Bidirectional Operation: 3. Specialized Maintenance:
Can pump fluid in either direction if Repair and maintenance require
required. skilled personnel and specialized tools.
4. Wide Operating Range: 4. Sensitivity to Dry Running
Capable of handling low to high flow Prolonged dry running can damage
rates and pressures. screws or seals.

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 Vane Pump
A vane pump is a type of positive displacement pump that
uses a set of sliding vanes mounted on a rotor to move fluid.
As the rotor spins within an eccentrically mounted casing, the
vanes slide in and out of slots, creating chambers of varying
volume. These chambers draw fluid in from the inlet, trap it,
and then discharge it under pressure at the outlet.
Key Features:
• Low Pulsation: The design of the sliding vane mechanism provides relatively smooth, continuous flow with minimal pulsations,
which is beneficial for sensitive processes.

• Compact Design: These pumps are relatively compact and have a simple design, making them easy to install and maintain.

• Rotary Action: The pump’s mechanism consists of vanes that slide in and out of slots as the rotor turns, trapping fluid in
pockets and pushing it through the pump.

• Variable Flow Capacity: The flow rate can be adjusted by varying the speed of the pump, making them versatile for different
flow requirements.

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Key Components of a Vane Pump
1. Casing: The stationary outer shell of the pump. It contains the rotor
and vanes, maintaining the pressure differential and providing
Suction Port structural support.

Sliding vane Discharge 2. Sliding Vane: These are movable vanes located in slots on the
Port
rotor. They slide in and out due to centrifugal force and the pressure
differential, creating sealed compartments to trap and move the
fluid.

3. Rotor: The central rotating component of the pump that houses the
sliding vanes. It spins within the pump casing, driving the motion of
Rotor Casing the vanes.

4. Ports:

• Suction Port: This is where the fluid enters the pump. It

connects the pump to the supply line, drawing the fluid into the
chamber.
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
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PumpsDischarge Port: The fluid exitsStudies
Issues NDEport
the pump through this
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Operating Principle of a Vane Pump
1. Rotor and Vanes: The rotor, positioned eccentrically in the

casing, has sliding vanes that move radially in and out of

slots.

2. Suction: As the rotor turns, expanding chambers between

vanes create a low-pressure zone, drawing fluid in through

the suction port.

3. Transport: The trapped fluid is carried around the casing by

the vanes.

4. Discharge: On the discharge side, shrinking chambers

compress the fluid, forcing it out through the discharge port.

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Operating Principle of a Vane Pump

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Adv./Disadv. Of Sliding Vane Pump
Advantages Disadvantages
1. Self-Priming: 1. Wear and Maintenance
Sliding vanes can wear out over time
Excellent at creating suction, even
due to constant contact with the
with a dry start
casing, requiring regular replacement.
2. Smooth Flow: 2. Limited Pressure Range:
Provides a steady, low-pulsation fluid Not suitable for very high-pressure
flow. applications.
3. Handles Viscous Fluids: 3. Fluid Compatibility:
Effective with a wide range of fluid Sensitive to abrasive fluids or those
viscosities, from light solvents to with solid particles, as these can
heavy oils. damage the vanes and casing.
4. Efficiency: 4. Lubrication Dependence
Requires the pumped fluid to provide
Maintains high volumetric efficiency
lubrication for vanes and casing;
due to the tight seal between vanes
unsuitable for completely dry
and casing.
pumping.

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 Lobe Pump
A lobe pump is a type of positive displacement pump that uses
two or more intermeshing lobes (rotating elements) to move fluid
through the pump. The lobes are mounted on parallel shafts and
rotate in opposite directions within a casing. These pumps are
widely used for transferring viscous fluids and solids-laden liquids
in industries like food, pharmaceuticals, and chemicals.
Key Features:
• Gentle Fluid Handling: The lobes do not come into contact with each other, minimizing shear and preventing
damage to delicate materials.

• High Efficiency: Maintains consistent flow and pressure, even with thick or abrasive fluids.

• Sanitary Design: Often used in hygienic applications due to their ability to be easily cleaned (CIP/SIP systems).

• Non-Pulsating Flow: Provides a smooth, continuous flow with minimal pulsations.

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Key Components of a Lobe Pump
1. Casing: The stationary outer housing that encloses the lobes and
Lobe
Casing maintains the pump's structural integrity.
Suction Port Discharge Port 2. Lobes: The rotating elements (typically two or more) shaped like

gears or paddles that intermesh but do not touch.

3. Ports:

• Suction Port: Positioned on the low-pressure side, it allows the

fluid to be drawn into the pump chamber as the rotating lobes

create a vacuum.

• Discharge Port: Positioned on the high-pressure side, it

delivers the fluid to the system at a steady flow rate.

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Operating Principle of a Lobe Pump
1. Rotor Movement: The pump consists of two or more lobes mounted

on parallel shafts. These lobes rotate in opposite directions, creating

cavities between them as they move.

2. Fluid Intake: As the lobes rotate, they create an expanding space

(vacuum) on the inlet side of the pump, drawing fluid in from the

suction port.

3. Fluid Transport: The fluid is trapped in the pockets between the

lobes and the pump casing.

2. Fluid Discharge: As the lobes continue to rotate, they move the

trapped fluid towards the discharge side. The volume between the

lobes decreases, forcing the fluid out through the discharge port.
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Operating Principle of a Lobe Pump

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Adv./Disadv. Of Lobe Pump
Advantages Disadvantages
1. Gentle Handling: 1. Space and Size
The pumping action is gentle, making them
Lobe pumps are relatively large compared to
ideal for delicate or shear-sensitive
other types of pumps, which might require
products, such as food, cosmetics, or
more space in certain installations.
pharmaceutical applications.
2. Versatile: 2. Complex Maintenance:
Lobe pumps can handle fluids with varying Due to the intricate design, they may require
viscosities, solids, and even some abrasive more maintenance and specialized service,
materials, making them suitable for a wide including rotor replacement and bearing
range of applications. adjustments.
3. Durability: 3. Higher Initial Cost:
They are built to last, with robust
Lobe pumps tend to have a higher upfront
construction that can handle harsh
cost compared to other pump types, such as
operating conditions, making them durable
centrifugal pumps.
in industrial applications.
4. Pulsation-Free Flow: 4. Noise:
They offer a consistent, smooth, and near- They can generate more noise compared to
pulsation-free flow, which is important in other pumps, especially when handling thick
processes where a steady flow is needed. or abrasive fluids.
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Comparison
Feature Gear Pump Vane Pump Screw Pump Lobe Pump

Operating Uses meshing gears Rotating vanes in a Two or more screws Rotating lobes trap
Principle to trap and move chamber move fluid. move fluid through and move fluid in a
fluid. the pump. cavity.
Flow Type Pulsating flow, though Smooth flow with low Smooth, continuous Smooth, near-
less than pulsations. flow with minimal pulsation-free flow.
reciprocating pumps. pulsations.
Viscosity Handles a wide range Handles low to Ideal for handling Ideal for high-
Handling of viscosities, medium viscosity high-viscosity fluids. viscosity fluids, even
especially high fluids. slurries.
viscosities.
Pressure Can handle high Can handle moderate Excellent for high- Good for moderate to
Handling pressure. pressure. pressure high pressures.
applications.
Efficiency Efficient, but can lose High efficiency in low- High efficiency for High efficiency for
efficiency with low- viscosity fluids. viscous fluids. viscous fluids, but
viscosity fluids. less efficient for low-
viscosity.
Flow Consistency Can be slightly Consistent, with low Continuous and Consistent and
pulsating. pulsations. smooth flow. smooth, near-
pulsation-free.
Maintenance Simple design, but Moderate More complex; Requires
gears can wear over maintenance, with requires maintenance maintenance of lobes
time. vane wear as a of screws. and bearings.
concern.
Durability High durability, Moderate durability; Very durable, Very durable, but
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
especially in rugged wear occurs with especially for harsh wear can occur with
Pumps Criteria Pumps Issues Studies NDE
conditions. abrasive fluids. conditions. abrasive materials.
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Comparison
Feature Gear Pump Vane Pump Screw Pump Lobe Pump

Cost Generally low to Compact, depending Larger in size, Higher initial cost,
moderate cost. on design especially for high especially for large
capacities models.
Size Relatively compact Smooth flow with low Smooth, continuous Smooth, near-
pulsations. flow with minimal pulsation-free flow.
pulsations.
Applications Hydraulic systems, Vacuum pumps, Oil and gas, food Food and beverage,
fuel transfer, refrigeration, processing, chemical pharmaceuticals,
lubrication. automotive. industries. chemicals.

