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Understanding

Centrifugal Pumping

BOOK

Turbine Technologies, Ltd., 410 Phillips Street, Chetek, WI, 54728 USA.Phone: 715-924-4876, Fax: 715-924-2436, www.turbinetechnologies.com

2 Lab Work



2UNDERSTANDING CENTRIFUGAL PUMPING

Copyright © 2013 by Turbine Technologies, Ltd.

BOOK 2: Understanding Centrifugal Pumping - Lab Work

UNDERSTANDING CENTRIFUGAL PUMPIN

INTRODUCTION

Upon completion of this book, the student will have solid, hands-on experience running a centrifugal pump-ing system. e pump system will be thoroughly introduced, including all components that make up the actualpumping machinery, its integrated data acquisition system and virtual instrument panel. From there, operatingthe pump system will allow the student to experience and study important performance parameters such as; TotalDynamic Head (TDH), System Curve, Net Positive Suction Head (NPSH), Capacity Curve, Brake Horsepower,and Efficiency. is training will provide knowledge and condence for a student who eventually works in a uidprocessing environment as a part of their career.

Turbine Technologies, Ltd., LabVIEW, National Instruments are trademarks of respective systems and equipment used in equipment

manufactured by Turbine Technologies, Ltd.

Copyright 2013 by Turbine Technologies, Ltd.

All rights reserved. No part of this lesson series may be reproduced, translated or transmitted in any form or by any means without

the permission of Turbine Technologies, Ltd.

Turbine Technologies, Ltd., 410 Phillips Street, Chetek, WI, 54728 USA.

Phone: 715-924-4876, Fax: 715-924-2436, www.turbinetechnologies.com






NDERSTANDING CENTRIFN UGAL PUMPING

TABLE OF CONTENTS

Book 2: Understanding Centrifugal Pumping - Lab Work

Lesson 1: PumpLab™ System Orientation...................................................................................................4

Focus 1: Reservoir

Focus 2: Piping

Focus 3: Sensors Focus 4: Pump

Focus 5: Other Components

Knowledge Certification Quiz: Lesson 1

Lesson 2: Data Acquisition Orientation......................................................................................................12

Focus 1: Starting up the Data Computer

Focus 2: Tour of Virtual Instrument Panel


Lesson 3: Data Gathering .............................................................................................................................20

Focus 1: Total Dynamic Head (TDH) (AKA Pump Curve)

Focus 2: System Curve Focus 3: Net Positive Suction Head (NPSH)

Lesson 4: Plotting Your Data .......................................................................................................................38

Lesson 5: Developing the Pump Performance Curves ...........................................................................42

Focus 1: Graph Head - Capacity Curve

Focus 2: Graph Break Horsepower (bHp)

Focus 3: Graph Efficiency

Focus 4: Graph Net Positive Suction Head

Lesson 6: Applying Pump Performance Curves .......................................................................................55

Focus 1: Baseline Calculation Focus 2: On The Job Scenario







Lesson 1: PumpLab™ System Orientation

e goal of this lesson is to familiarize the operator with all the features of the PumpLab™, to start it up and run it to

gain a basic understanding of what to expect when operating the system to run your lab lessons.

Figure 1.1.1: PumpLab™ System Features

Approximate Lesson

Duration: 25 min.







Clear View Flow Circuit: e see-through piping and pumpcircuit which allow operators to see what is happening inside aflow system.

Action: Trace the see-through flow circuit, starting from theintake pipe located inside the tank, going through the lowerpiping section above the cabinet into the volute (center of theimpeller), then out of the volute exit, across the top piping sectionof the unit all the way back to the tank. Notice the square block

section on the lower level; this provides better optics to see whatis going on in that part of the flow circuit. Its primary purpose isto show the phenomenon of “cavitation” clearly (cavitation is a

major topic which will be covered). Also note that the intake pipe in the tank can be likened to a straw when drinking liquidfrom a glass. is intake pipe features a check valve at the bottom of the pipe that allows fluid to be pulled up through it (justlike sucking on a straw), but will not allow the fluid to flow backwards once the sucking action ceases. is allows the inletpiping to remain “primed” (which will be discussed in the Prime Pump section).

Focus 1: ReservoirFluid Tank: Fluid reservoir for system-holds 15 gallons of water. System is recirculating,so water leaves tank, flows through system and returns to tank.

