CEE Laboratory 1. Laboratory 1 Centrifugal Pumping Equipment Test. Noah Dufoe-Giles, Nick Hayden, Megan Long, Senn Mettel

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1 CEE Laboratory 1 Laboratory 1 Centrifugal Pumping Equipment Test Noah Dufoe-Giles, Nick Hayden, Megan Long, Senn Mettel University of Wisconsin-Madison CEE 410 October 29 th, 2014

2 INTRODUCTION The purpose of Laboratory 1 was to perform a field pumping test on an installed pump and compare actual pump performance with the manufacturer s published information. Data Commented [g1]: Your introduction is actually a summary of methods and document organization. Commented [g2]: Concisely stated objective. collected from the booster pump at Madison s Water Utility (WMUMWU) Unit Well 30 (UW30) were used to develop head-discharge curves for a variety of pumping scenarios including full power, reduced rotational speed, and manual throttling. Both directly-measured curves and curves extrapolated via affinity laws were compared to published curves, and power calculations were used to estimate motor and pump efficiencies. Recommendations for pump maintenance or replacement were made based on these results. Additionally, a literature review of three major pump types was conducted to gain increased pumping station knowledge and validate the recommendations and analyses made. Literature Review Overview Pumps can be split into two main categories: dynamic pumps, and positive displacement Commented [g3]: Good overview, perhaps a bit more than needed. pumps. Dynamic pumps, also called kinetic pumps, use a motor to drive motion of the pump, adding velocity to the water and causing pressure changes that suck the water from a source into the pump and discharge it to a piping system. Dynamic pumps can be broken into several categories: centrifugal pumps and vertical turbine pumps. Centrifugal pumps use specially angled blades called vanes to draw water into the center of the pump, where vanes at a reverse angle will use centrifugal force to push the water away from the center. The pump is enclosed inside a case, so the water that was pushed from the center Commented [g4]: And the collection of vanes is called an impeller.

3 is collected and pressurized within a volume then diverted out of a discharge opening (Kristal Commented [g5]: Volute? 1940). Vertical turbine pumps can be classified as axial or mixed flow, depending on the orientation of the vanes. Like a centrifugal pump, a motor drives a shaft, which spins the vanes of the pump. The speed and angle of the blades create a suction pressure below the vanes, lifting the water up through the pump and into a discharge pipe. Axial flow pumps rely solely on the pressure differential across the impeller to drive water up, while mixed flow pumps also include a bowl, much like the case on a centrifugal pump, to pressurize and direct the water up to the piping system (Dickenson 1992). Positive displacement pumps use gears and other mechanisms to push water from the main body of the pump out to the distribution piping. Rotary pumps and reciprocating pumps are two subsets of positive displacement pumps. A rotary pump uses specially shaped rotors, like gears, in a casing to allow a fluid into a cavity, then move it around the shaft to an opening as the rotating lobes of the rotor open and close subsequent cavities. These pumps can operate at constant speeds, effectively independent of head, so they are useful for applications that require a steady flow. Because of the precision required to seal cavities with the rotating lobes, viscous fluids at low pressures are ideal because Commented [g6]: Can they pump against unlimited head? What are the limitations on this? they reduce leakage (Black 1970). Another positive displacement pump is the reciprocating pump, which utilizes an up and down or back and forth motion of a piston or plunger to incrementally pull water from a source and displace it to an outlet. Using a plunger to change the pressure in the cylinder, water can be sucked into the cylinder, then pushed out a discharge opening by raising the plunger (Black 1970).

4 Horizontal Split Case Pumps One common pump from the centrifugal pump category is the horizontal split case pump. As a centrifugal pump, it uses rotation and water velocity to push the water through the pump. A motor causes a shaft connected to an impeller to rotate. At the center of the shaft, on the suction side of the pump, the impeller blades are angled to create a vacuum pressure when they spin. The inlet of the pump, always submerged under water with sufficient head, draws water from a Commented [g7]: Always be consistent in use of terminology. Your previous section used vanes and this sentence is using blades. They are the same but consistency helps limit confusion for readers who aren t well versed in the terminology. connected source to fill the void left by the negative pressure. When water flows into the center of the pump, curved vanes force the water radially outward. The case around the pump, called a volute, contains and channels the water creating high pressure. The pressurized water flows through a spiral of gradually increasing size to slow the velocity of the water and increase the pressure head. At the end of the spiral, the discharge end, the pump is joined to a pipe network (Kristal 1940). The performance of these pumps is evaluated with characteristic curves, which show the head the pump can deliver to the water at different flow rates for a given operating speed. The pump can be throttled with a valve or a variable frequency drive can change the speed of the pump, and curves are created for various different operating speeds. By measuring power input and output at each point as well, efficiencies of the pump can be determined (Jones 2008). An