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Selection Criteria
• There are a lot of factor affecting pump selection. The major ones are
listed as under:

• Discharge Flow Rate

• Required Head

• Service Conditions (Viscosity, Temperature)

• Chemical compatibility

• System and Design Layout

• Operational Condition (Shaft Power)

• Efficiency

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

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 Performance Curves
1) H-Q Curve
• Performance curves of pumps help us in understanding
and selecting the Pumps.

• A pump can only deliver a specific flow rate at a certain

pressure, and as the pressure increases the flow rate
decreases.

• This curve is also referred as the H-Q curve, where H is

the head and Q is the liquid flow rate.

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Performance Curves
2) Variable Speed
• Pumps can operate at multiple speed and there will be multiple
H-Q curves for each operating speed.

• It is important to note only the values of head and flow rate on

the curve can be given by the pump, nothing in between.

3) Size of Impeller
• Similarly, impellers can have multiple sizes, and these can have
different H-Q curves as shown in the figure.

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Performance Curves
4) Power Requirement
• Pump power requirement is given by OEM, and it is used to size the motor. Pump Power is
dependent on flow rate, as we can see increasing the flow rate increases the power requirement.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

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Performance Curves
5) Efficiency
• Efficiency of pump is the ratio of work required for motor to operate to the actual work done by pump. It is given
in form of these complex lines, and we can see the efficiency decrease with decreasing impeller size.

Efficiency

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Performance Curves
5) Net Positive Suction Head (NPSH)
• We can see that as the flow rate increases, the NPSH required for a pump to operate

without cavitation also increases.

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Performance Curves (RO230109)
• This is the performance curve (MS-2011148-Sp) supplied by manufacturer for centrifugal pumps for
transfer skid.
• BEP – Best Efficiency Point
• AOR – Acceptable Operating Range
• POR - Preferred Operating Range
• MCSF – Minimum Continuous Stable Flow
• The green line shows the rated flow of
motor is 20 m3/h and the power
requirement at that flow in 1.38 kW while
the NPSHr is 1.02m.
• The efficiency at this point is 38.2%.
• The impeller Dia can range from 203 to 272
mm, but the chosen Dia for our case is
263mm.

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Pump Comparison Sheet
PD Pumps Centrifugal Submersible
Pumps Pumps
Operating Principle Trapping a fixed volume Centrifugal force Moves fluid by immersion

Flow Rate (lpm) Medium High Low

Total Head (bar) High Medium Low
S.R.V Yes No No
Maint. Cost High Low Medium
Pulsation Yes No No
Priming No Yes No

Advantages
High-pressure capability,
Best suited for medium to Can pump fluids from
Pressure Handling ideal for viscous or thick
low-pressure systems. significant depths efficiently.
fluids.
Handles viscous, abrasive, or
Best for thin, clean, and Designed to handle solids,
Fluid Handling shear-sensitive fluids
moderate-viscosity liquids. debris, and wastewater.
effectively.
Energy-efficient for high- Efficiency is high if the
Highly efficient near the
Energy Efficiency viscosity or low-flow
Best Efficiency Point (BEP).
operation at the source of
applications. fluid.
Precise and reliable, ideal for Handles high-volume flow
PD Pumps Centrifugal Selection Flowfor
Piping adjusts to system
Pump Calculations &
Flow Control metering or dosing for dewateringCase
or
Pumps Criteria resistance automatically.
Pumps Issues Studies NDE
applications. wastewater removal.
Calculations
There are number of parameters which can be calculated for pumps. Here only relevant
ones will be discussed:

1. Head
2. NPSH
3. Specific Speed
4. Affinity Laws
5. Power

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump Issues
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Head
• Head is a measurement of the height of a liquid column which the pump could create
resulting from the kinetic energy the pump gives to the liquid.
• Head is measured in feet (ft) while pressure is measured in pounds per square inch (psi)
related as;

• For water at atmospheric pressure head comes out to be 33.9 ft. This is the theoretical
maximum suction lift for a pump at sea level.
Types
• Static Head: Is the vertical distance from the water level at the source to the highest point where
the water must be delivered. It is the sum of static lift and static discharge.
• Static Suction Head: Or static lift is the vertical distance between the center line of the pump and
the height of the water source when the pump is not operating.
• Note: The Static Suction Head (h) is positive when liquid line is above pump centerline and negative
when liquid line is below pump centerline.
• Static Discharge Head: The static discharge head is a measure of the elevation difference
between the center line of the pump and the final point of use.

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Head
• Total Dynamic Head: Is the vertical distance from
source water level to point of discharge when pumping
at required capacity, pins Velocity Head, friction, inlets
and exit losses.
• Total Dynamic Discharge Head: Is the Total Dynamic
Head minus Dynamic Suction Lift or plus Dynamic
Suction Head.
• Total Dynamic Suction Head: Is the vertical distance
from source water level to centerline of pump, minus
Velocity Head, entrance, friction, but not minus internal
pump losses.
• Pressure Head: Refers to the pressure on the liquid in
the reservoir feeding a pump operating in a pressurized
tank.
• Velocity Head: Velocity head also known as dynamic
head is a measure of a fluid’s kinetic energy. In most
installations velocity head is negligible in comparison to
other components of the total head (usually less than
one foot). Velocity head is calculated using the
following equation:
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Net Positive Suction Head (NPSH)
• NPSH refers to the suction head which is required to avoid cavitation or to achieve the
pump dynamics during normal operation.
• It is classified in two types NPSHa (available) and NPSHr (required).
• The NPSHr can be found in a manufacturing catalog of pumps. The manufacturer
always shows the graphic curves of all line pumps manufactured by the company,
indicating the required NPSH for each pump.
• The NPSHa is calculated using the following equation. It should always be greater than
required so that fluid doesn’t vaporize during operation.

• = Atmospheric head available dependent on sea level. Calculated through eq. (1)
• = Static Suction head. It Is positive when liquid line is above pump centerline and
negative when liquid line is below pump centerline.
• = Head due to vapor pressure. It is temperature dependent and is also calculated
through eq. (1)

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Net Positive Suction Head (NPSH)
• = Friction head loss as the fluid moves through a piping system. Calculated through
Darcy Weisbach Equation

• = Safety factor. Any auxiliary component in suction that can cause head loss.

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Specific Speed (Ns)
• Specific speed is a dimensionless parameter that describes the geometric similarity between pumps.
• Pumps of the same specific speed (Ns), but with different sizes are considered to be geometrically
similar.
• Specific speed helps in selecting the most efficient pump design for a given application.

• = Pump Speed, RPM

• = Flow capacity at best efficiency point at maximum impeller diameter, GPM
• = Head at maximum impeller diameter, ft

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Affinity Laws
• The pump performance parameters (flow rate, head
and power) will change with varying rotating speeds.
The equations that explain these relationships are
known as the “Affinity Laws”
1. Flow rate (Q) is proportional to the rotating speed
(N).
2. Head (H) is proportional to the square of the rotating
speed.
3. Power (P) is proportional to the cube of the rotating
speed.
• As can be seen from the above laws, doubling the
rotating speed of the centrifugal pump will increase
the power consumption by 8 times. This forms the
basis for energy conservation in centrifugal pumps
with varying flow requirements.

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Power
Brake Horsepower: Actual horsepower delivered to the pump shaft after losses.

Water Horsepower: Number of losses incurred within the pump through friction, leakage
and recirculation

• : Capacity in gallons per minute

• : Total Differential Head in absolute feet
• : Specific Gravity of the liquid
• : Pump efficiency as a percentage

hydraulic, and volumetric inefficiencies). The efficiency ( 𝜂) accounts for these losses and
• NOTE: WHP is always less than BHP due to energy losses in the pump (mechanical,

determines how much of the input power is effectively used for pumping.

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Non-Destructive Testing / Examination (NDT/NDE)
Some famous NDE include:
Non-Destructive Testing methods are
used to inspect materials and
1. Liquid Penetrant Examination (LPE)
components without causing damage
2. Magnetic Particle Examination (MPE)
or altering the material properties, to
3. Ultrasonic Examination (UTE)
ensure conformance to specified
4. Radiographic Examination (RXE)
requirements.

