PUMPS & MOTORS

Key Words and Concepts

Capacitor – A capacitor stores energy and consists of a pair of metallic plates that are separated by an
insulating material called a dielectric. Used with induction motors to raise the power factor of the
electrical system driving the motors.

Cavitation – A condition that can occur when pumps are run too fast or water is forced to change
directions quickly. Cavitation in a pump can cause pitting of the impeller and reduce pump efficiency.

Critical Speed – The critical speed is the theoretical angular velocity that excites the natural frequency of
a rotating object, such as a shaft. Manufacturers typically design pumps so that the first critical speed is
at least 20% higher or lower than rated speed of the pump to prevent shaft vibration.

Demand Meter – A demand meter is used to measure the average power of a load over a specific time
interval as well as recording the peak power consumption during the period.

Differential Relay – A differential relay is frequently used on large equipment to check whether all the
current entering a system comes out of the system. It will shut down a system that is losing current as a
safety precaution.

Frequency Relay – A frequency relay is used when power is generated locally to respond to changes in
the frequency of an AC power supply. They are also used on synchronous motor starters to sense when
the motor has reached synchronizing speed.

Friction Head – Friction head is the amount of energy in feet required to overcome resistance to flow in
a pipe.

Head – The energy possessed by water in a hydraulic system measured in feet.

2.31 feet of head = 1 psig

Hydraulics – The study of fluids in motion is called hydraulics.

Impeller – A rotating set of vanes that forces water through a pump. The impeller is often called the
heart of the pump.

Lantern Ring – A lantern ring is used to prevent air leakage along the pump shaft when it is operating
under suction lift conditions. Also called a Seal Cage.

Mechanical Seal – A seal placed on a pump shaft to prevent water from leaking out along the shaft.
They can also prevent air from entering the pump. A mechanical seal is used in place of packing when
the pump suction pressure is ≥ 60 psi.

Ohm’s Law – An equation expressing the relationship between Volts, Current and Resistance in an
electrical system.

Volts = (Amps) x (Ohms)

Packing – Rings of graphite impregnated cotton, flax, or synthetic materials used to control pump shaft
or valve stem leakage. Pump shaft packing is designed to wear out over time during normal use.
1
© American Water College
Packing Gland – A follower ring that compresses the packing placed in the stuffing box. The packing
gland is tightened or loosened to control shaft leakage.

Parallel Operation – Two or more pumps whose discharges are entering a common pipe to increase the
volumetric flow rate.

Pressure Head – The measure of the amount of energy in water due to water pressure. The amount of
liquid that can be raised vertically by a given pressure is called pressure head.

Pump Head – The amount of energy in feet that a pump supplies to a fluid.

Racking – A condition where a pump is subject to frequent on/off cycling due to pressure surges that
effect the pump controller.

Radial Load – A load acting at a right angle to the shaft. A radial bearing supports a shaft and allows it to
rotate freely around its axis, compensating for these angular forces.

Rectifier – A piece of electrical equipment that changes alternating current to direct current by allowing
the electric current to flow in one direction but blocking flow in the opposite direction.

Series Operation – One pump discharging into the suction line of another pump to increase the overall
discharge head.

Slip – Recirculation within a centrifugal pump casing around the impeller due to a blockage of the pump
discharge.

Stuffing Box – The stuffing box houses the packing and lantern ring in a centrifugal pump.

Thrust Load – A load that acts parallel to the axis of rotation. A thrust bearing compensates for the axial
thrust of a shaft.

Thermal Overload Relay – An overcurrent protection device placed on each phase of a power supply to
open up a control circuit and stop a motor, if the current becomes excessive.

Voltage Relay – An electrical device used to detect power loss and initiate an automatic switchover to
another power supply.

Wear Ring – Rings made of brass or bronze placed on the impeller and/or casing of a centrifugal pump
to separate the suction side of the pump from the discharge side.