5 example of characteristic curves and efficiency curves are show in figure 1 below. Figure 1 Characteristic curves of a split case pump (Jones 2008) When designing a water distribution system, it is important to measure the discharge Commented [g8]: This is a pump term. demand and head loss across the proposed system and create a system head curve that depicts their relationship, such as the one shown in figure Figure 2 below. This curve can be compared to characteristic pump curves provided by manufacturers to find a pump that operates efficiently Commented [g9]: There is no need to tell the reader where to find the figure if you number the figure. at the design flow rate.

6 Figure 2 System head curve In the water distribution industry, these types of pumps are typically used for pumping water from a reservoir into the piping network of the distribution system. They are a preferred type of pump because the case can be easily removed for pump maintenance (Boman 2002). Commented [g10]: Good description of the horizontal splitcase/ Deep Well Vertical Turbine Pumps Deep well vertical turbine pumps are used for extracting water from wells for drinking water, but they can also be used for circulating and cooling of water in industrial settings (Boman 2002). A deep well vertical turbine pump has two major sets of components, the motor above ground, and the pump in a deep shaft in the ground. The motor drives the rotation of a Commented [g11]: This is generally true. I should note that Madison s Unit Well 16 uses vertical turbine pumps to pump from the reservoir into the distribution system. vertical shaft, which rotates the turbines in the well. The turbines, much like impellers in a centrifugal pump, create a pressure differential, allowing them to pull water upwards into the pump. The turbines are encased in bowls to help increase the pressure the pump can deliver to the system (Kristal 1940). For very deep wells with high amounts of head to overcome, multiple pump bowls can be used in series. An example of this can be seen in figure Figure 4. Commented [g12]: Need a statement that clearly shows you understand that each bowl contains just one impeller (or turbine) and that each bowl is a single pump (two bowls in series are two pumps in series). Commented [g13]: When referring to a specific figure by number, capitalize the word Figure. The same rule applies to tables, chapters, appendices, etc.

7 Figure 3 Pump curve for deep well pump (Boman 2002) Figure 4 Deep well pump (Boman 2002) The performance of these pumps is measured with characteristic curves, much like a horizontal split case pump, by evaluating the head that can be delivered by the pump at given flow rates (Boman 2002). As shown in figure Figure 3 above, instead of creating curves for different pump speeds, the curves correspond to different impeller diameters available for the pump. The process for selecting a pump is the same as with centrifugal pumps. A system head Commented [g14]: This implies that some other pump uses curves based on different pump speeds. Note that your centrifugal pump had different impeller diameters, too. Most manufacturers show the impeller curves rather than the speed curves. curve is plotted and compared to manufacturers characteristic curves, and the best fit for the design flow rate is selected. Commented [g15]: Again, generally good demonstration of how these pumps work. Peristaltic Pumps The peristaltic pump is one specific example of a positive displacement pump. Peristaltic pumps rely on cams or rollers that drive alternating compression and expansion of flexible tubing (Springer, 2014). A pump cycle consists of suction-driven fluid flow into tubing during expansion and flow out of the tubing during compression. The rollers in peristaltic pumps are