• The intention of these inspections is to detect discontinuities/flaws in the material that

could indicate possibility of reduced life of the part (i.e., failure in the field because of
cyclical stresses from operation).
• Once detected, flaws are compared with the acceptance criteria and repaired/eliminated,
as necessary.
• RXE and UTE are NDTs for detecting below surface cracks while LPE and MPE are for
surface crack detection.
• Radiography is the most stringent test (will identify the most/smallest flaws) and is the
highest cost because it requires very specialist equipment, methods and interpretation.

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Liquid Penetrant Examination (LPE)
What:
• LPE is used to detect surface defects by applying a liquid dye, removing the excess, and
using a developer to reveal flaws.
How:
• It works by using two characteristics of a fluid, which are Surface Tension & Capillary action.
• Basically, if a liquid is thin enough and has a low surface tension & viscosity, when sprayed
over a crack, the resulting capillary action will draw the liquid into the crack.
• Then by removing excess liquid from the surface, the liquid remaining within the crack is
made more visible using a “developer”, or by using a “black light” (ultra-violet light),
depending on the process.
Interpretation:
• Length and shape of the crack is clearly visible, and it can be compared with acceptance
criteria that is applicable.
• Since LPE is only used for surface detection, it does not show how deep the crack is, or its
extent below the surface.

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Liquid Penetrant Examination (LPE)
Steps:
1. Pre-Cleaning: The surface must be cleaned of dirt, paint, oil, grease, or loose scales to ensure defects
are open, dry, and contamination-free.
2. Application of Penetrant: Penetrant is applied and allowed 10-30 minutes to soak into flaws by
capillary action, with thinner cracks requiring longer penetration time.
3. Excess Penetrant Removal: Excess penetrant is removed using methods based on the penetrant
type; solvent must not be sprayed directly to avoid removing penetrant from cracks.
4. Application of the Developer: A white developer is applied to draw penetrant from defects, forming
visible indications (bleed-out) to locate and identify defect types.
5. Inspection: Inspectors use visible or ultraviolet light to find dye penetrant, observing the surface for
cracks and flaws after 10 minutes.
6. Post Cleaning: The surface is cleaned after inspection and defect recording, especially before coating
or painting processes.

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Liquid Penetrant Examination (LPE)
Advantages Disadvantages
High sensitivity to small surface cracks. Only surface-breaking defects can be detected.

Can be used on many materials, both metallic and non- Only materials with a non-porous surface can be
metallic, as long as they are non-absorbent. inspected.

Can be used on magnetic, non-magnetic, conductive, Pre-cleaning is critical, as paint or contaminants can
and non-conductive materials. hide defects.

Covers large areas and volumes of parts quickly and at Inspector must have direct access to the surface being
low cost. inspected.

Surface finish and roughness can affect inspection

Easily inspects complex-shaped parts.
sensitivity.

Produces indications directly on the surface, visually

Post-cleaning is required, especially before welding.
representing cracks.

Penetrant materials in aerosol spray cans are portable. Proper disposal of materials is required.

Correct ventilation is necessary due to hazardous and

Penetrant materials and equipment are inexpensive.
flammable fumes.
Easy to use and does not require excessive training.

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Magnetic Particle Examination (MPE)
What:
• MPE is used for detecting cracks or flaws both on the Surface, or just
beneath the Surface for shallow depth flaws in ferromagnetic materials.
How:
• It works by magnetizing the part being examined. So, it can only be used
on Ferromagnetic Materials (Ferromagnetism refers to materials, such as
Steel, Iron or Nickel. Which can retain their magnetic properties when the
magnetic field is removed).
• The magnetic field will change at or near a crack or flaw.
• This effect is then made visible by using iron filings spread over the
component.
• The process can be wet or dry.
Interpretation:
• Length and shape of the crack is clearly visible, and it can be compared
with acceptance criteria that is applicable
• MPE will detect near-surface cracks that do not actually break the
surface. Some indication of the size and depth of the flaw can be
interpreted.

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Magnetic Particle Examination (MPE)
DRY MPE WET MPE

1- Preparing the Surface of the Part: Clean the 1- Preparing the Surface of the Part: Ensure the
surface to remove grease, oil, moisture, loose dirt, surface is smooth, clean, and free from grease, oil,
paint, rust, or scale; thin coatings (up to 0.003 or moisture; thin coatings (up to 0.003 inches non-
inches non-conductive or 0.001 inches conductive or 0.001 inches ferromagnetic) may
ferromagnetic) may remain. remain.
2- Apply the Magnetizing Force: Use an 2- Applying the Liquid Carrier (The
electromagnetic device to magnetize the part, Suspension): Before magnetizing, gently spray or
ensuring the magnetic field is strong enough for flow the suspension of wet magnetic particles over
MPE. the part's surface.
3- Magnetic Particles: Sprinkle dry metallic 3- Apply the Magnetizing Force: Apply the
particles thinly on the test area, gently blow away magnetizing force in 2-3 short bursts (2 seconds
excess, and terminate the magnetizing force if each) to allow wet particles to overcome the liquid's
using an electromagnet. surface tension and move.
4- Inspect for Indications: Look for clustered 4- Inspect for Indications: Observe where wet
magnetic particles; magnetic flux must be magnetic particles combine, with surface cracks
transverse or diagonal to flaws, requiring a 90- forming sharp lines and subsurface cracks
degree field change to check all directions. producing less obvious indications.

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Magnetic Particle Examination (MPE)
Demagnetizing After MPE
• Both wet and dry MPE require demagnetization after
inspection. This is critically important.
• If magnetization is left in component it can lead to following
negative effects:
1. Residual magnetic fields after MPE can cause arc-blow,
deflecting the welding arc and repelling molten filler metal. INDICATION OF CRACKS IN A WELD

2. Machining may magnetize metal turnings, causing them to

stick to the component.
3. A magnetized component can interfere with electronic
equipment, such as eddy current vibration probes.
4. Assembly may become difficult due to attraction between
magnetized components.
5. Magnetized components can cause abrasive particles to
cling to bearings or wearing surfaces, increasing wear. INDICATION OF FLUORESCENT CRACKS IN A
BEARING

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Magnetic Particle Examination (MPE)
Advantages of Wet MPE over Dry:
• Wet testing can quickly spray a uniform layer of Particles over the
entire surface of the Smooth Component. Even if the area is large.
All the Smooth Surfaces of the Component can be easily covered
with a uniform layer of Particles.
• The Liquid Carrier allows the small wet Particles to float to small
cracks.
• Wet-Particle MPE is considered better than Dry Particles for detecting INDICATION OF FLUORESCENT CRACKS IN A
very small cracks on smooth surfaces. DRIVE-SHAFT

• Unlike dry particles, Wet Magnetic Particles come in two forms: Non-
Fluorescent and Fluorescent When exposed to Ultraviolet Light
( Black light), Fluorescent particles shine. Making it easier to detect
surface faults in the component.
Disadvantages of Wet MPE over Dry:
• On Rougher surfaces, these smaller Wet-Particles, being in
suspension within the liquid carrier, will settle in the surface valleys
and lose mobility which means they are less effective than Dry
Particle MPE at showing surface Cracks, if the Component has a INDICATION OF FLUORESCENT CRACKS IN A
Rough Surface. FASTENER HOLE

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Ultrasonic Examination (UTE)
What:
• Ultrasonic Examination is used for detecting cracks or faults below the
surface; and can also determine material thickness.
How:
• Ultrasonic, is a high-frequency sound wave signal (beyond human
hearing), which is passed into a component.
• Any crack or faults within the component will cause a change in the
reflection of this ultrasonic signal.
• This change is seen on a Display or Diagnostic Machine.
• This signal reflection & strength can then be used to determine the depth,
size and shape of the crack or fault.
Interpretation:
• The strength of the Returned (Reflected) Signal gives an indication of the
Size of the Crack.
• Also, the Time Taken for the various Signal Returns through the
Component, gives an indication of the Depth and Location of the Crack.

