ENSC3003 Lab3: Pumps Page 1

ENSC3003 Fluid Mechanics

Lab 3
Pumps


Student Name: __________________________________________________

Student No: __________________________________________________

Lab Date/Time: __________________________________________________


INTRODUCTION

The objective of this laboratory is for you to gain skills in analysing real pumps and
pumping systems. The rig being used differs from an industrial pumping system
only in scale, so the skills learned are likely to be useful in your working future. The
laboratory will also demonstrate a link between the theory learned in lectures and a
real application. This lab is also designed to emphasise safe working practices
likely to be found in industry.

At the completion of this laboratory, you should be able to:
Recognise pump and system components and their purpose
Determine a pump curve
Understand the effect of changes in the system on the operating point of the
pump
Appreciate the effect of assembly, installation and operating practices on the
life cycle of the pump
Be familiar with common pipe and pump symbols on P+IDs
Have appreciation of safe practice around industrial equipment


SAFETY BRIEFING
The pump test rig located in G50M is an industry-sized facility using standard
industrial equipment. The specific hazards involved in operating the test rig are
discussed below. The following general safety guidelines must be observed.
1. Personal Protective Equipment (PPE). Long pants, Long-sleeved shirt, and
enclosed footwear must be worn. Hooded jackets are not permitted. Where
appropriate, long hair must be tied back. Safety Glasses are supplied, and
must be worn when in the presence of the Pump Test Rig.
2. Be aware that the pump rotates at 1500 rpm.
3. Be careful of fragile instrumentation cables
4. Connect the motor electrical supply only when directed by supervisor.
Unplug the motor electrical supply when the laboratory is completed.
5. Be aware that the rotor in the Cut-Away Demonstration Unit can rotate.


ENSC3003 Lab3: Pumps Page 2
HAZARD IDENTIFICATION
The pump laboratory involves inspection of the pump and piping system, and
operation of the motor and pump. The main hazards of running the pump are:


LABORATORY ORGANISATION

Students attending each session are divided into two groups of (up to) 5,
designated as Groups A and B (refer to the laboratory assignments spreadsheet to
determine your group).

Group A will start the lab session by undertaking Exercise 1, which entails pump
component identification using the cut-away pumpset demonstration unit located in
the main laboratory (G50K). They will then move on to Exercise 2, system
component identification and pump curve measurement, using the pump test rig
located in the southwest corner of G50M.

Group B will undertake the exercises in reverse order, starting with Exercise 2 and
moving onto Exercise 1. It is anticipated that each exercise should be completed in
30-45 minutes. Note that due to space restrictions, each group must remain at its
designated workstation until it is time to change over (ie when both groups have
completed the first exercise).


Unit Hazard Mitigation
Electrical supply The power supply from the
wall to the motor is high
voltage (440v).
Check wiring and plug
condition. Do not stand on
cable. Only plug in when
ready to run the pump.
Motor Motor Fan Do not place anything near
fan end of motor. A cowling
guards the fan.
Pump coupling Spinning shaft/coupling The coupling and shaft are
guarded by a cover
Suction side
valves
Closing the suction valves
will starve the pump of fluid
resulting in a build up of
temperature.
Ensure suction valves are
open.
Discharge side
valve
Closing the discharge valve
completely will dead-head
the pump resulting in a
build up of pressure in the
casing.
Do not completely close the
valve. Do not run with the
valve 5-20% open for long
periods.
Rotor in the
Cut-Away
Demonstration
Unit
Rotor can rotate causing
fingers to jam.
Do not expose fingers or
other body parts to small
clearances in rotating
equipment. Only 1 person to
touch the Cut-Away
Demonstration Unit at a time.

ENSC3003 Lab3: Pumps Page 3
REPORT

For your report, you are required to answer the questions in this procedure, using
the spaces provided on this procedure document. This document is then to be
handed in to the ENSC3003 Assignment Box by 4:00 pm on Friday, June 1st






EXERCISE 1: PUMP COMPONENT IDENTIFICATION

1. Inspect the Cut-Away Demonstration Unit.
1


2. Identify the components listed in the following Table 1A. Label the photograph
below with the components and discuss their function.




1
This demonstration unit was prepared by a 3
rd
year Mechanical Student as an EP307 project.

ENSC3003 Lab3: Pumps Page 4
Table 1A: Pump Component Identification Table
Component Located Function
Suction flange
Impeller
Impeller hub and shroud
Impeller locking nut
Seal chamber
Volute
Discharge flange
Casing seal
Pump bearings and type
Shaft spacer
Coupling
Shaft key
Grease Nipples
Motor bearings and type
Motor stator
Motor rotor
Pecker Head (US)
Junction Box (Aust)

Pump and motor feet

ENSC3003 Lab3: Pumps Page 5
QUESTIONS: EXERCISE 1

What are the potential failure modes of the following components and what
techniques would you use to identify/detect each failure.


a. Impeller









b. Pump bearings








c. Coupling








d. Motor windings








e. Pump and motor assembly







ENSC3003 Lab3: Pumps Page 6
EXERCISE 2: SYSTEM COMPONENT IDENTIFICATION AND PUMP CURVE
MEASUREMENT

1. Inspect the pump rig and identify its components. Starting at the tank, move
around the rig and name each fitting. A P & ID (Piping and Instrumentation
Diagram) with standard symbols is provided in Figure 2A. Several items on the
drawing are incorrect, correct the drawing. (Mark on diagram)

2. Identify where the suction and discharge pressure gauges and flowmeter are
located. Are they all located in the correct place on the P&ID?
2
(Mark corrections on
diagram if required)