Action: Locate tank and note water level. Now, compare water level to center of pumpinlet. Notice water level is approximately 12 inches (300mm) lower than the pump inlet.is is referred to as a negative head pressure (the water weight isn’t above pump where itcan use gravity to help it fall into the pump), so it needs to be “sucked” into the pump, justlike sucking a drink (positioned below our mouth) through a straw. It’s a similar scenarioto our PumpLab™; the liquid level in the tank (drinking glass) is lower than the pumpentrance (our mouth).

System Item Descriptions

Locate each item on the PumpLab™ and perform the action that is indicated. Be sure you understand how each

individual function works before you move on to the next.

Focus 2: Piping







Inlet Valve: Allows control of the amount of water that can flow into the pump.

Action: Locate inlet valve (blue body on lower pipe section). Turn handle on top of valveclock-wise. Notice body of valve lowers across the cross-section of the pipe, essentiallyclosing it off. Reversing this action slowly opens it up.

Outlet Valve: Allows control of the amount of water that flows out of the pump.

Action: Locate outlet valve (black handled valve on upper pipe section). Just like inlet valve, turning valve handle clock-wise closes valve body, counter clock-wise opens it.

Focus 3: SensorsInlet Pressure Sensor: Senses the inlet pressure of the water flowing into the pump.

Action: Locate inlet pressure sensor in the inlet piping circuit in the “square view” sectionof the inlet tubing. Note its position and follow its signal wire back into where it enters thecabinet.

Outlet Pressure Sensor: Senses the outlet pressure of the water flowing out of the pump.

Action: Locate outlet pressure sensor in the outlet piping circuit above the pump volute.Note its position and follow its signal wire back into where it enters the cabinet.

Flow Rotometer: A highly visual flow sensor that allows operator to actually see Flowrate,while the sensor sends a flow signal to the data acquisition system.

Action: Locate the flow rotometer on the top section of piping. Notice the impeller inside.is impeller is forced to spin as water starts flowing against it. Little magnets on the tips ofthese impeller blades go past an embedded sensor called a hall-effect sensor (located at thebottom of the housing). e hall-effect sensor is energized by the magnet in the impellerblade tip and “reads” that magnet passing by as a pulse. ere are three evenly spacedmagnets in the impeller. e system is calibrated against time to indicate how much flowwe have by how many pulses we record over a given period of time.







Focus 4: PumpPump Casing (Volute): is is the see-through body of the pump which houses theimpeller. e volute is internally shaped to provide proper pump flow capability.

Action: Locate Volute. Notice black C-shaped clamps around the volute. ese can beremoved to allow impeller to be exchanged. Notice Vent screw on top of volute. is isopened to allow air to escape out of volute when priming the system (see changing pumpimpeller instructions in operators manual). Notice piping inlet which enters volute at thecenter of impeller location. Notice piping outlet which is at the top of volute.

Pump Impeller: is is the heart of the pump. e impeller spins, imparting energy to thewater and “flinging it” out of the system. e ridges on the face of each impeller are called vanes and they are what grab the water and fling it. Vanes can be configured for differentoperation.

Action: Locate impeller in the volute. Also, locate the replacement impellers that are in thestorage area in the cabinet. Notice that the red impeller has straight vanes, black has forwardswept and gold has rearward swept vanes. Also notice the gold impeller has some mini- vanes called splitter vanes. When the impeller is mounted in the volute, notice the spacing

around impeller gradually gets larger as flow gets closer to the outlet of the volute.

Pump Impeller Spinner Tool: Located in the PumpLab™ Cabinet Accessory Section, thetool is used to help remove the impeller spinner which holds the impeller into the drivesha.

Action: Locate Pump Impeller Spinner Tool in accessory section. Refer to Changing PumpImpeller section of Operator’s Manual on how to use it.

Drive Motor: Electric Motor which drives the pump impeller. It is a 3 phase industrialrated electric motor that is powered by a single phase 208V controller.

Action: Locate the electric drive motor which is located behind the pump volute.







Focus 5: Other ComponentsLockable Casters: is allows unit to be rolled around and then locked in place so it doesn’troll away during operation.

Action: Unlock all casters and roll unit to get a feel for its movement. Make sure power tounit is unplugged before moving and be sure unit is clear of other close proximity equipmentto avoid bumping into it. Lock the casters to get the feel for how to do it.