2
© American Water College
Pump Characteristic Curves
Pump Curves

Characteristics displayed on pump curves:

 Capacity
 Head
 Power
 Efficiency

Pump Station Design Considerations

 System head requirements

 Static pressure
 System head loss
 Elevation difference

3
© American Water College
Pump Types
Velocity Pumps
 Use an impeller or propeller to accelerate water to a high velocity within the pump casing
 High velocity (low pressure) converted to high pressure (low velocity) as casing volume increases
 Volume increases two ways:
o Volute – centrifugal pumps
o Diffuser vanes or channels – vertical turbine pumps

Radial Flow

 Most commonly used in water systems

 Water thrown outward from the center of impeller and into the volute or diffusers
 Velocity is converted to pressure in the volute or diffusers
 Multistage pumps increase pressure at each stage but flow capacity limited to first stage

Axial Flow

 Referred to as a propeller pump

 Doesn’t have a volute of diffuser vanes
 Propeller shaped impeller increases head by the lifting action of the blades
 Water moves parallel to the pump shaft
 Pump can move large volumes of water but adds very little head
 Shaft rotates between 9,000 and 15,000 rpm

Mixed Flow

 Combination of radial-flow and axial-flow pumps

 Impeller is shaped so centrifugal force will impart some radial force
 Used in applications where the water contains a high solids concentration

Centrifugal Pumps

 Volute-type of centrifugal pump is most commonly used by water systems

 By varying shape and size of impeller, a wide range of flows and pressures can be achieved
 Can develop as much as 250 feet of head per stage
 Range in efficiency between 75% and 85%.
 Theoretical suction lift at sea level is about 34 feet
 Practical suction lift is 15-25 feet due to various losses
 Relatively inexpensive and require very little maintenance

4
© American Water College
Centrifugal Pump Advantages:

 Wide capacity range

 1 gpm-50,000 gpm and 5 ft -700 ft of head
 Uniform flow at constant speed and head
 Minimal suspended matter will not jam pump
 Low to moderate initial cost
 Adaptable to different drive types
o Motor, engine, turbine
 Moderate to high efficiency at optimal operation
 No need for internal lubrication
 Relatively low operating noise level
 Ability to operate against closed discharge valve

Centrifugal Pump Disadvantages:

 Narrow range of discharge flows and head for optimal efficiency

 Flow capacity is dependent upon discharge pressure (higher pressure = lower flow)
 Not self-priming
 Potential for backward rotation if stopped with open discharge valve (can cause pump and
motor damage)
 Impeller can be damaged by abrasive material in the water being pumped

Vertical Turbine Pumps

 Impeller rotates within a channel of constant cross-sectional area

 Flow velocity is converted to pressure by diffuser guide vanes
 Guide vanes direct flow to next stage bowl or to pump discharge
 Most efficient of all velocity pumps and is capable of generating the highest head
 Pump efficiency ranges between 90% - 95%
 More expensive to purchase and more difficult to maintain than centrifugal pumps

Vertical Turbine Pump Advantages:

 Uniform flow at constant speed and head

 Simple construction
 Multiple head capacities available in a single model
 Adaptable to several drive types
o Motor, engine, turbine
 Moderate to high efficiency under proper head conditions
 Little space occupied for a given capacity
 Low operating noise level

5
© American Water College
Vertical Turbine Pump Disadvantages:

 High initial cost

 High repair costs
 Lubrication is required for the support bearings within the casing
 Cannot pump water with any suspended material
 Narrow range of discharge flows and head for optimal efficiency

Deep-well Pumps

 Vertical turbine pumps with very long pipe column housings and drive shafts
 Drive unit remains above ground
 Piping, shaft sections, and multiple stages are lowered into the well
 Requires careful installation to ensure proper alignment of shafting and impeller stages

Submersible Pumps

 Multistage mixed-flow centrifugal pumps or turbine pumps with a close-connected motor

 Designed to operate while completely under water
 Pump and motor unit are placed below the water level in a well

Booster Pumps

 Vertical turbine pumps are often used as in-line booster pumps within distribution systems
 Motor and pump usually close-coupled and pump draws suction on water collection sump
 Commonly referred to as a “can pump”

Positive-Displacement Pumps
 Main use by water systems is for metering treatment chemicals into the system
 Deliver a fixed volume of liquid for every stroke or revolution regardless of discharge pressure

Reciprocating Pumps

 Piston moves in an out of a cylinder

 Liquid is drawn in and discharged through check valves
 Creates a pulse in discharge minimized by use of multiple cylinders or pulsation dampeners

Rotary Pumps

 Use closely meshed vanes, gears or lobes rotating within a tight chamber to move liquid
 Gears and lobes are most common type of rotary pumps in use

6
© American Water College
Diaphragm Pumps

 Use a flexible diaphragm to vary the size of a chamber (similar to reciprocating pump)
 Check valves allow flow in and out with each stroke of the drive unit.

