Horizontal And Vertical Line-shaft Pumps: Awwa Standard

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ANSI/AWWA E103-07 (First Edition)

The Authoritative Resource on Safe Water®

AWWA Standard

Horizontal and Vertical Line-Shaft Pumps SM

Effective date: August 1, 2008. This first edition approved by AWWA Board of Directors June 24, 2007. Approved by American National Standards Institute March 27, 2008.

6666 West Quincy Avenue Denver, CO 80235-3098 T 800.926.7337 www.awwa.org

Advocacy Communications Conferences Education and Training Science and Technology Sections

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AWWA Standard This document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standards describe minimum requirements and do not contain all of the engineering and administrative information normally contained in specifications. The AWWA standards usually contain options that must be evaluated by the user of the standard. Until each optional feature is specified by the user, the product or service is not fully defined. AWWA publication of a standard does not constitute endorsement of any product or product type, nor does AWWA test, certify, or approve any product. The use of AWWA standards is entirely voluntary. This standard does not supersede or take precedence over or displace any applicable law, regulation, or codes of any governmental authority. AWWA standards are intended to represent a consensus of the water supply industry that the product described will provide satisfactory service. When AWWA revises or withdraws this standard, an official notice of action will be placed on the first page of the classified advertising section of Journal AWWA. The action becomes effective on the first day of the month following the month of Journal AWWA publication of the official notice.

American National Standard An American National Standard implies a consensus of those substantially concerned with its scope and provisions. An American National Standard is intended as a guide to aid the manufacturer, the consumer, and the general public. The existence of an American National Standard does not in any respect preclude anyone, whether that person has approved the standard or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standard. American National Standards are subject to periodic review, and users are cautioned to obtain the latest editions. Producers of goods made in conformity with an American National Standard are encouraged to state on their own responsibility in advertising and promotional materials or on tags or labels that the goods are produced in conformity with particular American National Standards.

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CAUTION NOTICE: The American National Standards Institute (ANSI) approval date on the front cover of this standard indicates completion of the ANSI approval process. This American National Standard may be revised or withdrawn at any time. ANSI procedures require that action be taken to reaffirm, revise, or withdraw this standard no later than five years from the date of publication. Purchasers of American National Standards may receive current information on all standards by calling or writing the American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036; (212) 642-4900.

All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information or retrieval system, except in the form of brief excerpts or quotations for review purposes, without the written permission of the publisher.

Copyright © 2008 by American Water Works Association Printed in USA

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Committee Personnel --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

The AWWA Standards Committee on Horizontal and Vertical Line-Shaft Pumps, which reviewed and approved this standard, had the following personnel at the time of approval: Horton Wasserman, Chairman James I. Hurst, Secretary General Interest Members J.B. Allen,* Standards Engineer Liaison, AWWA, Denver, Colo.

(AWWA)

J.D. Anspach, John Anspach Consulting, Deerfield, Ill.

(AWWA)

P.W. Behnke, Bechtel Power Corporation, Frederick, Md.

(AWWA)

E.P. Butts, 4B Engineering, Salem, Ore.

(AWWA)

C.R. Dugan,* Standards Council Liaison, Bath, Mich.

(AWWA)

S.N. Foellmi, Black & Veatch Corporation, Irvine, Calif.

(AWWA)

J.J. Gemin, Earth Tech (Canada) Inc., Kitchener, Ont., Canada

(AWWA)

J.T. Hill, Peerless-Midwest Inc., Westfield, Ind.

(AWWA)

J.L. Hogan, JLH Engineering P.C., Norfolk, Va.

(AWWA)

J.I. Hurst, HNTB Corporation, Indianapolis, Ind.

(AWWA)

C.T. Michalos, MWH, Colorado Springs, Colo.

(AWWA)

A.M. Naimey, CH2M Hill, Santa Ana, Calif.

(AWWA)

M.S. Solomon, Winzler & Kelly Consulting Engineers, Santa Rosa, Calif.

(AWWA)

H. Wasserman, Malcolm Pirnie Inc., White Plains, N.Y.

(AWWA)

Producer Members E.W. Allis, Peerless-Midwest Inc., Indianapolis, Ind.

(AWWA)

J. Bird, Flowserve Corporation, Taneytown, Md.

(AWWA)

J. Claxton, Patterson Pump Company, Toccoa, Ga.

(AWWA)

Y.J. Reddy, Reddy-Buffaloes Pump Inc., Baxley, Ga.

(AWWA)

G. Romanyshyn, Hydraulic Institute, Parsippany, N.J.

(AWWA)

A.R. Sdano, Fairbanks Morse Pump Corporation, Kansas City, Kan.