8 configured so that a known volume becomes pinched between the rollers and is then pushed towards the pump outlet as the rollers continue their circular motion. The flow rate of these pumps can be specified by choosing operating rpm and tubing diameter. A major advantage of Commented [g16]: I m not sure how well known it is but it can be estimated. Commented [g17]: There must be some limitations on head. peristaltic pumps is that fluid touches only the inside of the tubing, which allows for their usage in medical (or other) situations where contamination is a concern and also with caustic fluids where corrosion of pump parts is a concern. Additionally, most of the wear and tear is on the tubing and not the pump, and the tubing is quite inexpensive and quick to replace (Watson-Marlow, 2014). Because peristaltic pumps deliver a pulse of fluid, they would not be ideal for situations where an exactly constant flow of fluid is needed. Figure 5 Peristaltic pumping mechanism (Watson-Marlow 2014) Commented [g18]: This is definitely a disadvantage. EXPERIMENTAL METHODS AND PROCEDURE UW30 is located at 1133 Moorland Rd., Madison, WI. The experimental data was were collected on-site between 1:30 pm and 4:30 pm on Wednesday, October 15, The purpose of the experiment was to assess pump performance for two distinct regimes: 1) flow throttling by pump speed reduction via the motor s variable frequency drive and 2) flow throttling by system head increases via semi-closure of a gate valve. For both procedures the following data was were collected: hertz supplied to and amperes drawn by the motor, pressure on the suction side of Commented [g19]: Note that this word is generally a plural word. Commented [g20]: We normally wouldn t use this word for this flow control mechanism. Commented [g21]: Correct for this lab. This doesn t need to be a gate valve any isolation or flow control valve will do. For example, a butterfly valve can be used in larger pipes (larger than 4 inches). Ball valves and needle valves can be used for smaller pipes.

9 pump, pressure on the discharge side of pump, and volumetric flow rate through the discharge pipe. Measurements were taken from the operating panel (hertz and amperes), pressure gages, and an electromagnetic flow meter. Additional measurements were taken for a later laboratory. These include reservoir elevation and flow rate from a second, acoustic flow meter. Commented [g22]: No need to say this. stay focused on the task at hand in reports. Commented [g23]: Same thing here. Picture 1 - Pump Name Plate Commented [g24]: Every picture, figure, and table placed in a report needs to be described and referred to in the text. You can t just let the reader try to figure out why these pictures are in here. Picture 2 - Motor Name Plate

10 Picture 3 Booster Pump #2 Picture 4 - Gate valve Picture 4 Pump Control Panel

11 Each of the two flow throttling regimes was conducted at various levels of throttle and run for long enough to collect several data points and to reach a short-term equilibrium. The pump speed reduction was controlled by reducing the frequency of the electricity supplied to the motor from its maximum (60 Hz) to four lower levels: 59, 55, 52, and 47 hzhz. This gave five conditions for which head was averaged (discharge pressure minus suction pressure) and flow. Commented [g25]: What do you mean by this? Do you think the performance would change significantly if you let it run for a longer period of time? My sense is no. Commented [g26]: Need to state the position of the valve for each of these sppeds I assume it was full open. Commented [g27]: Did you average the flow too? The gate valve throttling was controlled by starting at full power and partially closing a gate valve downstream from the flow meter to increase system head. The gate was throttled three times giving us a total of four data points for head and flow. While there was a short period between the two tests where the system was returned to full power, few data points were Commented [g28]: Need to state the electrical frequency used for the pump during each of these (60 Hz). collected for this second full-speed state so the original full power data point for full speed was used for both throttling regimes. The two tests represent two different ways that WMU MWU can adjust flow at UW30, although the presence of the variable frequency drive motor and the ability to control it remotely make the speed-throttling seem like the better alternative for times when reduced flow rates are required. Commented [g29]: I think this is worth mentioning but it helps the reader if you explain why this is has the potential to be important. It is plausible that the pump is pumping from a different suction head to a different discharge head. If so, this could influence the flow rate. Nevertheless, the data point will still be on the pump curve and you will still be able to define the pump curve with the valve closure. Hence, the lack of data here has little impact on your ability to meet the objective of the study. Commented [g30]: This is best mentioned in your discussion of results. At this point in the report, you have no information to justify making this statement. SUMMARY OF EXPERIMENTAL RESULTS Comparison of Full-Speed Test with Published Data Figure 6 compares the manufacturer s head-discharge curve with a curve generated from full-speed testing data points. Note that the manufacturer s pump data was provided for 1,750 rpm but the UW30 booster pump motor has a maximum rpm of 1,785; it is unclear whether the Commented [g31]: Good to mention this just make sure it gets mentioned in the methods, too. pump or the motor would be limiting, so the assumption that the full-speed data points were at 1,750 rpm was used and the data were not adjusted from the manufacturer s points with affinity Commented [g32]: Good to have this, too. I note that you are stating this in a section on results and the statement actually describes a method or approach instead. Make sure you place your statements where they belong.