Pump Operation
Starting and Stopping
 Sudden starting and stopping of pumps can cause a pressure surge producing water hammer
 Water hammer can damage distribution system components
 Water hammer must be minimized by following proper operating sequence when starting or
stopping pumps

Centrifugal Pumps

 Check pump lubrication

 Ensure pump is primed by ensuring the impeller is free of air and completely submerged.
Water-pumps with foot valves require the suction piping to be filled as well
 Start with discharge valve closed
 Slowly open discharge valve once motor has reached full speed
 Do not throttle discharge valve
 Shutdown order is the reverse

Positive Displacement Pumps

 Check lubrication
 Open suction and discharge valves
 Start the pump
 Shutdown order is the reverse

Maintaining Prime

 Centrifugal pumps cannot generate a suction without a full impeller

 A foot valve (check valve) placed on suction side of the pump to keep water in pump casing
 Pump prime can also be maintained by removing air with a vacuum connection

7
© American Water College
Loss of Power

 Discharge valve needs to be shut to prevent reverse flow (causes damage)

 Battery or hydraulic back-up systems are used when electrical power is lost

Controlling Flow

 Throttle discharge valve

o Never throttle with a gate valve
 Cycle pumps
o Not good for medium to large motors
 Vary pump speed
o Requires special speed control system
 Frequent cycling of medium to large pumps for system pressure control should be avoided if
possible
 Throttling at the pump discharge is a waste of energy and should not be used as a means of
controlling system pressure
 The most efficient solution is a variable speed drive that can match system demand

Monitoring
Operational variables monitored include:

 Suction and discharge head

 Bearing and motor temperature
 Vibration
 Speed

Differential Pressure

 Suction and discharge pressure should be regularly monitored and documented

 Loss of efficiency due to internal wear detected by reduction in pump’s differential pressure

Key Temperatures

 Excessive bearing and motor temperatures indicate a problem (pump should be shut down)
 Operators use their sense of feel to determine if bearing and motor temperatures are normal
 Temperature monitoring devices can also be used to alert operators of a hot bearing or motor
 Bearing temperatures should be checked with a thermometer on a monthly basis

8
© American Water College
Pump Vibration

 Operators should have a good feel for what is a normal feel and sound of each pump
 Any variation from normal feel and sound must be investigated to determine the cause
 Vibration detection equipment can also be used to monitor large pumps
 Vibration may indicate pump and motor misaligned or bearing is about to or has failed
 Detecting minor vibrational changes early helps operators correct minor problems and avoid
costly failures

Pump Speed

 Monitoring the rotational speed of variable speed pumps is important to avoid cavitation
 Under-speed and over-speed alarms can be installed to alert the operator

Routine Observations

 Appropriate packing leakage

o Small drips from packing
o No leakage from mechanical seal
 Abnormal noises
 Abnormal vibrations
 Excessive seal leakage
 Abnormal smells
 Hot bearings, motors or packing

9
© American Water College
Centrifugal Pump Components
Pump Casing

 Shaped to convert kinetic energy of water leaving the impeller to pressure energy
 Usually made from cast iron (ductile iron, bronze and steel can be special ordered)
 Single suction design – water enters the pump at one end and discharges at 90o angle to inlet
o Water enters the pump housing at one point but is directed to impeller from both sides
o Water then discharges away from the middle of the pump where it enters the volute
 The double-suction pump is commonly referred to as a horizontal split-case pump
o Able to pump large volumes of water at high discharge pressures:
 Flow = > 10,000 gpm
 Pressure = 350 psi

Impeller

 Prime mover of water

 Most are made of bronze
 Cast iron and stainless steel are alternative materials
 Single suction pumps have semi-open or closed designs
 Closed design is most common
 Used for pumping water with a low solids concentration
 Double suction pumps use closed design

Wear Rings

 Restrict flow between the impeller discharge and pump suction

 Single wear ring applications have the ring mounted in the case
 Double wear ring applications have rings mounted in the case and on the shaft
 Rings will wear over time and need to be replaced when pump efficiency drops off
 When replacing the wear rings, the wear rings can be heated to make removal and installation
easier since the metal will expand as temperature increases

Shaft

 Transmits torque to the impeller which causes it to rotate

 Usually made of steel or stainless steel
 Impeller is keyed to the shaft on double-suction pumps
 Impeller is attached to the end of the shaft with a key nut on end suction pumps