(AWWA)

C. Yang, ITT Industries Inc., Goulds Pumps, Lubbock, Texas

(AWWA)

* Liaison, nonvoting iii Copyright American Water Works Association Provided by IHS under license with AWWA No reproduction or networking permitted without license from IHS

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User Members S. Ahmed, Detroit Water and Sewerage Department, Detroit, Mich.

(AWWA)

J.S. Casagrande, Connecticut Water Service Inc., Clinton, Conn.

(AWWA)

J.E. Goodman, Seattle Public Utilities, Seattle, Wash.

(AWWA)

K.W. Gruber, East Bay Municipal Utility District, Oakland, Calif.

(AWWA)

D.W. Kirkland, Wichita Water & Sewer Department, Wichita, Kan.

(AWWA)

C.S. Mansfield Jr., Biddeford & Saco Water Company, Biddeford, Maine

(AWWA)

P.T. Miller, City of Elgin Water Department, Elgin, Ill.

(AWWA)

D.M. Reidy, Veolia Water, Indianapolis, Ind.

(AWWA)

J.P. Taylor, Granite City, Ill.

(AWWA)

iv --`,`,`,`,``,,,,,,

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Contents All AWWA standards follow the general format indicated subsequently. Some variations from this format may be found in a particular standard. SEC.

PAGE

SEC.

Foreword

4.2

PAGE

General Design: Common to

I

Introduction ................................... vii

I.A

Background .................................... vii

4.3

General Design: Horizontal Pumps . 18

I.B

History ........................................... vii

4.4

General Design: Vertical Pumps ..... 19

I.C

Acceptance ..................................... vii

4.5

Coatings ......................................... 24

II

Special Issues ................................... ix

5

Verification

II.A

General ........................................... ix

5.1

Factory Tests ................................... 25

II.B

Advisory Information on Product

5.2

Submittals ...................................... 25

6

Marking, Preparation for Shipment,

Application.................................... x

Horizontal and Vertical Pumps .... 16

II.C

Pump Tests ...................................... xi

III

Use of this Standard ........................ xi

III.A

Information for Manufacturers ....... xii

III.B

Basic Data for Vertical Pumps ....... xvi

III.C

Basic Data for Horizontal Pumps . xvii

IV

Modification to Standard ............. xvii

V

Major Revisions............................ xvii

A

Pump Cross-Sections ..................... 27

VI

Comments ................................... xvii

B

Field Testing of Pumps

B.1

Purpose of Field Tests ..................... 33

B.2

Accuracy of Field Testing ................ 34

B.3

Definitions and Symbols ................ 39

B.4

Instrumentation ............................. 40

B.5

Test Procedure ................................ 47

C

Suggested Data Form for the

Standard 1

General

1.1

Scope ............................................... 1

1.2

Purpose ............................................ 2

1.3

Application....................................... 2

2

References ....................................... 3

3

Definitions...................................... 4

4

Requirements

4.1

Materials .......................................... 9

and Affidavit 6.1

Marking ......................................... 26

6.2

Preparation for Shipment ............... 26

6.3

Affidavit of Compliance ................. 26

Appendixes

Purchase of Horizontal Pumps ... 53 D

Suggested Data Form for the Purchase of Vertical Line-Shaft Pumps ...... 55

v Copyright © 2008 American Water Works Association. All Rights Reserved. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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SEC.

E

PAGE

Engineering Information and

SEC.

B.4

Recommendations E.1

Common for Horizontal and Vertical

PAGE

Field-Test Diagram for EndSuction Pumps ........................... 42

B.5

Pumps ......................................... 57

Pipe Requirements for Orifice, Flow Nozzles, and Venturi Tubes 43

E.2

Horizontal Pumps .......................... 57

B.6

Expected Accuracy of Field Test..... 50

E.3

Vertical Pumps ............................... 57

B.7

Pump Field-Test Report ................. 51

E.1

Horizontal Pump Nominal

Figures A.1

Impeller-Ring Diametrical

Separately Coupled, Single-Stage,

Clearance .................................... 59

Inline, Flexible Coupling With Overhung Impeller ...................... 28 A.2

Separately Coupled, Single-Stage,

E.2

Friction Loss in Discharge Heads ... 60

E.3

Friction Loss for Standard Pipe Column....................................... 61

Inline, Rigid Coupling With Overhung Impeller ...................... 29 A.3

Separately Coupled, Single-Stage, Frame-Mounted Pump With

E.4 Tables 1

Overhung Impeller ...................... 30 A.4

Separately Coupled, Single-Stage,

Pump (Horizontal or Vertical) Parts, Materials, and Definitions .. 11

2

Axial (Horizontal) Split-Case Pump With Impeller Between

Mechanical Friction in Line Shafts... 62

Horizontal Pump Parts, Materials, and Definitions ........................... 12

3

Bearings ...................................... 31

Vertical Pump Parts, Materials, and Definitions .................................. 14