MASTER Power Switch: is keyed switch activates the electric power to run the system.e key is turned clock-wise for “ON”, counter-clockwise for “OFF”. e key can beremoved to prevent unauthorized system operation. PRIME Switch: is two positionswitch operates the Prime Pump. A green indicator light will glow when the switch is

flipped up into its ON position.Action: Locate the keyed switch and PRIME Switch in the control panel section of thecabinet right below the pump volute. Do not activate it at this time.

PRIME Pump and PRIME/DRAIN Valve: Because the reservoir tank (and its water level)is lower than the pump location, the system must be primed (filled with water) with theon-board primer pump. e PRIME/DRAIN Valve is a 2 position valve (located in thecabinet accessory section) that can be positioned to either allow the primer pump to fill theinlet flow circuit with water or to pump the water out of the tank before the unit is placedinto long-term storage. A PRIME/DRAIN Valve Wrench (located in the cabinet accessorysection) is used to position this valve for either function.

Action: If volute and inlet piping are filled with water, drain the circuit by opening VoluteVent (threaded sha with knurled knob; unscrew counter-clockwise) on top of volute toallow pressure to equalize in the system with atmospheric pressure, which allows the inletpiping circuit water to flow back into the tank. Allow all the water in the inlet circuit to drainback into the tank. Check PRIME/DRAIN Valve position by inserting PRIME/DRAINValve Wrench into PRIME/DRAIN Valve and turning counter-clock-wise to be sure it is inthe priming position. Turn PumpLab™ MASTER Power Switch “ON”. Turn PRIME PumpOn/Off Switch “ON”. Observe the piping coming from the tank. Water should start to risefrom the tank through the inlet tube. As the water level in the volute starts to approach thetop of it, start screwing in the vent screw on top of the volute to seal the system and thenshut off the PRIME Power Switch. Be prepared to get this done quickly, otherwise you willstart pumping water out of the vent hole.

DRAIN FITTING: Provides a hose connection to allow system to be drained for waterchange-out or for long-term storage. It is located in the cabinet accessories section.

Action: Connect the system drain hose to the DRAIN FITTING by inserting hose intofitting. Find a bucket that you can put the drain hose into for water capture. Insert thePRIME/DRAIN Valve Wrench onto PRIME/DRAIN Valve and turn clock-wise. ispositions the valve to allow water to flow out the DRAIN FITTING when the PRIME PUMPis turned ON. Turn on MASTER Power Switch. en turn on PRIME Power Switch. Watershould start flowing through hose into bucket. Once it does, turn off PRIME Power Switch,remove hose by pushing the button on top of the fitting and close PRIME/DRAIN Valve byturning PRIME/DRAIN Valve Wrench counter-clockwise.







Pump Control Key Pad: Provides primary speed and programming controls for the PumpDrive Motor.

Action: Verify that the system is primed by checking to see that the inlet piping and voluteare full of water. Verify Inlet and Outlet valves are open. en turn MASTER Power Switchto the ON position. e Pump Control Key Pad will also light up. ere is plenty to studyregarding all the functionality of the key pad. However, the primary purpose of this keypadis to control an on-board variable frequency drive which controls the speed of the pumpthrough a range of 0-1800 RPM. Press the LOCAL/REMOTE button to clear pad for localoperation. Press the FWD button (forward) on the pad and then press the up indicatorarrow. e motor will start to ramp up in speed the longer this button is held in. e unit

will accelerate all the way to approximately 1800 RPM if the button is continuously held in.e variable frequency drive will allow you to run the motor speed at any point desired inthe speed range. Pressing the up and down arrows demonstrate the ability of speed to bemanually increased or decreased. Press the down arrow to reduce speed until it comes to astop. en press the Stop button to initiate the stop.

Strobe Light: Allows operator to view boundary layer of impeller during operation,especially during cavitation.

Action: Plug in strobe light into power plug outlet located on side of PumpLab™ cabinet.Turn MASTER Power Switch ON. Press FWD on Pump Control Key Pad. Push up arrowindicator and bring unit speed up to its maximum level (approximately 1780 RPM). Startclosing Inlet Valve by turning handle on top of valve in a counter-clockwise direction. As

valve slowly starts closing off the inlet piping, vapor bubbles will start to form at the bottomof the valve, which will get stronger and more intense as the valve closes. Aim the strobelight at the pump impeller and adjust the strobe speed so that the impeller vanes can beseen standing still. Observe the air vapor bubbles around the vanes. Continue to closethe inlet valve and observe the conditions change in the impeller. Now, start opening InletValve and observe the conditions around the impeller vanes change. Continue openingthe Inlet Valve until fully opened. Press downward arrow on Pump Control Key Pad untilRPM is stopped. Press Stop button.

