Pump Selection and Troubleshooting Field Guide-American Water Works Association (AWWA) (2009)

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INDEX Note: f. ind icates figure.

Index Terms

Links

A Actual horsepower defined example problem Actual motor, defined

8 10 vii

B Bernoulli's equation (adapted) Brake, defined

4 vii

Brake horsepower curves

20

22f.

defined

8

20

equation

8

selecting for centrifugal 23

24f.

Capital improvements plan

54

70

Cavitation, defined

vii

pumps

C

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Index Terms

Links

Centrifugal pumps and air release valves

61

and application problems

60

brake horsepower

23

and cavitation

59

close coupled

16

design point in evaluation of

59

efficiency

23

factors in low flow or pressure

59

family of curves

9f.

17

21f.

22f.

flowmeter in capacity testing

58

frame mounted

16

motor size

23

24f.

17f.

24f.

18f.

19f.

20f.

62f.

nonoverloading across the range

25

44

operations and maintenance manual performance evaluation

107 58

and piping connection problems

61

pressure boost

27

pressure boost in evaluation of

59

pressure/flow relationship

26

26f.

pump curve shape

25

26f.

and restriction in inlet piping

60

selection factors

22

and small inlet piping

60

27f.

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Index Terms

Links

Centrifugal pumps (Cont.) and too-high flow rate

60

troubleshooting

57

vertical

16

vibration evaluation

57

17f.

Chemical feed pumps

71

72f.

Chemical feed systems

71

105

accessories

79

82f.

backpressure valves

81

82f.

calibration chambers

82

82f.

capacity range of pump

18f.

103

chemical compatibility of construction materials chemical monitors

86

115

100

chemical system schematic

79

82f.

diaphragm pumps

71

72f.

73f.

75f.

76f.

77f.

and dilution

76

77f.

90

direct injection

94

96f.

97f.

dry feeders

91

92f.

flash mixing

85

98

96

104

74f.

99f.

flexible tubing adjacent to diaphragm pump and injector flow sensors

83

flowmeters

83

fluoride

94

95f.

flushing systems

83

84f.

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Index Terms

Links

Chemical feed systems (Cont.) gauge isolators

82

injection quills

85

85f.

large system installation

89

91f.

loss of prime

101

103

maintenance

104

mix and day tank installation

90

mixers

80

multifunction valves

81

new pumps, checking

96

98f.

82f.

104

operations and maintenance manual peristaltic pumps pressure-relief valves process mixing

107 78 80f.

81

94

96f.

82f.

process problems and solutions progressive cavity pumps

101 79

79f.

82

82f.

pulsation dampeners (surge suppressors) pump rate calculations

86

pump sizing calculations

87

recalibration of pumps small system installation

104 89

solids residue

103

spare parts kits for pumps

104

90f.

105f.

storage and containment of chemicals

86

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Index Terms

Links

Chemical feed systems (Cont.) suction tube shields

89

tanks

80

82f.

valves

81

82f.

weirs

98

100f.

86

115

16

17f.

58f.

34f.

37

Chemical resistance of construction materials Close coupled centrifugal pumps operations and maintenance manual

107

troubleshooting

57

D Deep well pumps

33

operations and maintenance manual

107

Demand management. See Flow variations Design discharge pressure Design efficiency Design flow

4 23

24f.

3

Diaphragm pumps assembly

72f. 71

73f.

basic operation

71

72f.

capacity

75

and dilution

76

77f.

discharge cycle

74

76f.

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Index Terms

Links

Diaphragm pumps (Cont.) and flexible tubing

96

and flooded suction

75

operations and maintenance manual

107

pump control

74

pump head assembly

71

74f.

104

105f.

suction cycle

71

75f.

and viscous solutions

74

77f.

spare parts kits

Discharge pressure Defined Dry chemical feeders

3 vii 91

pump sizing

93

for sodium fluoride

94

vibrators

93

Dynamic pressure, defined

92f.

5

E Efficiency. See Electrical efficiency; Motor efficiency; Pump efficiency factors Electrical efficiency

8

See also Motor efficiency

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Index Terms

Links

F Family of curves

1

8

brake horsepower curve

20

22f.

centrifugal pumps

9f.

17

21f.

22f.

hydraulic efficiency curve

20

21f.

impeller curve

17

NPSHR curve

21

23f.

solids handling pumps

33

35f.

Flow (Q)

19f.

20f.

1

Defined

vii

Flow variations

55

anticipating future demand

9f.

54

by automated on/off controls on pumps

41

42

42

51

avoiding frequent turning off and on of pumps

54

and capital improvements plan in water system optimization

54

by flow rate control valves

41

liability of only one pump

54

and pump capacity options

53

sizing strategies

41

and system redundancy

41

and system size

54

53

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Index Terms

Links

Flow variations (Cont.) by variable-speed-drive motors

41

46

and variations in system demand

54

See also Throttling; Variablefrequency drives Flow

14

Fluoride dry feed

94

liquid feed

94

saturators

94

95f.

16

18f.

Frame-mounted centrifugal pumps general troubleshooting

61

62f.

57

operations and maintenance manual

107

seal problems

62

and vibration

63

Friction loss

3

calculating

4

defined

5

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Index Terms

Links

H H. See Discharge pressure Head defined

14

See also Pressure Horsepower actual, defined

8

availability of calculations

3

definition and equation

7

example problems

12

10

information for reading pump curves

3

See also Brake horsepower; Water horsepower 20

21f.