A.5

Deep-Well Pumps .......................... 32

4

Materials ........................................ 16

B.1

Field-Test Diagram for Line-Shaft

B.1

Limits of Accuracy of Pump Test

Vertical Turbine Well Pumps ....... 41 B.2

Field-Test Diagram for Vertical

Measuring Devices in Field Use ... 35 E.1

Turbine Pumps for Booster

Diameters and Weights of Standard Discharge Column Pipe Sizes ..... 60

Service ......................................... 41 B.3

Field-Test Diagram for Horizontal Split-Case Pump.......................... 42

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Foreword This foreword is for information only and is not a part of ANSI/AWWA E103. I. Introduction. I.A. Background. In 1994, AWWA’s Standards Council approved development of a new standard for Horizontal Centrifugal Pumps. The new standard was assigned to AWWA Standards Committee 276 for Horizontal Centrifugal Pumps. Upon review of pump standards development in 1996, AWWA’s Standards Council modified the development process to include two new pump standards to replace ANSI/AWWA E101-88, Standard for Vertical Turbine Pumps—Line Shaft and Submersible Types. As part of this action, two committees were renamed. AWWA Standards Committee 276 for Horizontal Centrifugal Pumps was changed to AWWA Standards Committee 276 for Horizontal and Vertical Line Shaft Pumps. Committee 276 was charged with development of ANSI/AWWA E103, Standard for Horizontal and Vertical Line Shaft Pumps. AWWA Standards Committee 375 for Vertical Turbine Pumps was changed to AWWA Standards Committee 375 for Submersible Vertical Turbine Pumps. Committee 375 was charged with development of ANSI/AWWA E102, Standard for Submersible Vertical Turbine Pumps. During development of these two replacement standards, ANSI/AWWA E101-88 was withdrawn effective June 2000. This first edition of E103 was approved by the AWWA Board of Directors on June 24, 2007. I.B. History. The original standard for vertical line shaft turbine pumps presented the composite findings from studies conducted from 1949 to 1986 by committees consisting of manufacturers, consumers, and engineers. The first standard was published in 1955. In 1961, the standard was revised to include standards for submersible vertical turbine pumps. Additional technical changes were added in the 1971 revision. Solid shaft motors were added in the 1977 revision, together with numerous editorial changes and conversions to the international system of units. The 1977 standard was reaffirmed in 1982 without revision. Additional revisions were made in 1988. E101-88 was withdrawn in 2000. I.C. Acceptance. In May 1985, the US Environmental Protection Agency (USEPA) entered into a cooperative agreement with a consortium led by NSF International (NSF) to develop voluntary third-party consensus standards and a certification program for direct and indirect drinking water additives. Other members of the original consortium included the American Water Works Association Research Foundation (AwwaRF) and the Conference of State Health and Environmental