12 laws. The two curves lie nearly on top of each other, with only a slight separation at the highest flow data point. It appears that the pump has not lost any significant performance over time although the maximum rpm issue creates some room for error. It is also possible that the flow meter or pressure gages are not perfectly calibrated or functioning, which could explain the highest flow data point being above the manufacturer s chart. A later laboratory focusing on flow Commented [g33]: Engineers need to be quantitative in their writing, not qualitative. For a given head, what is the difference or percentage difference in measured flow rate versus expected flow rate? For a given flow rate, what is the difference or percentage difference in measured head versus expected head? Answering these in a quantitative way makes a big difference in making your case. Commented [g34]: This is what happens when you write things in a qualitative way it makes you indecisive in your interpretation of the data. I would simply conclude from my calculations that there was no observable difference between the measured curve and the reported curve, so there is no need to even talk about that one data point. meter testing will explore this assumption. 240 UW30 Full-Speed Head-Discharge Curves 220 Head [ft] H = -1E-05Q Q H = -1E-05Q Q Measured Pump Curve Manufacturer Pump Curve Q [gpm] Figure 6 - Comparison of measured and manufacturer's full-speed pump curves Comparison of Reduced-Speed Test with Published Data Commented [g35]: Nice figure. I would suggest having more data for the manufacturers curve to be more complete. I would also plot that curve without the data points. Note that your regression analyses would allow you to quantitatively answer the questions I posed above. Figure 7 compares the reduced-speed measured data points with the affinity law-derived curves based on the manufacturer s full-speed data points. As with the full-speed comparison, the measured data points line up quite well with the affinity law-derived curves. These affinity laws for assume that the efficiency remains the same when transferring from a given point on Commented [g36]: Again, there is a need to be quantitative in your analysis.

13 one pump curve to a homologous point on another curve (Jones, Sanks, Bosserman, & Tchobanoglous, 2008) which may not always hold true for a given system, but here using the Commented [g37]: I m not sure why efficiency is brought up in their discussion here, unless their discussion is focused on the affinity law for power. equations does not appear to introduce any noticeable errors to the analysis. One data point (the lowest rpm test) has a flow range outside the provided data but appears to follow a visual extrapolation of the reduced-speed curve. Commented [g38]: The manufacturer curve goes to zero flow rate, though. Why not use that to extend the 1371 rpm curve to zero flow rate? Head [ft] rpm UW30 Reduced-Speed Test 1517rpm 1721 rpm 1604 rpm Measured Data Manufacturer Pump Curve (Affinity Calc.) 1750 rpm 1750 rpm 1721 rpm 1604 rpm 1517 rpm rpm Q [gpm] Figure 7 - Comparison of measured data points to affinity-law derived manufacturer's curves Efficiency Calculations and Comparison to Published Data Commented [g39]: This is also a nice figure. One thing we didn t discuss in class is that these green data points actually define your system head curve for that valve being full open. This assumes that the static head is the same for all observations. It appears that the static head is about 140 ft for this pump. Is this consistent with expectation? My conclusions from the graph are the same as yours. The wire-to-water efficiency and pump hydraulic efficiency were calculated using the measured voltage, current, flow rates and heads calculated in previous sections and the power factor and motor efficiency provided on the motor nameplate (calculations B3-B8 in Appendix B). The head vs. flow points measured in lab were plotted on the manufacturer efficiency curves, Commented [g40]: Once again, you re writing about methodology in a results section. Put your methods in the methods section of the report.

14 as seen in Figure 7, and the experimental pump hydraulic efficiencies for these points were compared to the manufacturer s efficiencies for the points shown on the graph belowin Figure 8. The pump hydraulic efficiencies calculated from lab data were found to be much lower than expected, as calculated (experimental) pump hydraulic efficiencies were consistently 5-7% lower Commented [g41]: Always refer to figures by number and not by location. Commented [g42]: Nice to see a quantitative analysis. than those shown on the provided manufacturer s curve (Figure 7). This difference is most likely attributed to operating speed error. The manufacturer only provides efficiency curves for motors operating at 1750 rpm, and in lab, the speed of the motor was varied significantly. Wear and tear on the system from operation could also contribute to the discrepancy. Commented [g43]: I don t follow the point here. The speed was full speed for the points being compared on the figure. Commented [g44]: I d believe this before the speed issue you re trying to raise. Experimental ηp Expected ηp Full T T T Figure 8 - Measured data points on manufacturer s pump efficiency chart, shown with overlaid table of calculated and expected pump hydraulic efficiency values for conditions tested. Commented [g45]: Nice comparison chart showing the applicable points. CONCLUSIONS AND RECOMMENDATIONS Commented [g46]: Never leave a title orphaned at the bottom of a page.