3. In your group, discuss the purpose of each fitting why is it necessary?
(Discussion only)

Identify on pump test rig Value + Units (if applicable)
Pump maximum impeller size

Pump actual impeller size

Pump make and model

Pump inlet diameter

Pump outlet diameter

Motor Voltage

Motor Frequency

Motor Power


2
In some situations the pressure gauge mounting points will not always be located right on the
pump flanges. When this occurs the static head and friction head losses between the pump
discharge and the location of the pressure gauge must be calculated and the measured value on the
pressure gauge adjusted

ENSC3003 Lab3: Pumps Page 7
Figure 2A: Piping and Instrumentation diagram (P&ID) for the Pump Test rig

ENSC3003 Lab3: Pumps Page 8


ENSC3003 Lab3: Pumps Page 9
EXERCISE 2 (Cont): PUMP CURVE DETERMINATION

Part of the laboratory involves determination of the pump curve. A pump curve
shows pump head against flow rate at a constant motor speed. The pump head is
measured using pressure gauges on the suction and discharge of the pump. Flow
rate is measured on the flowmeter and a kilowatt meter measures power.

Turning on any pump rig involves several checking steps. Below are some basic
checks:

Checks before operation

1. Check for general hazards lying around the rig.
2. Check that there is water in the tank
3. Check that both the suction valves are fully open
4. Check that the discharge valve is HALF open
5. Locate the on and off buttons
6. Turn on the power to the VFD at the switch on the wall.

Procedure

1. Begin by turning the pump on and increasing the speed with the VFD until
the motor is running at 50Hz/ 1500 rpm. Leave the pump operating at this
speed throughout the test.

2. Wait until the system is static and record the flow rate for this setting in the
given table

3. Fill in the table by measuring the suction head and discharge pressure at this
flow rate, and the power drawn by the motor.

4. The aim is to fill the table in at four different flow rates. The measurements
are used to determine the Total Head on the pump at each flow rate. This is
then plotted as a curve on the actual pump curve and the design v actual
curves compared.

5. Flow rate can be adjusted either by varying the speed of the motor (if there is
a variable speed drive) or more commonly by throttling the flow using valves.
Identify the valve used to adjust flow it is a large brass valve with a red
handle on the discharge line.

6. Partially close/open the valve to obtain the different trial points. Wait for the
system to settle. Once again fill in the table with the suction and discharge
pressures and the motor power. Repeat to complete the table. Perform the
calculations (in bold print). You need to collect enough points to draw a
Head-Flow curve for the pump across the flow range indicated on the pump
curve on the following page.

7. At the end, turn off the pump, shut the main suction valve and turn off the
power.


ENSC3003 Lab3: Pumps Page 10


Calculations

A pressure gauge placed on the discharge of the pump will read the following
terms.

) (
.
D L D D D
h g z g p P ! ! + " + =

From the General Energy equation in your notes, we derived an expression for the
Total Head H
P
on the pump.

!
H
P
=

W
H
m g
=
P
D
" P
S
( )
#g
+
U
D
2
"U
S
2
( )
2g
$
%
&
&
'
(
)
)


The values U
D
and U
S
are the velocity in the pipe at the pump suction and
discharge. This is a function of the flow rate Q and the line diameter D.

Trial 1 Trial 2 Trial 3 Trial 4
Flow Rate (Q) m
3
/hr
Flow rate (Q) m
3
/s
Suction Head manometer level (m)

Suction Head (kPa) P
S
Line velocity at suction gauge
(m/s) U
S

U
s
2
/2g
Total Suction Head (m) H
S

(P
s
/!g + U
2
S
/2g)

Discharge Pressure (kPa) P
D
Discharge Head (m)
Line velocity at disch. gauge (m/s)
U
D


U
D
2
/2g
Total Discharge Head (m) H
D
Total Head H
P
(m)
Motor Power (kW)
Pump efficiency (%)
Table 1.6.3A: Pump operation data entry

ENSC3003 Lab3: Pumps Page 11
(U = Q/A = 4Q/(!D
2
), U = line velocity m/s, Q = flow rate m
3
/s, A = inside pipe area
m
2
, D = inside diameter m). If the line sizes are the same ID for suction and
discharge, the velocity term can be ignored.

The pump efficiency is a ratio between the energy transmitted to the fluid by the
impeller and the energy transmitted from the motor to the impeller.

"
P
= Hydraulic Power (
!

W
H
) / Power input to the pump shaft from the motor (
M
W
!
)
where
!

W
H
= "gQH
P
and
M
W
!
is the motor power in kW. (It is usually necessary to take
into account motor efficiency as well).

ACKNOWLEDGEMENTS

The pump test rig was designed by Claire Dean (Honours, 2001), and built by
Blakers Pump Engineers. Alicia Webb (Honours, 2003) developed the procedures
and principles on which this laboratory is based, and Daniel Kefford and Melinda
Hodkiewicz compiled the procedure that this document was based on.




ENSC3003 Lab3: Pumps Page 12
QUESTIONS : EXERCISE 2

1. A copy of the manufacturers pump curve is attached. On this head-flow graph,
plot the values for your Total Head H
P
v Q graph. How does your curve
compare with the design curve for this installation?






















2. Why is the measured efficiency of the pump so low?

























ENSC3003 Lab3: Pumps Page 13
3. If the flow through the system is lower than expected, what are the possible
causes?
















EXTRA WORKING SPACE






























ENSC3003 Lab3: Pumps Page 14