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Managers (COSHEM). The American Water Works Association (AWWA) and the Association of State Drinking Water Administrators (ASDWA) joined later. In the United States, authority to regulate products for use in, or in contact with, drinking water rests with individual states.* Local agencies may choose to impose requirements more stringent than those required by the state. To evaluate the health effects of products and drinking water additives from such products, state and local agencies may use various references, including 1. An advisory program formerly administered by USEPA, Office of Drinking Water, discontinued on Apr. 7, 1990. 2. Specific policies of the state or local agency. 3. Two standards developed under the direction of NSF,† NSF/ANSI‡ 60, Drinking Water Treatment Chemicals—Health Effects, and NSF/ANSI 61, Drinking Water System Components—Health Effects. 4. Other references, including AWWA standards, Food Chemicals Codex, Water Chemicals Codex,§ and other standards considered appropriate by the state or local agency. Various certification organizations may be involved in certifying products in accordance with NSF/ANSI 61. Individual states or local agencies that have authority to accept or accredit organizations may vary from jurisdiction to jurisdiction. Annex A, “Toxicology Review and Evaluation Procedures,” to NSF/ANSI 61 does not stipulate a maximum allowable level (MAL) of a contaminant for substances not regulated by a USEPA final maximum contaminant level (MCL). The MALs of an unspecified list of “unregulated contaminants” are based on toxicity testing guidelines (noncarcinogens) and risk characterization methodology (carcinogens). Use of Annex A procedures may not always be identical, depending on the certifier. ANSI/AWWA E103 does not address additive requirements. Thus, users of this standard should consult the appropriate state or local agency having jurisdiction in order to 1. Determine additives requirements, including applicable standards. 2. Determine the status of certifications by parties offering to certify products for contact with drinking water. * Persons outside the United States should contact the appropriate authority having jurisdiction. † NSF International. 789 North Dixboro Road, Ann Arbor, MI 48105. ‡ American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036. § Both publications available from National Academy of Sciences, 500 Fifth Street, N.W., Washington, DC 20001. viii --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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3. Determine current information on product certification. II. Special Issues. II.A. General. Conditions under which a pump will operate must be carefully evaluated by the purchaser and described by the purchaser. II.A.1 Operating range. Evaluations should include the determination of the hydraulic characteristics of the pumping system and the extremes (maximum and minimum) of heads and flows under which the pump will be required to operate. II.A.2 Inlet conditions. Pump field performance and service life can be significantly reduced if pump inlet conditions, including net pump suction head (NPSH), are not appropriate. Anticipated pump performance curves, including net pump suction head required (NPSHR) curves provided by manufacturers, are based on a flow pattern at the pump inlet being uniform, steady, and free from swirls and vortices. Inadequate pump inlet conditions can result in damaging vibrations, excessive component stresses, and reduced performance. Hydraulic Institute (HI) standard ANSI/HI 9.8, Pump Intake Design, provides recommendations for both suction pipe arrangements and wet pits (sumps). II.A.3 Operating region. This standard does not require pumps to be furnished that will operate within a preferred operating region (POR) or within an allowable operating region (AOR) as defined by ANSI/HI 9.6.3, Centrifugal and Vertical Pumps for Allowable Operating Region. Operation outside these regions will have an adverse effect on the life of the pump. Purchasers should be aware of the operating limits when specifying pumps and should, as a minimum, define the maximum and minimum anticipated operating heads and flow rates. Purchasers may require submittal of data by manufacturers, which define the operating regions and anticipated bearing life when operating within these regions. Refer to Sec. III of this foreword. II.A.4 Drivers. This standard does not include requirements for drivers (motors, engines, gear drives, etc.). Driver torque characteristics must be suitable for the pump torque requirements and the pump starting and stopping method. Driver requirements should be provided by the purchaser. II.A.5 Driver mounting and compatibility. Drivers are an integral part of a pumping unit. Drivers affect pump-to-driver coupling requirements, motor stands (vertical turbine pumps), base plates (horizontal pumps), shaft seals, and vibration levels. Bearings in drivers that support rotating elements of the pump must be designed for static and dynamic thrust loads. This standard does not require the pump manufacturer to furnish the driver nor to mount the driver to the pump. If this is a concern, requirements for furnishing or mounting the driver should be provided by the purchaser.

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II.A.6 Can pumps. Pump barrels or cans, while not an integral part of a vertical pumping unit, can significantly affect pump performance, as can any sump arrangement that affects the flow pattern at the pump inlet. Pump barrels can be fabricated from many materials, including concrete and steel pipe. Barrel inlet piping inlet velocity and barrel dimensions will affect pump performance. Barrel inlets located too close to the pump suction inlet may produce turbulence affecting performance or causing vibration. Flow vanes and/or suction inlet devices may be required. This standard does not include pump barrel requirements. Requirements for pump cans, including installation, can be found in ANSI/HI 9.8, Pump Intake Design. This standard does not require the pump manufacturer to furnish the barrel nor mount the barrel to the pump. If there is a requirement for furnishing the barrel or mounting the pump in the barrel, this should be noted by the purchaser. II.B. Advisory Information on Product Application. This standard does not cover applications or manufacturing technologies. Some waters may have high conductivity levels well in excess of 200 microhms/cm, where it may be advisable to consult with a metallurgist or corrosion expert to determine whether special materials or techniques to deal with galvanic corrosion are required. The purchaser should identify special requirements and deviations from this standard, and include appropriate language in purchase documents. (For example, Sec. 4.4.3.2.3 of this standard requires vertical pump suction cases and bells to have grease-packed CA [bronze] bearings. If other types of bearings are required, this should be stated in the purchase documents.) II.B.1 Materials. Materials required by this standard are selected based on suitability for operation with water as described in the scope. Selection is based on successful experience in the waterworks industry. II.B.1.1 Treatment chemicals. The potential for corrosion because of chemicals added to the water should be considered. Materials, including some bronzes and rubber compounds exposed to water containing chlorine, chloramines, or other chemicals, may not be suitable. If such problems are anticipated, the purchaser should identify the maximum expected concentrations of these chemicals and other factors, such as pH and temperature ranges, that may affect the corrosivity of these chemicals. The purchaser should consult with the manufacturers and, if appropriate, specify special requirements for these materials. II.B.1.2 Disinfection chemicals. Pumps are often disinfected prior to being placed in service initially or after a repair. During the disinfection process, wetted surfaces are exposed to liquids far more corrosive than that allowed by the scope of

