Volk M. Pump Characteristics and Applications

2nd edition. - CRC Press Taylor & Francis Group, 2005. - 568 p.
This hands-on reference offers a practical introduction to pumps and provides the tools necessary to select, size, operate, and maintain pumps properly. It highlights the interrelatedness of pump engineering from system and piping design to installation and startup.
This updated second edition expands on many subjects introduced in the first edition and also provides new in-depth discussion of pump couplings, o-rings, motors, variable frequency drives, pump life-cycle cost, corrosion, and pump minimum flow.
Written by an acclaimed expert in the field, Pump Characteristics and Applications, Second Edition is an invaluable day-to-day reference for mechanical, civil, chemical, industrial, design, plant, project, and systems engineers; engineering supervisors; maintenance technicians; and plant operators. It is also an excellent text for upper-level undergraduate and graduate students in departments of mechanical engineering, mechanical engineering technology, or engineering technology.
About the Author
Michael W. Volk, P.E., is President of Volk & Associates, Inc., Oakland, California (www.volkassociates.com), a consulting company specializing in pumps and pump systems. Volk's services include pump training seminars; pump equipment evaluation, troubleshooting, and field testing; expert witness for pump litigation; witnessing of pump shop tests; pump market research; and acquisition and divestiture consultation and brokerage. A member of the American Society of Mechanical Engineers (ASME), and a registered professional engineer, Volk received the B.S. degree (1973) in mechanical engineering from the University of Illinois, Urbana, and the M.S. degree (1976) in mechanical engineering and the M.S. degree (1980) in management science from the University of Southern California, Los Angeles.Introduction to PumpsWhat Is a Pump
Why Increase a Liquid’s Pressure?
Pressure and Head
Classification of Pumps
Principle of Energy Addition
Kinetic
Positive Displacement
How Energy Addition Is Accomplished
Geometry Used
How Centrifugal Pumps Work
Positive Displacement Pumps
General
When to Choose a P.D. Pump
Major Types of P.D. Pumps
Sliding Vane Pump
Sinusoidal Rotor Pump
Flexible Impeller Pump
Flexible Tube (Peristaltic) Pump
Progressing Cavity Pump
External Gear Pump
Internal Gear Pump
Rotary Lobe Pump
Circumferential Piston and Bi-Wing Lobe Pumps
Multiple-Screw Pump
Piston Pump
Plunger Pump
Diaphragm Pump
Miniature Positive Displacement PumpsHydraulics, Selection, and CurvesOverview
Pump Capacity
Head
Static Head
Friction Head
Pressure Head
Velocity Head
Performance Curve
Horsepower and Efficiency
Hydraulic Losses
Volumetric Losses
Mechanical Losses
Disk Friction Losses
NPSH and Cavitation
Cavitation and NPSH Defined
NPSHa
NPSHr
Calculating NPSHa: Examples
Remedies for Cavitation
More NPSHa Examples
Safe Margin NPSHa vs. NPSHr
NPSH for Reciprocating Pumps
Specific Speed and Suction Specific Speed
Affinity Laws
System Head Curves
Parallel Operation
Series Operation
Oversizing Pumps
Pump Speed Selection
Suction Specific Speed
Shape of Pump Performance Curves
Maximum Attainable Efficiency
Speeds Offered by Manufacturers
Prior ExperienceSpecial Hydraulic ConsiderationsOverview
Viscosity
Software to Size Pumps and Systems
General
Value of Piping Design Software
Evaluating Fluid Flow Software
Building the System Model
Copy Command
Customize Symbols
CAD Drawing Features
Naming Items
Displaying Results
The Look of the Piping Schematic
Calculating the System Operation
Sizing Pipe Lines
Calculating Speed
Showing Problem Areas
Equipment Selection
Alternate System Operational Modes
Communicating the Results
Viewing Results within the Program
Incorporating User-Defined Limits
Selecting the Results to Display
Plotting the Piping Schematic
Exporting the Results
Sharing Results with Others
Sharing Results Using a Viewer ProgramList of Software Vendors
Piping Layout
Sump Design
Field Testing
General
Measuring Flow
Magnetic Flowmeter
Mass Flowmeter
Nozzle
Orifice Plate
Paddle Wheel
Pitot Tube
Segmental Wedge
Turbine Meter
Ultrasonic Flowmeter
Venturi
Volumetric Measurement
Vortex Flowmeter
Measuring TH
Measuring Power
Measuring NPSHCentrifugal Pump Types and ApplicationsOverview
Impellers
Open vs. Closed Impellers
Single vs. Double Suction
Suction Specific Speed
Axial Thrust and Thrust Balancing
Filing Impeller Vane Tips
Solids Handling Impellers
End Suction Pumps
Close-Coupled Pumps
Frame-Mounted Pumps
Inline Pumps
Self-Priming Centrifugal Pumps
Split Case Double Suction Pumps
Multi-Stage Pumps
General
Axially Split Case Pumps
Radially Split Case Pumps
Vertical Column Pumps
Submersible Pumps
Slurry Pumps
Vertical Turbine Pumps
Axial Flow Pumps
Regenerative Turbine Pumps
Pump Specifications and Standards
General
Liquid Properties
Hydraulic Conditions
Installation Details
ANSI
API
ISO
Couplings
Electric Motors
