pressure: troubleshooting problem pump installationsc.ymcdn.com/sites/ · · 2018-01-08pressure:...
TRANSCRIPT
![Page 1: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/1.jpg)
© 2017 HDR, Inc., all rights reserved.
Performance Under Pressure: Troubleshooting Problem Pump InstallationsBrian Thorsvold, PE
![Page 2: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/2.jpg)
01 Introduction/Purpose
02 Centrifugal Pump Basics
03 Pump Testing Basics
04 Problem Pump Case Studies
Agenda
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Certified pump testing Start-up / field testing Testing for preventative maintenance Optimizing operational efficiency Maximize operational life Find problems before damage occurs
Why Test?
![Page 4: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/4.jpg)
System Head Curve
Static head Pressure Head Total Head Flowrate
Typical Centrifugal Pump Curve
Filters 1 – 18 in operation Filter pump 2 on at 24 MGD Filter pump 5 on at 24 MGD Total flow = 48 MGD Water surface elevation =
541.85 ft.
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Effic
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Pump Head (ft) System Head Hi (ft) Efficiency (%)NPSHR (ft) NPSH3 (ft) NPSHA (ft)
PRESSURE HEAD
STATIC HEAD
Low WetwellLevel
![Page 5: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/5.jpg)
System Head Curve
Static head Pressure Head Total Head Flowrate
Typical Centrifugal Pump Curve
Filters 1 – 18 in operation Filter pump 2 on at 24 MGD Filter pump 5 on at 24 MGD Total flow = 48 MGD Water surface elevation =
541.85 ft.
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Effic
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Head
, NPS
H (ft
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Pump Head (ft) System Head Hi (ft) System Head Lo (ft) Efficiency (%)NPSHR (ft) NPSH3 (ft) NPSHA (ft)
High Wetwell Level
PRESSURE HEAD
STATIC HEAD
![Page 6: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/6.jpg)
Pump Head-Capacity Curve
Pump operating point
Typical Centrifugal Pump Curve
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Effic
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Head
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H (ft
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Pump Head (ft) System Head Hi (ft) System Head Lo (ft)Efficiency (%) NPSHR (ft) NPSH3 (ft)NPSHA (ft)
![Page 7: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/7.jpg)
Efficiency Curve
Best Efficiency Point (BEP)
Typical Centrifugal Pump Curve
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Effic
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Head
, NPS
H (ft
)Flow (gpm)
Pump Head (ft) System Head Hi (ft) System Head Lo (ft) Efficiency (%)NPSHR (ft) NPSH3 (ft) NPSHA (ft)
![Page 8: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/8.jpg)
BEP – best efficiency pointo The point on the pump curve where efficiency is greatest.
POR – preferred operating rangeo The range where the pump will satisfactorily operate without vibrations above standards or
damageo Varies depending on pump size, typically between 70% to 115% of the flow rate at BEP
AOR – allowable operating rangeo The range where the pump will operate satisfactorily but will experience some cavitation,
vibration above standards and shorter service life. The pump manufacturer will determine this range
o Generally in the flow rate range is 60%-120% of the flowrate at BEP Obtain these values from pump manufacturer for specific pumps being
considered
Defined Terms
![Page 9: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/9.jpg)
Best Efficiency Point (BEP)
Preferred Operating Range
Acceptable Operating Range
Pump Operating Ranges
Filters 1 – 18 in operation Filter pump 2 on at 24 MGD Filter pump 5 on at 24 MGD Total flow = 48 MGD Water surface elevation = 541.85
ft.
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Effic
iency
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Head
, NPS
H (ft
)
Flow (gpm)Pump Head (ft) System Head Hi (ft) System Head Lo (ft) Efficiency (%)NPSHR (ft) NPSH3 (ft) NPSHA (ft)
ACCEPTABLE OPERATING RANGE
PREFERREDOPERATING RANGE
![Page 10: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/10.jpg)
LEFT OF BEP: High shaft deflection Vibration Temperature Build-up Excess recirculation Very inefficient
Operating Outside the Acceptable Range
![Page 11: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/11.jpg)
LEFT OF BEP: High shaft deflection Vibration Temperature Build-up Excess recirculation Very inefficientRIGHT OF BEP: Cavitation High flow – high velocity – high wear Motor overload
Operating Outside the Acceptable Range
![Page 12: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/12.jpg)
Damage Caused by Cavitation / Vibration
![Page 13: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/13.jpg)
Variable Speed Pumping Flow function of speed Head function of square of
the speed
Typical Centrifugal Pump Curve
Filters 1 – 18 in operation Filter pump 2 on at 24 MGD Filter pump 5 on at 24 MGD Total flow = 48 MGD Water surface elevation = 541.85
ft.
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Head
, NPS
H (ft
)Flow (gpm)
Pump Head (ft) System Head Hi (ft) System Head Lo (ft) Efficiency (%)NPSHR (ft) NPSH3 (ft) NPSHA (ft)
![Page 14: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/14.jpg)
Variable Speed Pumping Check operating condition
at min. speed also
Typical Centrifugal Pump Curve
Filters 1 – 18 in operation Filter pump 2 on at 24 MGD Filter pump 5 on at 24 MGD Total flow = 48 MGD Water surface elevation = 541.85
ft.