this standard. Materials required by this standard may not be suitable for prolonged exposure to corrosive chemicals, including chlorine and sodium hypochlorite. Therefore, these chemicals should be removed and surfaces flushed with water meeting scope requirements immediately after disinfection. II.B.1.3 Dealloying. Some waters promote dealloying corrosion of some copper alloys in the form of dezincification or dealuminization, particularly when the material is exposed to water at high velocity. If this is a concern, purchasers should consult with the manufacturer and, if appropriate, specify alternate materials. II.B.2 Coatings. This standard requires that ferrous (except for stainless) surfaces of pumps exposed to water be coated. The purchaser should delete this requirement if coatings are not required. II.C. Pump Tests. II.C.1 Factory tests II.C.1.1 Procedures. This standard requires factory tests to be performed in accordance with the current version of ANSI/HI 1.6, Centrifugal Pump Tests, and ANSI/HI 2.6, Vertical Pump Tests. II.C.1.2 Extent. This standard requires nonwitnessed hydrostatic testing only. 1. For horizontal pumps: the assembled pump. 2. For vertical pumps: the bowl assembly and discharge head. II.C.1.3 Additional factory tests. Additional factory tests, including hydrostatic tests of an assembled vertical pump, vertical pump column section, performance, NPSHR, mechanical, and witnessed tests, may be included by the purchaser. II.C.2 Field Tests. This standard does not include field performance testing requirements. The following can be used to define field-test requirements. 1. ANSI/HI 1.6 and 2.6 test standards, as described above for factory tests, may be used for field testing at the discretion of the purchaser. ANSI/HI test standards require minimum pipe lengths, internal straightening vanes, and other criteria that, while practical in a controlled test loop, may not be available in the field. Application of this standard for field testing requires parties to agree on the scope and protocol of the test prior to the test. 2. ASME-PTC 8.2, Centrifugal Pumps, relies on the parties’ agreement beforehand on the scope and protocol of the test. The code does not include acceptable performance tolerances and does not address how test results shall be used to compare with guarantees. 3. Appendix B included with this Standard. III. Use of this Standard. It is the responsibility of the user of an AWWA xi

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standard to determine that the products described in that standard are suitable for use in the particular application being considered. III.A. Information for Manufacturers. When placing orders for pumps, purchasers should provide basic data to manufacturers, so that pumps will meet purchaser’s requirements. Suggested forms that can be used to order pumps are located in appendixes C and D. III.A.1 Basic data for vertical and horizontal pumps. III.A.1.1 Standard used—that is, ANSI/AWWA E103, Standard for Horizontal and Vertical Line-Shaft Pumps. III.A.1.2 Installation location (country, state, or province). III.A.1.3 Water data. III.A.1.3.a Temperature range. III.A.1.3.b pH range. III.A.1.3.c Vapor pressure range (function of altitude and temperature). III.A.1.3.d Maximum concentration of corrosive chemicals, including but not limited to 1. Free chlorine. 2. Chloramine. 3. Chlorides. 4. Ozone. 5. Other (include other oxidants and corrosive chemicals). III.A.1.3.e Solids. 1. Maximum sand concentration after a 15-min pumping interval. 2. Maximum size of solids allowed to pass through the pump. III.A.1.4 Operating conditions. III.A.1.4.a Altitude at impeller shaft (for vertical pumps, use the eye of the lowest impeller). III.A.1.4.b Maximum suction pressure or maximum static suction lift. III.A.1.4.c Pump startup and shutdown conditions: 1. Describe in detail if discharge valve is other than a mechanical gravityactuated type of check valve. 2. If the driver is variable speed and the discharge valve is other than a mechanical nonactuated type of check valve, describe the timing and coordination of valve opening and closure with pump speed ramp-up and ramp-down times. III.A.1.4.d Reverse rotation. 1. Indicate if the pump system will or will not be equipped with means to pre--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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vent reverse shaft rotation. Nonreverse ratchets are required for motors that drive open line shaft vertical turbine pumps having a minimum water level that is 50 ft (15 m) or more below the elevation of the shaft seal in the discharge head. 2. For pump systems without means to prevent reverse rotation, indicate the maximum differential pressure across the pump during flow reversal. III.A.1.4.e Speed. Specify speed for constant speed pumps (usually maximum speed based on a review of pump curves and discussions with manufacturers). If variable speed pumps are required, specify an operating speed range. III.A.1.4.f Sanitary codes. Provide information necessary for the pump to be constructed to meet applicable code requirements. III.A.1.5 Performance Requirements. Refer to Section 3 of this standard for definition of terms. III.A.1.5.a At rated condition point. 1. Rate of flow. 2. Total head or bowl assembly total head. Note: Total head must be used for horizontal pumps. Either total head or bowl assembly total head can be used for vertical pumps. The latter is used when the purchaser accounts for and is responsible for head losses in the strainer, suction pipe (if used), suction vessel (can pumps), column, and discharge head. 3. Minimum efficiency: a. Pump efficiency; or b. Bowl assembly efficiency, if bowl assembly total head is specified; or c. Overall (wire-to-water) efficiency. Note: This can be specified only if the drive is supplied by the pump manufacturer. 4. Net positive suction head allowed (NPSHA) range. III.A.1.5.b At other condition points. Pumps are usually required to provide a minimum rate of flow under high head conditions, which may exist when multiple pumps operate, when the discharge gradient is at a maximum, or when the suction gradient is at a minimum. Pumps are also required to operate under minimum head conditions, which may exist when only one pump in a station that has multiple pumps operates, when the discharge gradient is at a minimum, or when the suction gradient is at a maximum. Including a system head curve, especially on multiple pump installations and variable speed systems, will allow the pump supplier to select the most suitable pump curve shape for the application. 1. Maximum head condition. Include data listed above for the rated condition point except: xiii