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Ultrasonic Examination (UTE)
Steps:
• Preparing the Surface of the Part: Clean the part, ensuring
it is free from grease, oil, moisture, and loose dirt, paint, rust, or
scale, then dry it.
• Applying the Liquid Couplant: Coat the area with ultrasonic
couplant liquid (e.g., oil) to ensure efficient signal transmission
between probes and the component.
Note: For the reflective technique, coat only one surface; for the
attenuation technique, coat both surfaces.
• Crack or Fault Detection: The ultrasonic display shows signal
reflection, with cracks at 90 degrees to the beam producing the
clearest signal; angled probes may be used for better detection.
• Removal of the Liquid Couplant: After inspection, remove
the couplant, and clean and dry the surface, especially before
further processing.

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Ultrasonic Examination (UTE)
Reflection Method

• In reflection mode, the single Ultrasonic

Transducer performs both the Sending and the
Receiving of the pulsed waves, as the "sound" is
reflected back to the device.
• For this method, a liquid couplant such as oil is
used on the surface of the part where the
ultrasonic transducer is located. The purpose of
the Liquid Couplant is to form a layer between
the surface of the component and the ultrasonic
transmitter/receiver probes to reduce losses in
the UT signal.
• Reflected Ultrasound comes from the Back Wall
of the Component, or from a Crack or Fault
within the Component ,or from a Variation in
Density of the material (e.g.Porosity).
• The depth of crack is determined by the arrival
time and amplitude of reflection.

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Ultrasonic Examination (UTE)
Attenuation Method

• The Attenuation method, uses 2 probes… a

TRANSMITTER & a RECEIVER.
• In Attenuation Mode, a transmitter sends
ultrasound through one surface. Then a
separate receiver detects the amount that has
reached it on the opposite surface. After
traveling through the component. The liquid
couplant needs to be coated on both surfaces
with this technique.
• Cracks and faults, in the space between the
Transmitter and Receiver Probes, allow the
Depth of the Cracks and Faults to be detected.
• Using the liquid couplant between both Probes
and the surfaces of the component, reduces the
ultrasonic losses. It makes the ultrasonic Probes
more accurate and more efficient in detecting
cracks at depths.

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Ultrasonic Examination (UTE)
Advantages Disadvantages
High Penetrating Power, which allows the detection of Use of ULTRASONIC TESTING requires Understanding by
Cracks & Flaws Deep in the Component. Skilled, Trained & Experienced Technicians.

High Sensitivity, permitting the detection of extremely Detailed Technical Knowledge is required to choose the
Small Cracks & Flaws. most accurate Ultrasonic Inspection Procedures.

Only One Surface need be accessible, (for the Single Components that are Rough, Irregular in shape, Very
Probe REFLECTIVE method, not the Two Surface & Two Small or Thin, or are Not Solid. Are difficult to Inspect
Probes ATTENUATION methods). using Ultrasonic Techniques.
Greater Accuracy than other Non-destructive methods,
Surfaces must be prepared by Cleaning, Removing
in determining the depth of internal Flaws, and also the
Loose Scale & Paint.
Thickness of Components with Parallel Surfaces.
Inspected Components must have the Liquid Couplants
Ability to assess the Size, Orientation, Shape and removed from their surfaces. To prevent the possibility
Nature of Cracks & Flaws. of rust forming on Steel Components, if the Liquid
Couplant used was Water.
Non-hazardous to nearby Personnel. Also, ULTRASONIC
TESTING (UT) has no effect on equipment and materials
in the vicinity Unlike Mag-Particle Inspection.

UT is also capable of being very Portable or highly

Automated Operation.

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Radiographic Examination (RXE)
What:
• This is a Non-Destructive Test for detecting cracks & faults below the surface of any material,
(except lead which is too dense). It is suitable for Thin and very Thick parts.
• This method of NDE is the most specialized of all NDE and requires many safeguards and skillsets
for safety due to the use of dangerous ionizing radiation.
How:
• Radiography uses two sources: X-rays (produced electronically through a generator) and Gamma
rays (produced through a radioactive isotope)
• Both the X-rays & gamma rays are targeted to pass through the part to be inspected.
• A photographic film is then placed at the other side of the part. Ready to be affected by the
Ionizing X-rays & gamma rays, after they have passed through the part being inspected.
Interpretation:
• Interpretation of the developed film is carried out using a “Viewer” which requires skills and
training, to evaluate the dark shadows shown on the developed film.
• Flaws & cracks are seen as dark (negative) shadows on the film, after it is exposed & developed.

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Radiographic Examination (RXE)

X-Ray Method

• The Cathode Ray Tube contains a small filament similar

to a light bulb.
• The electric current passing through the filament heats
it up. This causes electrons to be stripped off.
• Then high-voltage causes this Electron Cloud to be
pulled towards the target material called an Anode,
which is usually made of Tungsten.
• The Anode has an angled surface so that when the
electrons impact onto the anode the impact causes an
energy exchange. This results in X-RAYS being
generated from the anode in the reflected direction of
the angled surface, targeted to pass through the part
being examined, onto the film behind the part.

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Radiographic Examination (RXE)
Gamma Ray Method

• Gamma-Rays are produced continuously, by the

decay of unstable atoms, from a man-made
Radio-Active Isotope.
• The Isotope is stored in a heavily LEAD-
shielded Container for safe use.
• The Container has a handle controlling the
Drive-Cable attached to one side. With a long-
shielded Source-Cable on the other side.
• At the end of the Source-Cable is the
COLLIMATOR, where the Isotope is fed.
• The intent is to lead the Source-Cable &
Collimator to the Part being examined after
placing the Film on the other side of the Part.
• The User winds the Drive-Cable handle which
pushes the Radio-Active Isotope through the
Source-Cable, into the Collimator at the end
where the Gamma-Rays pass through the Part
& cause an image to form on the Film.

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Radiographic Examination (RXE)
Advantages Disadvantages
Ability to examine faults and defects below the surface
Relatively high cost.
components even if they are very thick.

Minimum surface preparation is required. Can take much time.

Nothing is invisible. Specialized skills required.

Most areas can be examined. Special safeguards to be taken, to minimize the Danger

No Limitations on Materials, except LEAD cannot be

Skilled trained interpretation of film shots required.
tested Radiographically.

Provides a permanent record of the Inspection, with Access to both sides of the Part is required, (unlike
Developed Films. Ultrasonic Reflective Examination).

Determination of depth of the Fault is not possible,

without additional angled Radiographic testing.

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API 610 Requirement

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API 610 Requirement

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API 610 Requirement

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Factory Acceptance Test
• A factory test is a pump test coordinated and performed by the pump
manufacturer at the pump manufacturer’s testing facility.

• Formal acceptance of most custom-engineered centrifugal pumps by

the purchaser is unwitnessed, the satisfactory completion and
approval of pump tests conducted by the pump manufacturer at the
manufacturer’s factory.

• Some factory tests are witnessed by the purchaser, but in most

cases, they are unwitnessed, and the results are certified as
accurate by the pump manufacturer’s engineering department –
also called a factory-certified test.
Hydrostatic Pressure Test

1 Casing Integrity 2 Pressurization

Verifies pump casing Exceeds max operating
material integrity pressure.

3 Factory-Certified
Virtually every pump receives one.
Mechanical Run Test

Vibration Bearing Noise Levels

Levels Temperature
s
Appropriate Reasonable Acceptable noise
vibration levels. bearing levels.
temperatures.
Performance Test

Head and Flow

Measures head and flow at points.

Repeatability and Accuracy

Ability to deliver same flow and head consistently.

Efficiency
Determines pump efficiency.
NPSH Test
• An NPSH test involves reducing the suction pressure to a

pump to verify that the NPSH required by the pump is

comparable to the NPSH values shown on previously

submitted and approved pump curves.

• To determine the suction pressure required.

• To verify the NPSH matched the pump curves.

 Auxiliaries
Auxiliaries of positive displacement (PD) pumps are additional components and systems that enhance their

performance, reliability, and safety. These auxiliaries are crucial for ensuring the pump operates efficiently,

meets process requirements, and avoids damage. Below are some common auxiliaries for PD pumps:

Pulsation Dampener Suction Stabilizer Calibration Pot Pressure Relief Valve Packing Seals

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Pulsation Dampener
A pulsation dampener is a device used in fluid systems to reduce
pressure and flow fluctuations, known as pulsations, which are typically
caused by the cyclic operation of positive displacement pumps. These
pulsations can lead to vibration, noise, system wear, and inconsistent
fluid delivery.
Working Principle:
• The pulsation dampener uses a compressible medium, such as a gas (e.g.,
nitrogen) or a spring-loaded mechanism, combined with a flexible diaphragm,
bladder, or piston.

