Created by Ankur Sharma, Gurudayal Srivastava, Vikram Singh, Sanket Tamhane

Pump Types and Operation

Introduction
A Pump is a mechanical device used to transfer liquids from one point to other by imparting energy supplied by a prime mover to the
liquid. The prime mover can be an electric motor, an I.C. engine, or a steam engine or turbine. The power required to pump the liquid
depends on the quantity of the liquid, the height (Head) to which it is to be lifted, and the viscosity of the liquid.
How Does a Pump Work?
A Pump works by imparting energy supplied by the prime mover, to the liquid, in two ways namely;
1. By imparting kinetic energy to the liquid by an impeller as in Centrifugal Pumps
2. By physically pushing (displacing) the liquid as in Displacement Pumps
Centrifugal Pumps work on the principle of Centrifugal Force acting on any mass when rotating. The liquid entering the eye of the
impeller comes in contact with the rotating impeller, takes up the kinetic energy from it, and is acted upon by Centrifugal
Forcecausing it to move towards the periphery of the impeller. On leaving the periphery of impeller, it enters the Volute Chamber or
the Diffuser Vanes where its kinetic energy is converted into pressure. This pressure in the liquid causes it to move ahead in the pipes
to its delivery point.
More than one impeller may be fitted on same shaft operating in similarly designed casing. Such Pumps are called Two-Stage, Three
Stage, or Multi-Stage Centrifugal Pumps.
Displacement Pumps are of mainly two types: Reciprocating Piston Pumps and Rotary Pumps. There are several variants
in Reciprocating Piston Pumps. Similarly, there are several Rotary Displacement Pumps like Gear Pumps, Screw Pumps, and Vane
Pumps. All the Displacement Type Pumps work on the same principle, i.e. by physically displacing the liquid by pumps moving parts.
A Reciprocating Pump has a piston or plunger moving up and down via a crankshaft rotated by an electric motor. The top space above
the piston is connected to suction and delivery pipes through suction and delivery valves. When the piston moves down, the suction
valve opens and liquid from the suction pipe enters and fills the cylinder space above piston. Similarly, when the piston moves up, the
liquid in the space above piston is pushed out through delivery valve into the delivery pipe.
When only space above the piston is used, the pump is called Single Acting Pump. However, the under side of the piston also can be
fitted with suction and delivery valves, connecting to suction and delivery pipes and used as separate unit. The pump using both sides
of the piston is called Double Acting Pump.
You can have more than one piston operated from the same shaft with more than one
number of crank throws. Such a pump with two pistons is termed as Duplex Pump and
one with three pistons is termed as Triplex Pump.
Rotary Type Displacement Pumps do not require Suction and Delivery
Valves connecting to suction and delivery pipes as, the liquid is always pushed in one
direction and there is no reversal of motion as in Reciprocating Pumps. All of the
Rotary Displacement Pumpslike Gear Pump, Screw Pump, Vane Pump etc. work on
same principle: the liquid is trapped between teeth, threads, or vanes and is pushed
from the suction side to the delivery side by rotating parts. Screw Pumps can have a
Single Screw, Double Screw, orTriple Screw to work as multiple units.

Types of Pumps
A pump is essentially a mechanical device that is used to move a fluid, normally uphill, or from a tank or reservoir. Pumps function by
increasing the pressure of the fluid, so the pressure of the fluid exiting the pump is enough to push it uphill, into a tank, or wherever it
is supposed to go. The main two classifications of pumps are the centrifugal pump and positive displacement pump. A centrifugal
pump uses a rotating impeller to draw a vacuum at the inlet side of the pump and to send the fluid out at an increased pressure at the
pump outlet. There are several different types of positive displacement pumps, including piston pumps, gear pumps, and peristaltic
pumps. All of the positive displacement pumps physically draw fluid into the pump at the inlet and force it out of the pump outlet.