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a. Instead of rate of flow, specify minimum rate of flow. b. Instead of total head or bowl assembly total head, specify maximum total head or maximum bowl assembly total head. 2. Minimum head condition. Include data listed above for the rated condition point except: a. Instead of rate of flow, specify maximum rate of flow. b. Instead of total head or bowl assembly total head, specify minimum total head or minimum bowl assembly total head. c. Instead of NPSHA, specify a maximum NPSHR. III.A.1.5.c Allowable suction specific speed (maximum or range). III.A.1.5.d Pump input power (brake horsepower). Specify the maximum input power required for the pump assembly over the required pump operating range. Note 1: Thrust-bearing power requirements must be considered by the purchaser and added to the pump input horsepower when pump thrust bearings are provided in the driver and the driver is not part of the pump assembly. Gear drive power requirements must also be considered if the gear drive is not part of the pump assembly. Note 2: Vertical turbine pump line-shaft bearing losses must also be considered by the purchaser and added to pump input horsepower when bowl assembly performance has been specified. III.A.1.5.e Best efficiency point (BEP). 1. Specify the minimum efficiency required at the BEP. 2. Flow at BEP. Pumps should be selected for maximum efficiency at the normal condition point. Constant speed pumps in a multiple pump system normally operate at a higher flow rate when not operating in parallel with other pumps. Variable speed pumps normally operate at a lower flow rate than the flow at the rated condition point, when the rated condition point is based on the maximum speed. Specify a range of flows or heads that the BEP must fall within. III.A.1.6 Construction requirements. III.A.1.6.a Impeller type: open, semi-open or enclosed. III.A.1.6.b Impeller wear rings. Wear rings can be specified for enclosed impellers. Thrust balance type rings can be specified for both semi-open and enclosed impellers. III.A.1.7 Stuffing box arrangement. Specify the type of sealing required. Select packing, single mechanical seal, or double mechanical seal. III.A.1.8 Packing or mechanical seal cooling and lubricating water requirements. III.A.1.8.a Water must be supplied to the packing or seal when the shaft is rotating. Water suitable for this purpose may be available from the fluid being pumped. xiv