Impellers

17f.

19

curves

17

17f.

Jockey pumps

54

Hydraulic efficiency curves

I

20f.

J

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Index Terms

Links

M Maintenance. See Operations and maintenance Mechanical seals. See Packing and mechanical seals Metric horsepower

9

Motor efficiency

8

example problem

12

Motor horsepower (HP)

1

equation

16

8

9

N Net positive suction head (NPSH) defined

14

14f.

15f.

vii

Net positive suction head required (NPSHR)

21

curves

21

defined

vii

and throttling

44

Nonoverloading across the range

25

23f.

44

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Index Terms

Links

O Operations and maintenance (O&M)

vii

and capital improvements plan

70

of chemical feed systems

104

chemical pumps manual

107

crisis maintenance

1

68

evaluation of each pump station and wet well and hydraulic model of system

70 70

information needed by O&M personnel

3

maintenance chart

69

12

maintenance requirements and checklist on-site manuals process pumps manual

108 68

107

107

and pump accessory availability

108

recommended maintenance

68

repair records

69

spare parts inventory

108

system-wide plan (green system)

70

written procedure for each pump

108

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Index Terms

Links

P Packing and mechanical seals troubleshooting on framemounted centrifugal pumps

62

on vertical line shaft turbine pumps

30

Performance estimation

38

pressure gauges

39

Performance factors Peristaltic pumps

40f.

3 78

78f.

operations and maintenance manual Power cost, example problem

107 11

Pressure boost

3

defined

6

in evaluating operating condition Pressure

59 1

3

Pressure gauges

39

location

39

40f.

79

79f.

Progressive cavity pumps operations and maintenance manual

107

and polymer day tanks/mix tanks

79

80f.

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Index Terms

Links

Pump curves centrifugal pumps

25

26f.

inflection

31

32f.

31

32f.

27f.

vertical line shaft turbine pumps Pump design

13

Pump efficiency factors

15

Pump sizing strategies

1

53

41

Pumping height. See Static head Pumps estimating performance of

38

40f.

as most expensive part of water system to operate purpose of

1 57

See also Centrifugal pumps; Chemical feed systems; Close coupled centrifugal pumps; Deep well pumps; Diaphragm pumps; Framemounted centrifugal pumps; Peristaltic pumps; Progressive cavity pumps; Solids handling pumps; Submersible pumps; Vertical in-line centrifugal pumps; Vertical line shaft turbine pumps

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Index Terms

Links

Q Q. See Flow

R Replacement evaluation

16

S Seals. See Packing and mechanical seals Solids handling pumps

33

efficiency

33

installation

34

motor alarms

33

33f.

36f.

operations and maintenance manual

107

typical pump curve

33

wet well design

35

35f.

Static discharge head, defined

4

5f.

Static head

3

4

5f.

6f.

13 Submersible pumps centering

33 37

35f.

36f.

deep well pumps

33

34f.

37

drawdown

37

and excessive alarms

67

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Index Terms

Links

Submersible pumps (Cont.) and frequent starting and stopping level controls

68 38

operations and maintenance manual solids handling pumps

107 33

33f.

solids-handling pump problems

67

and too-high power draw

67

troubleshooting

66

well pump problems

66

Suction lift

13

14

Suction side pressure

3

15

System requirements

5f.

13

T Throttling

42

avoiding on suction side

43

effects of

42

43f.

effects on motor size

43

45f.

and increased NPSHR increasing pressure

44 44

and nonoverloading across the range

44

reducing pressure

44

and seasonal variations

45

45f.

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Index Terms

Links

Total discharge pressure defined

6

Train pump, defined

vii

Troubleshooting

57

centrifugal pumps

57

close coupled centrifugal pumps

57

frame-mounted centrifugal pumps

61

signs of need for

57

submersible pumps

66

vertical in-line centrifugal pumps

63

vertical line shaft turbine pumps wet well design

63 66

V Variable-frequency drives (VFDs)

46

and avoidance of frequent turning off and on of pumps benefits of

51 51

52f.

50

51f.

47

52

comparison of two operating conditions (1,750 rpm vs. 1,150 rpm) design

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Index Terms

Links

Variable-frequency drives (Cont.) determining whether to replace motor or entire pump diagram

52

53

46

46f.

47f.

49f.

effect of impeller curve on increasing speed

50

and high static head applications high-speed operating point

52 48

49f.

increased motor efficiency (last 20 years) low speed operating point

53 48

49f.

and need for larger motor and heavier wiring

52

and need to dissipate motor starter heat

52

pump curves at different motor speeds

48

49f.

46

47f.

16

17f.

and pump operational calculations Vertical in-line centrifugal pumps

18f.

operations and maintenance manual

107

troubleshooting

57

63

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Index Terms

Links

Vertical line shaft turbine pumps

27

application issues

64

bearings

30

and grit or dirty water

64

and inadequate submergence

63

intake screen

29f.

minimum height

28

minimum submergence

28

29f.

63

64f.

30

29f.

operations and maintenance manual

107 32f.

optimum operating range

31

packing or mechanical seals

30

and pipe column leaks

65

pump curve

31

32f.

29f.

30

shaft height adjustment

31

3If

starter

30

troubleshooting

63

and turbulence at pump inlet

65

unstable operation

31

and water quality

29

pump mounting

Volute

16

31f.

32f.

17f.

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Index Terms

Links

W Water horsepower defined

vii

equation

7

Water system components Wet well design troubleshooting

7

20

1 35 66

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