Glossary of Frequently Occurring Motor Terms
Amps
Code Letter
Design Letter
Efficiency
Frame Size
Frequency
Full Load Speed
High Inertial Load
Insulation Class
Load Types
Phase
Poles
Power Factor
Service Factor
Slip
Synchronous Speed
Temperature
Time Rating
Voltage
Motor Enclosures
Open Drip Proof
Totally Enclosed Fan Cooled
Totally Enclosed Air Over
Totally Enclosed Non-Ventilated Hazardous Location
Service Factor
Insulation Classes
Motor Frame Size
Historical Perspective
Rerating and Temperature
Motor Frame Dimensions
Fractional Horsepower Motors
Integral Horsepower Motors
Frame Designation Variations
Single Phase Motors
Motors Operating on Variable Frequency Drives
NEMA Locked Rotor Code
Amps, Watts, Power Factor, and EfficiencyPower Factor
Efficiency
AmperesSealing Systems and Sealless PumpsOverview
O-Rings
What Is an O-Ring
Basic Principals of the O-Ring Seal
The Function of the O-Ring
Static and Dynamic O-Ring Sealing Applications
Other Common O-Ring Seal Configurations
Limitations of O-Ring Use
Stuffing Box and Packing Assembly
Stuffing Box
Stuffing Box Bushing
Packing Rings
Packing Gland
Lantern Ring
Mechanical Seals
Mechanical Seal Advantages
Lower Mechanical Losses
Less Sleeve Wear
Zero or Minimal Leakage
Reduced Maintenance
Seal Higher Pressures
How Mechanical Seals Work
Types of Mechanical Seals
Single, Inside Seals
Single, Outside Seals
Single, Balanced Seals
Double Seals
Tandem Seals
Gas Lubricated Non-Contacting Seals
Sealless Pumps
General
Magnetic Drive Pumps
Bearings in the Pumped Liquid
Dry Running
Inefficiency
Temperature
Viscosity
Canned Motor Pumps
Fewer Bearings
More Compact
Double Containment
Lower First CostEnergy Conservation and Life-Cycle CostsOverview
Choosing the Most Efficient Pump
Operating with Minimal Energy
Variable-Speed Pumping Systems
Pump Life-Cycle Costs
Improving Pump System Performance: An Overlooked Opportunity
What Is Life-Cycle Cost?
Why Should Organizations Care about Life-Cycle Cost?
Getting Started
Life Cycle Cost Analysis
C_ic – Initial Investment Costs
C_in – Installation and Commissioning (Start-up) Costs
C_e – Energy Costs
C_o – Operation Costs
C_m – Maintenance and Repair Costs
C_s – Downtime and Loss of Production Costs
C_env – Environmental Costs, Including Disposal of Parts and Contamination
from Pumped Liquid
C_d – Decommissioning/Disposal Costs, Including Restoration of the Local Environment
Total Life-Cycle Costs
Pumping System Design
Methods for Analyzing Existing Pumping Systems
Example: Pumping System with a Problem Control Valve
For More Information
About the Hydraulic Institute
About Europump
About the U.S. Department of Energy’s Office of Industrial TechnologiesSpecial Pump-Related TopicsOverview
Variable-Speed System
Sealless Pumps
Corrosion
Galvanic, or Two-Metal Corrosion
Uniform, or General Corrosion
Pitting Corrosion
Intergranular Corrosion
Erosion Corrosion
Stress Corrosion
Crevice Corrosion
Graphitization or Dezincification Corrosion
Nonmetallic Pumps
Materials Used for O-Rings in Pumps
General
Eight Basic O-Ring Elastomers
Nitrile (Buna N)
Neoprene
Ethylene Propylene
Fluorocarbon (Viton)
Butyl
Polyacrylate
Silicone
Fluorosilicone
High-Speed Pumps
Bearings and Bearing Lubrication
Precision Alignment Techniques
Software to Size Pumps and SystemsInstallation, Operation, and MaintenanceOverview
Installation, Alignment, and Start-Up
General
Installation Checklist
Tag and Lock Out
Check Impeller Setting
Install Packing or Seal
Mount Bedplate, Pump, and Motor Check Rough Alignment
Place Grout in Bedplate
Check Alignment
Flush System Piping
Connect Piping to Pump
Check Alignment
Turn Pump by Hand
Wire and Jog Motor
Connect Coupling
Check Shaft Runout
Check Valve and Vent Positions
Check Lubrication/Cooling Systems
Prime Pump if Necessary
Check Alignment
Check System Components Downstream
Start and Run Pump
Stop Pump and Check Alignment
Drill and Dowel Pump to Base
Run Benchmark Tests
Operation
General
Minimum Flow
Temperature Rise
Radial Bearing Loads
Axial Thrust
Prerotation
Recirculation and Separation
Settling of Solids
Noise and Vibration
Power Savings, Motor Load
Ten Ways to Prevent Low Flow Damage in Pumps
Continuous Bypass
Multi-Component Control Valve System
Variable Frequency Drive
Automatic Recirculation Valve
Relief Valve
Pressure Sensor
Ammeter
Power Monitor
Vibration Sensor
Temperature Sensor
Maintenance
Regular Maintenance
Lubrication
Packing
Seals
Preventive Maintenance
Regular Lubrication
Rechecking Alignment
Rebalance Rotating Element Monitoring Benchmarks
Benchmarks
Hydraulic Performance
Temperature
Vibration
Troubleshooting
Repair
General
Repair Tips
Document the Disassembly
Analyze Disassembled Pump
Bearing Replacement
Wear Ring Replacement
Guidelines for Fits and Clearances
Always Replace Consumables
Balance Impellers and Couplings
Check Runout of Assembled Pump
Tag Lubrication Status
Cover Openings Prior to Shipment
Appendix A: Major Suppliers of Pumps in the United States by Product Type
Appendix B: Conversion Formulae