Centrifugal Pumps
Centrifugal pumps are in very widespread use. The diagram at the left shows a centrifugal
pump set up with a motor to drive it. The pump is partially cut away to show a bit about
how it works. The diagram at the right shows a cutawaycentrifugal pump diagram with the
parts labeled. The pump impeller rotates within the pump housing (sometimes called the
volute), thus causing a reduced pressure at the inlet (suction) side of the pump. The rotary
motion of the impeller drives the fluid to the outside of the pump volute, increasing its
pressure, and sending it out of the pump discharge, as shown in the diagram.
Both of these diagrams show a radial flow centrifugal pump, which has the flow pattern just
described above. This is the most common centrifugal pump flow pattern. Another
alternative is the axial flow centrifugal pump, which has an impeller shaped somewhat like
propeller, that draws fluid in along the pump axis and sends it out along the axis at the other
side of the pump.

Positive Displacement Pumps

A positive displacement pump forces a predetermined fluid quantity from the pump inlet to the pump discharge for each pump cycle.
These pumps produce a pulsating flow, with periods of fluid delivery separated by periods with no fluid delivery. This effect is less
pronounced with some types of positive displacement pumps. Unlike centrifugal pumps, these pumps supply the same fluid flow at a
specific speed, irrespective of the discharge pressure. A positive displacement pump should not be run with the discharge valve closed.
A centrifugal pump that is pumping against a closed valve will just build up to some maximum pressure for that pump, but a positive
displacement pump will continue to discharge fluid into the fixed volume ahead of the closed valve until the line busts or the pump is
damaged. Therefore, a discharge relief valve, or safety valve, is essential. An external discharge relief valve is normally installed, with
a line returning to the reservoir. Positive-displacement pumps are sometimes grouped into three categories: rotary pumps,
reciprocating pumps, and diaphragm pumps. Each is discussed briefly in the next several sections

Positive displacement pumps are sometimes classified as rotary pumps, reciprocating pumps, and diaphragm pumps. There
are several types of rotary pumps, including gear pumps, lobe pumps, screw pumps, and peristaltic pumps. All of these types of
positive displacement pumps draw fluid into a compartment at the inlet end and move it to the pump outlet for discharge. The piston
pump is the primary type of reciprocating positive displacement pump. In a diaphragm pump, the fluid being pumped is isolated from
the working parts of the pump, eliminating the possibility of leakage through pump seals.

Rotary Positive Displacement Pumps

Rotary positive displacement pumps draw fluid into some type of chamber, which is then moved
around by the rotary action of the pump from the inlet to the outlet of the pump, where the fluid is
discharged. The clearances between the moving parts are typically close, so the pump speed must be
kept relatively slow. If these pumps operate at excessive speeds, erosion will be caused by the fluids,
like polishing of stones by ocean waves. Excessive clearances are created due to such erosion that
permits slip of liquids, decreasing the pump efficiency. Several types of rotary positive displacement
pumps are described next.
Gear Pumps
Gear pumps consist of gears that are arranged with the teeth meshed, as shown in the diagram at the
left. The gears rotate in opposite directions, so that they pull fluid into the spaces between the gear
teeth and the pump casing. The fluid is finally released through the pump discharge due to the
movement of the teeth. A fairly constant fluid flow is maintained by smaller teeth, while bigger teeth
will produce a more pulsating fluid flow pattern.
Lobe Pumps
The principle of the lobe pump is very similar to that of the gear pump, except that a smaller number of
larger "lobes" mesh together as shown in the diagram of a disassembled lobe pump at the right. In this
case the fluid is moved through the pump in spaces between the lobes and the pump casing.
Screw Pumps

Screw pumps are fitted with two screws that have opposite threads, one turning clockwise while the other turns counterclockwise. The
screws are fixed on parallel shafts that have meshed gears. The shafts are rotated due to the gear movements. The fluid is drawn from
the pump due to the screws turning. The clearance between the moving components and the pump casing is necessarily quite small.
Peristaltic Pump
Peristaltic pumps, also sometimes called tubing pumps, don't quite fit the general description of
rotary positive displacement pumps given above, but this is still the closest classification for them.
For this type of pump, a rotor with lobes squeezes tubing against the inside of a cylinder as it rotates
and thus draws fluid through the tube. The principle is illustrated in the diagram at the right.