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It may also be desirable to provide water to packing when the shaft is not rotating, to prevent loss of prime (pumps with suction lifts) or prevent packing from drying out. III.A.1.8.b If the water contains materials that can cause rapid packing or seal wear, suitable clean water at the appropriate pressure from an external source should be applied to the lantern ring of the packing. If a mechanical seal is used, it should be a double seal with clean water applied between the seal elements. III.A.1.8.c If the pressure of the pumped fluid at the upstream face of the packing or seal is less than 10 psig (69 kPa), which may be the case with horizontal doublesuction and end-suction pumps, clean water should be supplied from a connection to the pump volute. III.A.1.8.d If water at a pressure of 10 psig (69 kPa) or greater is not available for a period exceeding 60 sec during startup (as may be the case with vertical pumps having deep settings or slowly rising water columns), clean water should be supplied from an external source during the startup period. III.A.1.8.e Specify cooling and lubricating water arrangement and requirements. III.A.2 Materials. III.A.2.1 Drinking Water Requirements. Refer to Sec. 4.1. The purchaser should state whether compliance with NSF/ANSI 61, Drinking Water System Components— Health Effects is required, in addition to the requirements of the Safe Drinking Water Act. If this certification is required, the purchaser should note, “This product shall be certified as suitable for contact with drinking water by an accredited certification organization in accordance with NSF/ANSI 61, Drinking Water System Components— Health Effects.” Note that if the purchaser specifies a wetted component that was not part of the tested and certified product, the certification may not be valid. Purchasers should be aware that the availability of NSF/ANSI 61-certified pumps is very limited, and this requirement may limit competition and add to the cost and delivery time of the pumps. Purchasers should also be aware that some states will allow installation of noncertified pumps, based on submittal and acceptance of materials used to construct the pump, especially if suitable certified pumps are not available. III.A.2.2 Alternative Materials. Purchasers may specify alternative materials or limit manufacturer’s choices of materials listed in this standard. For example, this standard lists silicon bronze, aluminum bronze, and stainless steel as impeller materials. Silicon bronze may not be suitable if the water contains a significant concentration of chlorine or chloramine. Aluminum bronze and stainless steel components may be more costly and difficult to fabricate then silicon bronze components. Purchasers should be

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aware that alternatives or limitations on manufacturer’s selections may increase costs and delivery time. III.A.3 Flanges. This standard requires flat-faced flanges. If other facing is required, it must be specified by the purchaser. III.A.4 Factory tests. III.A.4.1 Tests other than the hydrostatic tests described in Section 5 may be desired. Purchasers can specify the following additional tests in accordance with current ANSI/HI standards. 1. Performance. 2. NPSHR. 3. Mechanical. 4. Prime time for self-priming pumps. 5. Airborne sound. III.A.4.2 Witnessed Testing. Purchaser may specify optional witnessed testing for all or some of the factory tests. III.A.4.3 Special Testing. Purchaser may specify variations from the ANSI/HI standard tests. These variations may include duplication of field conditions. III.A.4.4 Other Testing. Purchaser may specify testing a sample pump selected at random for any test other than the prescribed hydrostatic tests. III.A.5 Submittals. This standard includes minimum requirements for submittals. If additional submittals (including affidavits of compliance) are required, they should be provided by the purchaser. III.A.6 Shop inspections. This standard does not provide for inspections at the manufacturer’s facility either during or after the pumps are constructed. If inspections are required, the extent should be defined by the purchaser. III.B. Basic Data for Vertical Pumps. III.B.1 Construction requirements. III.B.1.1 Specify type. Refer to ANSI/HI 2.1–2.2, Vertical Pumps for Nomenclature and Definitions, for a description of types. Select: 1. Barrel (can) pump with suction nozzle in discharge head or in barrel. 2. Deep well. 3. Wet pit with above-floor or below-floor discharge. III.B.1.2 Specify line shaft and bearing details. 1. Open or enclosed line shaft. 2. For open line shaft specify bearing material (bronze or rubber). 3. For enclosed line shaft specify lubrication (water or oil).

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III.B.1.3 Specify column pipe details. 1. Refer to appendix E for recommendations. 2. Specify nominal size, wall thickness, and material. III.B.2 Driver details. Although drivers are not included in this standard, they are an important component of a vertical pump. Refer to appendix E for recommendations. III.C. Basic Data for Horizontal Pumps. III.C.1 Construction requirements. III.C.1.1 Specify type. Refer to ANSI/HI 1.1–1.2, Centrifugal Pumps for Nomenclature and Definitions, for a description of types. Select: 1. Separately coupled, single-stage, inline, flexible coupling. 2. Separately coupled, single-stage, inline, rigid coupling. 3. Separately coupled, single-stage, end suction. 4. Separately coupled, single-stage, horizontal axial or mixed flow. 5. Single-stage, horizontal, double- or single-suction split case. 6. Vertically mounted, horizontal, double- or single-suction split case. IV. Modification to Standard. Any modification of the provisions, definitions, or terminology in this standard must be provided by the purchaser. V. Major Revisions. This is the first edition of this standard. VI. Comments. If you have any comments or questions about this standard, please call the AWWA Volunteer and Technical Support Group at 303.794.7711, FAX 303.795.7603, write to the group at 6666 West Quincy Avenue, Denver, CO 80235-3098, or e-mail at [email protected].