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Effic
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Head
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H (ft
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Flow (gpm)Pump Head (ft) System Head Hi (ft) System Head Lo (ft) Efficiency (%)
NPSHR (ft) NPSH3 (ft) NPSHA (ft)
![Page 15: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/15.jpg)
System curve Acceptable operating range Variable speed pumping curves Efficiency curves
Typical Variable Speed Pump Curve
![Page 16: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/16.jpg)
Pump speed (rpm) Discharge pressure (psi/ft) Flowrate (gpm) Power (HP) Correct to gage elevation
Certified Pump Testing
![Page 17: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/17.jpg)
Design Criteria
Designed to pump 5,000 – 8,000 gpm [6 – 10 gpm/SF filter backwash rate] Pump suction El. is 2’ higher than
discharge El. Variable speed
Case Study No. 1Filter Backwash Pump Testing
![Page 18: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/18.jpg)
Backwash piping configurationFilter Backwash Pump Testing
![Page 19: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/19.jpg)
Backwash piping configurationFilter Backwash Pump Testing
![Page 20: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/20.jpg)
Submittal Curve
Filter Backwash Pump Testing
![Page 21: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/21.jpg)
Initial Test Results: 7,550 gpm max (vs. 8,000 gpm required) Pump head? Pump speed?
Filter Backwash Pump TestingInitial Manufacturer Diagnosis: Air trapped in piping increasing head Piping change during construction added
head
![Page 22: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/22.jpg)
Field Testing
Pressure gage Manometer Tachometer Ladder
Filter Backwash Pump Testing
![Page 23: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/23.jpg)
Field Testing
![Page 24: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/24.jpg)
Initial Test ResultsFilter Backwash Pump Testing
Filters 1 – 18 in operation Filter pump 2 on at 24 MGD Filter pump 5 on at 24 MGD Total flow = 48 MGD Water surface elevation = 541.85
ft.
Backwash Supply Pump TestingTest Flowrate Pressure Gage Manometer Depth to Water Vel Head Corrected Gage Pressure Corrected HeadNumber (gpm) (PSI) (in H2O)1 (inches)1 (feet) (feet)2,3 (feet)3
1 3270 4.25 out of range 82 0.26 22.0 22.22 4140 3.1 out of range 82.5 0.42 19.4 19.83 4840 2.25 out of range 83 0.58 17.4 18.04 5480 1.65 137 83 0.74 18.3 19.15 6090 1.0 116 83 0.92 16.6 17.56 6520 0.5 102 83 1.05 15.4 16.57 6970 0.1 92 83 1.20 14.6 15.88 7550 0 62 84 1.41 12.2 13.6
1 All measurements use TOC (El. 544.50) as zero basis, (WSE approx 537.58)2 Gage height was 64" above TOC (El. 549.83)3 When both gage pressure and manometer height is available, manometer reading is used as assumed to be more accurate
![Page 25: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/25.jpg)
Pump Test No. 1
Filter Backwash Pump Testing
Certified Curve
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Dyn
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Head
(ft)
Flowrate (gpm)
Pressure Gage
Manometer
Certified Curve
![Page 26: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/26.jpg)
Pump Test No. 2
Filter Backwash Pump Testing
Certified Curve
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Retest Results
Certified Curve
![Page 27: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/27.jpg)
Backwash Piping ConfigurationFilter Backwash Pump Testing
![Page 28: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/28.jpg)
Pump Test No. 3
Filter Backwash Pump Testing
Certified Curve
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Flowrate (gpm)
103% speed
Certified Curve
Results Corrected pump
operation Overclocked pump
to achieve required flow in last filter
![Page 29: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/29.jpg)
Design Criteria
Mag drive centrifugal hypochlorite pump 50 gpm @ 14 ft TDH 3-inch suction line, 3-inch discharge
Case Study No. 2Chemical Recirculation Pump
![Page 30: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/30.jpg)
Damaged Components Broken sleeve bearing Damaged thrust washer Outer magnet assembly after exposed to fluid
Case Study No. 2Chemical Recirculation Pump
![Page 31: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/31.jpg)
System Curve Review
Chemical Recirculation Pump Testing
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Flowrate (gpm)
Full Tank
Empty TankSystemCurve
![Page 32: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/32.jpg)
System Curve Review
Chemical Recirculation Pump Testing
-5
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2-inch
3-inch
SystemCurve
![Page 33: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/33.jpg)
Results
Chemical Recirculation Pump Testing
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amic
Head
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2-inch
3-inch
SystemCurve
3-inch discharge pipe supposed to be 2-inch
Pump runout / cavitation
Pump failure after 2 months operation
Throttle pump back on curve
![Page 34: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/34.jpg)
Background / Review
Four 1,000 HP pumps (identical) One pump with lower outputo 6,900 gpm (each of 3 pumps)o 6,100 gpm (1 pump)
Case Study No. 3High Service Pump performance
![Page 35: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/35.jpg)
Design Criteria
Case Study No. 3High Service Pump performance
D
Pressure Gage
Control Valve
![Page 36: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/36.jpg)
Results
800 gpm more 25 psi less pressure Assume 2,000 hrs/yr Saves ~ $36,000/yr in electrical cost
Case Study No. 3High Service Pump performance
![Page 37: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/37.jpg)
Results and Conclusions
Factory testing to confirm pump meets design intent
Start-up testing to establish proper operation in system
Routine testing/checking to track operational performance
Pump Testing
![Page 38: Pressure: Troubleshooting Problem Pump Installationsc.ymcdn.com/sites/ · · 2018-01-08Pressure: Troubleshooting Problem Pump Installations Brian Thorsvold, PE. 01. ... NPSHR (ft)](https://reader034.vdocument.in/reader034/viewer/2022051602/5ae5f3267f8b9aee078c3e8c/html5/thumbnails/38.jpg)
Questions?Brian [email protected]