Shaft Sleeves

 Placed on shaft for packing rings to wear against

 Intended to protect the shaft from damage and are replaceable when worn
 Usually made from a bronze alloy

10
© American Water College
Packing Rings

 Prevents excessive leakage where the shaft goes through the pump case
 Made from graphite impregnated cotton, flax or synthetic material
 Multiple rings are installed in the stuffing box
 Packing ring ends should be staggered at least 90 degrees when installed (180 degrees if only 2
rings used)
 Packing gland can be adjusted to reduce packing leakage, however some leakage is required to
lubricate and cool the packing and shaft sleeve to prevent packing failure

Lantern Rings

 Used in applications where the pump is operating under a suction lift condition
 Designed to prevent air from entering the pump due to shaft leakage
 Pump discharge water is fed to the lantern ring and flows in two directions:
o towards pump suction
o away from packing gland
 Prevents air leakage and lubricates packing

Mechanical Seals

 Used in applications where the pump is operating under a high suction head (> 60 psig)
 Excessive pressure will compress packing rings
 Seal consists of two parts:
o one connected to the shaft
o one connected to the case
 Contact between the surfaces is maintained by spring pressure
 Leakage is an indication of a problem and requires immediate attention
 Mechanical seals should never exceed a temperature of 160oF
 Water cooling is required in applications where it is possible for the mechanical seal
temperature to reach 160oF

Bearings

 Most common are ball-type radial and thrust bearings

 Lubricated with grease or oil depending on type
 Noise level from bearings increases as they begin to fail
 Over lubrication with grease will cause the bearing to run hot and fail prematurely

11
© American Water College
Operational Checks

 Oil level in bearing housing

 Free movement of oil rings
 Proper oil flow in pressure feed systems
 Proper type of grease used in grease-lubricated bearings
 Proper amount of grease in the housing
 Bearing temperature

Oil-lubricated Bearings

 Oil should be changed after the first month of operation and then every 6-12 months depending
on usage and operating conditions
 The oil should be inspected for indications of bearing wear or excessive dirt each time it is
changed
 It is important that the bearing housing is not overfilled with oil

Grease-lubricated Bearings

 The bearing temperature should be closely monitored during the initial run-in period
 An operator should be able to touch the bearing housing with a bare hand and not get burned if
the bearing is operating properly
 After 1 month of initial service, the bearing should be re-greased
 Over-greasing a bearing will cause internal friction due to a churning action of the grease
 This will in turn cause the bearing to run hot and could lead to premature failure
 Bearings should be re-greased every 3 to 6 months depending on operating conditions

Couplings

 Primary function is to transmit the rotational energy from the motor to the pump shaft
 Flexible couplings allow for slight misalignment between the motor and pump shafts and
absorbs start-up shock when pump motor is turned on
 Shaft misalignment is a common cause of vibration and can lead to premature bearing failure
 Following installation, the pump and motor should be brought up to operational speed and
temperature, and then shutdown
 The alignment should be re-checked by performing a “hot alignment” check on the shaft
 The shaft alignment should be periodically checked (every 6 months) in the future and the
readings checked against the initial readings to determine if the shaft alignment has changed
 Changes in shaft alignment should be investigated to determine the cause and then the cause
should be corrected

12
© American Water College
Inspections/Maintenance
Cavitation

 Under certain conditions, the water in a pump impeller can flash to small vapor bubbles
 Vapor bubbles explode against impeller creating sound of marbles passing through pump
 Causes pitting on the impeller which will reduce its pumping efficiency over time
 Avoided by operating the pump within its design pressure range

Major Repairs

 The major repairs that may be required on centrifugal pumps at infrequent intervals include the
replacement of:
o Bearings
o Wear rings
o Shaft sleeves
o Impellers
 These repairs require prior planning and will usually be performed in the field
 Pumps too large to repair in the field must be brought back to the shop
 Extends the life of the pump at a fraction of the cost of replacing the pump

Electric Motors
Introduction

 Most pumps used by water utilities are powered by alternating current (AC) motors
o Smooth power output and high starting torque.
o Alternating current flows in one direction and then it reverses
o A voltage is produced by rotating a conductor through a magnetic field
o Voltage produces current flow

Ohm’s law shows the relationship between voltage, current flow, and the conductor’s resistance in an
electrical system.

