Pumping Systems

A methodology is presented for conducting effective pump system energy audits, based on the author’s over 46 years of experience in the pump industry, plus a two year energy audit conducted for a major pump user that identified over $2 million in annual energy savings. Specific topics covered include the importance of evaluating the total pump system and all of its elements; identifying the pumps that offer the greatest energy savings potential; how to accurately determine the magnitude of potential pump and pump system energy savings; and specific pump and system changes that can effectively reduce energy costs. Energy and maintenance expenditures can cost up to 10 times the initial purchase price, over the life of a pump.

1. Understand steps to quantify pump energy usage.
2. Be able to identify pumps that offer the greatest energy savings potential.
3. Accurately determine the magnitude of potential energy savings from pumps and pumping systems.
4. Identify pump / system changes to reduce energy costs.

In the water industry, many tasks take place in confined spaces. Confined space entry is hazardous and failure to follow proper safety measures can end in death. This operator education course will explain the dangers associated with Confined Space Entry, elements of a permit required CSE program and give an overview of proper entry procedures.

1. Understand what constitutes a confined space.
2. Understand hazards of confined spaces.
3. Be aware of other dangers associated with confined space entry.
4. Understand entry procedures.
5. Understand why confined space entry accidents still happen.

Cavitation damage can drastically shorten the life of the pump impeller, mechanical seals, bearings and possibly other pump components, and cavitation typically starts in pumps with NPSH Margins (NPSHA/NPSHR) of around 4.0 and higher. This means that cavitation exists in a high percentage of installed pumps. But not all pumps that experience cavitation will be damaged. So the big questions becomes, not will my pump cavitate, but will the cavitation that likely exists cause damage to my pump. Allan Budris has developed a relatively simple means of answering this question in the form of “Suction Energy”. This paper defines Suction Energy, Suction Energy Levels, Suction Energy Gating values for various pump types and how Suction Energy Ratios and NPSH Margin Ratios can predict relative pump life. Also explained are how Suction Energy can also predict suction recirculation damage, and when suction piping is critical to dependable pump performance. Suction pipe lengths are suggested for low and high pump suction energy levels. This new method for predicting cavitation damage in centrifugal pumps, which has been adopted by the Hydraulic Institute and major pump companies, can save thousands of dollars in unnecessary maintenance costs.

1. Learn how and when cavitation exists in and causes damage to centrifugal pumps.
2. Learn a method that can predict when cavitation will and will not cause damage to and shorten the life of centrifugal pumps.
3. Learn how the NPSH Margin to, and Suction Energy of a pump impacts pump reliability.
4. Learn about pump “Low Flow Suction Recirculation”, and when it will cause damage to a pump.
5. Learn when pump suction piping can cause pump damage, and recommended minimum straight suction pipe lengths.

This operator education course will address why a pump maintenance program is important. The design features and components of centrifugal pumps and positive displacement pumps are described along with the need for and maintenance of packing and mechanical seals in centrifugal pumps.

1. Explain the importance of a pump maintenance program.
2. Recognize the design features and components of a centrifugal pump.
3. Recognize various positive displacement pumps and their applications.
4. Recognize the need for packing in a centrifugal pump.
5. Describe the use of mechanical seals in a centrifugal pump.