• When the fluid pressure spikes during a pump cycle, the dampener absorbs the
excess energy by compressing the gas or spring.

• During low-pressure moments, the stored energy is released back into the
system, smoothing out the flow and pressure.

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Pulsation Dampener
Key Components:
1. Body/Casing: Houses the internal components and provides a
connection to the pipeline.

2. Diaphragm/Bladder/Piston: Separates the fluid from the

compressible medium

3. Gas Chamber: Filled with gas (usually nitrogen) that compresses to

absorb the pulsations.

Benefits:
1. Reduced Vibration and Noise: Prevents mechanical wear and
structural damage to pipelines and equipment.

2. Improves System Efficiency: Ensures a steady flow of fluid,

enhancing the performance of downstream components like meters or
control valves.

3. Extends Equipment Life: Minimizes cyclic stress on pump

components, piping, and fittings.
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Pulsation Dampener
Snifter: A
A snifter is a small valve or vent, typically installed on pumps,
pipelines, or other fluid-handling systems, to replenish air or gas
trapped within the pulsation dampener. It plays a critical role in
maintaining system efficiency and preventing operational issues
caused by loss of air.
Working Principle:
• On the backstroke, the pump draws some liquid from the snifter.
B
(A)

• The snifter in turn draws air from the atmosphere. (A)

• On the forward stroke, the pump forces liquid into the snifter.
(B)

• The rising level in the snifter closes the check valve from the
atmosphere, Centrifugal
PD Pumps forcing air into the chamber. (B)Piping for
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Animation of Pulsation Dampener

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Calibration Pot
A calibration pot is a device used to measure and verify the flow rate of a
pump, particularly in applications involving positive displacement pumps,
such as dosing or chemical injection systems. It provides an accurate and
straightforward way to calibrate the pump by determining the actual
volume of fluid delivered over a specified time.
Key Features:
1. Construction:
• A transparent graduated cylinder or tank with measurement markings.
• Made of materials like glass, plastic, or stainless steel to handle the specific fluid's properties (e.g., corrosive
or high-temperature fluids).
2. Capacity:
• Usually available in various sizes, ranging from small volumes (e.g., 50 mL) to larger capacities (e.g., several
liters), depending on the pump flow rate and application.
3. Valves:
• Equipped with inlet and outlet valves for controlled fluid flow.
• Allows isolation of the calibration pot from the main fluid line during testing.

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Operating Principle of a Calibration Pot
1. Isolation: The calibration pot is isolated from the main system and directly connected to the pump discharge or suction
line.
2. Filling: The pump is run to fill the calibration pot to a specific starting level.
3. Measurement:
• The pump operates for a known duration (e.g., 1 minute), and the fluid level in the pot is observed.
• The drop in fluid level corresponds to the volume of fluid delivered by the pump during that time.
4. Flow Rate Calculation:

Advantages Limitations
1. Accuracy: 1. Limited Capacity:
Provides precise measurement of pump
Not suitable for very high-flow pumps.
performance.
2. Ease of Use: 2. Manual Intervention:
Requires operator involvement for
Simple to install and operate.
calibration.
3. Cost Effective: 3. Fluid Compatibility:
Reduces the need for sophisticated flow The material must be compatible with the
meters for periodic calibration. fluid being pumped.

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Assembly of a Calibration Pot

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Pressure Relief Valves
A Pressure Relief Valve (PRV) is a safety device designed to protect
equipment, systems, and pipelines from overpressure conditions by
automatically releasing excess fluid (liquid or gas) when the system
pressure exceeds a predefined limit. Once the pressure returns to a safe
level, the valve closes to prevent further fluid loss.
Key Features:
1. Set Pressure:
• The specific pressure at which the valve opens to release excess pressure. This is pre-determined
based on the system’s design specifications.
2. Types of Operation:
• Spring-Loaded: Uses a spring to hold the valve closed until the pressure exceeds the set limit.
• Pilot-Operated: Uses a pilot valve to control the main valve, offering more precise operation.
3. Resetting:
• The valve automatically resets (closes) once the system pressure drops below the set pressure.

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Operating Principle of a PRV
1. Normal Operation: The valve remains closed during normal
operating conditions, with the system pressure below the set
pressure.
2. Overpressure:
• When the system pressure exceeds the set pressure, the valve
opens to release excess fluid.
• This reduces the pressure in the system to prevent equipment
failure or rupture.
3. Pressure Recovery: Once the pressure falls back within the safe
range, the valve reseats to prevent further fluid release.
Advantages Limitations
1. Safety Assurance: 1. Leakage:
Protects equipment and personnel by preventing
May leak over time if not maintained properly.
catastrophic failures due to overpressure.
2. Automatic Operation: 2. Calibration Requirement:
Requires no manual intervention to operate during Set pressure must be correctly calibrated to avoid
overpressure events. nuisance releases or insufficient protection.
3. Customizable Settings: 3. Fluid Compatibility:
Set Pressure can be adjusted to match system Not suitable for all fluid types without proper
requirements material selection.

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Operating Principal Animation of a PRV

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Packing
Packing refers to a seal created using flexible materials (e.g., braided fibers or soft
polymers) installed in a cavity, typically called the stuffing box, around the rotating
shaft.

Key Features:
1. Material: Common materials include PTFE, graphite, aramid, or synthetic fibers, often impregnated with lubricants
to reduce friction.
2. Installation: Placed in rings or coils inside the stuffing box and compressed using a gland follower.
3. Operation: The packing material forms a barrier against leakage by creating frictional resistance around the shaft.
Advantages Limitations
1. Ease of Use: 1. Regular Maintenance:

Simple design and easy to install. Requires regular maintenance to prevent wear and leakage.

2. Cost Effective: 2. Calibration Requirement:

Cost-effective for low-pressure applications. Generates friction, leading to heat and energy loss.
3. Versatility: 3. Not Suitable for High Pressure/Speed:

Suitable for a wide range of fluids. Limited suitability for high-pressure or high-speed applications.

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Packing Animation

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Mechanical Seals
Mechanical Seals are advanced sealing devices that consist of a
pair of precision-engineered surfaces, one stationary and the other
rotating, that form a tight seal to prevent leakage.

Key Components:
1. Primary Sealing Faces:
• One surface attached to the shaft (rotating face).
• The other fixed to the housing (stationary face).
2. Secondary Seals: O-rings or bellows to seal between the stationary/rotating parts and the equipment.
3. Spring Mechanism: Applies a consistent force to keep the sealing faces in contact.
4. Retainer: a structural component that holds the stationary sealing element securely in place within the pump or
equipment housing.

Working Principle:
A small, controlled film of fluid lubricates the sealing faces, minimizing wear while preventing fluid leakage.

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Mechanical Seals

Advantages Limitations
1. Elimination of Leakage: 1. Higher Initial Cost:
Higher initial cost and complexity compared to
Reduces or eliminates leakage completely.
packing.
2. High Pressure/Speed Application: 2. Precise Installation:
Operates efficiently under high pressures, Requires precise installation to avoid premature
temperatures, and speeds. failure.
3. Less Maintenance 3. Sensitive to Abrasive/Corrosive Fluids:
Requires less frequent maintenance compared to Sensitive to abrasive or corrosive fluids if not
packing. designed for them.

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Mechanical Seals Animation/Working

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Comparison
Aspect Packing Mechanical Seals
Leakage Allows some leakage for Designed for minimal or
cooling. zero leakage.
Cost Low initial cost. Higher initial cost.
Maintenan Requires frequent Requires less frequent
ce adjustment. maintenance.
Applicatio Low-pressure, low-speed High-pressure, high-
ns systems. speed systems
Efficiency Less efficient due to Highly efficient with low
friction. energy loss.
Service Shorter due to wear. Longer if properly
Life maintained.
Conclusion
• Packing is suitable for simpler, cost-sensitive applications where minor leakage is acceptable.
• Mechanical Seals are ideal for demanding conditions requiring high efficiency, durability, and leak-free operation.