15 To provide a final recommendation on pump maintenance, the Water Utility s acceptable variation from the given curve would be needed. Due to lack of this information, engineering judgment was used. It was found through this experiment that the pump is operating at an acceptable level. Throughout both pump speed reduction and valve throttling the data were found Commented [g47]: In most cases, the water utility would rely on you to recommend what s acceptable. I agree with you that the pump is behaving in an acceptable manner. to fit well with the curves created by adjusting the manufacturer s supplied full speed curve with the affinity laws. Due to this correlation no maintenance or replacement is recommended at this time.

16 REFERENCES Commented [g48]: Nice reference list. Madison Water Utility. (Unknown). Well 30 Booster Pump Data. Madison, WI, USA. Black, P. O. (1970). Pumps (Second ed.). Indianapolis: Howard W. Sams & Co. Inc. Boman, Brian J., Water and Florida Citrus. (2002). Gainsville, FL: University of Florida Institute of Food and Agricultural Science. Dickenson, C. (1992). Pumping Manual (8th ed.). Oxford, UK: Elsevier Science Publishers Limited. Jones, G. M., Sanks, R. L., Bosserman, B. E., & Tchobanoglous, G. (2008). Pumping Station Design (Rev. 3rd ed.). Amsterdam: Elsevier/Butterworth-Heinemann. Kristal, F. A., & Annett, F. A. (1940). Pumps: Types, Selection, Installation, and Maintenance (First ed.). New York: McGraw-Hill. Springer. (2014, 10 28). Peristaltic Pumps. Retrieved from Springer Reference: Watson-Marlow. (2014, 10 28). Watson-Marlow Pumps: Pumps for Industry. Retrieved from %20USA/b-industrial-us-04.pdf

17 APPENDIX A COLLECTED DATA A1. Manufacturer s Pump Curves and Performance Evaluation for 15.5 Impeller (Madison Water Utility, Unknown)

18 A2. Data Collected During Pump Test at UW30 Test Section Mean Head (ft) Mean flow rate (gpm) Alternating Current Frequency (Hertz) Electric Current (Amperes) Commented [g49]: Good summary of the data. Make sure you understand electrical terminology. Full Power Hz Hz Hz Hz Throttle # Throttle # Throttle #

19 APPENDIX B CALCULATIONS B1. RPM Calculations Frequency (hzhz) Revolutions per minute (RPM) Revolutions per minute were calculated for the reduced-speed tests by the following formula, where maximum frequency was 60 hz Hz and maximum rpm speed was 1,750 rpm based on pump name plate data (Madison Water Utility, Unknown): Sample calculation: 1, , B2. Pump Affinity Law Calculations for Manufacturer s Data Speed (rpm) point 1 point 2 point 3 point 4 point (given) H (ft) Q (gpm) H Q H Q H Q H Q Commented [g50]: This table shows the results of calculations rather than calculations. I like what you did for the rpm calculations. Formatted Table Commented [g51]: Always show units.

20 The only data set provided by the manufacturer was for a full-speed of 1750 rpm. Affinity laws (Jones, Sanks, Bosserman, & Tchobanoglous, 2008) were used to create head-discharge data for the four additional speeds at which UW30 was tested. For each pair of head and discharge measurements provided, the following equations were used in tandem: Sample calculations: ; , B3. Efficiency Calculations Test Section Mean Head (ft) Mean flow rate (gpm) P motor in (kw) P to pump (kw) P pump out (kw) η ww (%) η ph (%) Full Power Hz Hz Hz Hz Throttle # Throttle # Throttle # Sample calculations for full power: Commented [g52]: Did you consider using the power affinity laws to calculate expected efficiency at other pump speeds?

21 %. 76.4%. Where: P pump out = Power output to water by pump [kw] P motor in = Power input to input to motor [kw] P to pump = Power input to impeller by shaft [kw] γ = Specific weight of water [9.81 kn/m 3 ] Q = Flow rate [m 3 /s] H = dynamic head [m] PF = Power factor for pump (provided by manufacturer) V = Voltage supplied to motor [v] I = Current supplied to motor [amp] E motor = Efficiency of the motor (provided by manufacturer) η ww = Wire to water efficiency η ph = Pump hydraulic efficency

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