Data Display/Record Computer: Computer with a virtualinstrument panel which displays all the major data points of the

PumpLab™, records all operational data and enables computercontrol of the PumpLab™ System.

Action: Go to System Orientation Part 2: Overview of PumpLab™Virtual Instrument Panel aer taking section quiz.






1000UNDERSTANDING CENTRIFUGAL PUMPIN


Without referring to your notes, place the description number near component in the picture for the following:

1. Volute Vent

2. Pump Impeller (and alternates)

3. Pump Impeller Spinner Tool

4. Drive Motor

5. Fluid Tank

6. Clear View Flow Circuit

7. Inlet Valve

8. Outlet Valve

9. Inlet Pressure Sensor

10. Outlet Pressure Sensor

11. Flow Rotometer

12. Lockable Casters

13. MASTER Power Switch

14. PRIME Pump Switch

15. PRIME/DRAIN Valve

16. DRAIN FITTING

17. Drain Hose

18. Pump Control Key Pad

19. Strobe Light

20. Lockable Casters








Briefly define each element:

Pump Casing (Volute)_____________________________________________________________

Volute Vent _____________________________________________________________________

Pump Impeller (and alternates)______________________________________________________Pump Impeller Spinner Tool ________________________________________________________

Drive Motor _____________________________________________________________________

Fluid Tank ______________________________________________________________________

Clear View Flow Circuit ____________________________________________________________

Inlet Valve _______________________________________________________________________

Outlet Valve _____________________________________________________________________

Inlet Pressure Sensor ______________________________________________________________

Outlet Pressure Sensor _____________________________________________________________

Flow Rotometer __________________________________________________________________

MASTER Power Switch ____________________________________________________________

PRIME Pump Switch ______________________________________________________________

PRIME/DRAIN Valve _____________________________________________________________

DRAIN FITTING ________________________________________________________________

Drain Hose ______________________________________________________________________

Pump Control Key Pad _____________________________________________________________

I certify that I have answered all certification quiz questions correctly and am ready for the next section.

____________________________________ _____________________________

Your Signature Date







Lesson 2: Data Acquisition Orientation

e goal of this lesson is to familiarize the operator with all the details of the PumpLab™ Virtual Instrument Panel

(VI), locate and understand basic components of the soware and to gain a better understanding of this system.

Focus 1: Starting Up the Data Computer

Verify that data computer is connected via USB cable to the USB outlet on the PumpLab.

With the PumpLab OFF, turn the computer ON and let it fully boot up. Turn ON PumpLab MASTER Power Switch. Give it a few seconds to get itself set. Double Click PumpLab Icon on computer home screen to load the PumpLab Virtual Instrument Panel. e system is now ready to use. IF THIS PROCEDURE WAS NOT FOLLOWED, power down computer and PumpLab, and retry.

Focus 2: Tour of Virtual Instrument Panel

Let’s tour the VI so that you become familiar with its operation for the PumpLab™ portion of the system. Please keep in mindthat PumpLab also has another major capability called Process Control. is will be covered in a future educational module.

With the VI up and running, click Connect which connects the data computer to the PumpLab™. en click Pump Lab buttonto put the unit into Pump Lab Mode. e Process Control button will be used in another educational module and will notbe used for this training session. e Exit Application button is used when the work with the system is completed and theconnection for that session is to be ended.

Figure 2.1.1: PumpLab™ Virtual Instrument Panel (VI)

Approximate Lesson

Duration: 30 min.









On the center right of the panel, the Pump Lab remote motor control resides. is allows you to control pump motor speedright from the computer screen rather from the control key pad that resides on the unit.

e Pump Lab tab should be clicked to be in the right mode. (Process Control should not be used).

e Motor Speed Command can adjust the motor speed 2 different ways;

1. Press the curser on the graphical slider and drag it to the desired speed, or…

2. Arrow up or down the digital speed window shown below the slider.

e Run Motor button can then be pressed to start the motor running. Note: It is best if a low (or no) speed is selected on theslider/speed window before turning motor on to avoid a quick ramp up of the motor.

e Stop Motor button is pressed to stop the motor.