Reciprocating Positive Displacement Pumps

Reciprocating positive displacement pumps, also called piston pumps, are used for many vacuum
pumps. The pump consists of a cylinder and piston with two one-way valves, one at the inlet and one
at the outlet of the pump. On the suction stroke of the piston, the discharge one-way valve is drawn
shut and the inlet one-way valve opens due to the suction in the cylinder, thus drawing fluid into the
cylinder. As the piston reverses direction and begins the discharge stroke, the inlet valve is pushed
shut and the outlet valve is pushed open, so that fluid is pushed out of the discharge port of the
pump. This is shown in the schematic diagram at the left.
Diaphragm Positive Displacement Pumps
A diaphragm pump is shown in the diagram at
the right. Fluid is drawn in when the diaphragm is pulled back and the fluid is
forced out when the diapragm is pushed forward. One-way inlet and outlet valves
are needed as shown in the piston pump diagram above. The reciprocating motion
of the diaphragm may be caused by a camshaft and piston, as shown in the
diagram, or it may be caused by compressed air, or by a pulsating fluid pressure
from some other source. A useful feature of the diaphragm pump is that the fluid
being pumped is completely isolated from the drive mechanism. There will be no
leakage past seals, etc., as is possible in many other types of pumps.

Maintenance and Repair of Centrifugal Pumps

Centrifugal pumps have been used in industry for a hundred and fifty years or more. They are used to convert the energy from the
pump driver to kinetic and potential energy into the fluid, via the impeller. They are used aboard ships to circulate seawater and
freshwater cooling for the main engine.

A ship's engine room contains several different types of pumps including centrifugal pumps. In the next few sections, the
maintenance of centrifugal pumps is explained. Here we will have a look at the procedure to strip, inspect and reassemble a centrifugal
pump, forming part of the planned maintenance schedule on board ships for the purpose of maintaining the equipment in optimum
operating condition.
The first section gives an overview of a typical centrifugal pump operation

Overview
As we saw earlier; the centrifugal pump was developed in the mid 1800s, although it was used in a crude form before then. The main
design change was by John Appold in 1851; he replaced the impeller straight vanes by curved blades.
The pump converts mechanical energy from the drive to kinetic energy, with this being transferred to the fluid as pressure.
This takes place due to the two main components of the pump: the impeller and the volute. The rotating impeller converts the input of
mechanical energy to kinetic energy, while the stationary volute converts this to pressure.

The fluid to be pumped enters the pump through the suction pipe nozzle, where it is drawn directly to the impeller eye located in the
center of the impeller. The impeller spins the fluid tangentially and radially with centrifugal force outwards. The curved blades create
a low pressure at the eye that allows more fluid to be drawn from the suction nozzle to the impeller.
So basically, the pump operates on the transfer of mechanical energy from the drive motor from where it is converted to kinetic energy
that is transferred to the fluid as pressure energy. The rotation of the impeller with its curved vanes draws the fluid from the suction
nozzle; throwing it outwards, expelling it through centrifugal force from the discharge nozzle.

A sketch of a horizontal pump is shown below.

Removal of Pump for Inspection and Maintenance

1 Isolate pump electrical circuit breaker on main switch board and attach a warning notice. (Do Not Operate-Men at Work).
2. Switch off and lock pump supply at its local supply panel. Attach a warning notice to pump local supply panel.
3. Close suction and discharge valves, chain and lock hand wheels.
4. Open pump suction and discharge pipe drain valves to bilge and when water ceases to flow; crack open the pipes / pump flange
joints carefully to ensure that pump has drained off and is safe for opening.
5. Fix a shackle to lifting pad eye above pump and hang chain block; ensuring SWL of block, slings and shackles are satisfactory.
6. Use a center-punch to match/mark coupling and casing, then remove the coupling bolts.
7. Disconnect, fix i/d tag and remove motor supply cables; taping over bare ends with insulating tape.
8. Connect shackle and sling to motor eyebolt and lift motor clear of pump using overhead chain block. Lay motor on its side out of
harms way, protecting machined surfaces on both pump and motor coupling halves against damage. (Cardboard and masking tape is
quick and efficient method.)
9. Disconnect all external fittings from pump casing e.g. cooling pipe, pressure gauge, oil reservoirs and air cock.
10. Remove bolting from top cover and remove cover. Scrape off old gasket and check mating surfaces, and renew gasket on
assembly. (Light smear of grease on gasket / faces)
11. The pump shaft with impeller can be lifted out of casing.
12. Dismantle the impeller, and remove the wear ring.
13. Remove the gland packing and disregard; replacing it on rebuild. Remember to cut ends of packing at 45 and stagger joints when
repacking gland.