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Pump Standards
Aspect API 674 API 675 API 676
Pump Type Reciprocating Controlled- Rotary (gear,
(piston/plunger) volume screw, lobe,
(metering) vane)
Application Precise dosing Viscous and
High-pressure
s shear-sensitive
systems
fluids
Flow Range Medium to high Low to medium Medium to high
Pressure Up to 345 MPa Lower than API Typically, low
(50,000 psi) 674 to moderate
Pulsation Higher, requires Low pulsation Minimal
dampeners pulsation
Flow Moderate High (±1% or Moderate
Accuracy better)
Common Water, oil, Corrosive, High-viscosity
Fluids chemicals hazardous fluids fluids
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Piping Routing for Pumps
Piping routing for pumps is critical to ensure safe, efficient, and reliable
operations. Various industry standards and best practices govern the
design and routing of piping systems connected to pumps. Below are
the key applicable standards:

Key Standards:
Standard Scope
ASME B31.3 Process Piping - Covers design, materials, fabrication, and installation of piping systems
in industrial plants.
ASME B31.1 Power Piping - Applicable for piping systems in power generation facilities.
API 686 Recommended Practices for Machinery Installation and Installation Design - Includes
pump piping design best practices for alignment and vibration control.
API 610 Centrifugal Pumps for Petroleum, Petrochemical, and Natural Gas Industries - Addresses
piping loads, alignment, and installation considerations for centrifugal pumps.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Piping Routing for Pumps
Key Consideration:
Key Consideration Standard
Piping Stress and • ASME B31.3 (Process Piping)
Flexibility • ASME B31.1 (Power Piping)
Flange Loads • API 610 (Centrifugal Pumps)
• API 674 (Reciprocating Pumps)
• API 675 (Metering/Dosing Pumps)
• API 676 (Rotary Pumps)
Vibration and Thermal • API 686 (Guidance on alignment and vibration control in pump
Expansion Control piping)

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Piping Routing for Pumps
Piping Design and Layout:
Aspect Relevant Standards and Practices
Straight Length Requirement • API 610 (Centrifugal Pumps)
• API 674 (Reciprocating Pumps)
• API 675 (Metering/Dosing Pumps)
• API 676 (Rotary Pumps)
Pipe Supports and Anchors • ASME B31.3
• API 686
Thermal Expansion • Use expansion loops, joints, or bellows as per ASME B31.3.
Minimum Pressure Losses • Design suction piping with minimal elbows and pressure drop, following
guidelines in API 610.
Isolation and Maintenance • Install valves, strainers, and drains per ASME B16.34 and good piping
practices.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Piping Routing for Pumps
Standards for Pipe Components:
Standard Description
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.34 Valves - Flanged, Threaded, and Welding End
ASME B16.9 Factory-Made Wrought Buttwelding Fittings.

Key Takeaways:
• ASME B31.3 and ASME B31.1 are essential for general piping design and stress
management.
• API 610 provides specific requirements for centrifugal pump piping, especially for minimizing
suction-side turbulence and handling flange loads.
• API 674, 675 and 676 for minimizing suction-side turbulence and handling flange loads for
PD Pumps.
• PDAPI
Pumps Centrifugal Selection Piping for Pump Calculations &
686 - Guidance
Pumps
on alignment
Criteria
and vibration
Pumps
control inIssues
pump piping.Studies
Case
NDE
Reducers
• If the suction line has larger diameter than pump flange, often reducers are used for smooth
transition and minimize losses.
• Reducers also convert a part of fluid velocity to pressure at suction inlet and maintains proper
suction.

• Concentric reducers are generally avoided to prevent vapor buildup which might cause
problems down the line.
• Top Flat Reducers can generally be used in most of the piping layouts.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Definit Types Compone Primi Standa
ion nts ng rds
 Cavitation
• Cavitation occurs when the liquid entering a pump
contains a few bubbles of gas. The gas flows
through the impeller with the liquid and as its
pressure is increased in the Pump.

• A high centripetal force results from this collapse

and may cause severe, vibration and possible pump
damage. The pump will continue to pump liquid but
will be noisy and may vibrate.

• The common cause of cavitation is decrease in

suction pressure below vapor pressure of liquid.

NPSHa < NPSHr

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
Pumps Criteria Pumps Issues Studies NDE
 Vapor Lock
• Vapor lock occurs when gas enters the pump with
liquid and separates from the liquid inside the
pump and fills all or a part of the Pump. The pump
will compress the gas a slight amount, but not
nearly enough for the gas to flow out the discharge
line.

• The trapped gas prevents liquid from entering the

pump. The effect is that no liquid flows through the
pump.

• The damage caused by vapor lock and cavitation

are very similar.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Start-up Procedure
• Most of the centrifugal pumps need to be primed to get them
started, this is because centrifugal pumps create very little
suction, so liquid needs to be pushed in the eye of impeller to
start the pump.

• Some centrifugal pumps are self-priming which use check

valves to always contain fluid even in shut down condition.

• Centrifugal pumps can be primed in a variety of ways

depending on the type of pump and prime mover used,
manual priming and vacuum priming are some common
types.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Definit Types Compone Primi Standa
ion nts ng rds
 Controlled Volume Pump (RO230109)
APPLICABLE TO – The document
refers to the purchase phase of
the controlled volume pump
designed in accordance with API
675 (3rd Edition).

FOR – ROO – Rumaila Operating

Organization
SERVICE – Corrosion Inhibitor –
chemicals used to prevent or reduce
corrosion in pipelines, vessels, or
other equipment.
MANUFACTURER – EXAKTA SEKO –
Exakta is a division of SEKO Group, a
global innovator of chemical dosing
and control systems for cleaning and
hygiene and water-treatment
applications with an annual turnover
of €200m and over 1,300 employees
worldwide.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
No. of Motors Driven – This pump
is designed for continuous-duty
operation, meaning it is intended to
run consistently over extended
periods without frequent stops or
downtime.
Motor Provided By – ELNOR –
Motor Manufacturer
Capacity - The capacity values of
the pump indicate it is designed for
precise, low-flow-rate
applications with an adjustable flow
range of 0.0 to 4.4 l/h. Its rated
capacity of 4.85 l/h shows that it is
optimized for steady operation near
its upper limit, ensuring reliable
performance.
Discharge Pressure – 57 barg is
the upper limit of the pressure that
the pump can safely handle on the
discharge side.
12 barg is the absolute minimum
pressure at which the pump can
function effectively.
35 barg is the preferred or normal
operating minimum
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
Suction Pressure - This means the
pump is designed to operate with a
suction pressure that does not
exceed atmospheric pressure (0
barg).
Differential Pressure – It is same
as discharge pressure since max
suction pressure is 0 barg.

NPSH Available – 8 meters. The

inclusion of acceleration head in
the NPSHa calculation indicates that
the effect of pulsation or intermittent
fluid movement (common in positive
displacement pumps) has been
considered.
Turndown Ratio – 0 – 100%
indicates the pump's ability to adjust
its flow rate from zero (no flow) to its
maximum rated capacity while
maintaining accurate performance
and efficiency.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
Type or Name of Liquid – The
pump is specifically designed or
selected for injecting corrosion
inhibitors into a system.

Pumping Temperature – The

pumping temperature specifications
indicate the pump is designed to
handle fluids with a normal range
of ambient temperature, can
withstand extremes from -2°C to
53°C, and has a design limit of
85°C for safety.
Specific Gravity (KG/M3) – The
absence of specific maximum and
minimum values indicate that the
system does not expect fluids with The "NA" entries for
densities much lower or higher than Corrosive/Erroneous Agents,
the specified range. Viscosity – (CP) The viscosity Chloride Concentration (PPM),
Specific Heat – NA indicates the values (7 CP at 55°C, 23 CP at 20°C, and H2S Concentration (PPM)
specific heat value of the liquid and 56 CP at 2°C) indicate that the suggest that the fluid being pumped
being pumped is not provided or not pump is designed to handle a is not expected to be corrosive or
required for the design or operation viscous liquid that changes erosive, and does not contain
of the pump. significantly with temperature. significant levels of harmful agents
like chlorides or hydrogen sulfide.
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
Number of Feeds – It means it can supply
fluid to five separate lines or systems
simultaneously.
NPIP Required – similar to NPSH
required but specific to reciprocating
pumps. In this case, the system must
ensure NPSH available ≥ 6 m, including
all suction-side losses.
BHP Rated (KW) – Brake Horsepower –
Actual power required to drive the pump,
measured at the pump shaft. The relief
setting refers to the pump operating at the
maximum discharge pressure (88 barg),
typically when the relief valve is engaged.
Plunger Speed – The pump operates at a
normal speed of 60 strokes/min, with a
design maximum of 125 strokes/min to
handle increased demand or process Pressure - Maximum pressure (88 The pump, when powered by the specified
variability barg): The pump’s safe operating limit driver, is designed for a maximum
Diameter & Length of Stroke (mm) - during normal conditions. discharge pressure of 88 barg, which is
Plunger diameter (14 mm) and stroke Hydrotest pressure (132 barg): The the safe operating pressure for the system.
length (10 mm) indicate the pump is pressure used during testing to verify the
designed for precise, low flow rate pump's structural integrity, ensuring it can MAX BHP BASIS GEAR STRENGTH = NA
applications, with a displacement volume handle high pressures with a safety margin suggests that gear strength is not a
of 1.54 cm³ per stroke. of 1.5x the maximum pressure. This limiting factor in the pump’s design,
confirms the pump is reliable and built to indicating a potential use of alternate power
industry safety standards. transmission mechanisms or a design that
doesn't require gear strength considerations.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
"unheated" means the pump is not
equipped with frost protection, so it's
important to consider the climate
conditions where it will be used to prevent
damage.T3
Zone 2 – The pump is suitable for use in
hazardous areas where flammable gases or
vapors may be present under abnormal
conditions (Zone 2).