Volts (E) = Amps (I) x Ohms (R)

13
© American Water College
Volt

A measure of electrical pressure and can be compared to the measurement of water pressure

Ampere

The measure of electrical current flow through a conductor (similar to water through a pipe)

Ohm

The measure of the conductor’s resistance to current flow (similar to head loss in a pipe)

Motor Principles

 Use magnetism to generate rotational force required to power a pump

o Electromagnet created by wrapping wire around a rod and flowing current through it
o North and south poles are created by the current flow
o As current direction changes, so does the polarity of the magnet
 A simple motor can be created by placing a rotating magnet near an electromagnet
o As current flows through the electromagnet (stator windings) it creates a magnetic pole
o Pole attracts the opposite pole of the magnet (rotor)
o Magnetic field created in stator rotates and magnet attached to rotor follows rotating
magnetic field
 In larger motors, both the stator and rotor magnets are electromagnets in which the magnetic
field is produced by current flowing through wires

Motor Speed

 Speed at which the magnetic field rotates around the stator is called synchronous speed
 Expressed in revolutions per minute (rpm)
 Motors have a maximum rpm of 3,600 since the electrical system operates at 60 Hz

60 cycles/sec x 60 sec/min = 3,600 rpm

 A two pole motor can achieve 3,600 rpm while motors with more poles will operate at fractions
of 3,600 rpm:

4 pole = 1,800 rpm

6 pole = 1,200 rpm

 Induction motor speeds:

2 pole = 3,450 rpm

4 pole = 1,750 rpm

6 pole = 1,150 rpm

14
© American Water College
  Motor speed can also be controlled by electronic motor controllers so a single motor can
operate over a wide range of speeds

Starting Current

 Most motors draw more current during start-up than during normal operation
 Locked-rotor-current describes the current drawn the instant a motor is powered on
 Starting current is another name for this initial power surge
 Starting current is typically 5 to 10 times the normal operating current for most motors
 At start-up, the current draw is at its maximum and then it lowers to its normal operating level

Single-Phase Motors
 The electricity that comes from the power company is 3-phase current.
o Can be reduced to single phase current for lighting and small equipment.
o Most utility motors use a 3-phase power supply.
 Only small motors will use single-phase AC power.
o A motor with a single-phase winding cannot generate the torque required to start
o It requires special starting windings to generate the torque required.
 There are three types of single-phase motors:
o Split-phase motor
o Repulsion-induction motor
o Capacitor-start motor

Split-phase motor

 No windings in a split-phase motor.

 Draws high current when starting and has relatively low starting torque

Repulsion-induction motor

 More complex than the split-phase motor

 Draws a lot of current on start-up

Capacitor-start motor

 High starting torque along with a high starting current.

 Good for applications requiring it to be brought up to speed quickly and not cycled on and off

15
© American Water College
Three-Phase Motors

 Most motors used in water distribution systems and treatment plants powered by 3 phase AC
 Voltage rating can range from 230 V up to 4,000 V.
 Three classifications for three-phase motors:
o Squirrel-cage induction motor
o Synchronous motor
o Wound-rotor induction motor

Squirrel-cage Induction Motor

 Simplest type of all AC motors

 Rotor windings are steel bars placed in slots on the rotor and attached at each end
 Current flowing through the stator winding establishes a rotating magnetic field
 Magnetic field in turn induces a voltage in the rotor windings, which creates an opposing
magnetic field on the rotor causing the motor to turn
 Can be used in applications requiring a high starting torque without special starting circuitry

Synchronous Motor

 When power is supplied to the stator windings of a synchronous motor, a rotating magnetic
field is established and it rotates at what is called synchronous speed
 The rotor has the same number of poles as the stator
 Direct current is supplied to the rotor through slip rings (commutator) and brushes
 The magnetic field created by the rotor “chases” the rotating magnetic field created by the
stator and the motor rotates at synchronous speed, which is determined by the number of poles
in the motor, which we discussed earlier.
 Used in applications requiring a constant motor speed

Wound-rotor induction motor

 The stator of the wound-rotor induction motor is similar to the squirrel-cage induction motor
 The rotor windings are electrically connected to the power supply by slip rings
 Advantages of the wound-rotor induction motor include:
o Ease of starting
o Variable speed operation
o Low starting current
 seldom higher than full load

Variable-Frequency Drives

 Typically controls the speed of a wound-rotor induction motor

 Modulates current to the motor to vary the speed which in turn varies the output of the pump
 Allows a single pump to provide water at different flow rates to match system demand

16
© American Water College