Inspection Procedure for Pump and Motor

Pump
1. Impeller, pump shaft and internal volute/casing can now be inspected for erosion, pitting and wear.

2. If required rectify pitting or erosion in the impeller and casing with two part alloy epoxy putty. (See my article in the Reference
section)
3. Check main drive shaft bearings and thrust bearings for wear and replace if required.
4. Check wear ring clearance using feeler gauges; in my day at sea it was general practice is to replace with new rings at major
overhaul.
5. Check impeller / shaft key and keyways for damage and undue wear, Unscrew impeller shaft securing nut and check threads are in
satisfactory condition; retighten to manufacturers torque settings.
6. Give all parts a good clean removing any dirt/ medium residue before re- assembly using new parts as required.
7. Enter date of overhaul and parts renewed in the pump maintenance record card.
Drive Motor
1. Grip motor drive shaft /coupling firmly and check for excess axial and longitudinal movement. Rotate shaft at speed by hand,
allowing it to run to a stop whilst listening for excess noise from bearings. Any doubt on either counts, the bearings should be
replaced.
2. Megger check motor windings to ensure no dampness is present and windings are in good condition. Any suspect readings indicate
a full motor strip to check condition of rotor and stator.
3. If these checks are satisfactory, grease bearings as required. Some bearings are now sealed for life and will not require greasing.

Procedure to Start the Pump

1. Unlock and remove chains from inlet/outlet valve wheels and open both valves full.
2. Open air cock and expel air from line and pump while checking for any leaks
3. Turn the shaft coupling and ensure shaft is free to rotate.
4. Reconnect motor.
5. Remove danger notices from pump power supplies and reinstate breakers.
6. Start and record current drawn by the motor under starting and running conditions. Check and record the discharge pressure.
Types of pumps
Centrifugal pump

Water is led to the suction eye of the rotating

impeller. The water gains energy by the centrifugal
action of the pump and is discharged to the volute
outlet casing. The volute is created by increasing
the area of the outlet port and is greatest at outlet
from the pump. By this design the kinetic energy of
the water is converted to pressure energy.
Sealing is provided by a mechanical seal (one half
of which is shown above and in more detail below)
or by packed gland. For the former cooling water is
supplied from the discharge side of the pump. For
the latter cooling is provided by the allowance of
slight leakage, lubrication is by a grease filled
manual lubricator.

Mechanical seal

Packed gland seal

The pump unit shown above relies on the driving motor bearings for alignement. For larger pumps a leaded bronze or brass bush may
be fitted positioned just below the seal.For the largest pumps, especially those fitted with an inducer the shaft may be extended below
the impeller fixing and a second bearing fitted
Impellers
The kinetic energy of the fluid flowing through the
impeller is converted to pressure energy by the shape of
the volute casing. For high pressure pumps such as boiler
feed pumps a diffuser ring is fitted in the casing which
converts a greater portion of the pressure energy allowing
greater pressures to be generated.
A scroll type inducer may be fitted to the inlet which
improves the efficiency of unit and allows the pump to
operate with low suction pressures.
Wear rings
For efficient operation it is important to ensure that leakage from the high to low pressure side is kept to a minimum. This is achieved
by the use of wearing rings. Traditionally these are fitted to the casing,to increase the longevity of the impeller wear ring tyres may be
fitted.
The clearance given for wear rings is often a source of contention especially when dealing with on-ship made rings. A clearance of
1/1000 of the diameter of the bore is often quoted although this may be very difficult to achieve in practice.
Axial force
Without careful design an axial force is created by the action of the impeller. This is due to the low pressure acting on the suction eye
whilst the rest of the impeller is subjected to discharge pressure.
One solution is shown above where radial blades are cast into the back (stuffing box side) of the impeller. These blades are commonly
called pump-out vanes, and are meant to increase the centrifugal force of the fluid trapped behind the impeller. This causes the fluid to
be "thrown" outwards, reducing the pressure behind the impeller for the same reason that the impeller causes a reduction of pressure at
the suction eye.
Another method which may be found in conjunction with the pump-out vanes are the balancing holes. These are holes drilled near the
center of the impeller, connecting the space in the back of the impeller with the suction eye. This reliefs the pressure behind the
impeller by allowing the high pressure fluid trapped there to flow to the low pressure region at the suction eye. In order for this to be
effective, there must be a tight clearance between the impeller and the casing to reduce the flow of fluid into the back of the impeller.
Alternately dual back to back impellers may be fitted in common with a double casing