IIA/IIB - It is rated to handle gases from

Group 2A/2B, meaning it can be used in
environments with gases like propane,
methane, or ethylene.

T3 - The maximum temperature of the

pump surface is 200°C, ensuring it won’t
ignite
The the does
pump surrounding gases specific
not require under normal
operation.
modifications for cold weather
(winterization) or hot, humid climates
(tropicalization).
The pump is intended for installation in a
location with moderate to warm
temperatures that fall within the specified
temperature range.
The pump is likely built to handle abrasive
conditions and frequent exposure to
airborne particles.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
The pump is powered by a 24 VDC
electrical system, meaning it requires a 24-
volt direct current input for operation.

NA for heating, control, and shutdown

indicates that these features are not
applicable to this pump, meaning it
operates without specialized thermal
management, advanced control systems, or
integrated shutdown protections, and may
rely on simpler or external systems for these
Instrument
functions. air refers to clean, dry,
compressed air used to operate or control
pneumatic instruments, valves, and other
equipment in industrial processes.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
Instead of a flanged connection, pump uses
a threaded connection. NPT F (National Pipe
Thread – Female. This indicates that the
suction/discharge connection uses a
threaded fitting with a female thread. The
suction/discharge connection is located at
the bottom/top of the pump respectively.
It means that the liquid end of the pump
does not require a jacket.

Instrument air refers to clean, dry,

compressed air used to operate or control
pneumatic instruments, valves, and other
equipment in industrial processes.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
API 675 is a standard by the American
Petroleum Institute that specifies design,
performance, and testing requirements for
controlled-volume (metering) pumps
used in industries like oil, gas, and chemical
processing. It ensures reliability, accuracy,
and durability, particularly for pumps
handling precise flow rates, high pressures,
and challenging fluids.

This refers to a specific project, company,

or custom engineering specification that
governs the design, materials, and
manufacturing requirements of the pump.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
Complete detail related to pump parts and
the materials used to manufacture them in
the notes section.

The tubing material is tested to meet ASTM

A276 GR. 316L standards, which
guarantees its mechanical properties and
corrosion resistance.
This indicates a focus on quality and
reliability for fluid-contact components.
The "NA" indicates that low ambient
temperature conditions are not
considered for this pump's design, so it
may not be suitable for use in extremely
cold environments where materials need to
retain flexibility and strength at low
temperatures.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
it means the pump is controlled or monitored
directly at the pump's location, rather
than using a remote control system or
external devices (e.g., pneumatic or
electronic signals).
the pump does not use these automated or
remote stroke adjustment mechanisms.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
it means the pump is controlled or monitored
directly at the pump's location, rather
than using a remote-control system or
external devices (e.g., pneumatic or
electronic signals).
the pump does not use these automated or
remote stroke adjustment mechanisms.
 Controlled Volume Pump (RO230109)
The use of 3.1 certification ensures that all
materials meet the required standards for
strength, corrosion resistance, and
durability.
This indicates that the clearances (gaps or
tolerances) between components in the
pump’s final assembled state were checked
and verified to meet the required
specifications. These clearances are critical
for proper operation, efficiency, and longevity
of the pump.
Detail in the notes section.

Liquid penetrant testing was specifically

applied to inspect the pump heads for
surface defects. This is likely due to the
critical nature of the pump heads, where any
flaws could lead to leaks or operational
failures.
The absence of high discharge pressure testing
suggests that the pump is not designed for extreme
discharge pressures. It may operate at lower
pressures or be used in applications where pressure
handling is not critical.
The fact that hydrostatic, performance, complete
unit, and package factory acceptance tests need
to be witnessed highlights the importance of
ensuring the pump is tested thoroughly and according
to stringent standards.
PD Pumps Centrifugal Selection Piping for Pump Case Calculations &
Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
The lubrication fluids specified indicate that
the pump is designed for high-load
conditions with heavy-duty lubrication
for the crankcase (ISO VG320) and efficient
fluid flow for the hydraulic system (ISO
LI10). The absence of intermediate
lubrication means the system is likely
optimized for simplicity and efficiency,
focusing on essential lubrication needs to
ensure performance and reliability.
The pump system is equipped with a speed
reducer to adjust the rotational speed of the
pump's components.
Accessories are integrated into the pump
assembly rather than being a separate,
standalone component.

The pump operates at much lower speeds

than the motor, with the speed reducer
providing a 25 fold reduction in the pump’s
output speed.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 Controlled Volume Pump (RO230109)
the pump vendor (manufacturer or supplier)
will provide the necessary process piping
as part of the pump package.

The pump vendor is required to review

and approve the piping design drawings
for the system in which the pump will be
installed.
the pump vendor will provide pulsation
suppression devices as part of the pump
package.
Both internal (functional/wetted parts) and
external (structural) components of the pump
are verified for quality.

The internal relief valve (88 barg) protects

the pump, while the external valve (80 barg)
safeguards the downstream system.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
Controlled Volume Pump (RO230109)
Totally Enclosed Fan
Cooled
A rated KW of 0.25
indicates a low-power,
energy-efficient motor
that is ideal for smaller
pumps and applications
with modest power
Rated speed is the optimal or
requirements.
designed speed for peak
performance, while RPM refers to
the actual speed the motor or
pump is running at, which could
be equal to or differ from the
rated speed depending on the
Ex II 2G-EXD indicates that the
conditions.
pump is designed to be
explosion-proof and safe to use
in hazardous gas
atmospheres, specifically in
Zone 2 environments.
The pump's motor is designed to
be powered by three-phase
electrical power, suitable for
industrial applications requiring
higher power and efficiency.

PD Pumps Centrifugal Selection Piping for Pump Case Calculations &

Pumps Criteria Pumps Issues Studies NDE
 RO230109 Issues: RCA, Troubleshooting &
Recommendations
• During Internal FAT, number of issues were encountered for both Injection and Transfer pumps.
• These issues were promptly responded with vendor and INTECH engineering team collaboration.
• This section will discuss RCA, troubleshooting and future recommendations for these issues.
• These issues are divided in two sections:

Transfer Pump (Centrifugal) Injection Pump (Positive

Displacement)
1- Flush Ring Configuration
2- Oiler Location 1- Diaphragm Rupture
3- Pump Jam 2- Air Lock (Check Valves)
4- No Flow (Air Lock)
5- No Flow (Cavitation)
6- Manufacturing Faults
(Misaligned ‘Alignment Bolts’,
Bent Motor Covers, Broken Oilers,
Drain Valves Leakage)

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Flush Ring Configuration

Issue Description:
• On pumps first startup, visible water
leakage was observed near the flush ring
and mechanical seal outer O-ring.
• Pump was stopped immediately by
pressing the emergency shutdown button.
• Video presents actual onsite recording of
the issue.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Flush Ring Configuration
Troubleshoot:
• At first it was not clear whether the problem was with the seal or flush
ring. Concept Refresher