1. Logged Data Tab

In this view, a running line graph of datafills in as time advances. e elementsgraphed are:

Inlet Pressure (Pin) Outlet Pressure (Pout) Flow Speed (RPM) Torquee line color representation is shownfor each element around the borderof the graph. e Write Data to File button enables data accumulatedduring the run to be saved for lateranalysis. e Clear Plot button clearsthe screen of the accumulated data so

that a new plot can be initiated.

e bottom le of the screen houses the live graphical section of the PumpLab™. e primary elements of the system aregraphed in real time to give the operator a good idea of how each element works with and affects the other. ere are threedifferent views that can be used.

2. Map View Tab

In this view, the operator has the abilityto capture Power and Pressure versesFlow data points as time moves along.Floating target points, which representthe specific data point at that specifictime, allow the operator to “Map” these

specific data points at whatever pointof time is desired. is enables theoperator to build trend graphs with theplotted data points. ese trend graphsgive a good view of how conditions arechanging without requiring a constantbarrage of data, which makes thingsmuch cleaner. e data is also beingrecorded and can be saved using theWrite Data to File button for lateranalysis.







3. Graph View Tab

In this view, a running line graphprogresses across the screen displayingSpeed, Torque, Pressure and Flowwhile the time function moves alongwith it. is allows the real timeprogress of each data element to beseen (which gives another point ofreference to the Logged Data Tabwhich accumulates the data andcompresses the time axis when in Log

Data mode).







Action: Start the PumpLab™ System, plot and capture some data.

1. Use Connect button to establish connection to PumpLab™.

2. Verify Units are being displayed and saved in English units.

3. Click Run Motor button.

4. Click the Start DAQ button to start logging data. Green indicator bar should be lit.

5. Use Motor Speed Command to bring motor speed to 1500 RPM.

6. Click on the Logged Data Screen tab. Notice values of each data measurement item. Click on Log Data if

you want to see data accumulate on this screen.

7. Click on the Map View Screen tab. Notice the target points. Click the Map Point button. Notice theoriginal target points are mapped, while new floating target points are tracking the current conditions.

8. Click on the Graph View screen tab. Notice data is tracking past on a timeline that flows rather than

bunches up like the Logged Data screen when in Log Data (button) mode.

9. Use Motor Speed Command to increase motor speed to 1600 RPM.

10. Repeat steps 6, 7 and 8. Note the changes.

11. Use Motor Speed Command to increase motor speed to 1700 RPM.

12. Repeat steps 6, 7 and 8. Again, note the changes.

13. Click Write Data to File. is saves your logged data as a file that can be looked at later. Follow on screen

directions for saving the data file and save it to a known file folder.

14. Click Clear Plot. Notice all data screens are now cleared and data gathering and display starts over

(check each screen to verify). It will not clear Graph View.

15. Click Start DAQ button to shut off data gathering. Green indicator bar should be unlit.

16. Use Motor Speed Command to lower motor speed to 0 RPM.

17. Click Stop Motor.

18. Click Exit Application to end the use of the VI.

19. Turn MASTER power switch off on the PumpLab™.

20. Find and open the data file that was saved during the run. Export it to a spreadsheet program such asMS-Excel and graph the data for use later. Data conversion and graphing instructions are included in

a following section.








Only referring to the picture on page 19, please answer the following questions about the VI;

1. When starting the VI, do you turn the computer on before you turn on the PumpLab™?

Why?

2. Which button gives permission for the VI to talk with PumpLab™?

3. Which mode should the unit be in; Pump Lab or Process Control?

4. Which data items are displayed as numerical readouts?

5. Which data items are displayed as graphical readouts?

6. List 2 ways to control motor speed from the VI.

7. Is it the right process to set a high motor RPM and then hit the Run Motor button?

Why?

8. What units besides English can PumpLab™ display data as?

10. What does the Start DAQ button do?

11. What does the Log Data button do?

12. Describe what mapping a point with Map Point accomplishes.

13. Describe what is happening in the Logged Data graph.

14. Describe what is happening in the Map View graph.

15. What does Graph View accomplish for us?

16. If we want to save our data that we just gathered to a file we can retrieve later, what do we do?

17. Describe the best way to stop the motor aer data gathering is through.

18. When you’re done using the VI, which button do you press to indicate this?

19. When you save a data file, what is one good way to get the data in a useful format for analysis?

I certify that I have answered all certification quiz questions correctly and am ready for the next section.

____________________________________ _____________________________

Your Signature Date



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PumpLab Book 2 Preview