Materials suitable for general service

Shaft

Stainless steel

Impeller

Aluminium bronze

Casing

Bronze or cast iron

Wear ring Aluminium bronze or brass

Positive Displacement
This class of pump differs from the centrifugal class by several important factors
o Generally self priming whereas centrifugal generally require a priming means such as a belt driven priming pump
o Require the fitting of a safety valve to limit maximum pressure- this pump cannot be started against a shut discharge
valve.
Centrifugal pumps may be started against a shut or partially shut discharge valve. This is especially true for larger
pumps where the shutting of the discharge reduces starting and running load.
It should be noted that the partially shutting of the suction valve on both types of pumps leads to damaging
cavitation.
o Positive displacement pumps can handle high differential pressures
o More suited to low to medium flow rates
o May operate with higher viscosity fluids then centrifugal types
Gear

The pump shown above is of very common design. It is used for pumping many types of liquid and gas and is capable of delivering at
very high pressures. This makes it suitable for hydraulic supply.
The tooth profile is similar involute gear teeth for liquid pumps. For gas pumps special profiling with very fine tolerances is
employed.

Scroll

These pumps are seen in many applications and have a higher capacity then double row type. Fluid enters the pump and is screwed by
the idler shafts along the outer edge to the discharge port. Axial thrust of the idlers is absorbed by the integral thrust collar of the
driven shaft. The axial thrust of the driven shaft is absorbed by the thrust bearing.
The scroll sit in a replaceable insert which is sealed to the outer casing by o-rings.
Piston

This type of pump is in common use as a bilge pump or tank

stripping pump. For older vessels steam driven varieties served in
almost all systems.
The design is simple, robust and reliable. Materials are very much
dependent on the usage but bronze is common for larger parts and
stainless steel for piston rods
There are many other forms of positive displacement pump such as
rotary vane (often found in use as cooling water pumps, Scroll or
Screw pumps were the fluid passes axially along the shaft and
Diaphragm Pumps (commonly used as portable salvage pumps)
Axial Flow

These tend to fit somewhere between postive displacement and centrifugal. They tend to be of the very large capacity type and are
oftern seen in use for supply of cooling water for steam ship condensers. This is particularly true where 'scoops' are employed as the
axial flow pump offers very little resistance to flow when idling.
During operation cosiderable end trust occurs and a tilting pad thrust bearing is employed. Guide vanes smooth flow into and out of
the impeller.
Inducers
A type of axial flow pump is sometimes attached to the suction side of a centrifugal pump. This is called and inducer and is used
where the suction heads are very low or where suction occurs close to the vaporiation pressure of the fluid being pump. Typical
examples are the main condenser extraction pumps on steam ships and cargo pumps on LNG and LPG carriers
Cavitation
Disturbances in the water flow causes rapid localised pressure variations. This can lead to instantaneous vaporisation and bubble
formation. When these bubbles collapse there is a rapid in rush of water. When this occurs near to a surface this slug of water can
strike at speeds of up to 500m/s and lead to destructive erosion and removal of protective oixides thereby increaseing rates of
corrosion