• Engineering team engaged the OEM for issue resolution. Flush ring takes
portion of discharge
• Upon inspection, it was observed that the flush ring Drain port was stream and points that
connected to the fluid supply line while the flush port was free onto the mechanical
and plugged. This caused water to spurt out. seal to cool it. In our
• Flush ring connection was opened, and flush port was connected to case, it has three ports
the supply line with drain port plugged. named flush, drain
• OEM technicians performed the work, and NO commercial impact was and quench. Supply
beard by INTECH. line is connected to
Result: flush for flushing the
• Water leakage stopped and pump continued operation. mechanical seal, drain
is used to drain it
Future Recommendation: during maintenance
• Apart from material receiving inspection, where only pump component and quench is an
quantity is verified, thorough inspection as per GAD should be optional port for
performed before first startup. Extensive care should be taken while providing cool liquid at
reviewing component connections. (or INTECH witnessed is taken) atmospheric pressure.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Oiler Location
Issue:
• When pump oiler was filled and attached to the port, all the
oil went into the bearing chamber and increased its level
above 50%.
• Oiler kept filling the chamber rather than holding the oil and
filling it when level dropped in the chamber.
Troubleshoot:
• It was recognized by INTECH Engineering that the oiler is
connected at a higher level i.e., wrong port connection.
• As a result, all the oil was going into the chamber rather than
maintaining the level.
• OEM was notified about the issue. Their engineer connected
the oiler to the correct location.
Result:
• 50% oil level was maintained in the chamber and the oiler
was not completely draining.
Future Recommendation:
• Oiler connection check should be added as a step while doing
pump inspection before first startup.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Pump Rotor Jam
Issue:
• On pump startup, rotor was jammed, there was no
discharge, and the discharge gauge showed no
pressure developed.
• Shaft wasn’t rotating although the motor was ON.
Pump was immediately turned OFF by pressing the
emergency shutdown.
Troubleshoot:
• At first, there is a need to recognize whether the
problem is at motor end or rotor end.
• For this, remove the coupling and turn the motor
ON. If the shaft is rotating, then problem is at the
rotor end.
• Same was done by INTECH engineering, shaft at
motor end was rotating without coupling. It was
now sure that the jam is at rotor end.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Pump Rotor Jam
• OEM was contacted for this issue and some steps were recommended by them to check
whether there was truly a rotor jam.
• They advised to open the mechanical seal and rotate the plate anticlockwise 15°. The shaft
should become free after this. If not, then pump needs to be opened to free the shaft.
• Same was done by INTECH engineering and the shaft didn’t become free. OEM was
informed and their engineer came to open the pump.
• Upon opening the pump, it was observed that the impeller vanes were in contact with
the casing which caused the rotor to not rotate. Clearance between the vanes and casing
is very small and any slight misalignment between motor, rotor and skid might cause this.
• Pump was cleaned, closed, coupling was connected, and startup was performed. Issue was
resolved and pump started to work properly.
Result:
• Pump started to work after it was opened and impeller and casing clearance was cleared.
Future Recommendation:
• Before startup, perform manual check if the shafts are free to rotate. Also, keep lookout for
any misalignment between skid and pump that can ultimately lead to shaft misalignment.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
No Flow (Air Lock)
Issue:
• On startup, there was no discharge, and the
discharge gauge showed no pressure developed.
• Although the shaft was rotating this time, but no
discharge was obtained.
• Pump was turned OFF pressing the emergency
shutdown.
Troubleshoot:
• Pump rotor rotating and giving no flow are
indication of air has been trapped inside the pump.
This condition is called air lock where pump
performs work in compressing the air and flow
discontinuity happens.
• Air can get inside pump through number of inlets
i.e., piping connections, valve connections, hose
connection etc. This is an inevitable phenomena as
there will always be space for air to get inside pump
when left idle.
PD Pumps Centrifugal Selection Piping for Case Calculations & Pump
Pumps Criteria Pumps Studies NDE Issues
No Flow (Air Lock)
• To resolve this, before startup perform the following steps;
1. Close discharge valve.

2. Open all suction valves and connections and release the trapped air then close them.

3. Start the pump with discharge closed.

4. Slowly open the discharge valve and observe if pressure is developing.

• Same was done by INTECH Engineering, air lock was removed and pump started working.
Result:
• Air lock was removed by removing trapped air before startup and pump started working.
Future Recommendation:
• To efficiently counter Air lock, this activity should always be performed before pump
startup. Any break between pump startup consisting of significant amount of time i.e., a
day should trigger this activity.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
No Flow (Cavitation)
Issue:
• On pump startup, inadequate discharge pressure was
developed shown on discharge gauge.
• Pump started to vibrate with shar noise.
• Pump was turned OFF by pressing the emergency
shutdown.
Troubleshoot:
• Pump vibration followed up by sharp noise indicates
cavitation. Liquid inside pump vaporizes, bubbles
implode resulting in sharp noise and discharge pressure
loss.
• One of the main causes of cavitation is when NPSHa at
suction is less than the required. This was identified to
be due to long distance connection between suction and
inlet tank.
• On site two hose pipes were connected from tank to
pump suction. This increased the distance between
suction and tank, leading to more losses in line and
ultimately decreasing the available head at suction.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
No Flow (Cavitation)
• Instead of connecting two hose pipes, single pipe connection was used. This increased
the available head at suction and cavitation didn’t occur.
• One more thing that resulted in head loss was improper hose connection. The
connection was not completely locked which resulted in losses. Hoses connections were
opened and attached correctly.
Result:
• Inlet losses were reduced to increase available head at suction. This resulted in no
cavitation and desired discharge pressure was obtained.
Future Recommendation:
• Before startup ensure adequate head is available at suction and inlet tank is close to
suction to mitigate any losses.
• Also check for hose connection if any of them are loose and are not properly
connected.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Manufacturing Faults

• Transfer pumps came with number of Manufacturing issues

namely:
1. Misaligned Alignment Bolts:
Pumps came with misaligned alignment bolts. This was
corrected by INTECH with commercial impact. Vendor was
hired to carry out this activity.
2. Broken Oilers:
Glass oilers were broken. New oilers were procured to
replace them.
3. Bent Motor Covers:
Motor covers received were bent. New covers were
procured to replace them.
4. Drain Valve Leakage:
Pump drain valve was leaking when closed. OEM was
informed and valve was replaced.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Diaphragm Rupture
Issue:
• Some heads of injection pump were not showing
adequate pressure.
• Discharge gauge showed less pressure than required.
Troubleshoot:
• To check for rupture, remove air lock, close the
discharge valve and start the pump, then slowly open
the discharge valve. If pressure starts to develop at
discharge indicated by a PT, then the diaphragm is
good to go.
• If pressure is not developed at discharge, then
diaphragm might have ruptured. Diaphragm rupture is
indicated by the rupture PT connected to the pump as
shown in figure.
• Pressure developing on the PT indicates that
diaphragm has been ruptured and needs to be
replaced. In normal condition, no pressure should be
developed at the rupture PT.
PD Pumps Centrifugal Selection Piping for Case Calculations & Pump
Pumps Criteria Pumps Studies NDE Issues
Diaphragm Rupture
• Impurities in water or starting the pump with suction valve closed might lead to this.
• Pressure was observed at rupture PT by INTECH Engineering.
• Diaphragm was replaced with new one and pump started to work properly.
Result:
• New diaphragm was installed in replace of the ruptured one. Adequate discharge
pressure was achieved.
Future Recommendation:
• Use clean distilled water for testing and make sure suction valve is open before pump
startup.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues
Air Lock (Internal Check Valves)
Issue:
• On pump startup, no flow was observed at discharge.
• Diaphragm rupture PT showed no increase in pressure
and also no discharge pressure developed.
• Pump was turned OFF by pressing the emergency
shutdown button.
Troubleshoot:
• When no pressure is developed at discharge and the
rupture PT also shows no reading then the internal check
valves at pump suction and discharge might have
clogged.
• Rust can develop in them, hindering their movement
and ultimately causing no flow.
• INTECH Engineering identified this. Check valves at
suction and discharge were opened and cleaned with
WD-40.
PD Pumps Centrifugal Selection Piping for Case Calculations & Pump
Pumps Criteria Pumps Studies NDE Issues
Air Lock (Internal Check Valves)
• Cleaned valves were installed again and air was blown to see if flow is passing.
Result:
• Cleaning and re-installing the valves removed the developed rust and adequate
discharge pressure was obtained.
Future Recommendation:
• Properly drain the pump heads after usage to remove any residual fluid that can cause
rust.

PD Pumps Centrifugal Selection Piping for Case Calculations & Pump

Pumps Criteria Pumps Studies NDE Issues