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ANSI/AWWA E103-07 (First Edition))

AWWA Standard

Horizontal and Vertical Line-Shaft Pumps SECTION 1: Sec. 1.1

GENERAL

Scope This standard provides minimum requirements for horizontal centrifugal pumps and for vertical line-shaft pumps for installation in wells, water treatment plants, water transmission systems, and water distribution systems. 1.1.1 Service. Pumps described in this standard are intended for pumping fresh water having a pH range between 5.5 and 10.0, a temperature range from 33°F to 125°F (14°C to 37°C), a maximum chloride content of 250 mg/L, and a maximum suspended solids content of 1,000 mg/L, and which is either potable or will be treated to become potable. 1.1.2 Pumps covered by this standard. 1.1.2.1 Driver power range: 10 hp to 1,500 hp (7 kW to 1,100 kW). 1.1.2.2 Rate of flow (at BEP): 100 gpm to 40,000 gpm (23 m3/hr to 9,100 m3/hr). 1.1.2.3 Maximum discharge pressure ratings. The maximum steady-state pressure at the pump discharge (which considers the suction pressure, possible operation for short periods at shutoff head, and the elevation of the discharge) is

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2

AWWA E103-07

limited to the pressure rating for the ANSI/AWWA C207 class of flange shown for the pump types described below. 1. For horizontal pumps: –Discharge 42 in. (1,067 mm) and larger: Class E (275 psig, 1,900 kPa). –Discharge smaller than 42 in.: Class F (300 psig, 2,100 kPa). 2. For vertical line-shaft pumps: Class F (300 psig, 2,100 kPa). 1.1.2.4 Maximum steady-state suction pressure ratings. 1. For horizontal pumps: 50 psig (340 kPa). 2. For vertical line-shaft pumps: 100 psig (700 kPa). 1.1.3 Pump types included in this standard. 1.1.3.1 Horizontal pumps. Refer to Hydraulic Institute (HI) Standard ANSI/HI 1.1–1.2 for a description of types: 1. Separately coupled, single-stage, inline, flexible coupling. 2. Separately coupled, single-stage, inline, rigid coupling. 3. Separately coupled, single-stage, end suction. 4. Separately coupled, single-stage, horizontal, axial or mixed flow. 5. Single-stage, horizontal, double- or single-suction split case. 6. Vertically mounted, horizontal, double- or single-suction split case. 1.1.3.2 Vertical pumps. Refer to ANSI/HI 2.1–2.2 for a description of types: 1. Barrel (can) pump with suction nozzle in discharge head or in barrel. 2. Deep well. 3. Wet pit with above- or below-floor discharge. 1.1.4 Drivers. This standard does not include drivers. 1.1.5 Conditions not covered by this standard. 1. Conditions resulting from water hammer, cavitation, and hydraulic pulsations. 2. Excessive installed operating noise and vibrations, which may require special design, construction, and installation.

Sec. 1.2

Purpose The purpose of this standard is to provide minimum requirements for water system pumps of the types identified in Sec. 1.1.

Sec. 1.3

Application This standard can be referenced by the purchaser for pumps described in Sec. 1.1. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 3

SECTION 2:

REFERENCES

* † ‡ §

American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036. Hydraulic Institute, 9 Sylvan Way, Parsippany NJ, 07054. (www.pumps.org) ASME International, Three Park Avenue, New York, NY 10016. ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428.

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This standard references the following documents in their current editions. These documents form a part of this standard to the extent specified within the standard. In any case of conflict, the requirements of this standard shall prevail. ANSI*/AWWA C207—Steel Pipe Flanges for Waterworks Service—Sizes 4 In. Through 144 In. (100 mm Through 3,600 mm). ANSI/AWWA C210—Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines. ANSI/AWWA C550—Protective Epoxy Interior Coatings for Valves and Hydrants. ANSI/HI† 1.1–1.2—Centrifugal Pumps for Nomenclature and Definitions. ANSI/HI 1.6—Centrifugal Pump Tests. ANSI/HI 2.1–2.2—Vertical Pumps for Nomenclature and Definitions. ANSI/HI 2.6—Vertical Pump Tests. ANSI/HI 9.6.3—Centrifugal and Vertical Pumps for Allowable Operating Region. ANSI/HI 9.8—Pump Intake Design. ASME‡ B1.20.1—Pipe Threads, General Purpose, Inch. ASME B4.1—Preferred Limits and Fits For Cylindrical Parts. ASME B16.1—Cast Iron Pipe Flanges and Flanged Fittings. ASME B46.1—Surface Texture (Surface Roughness, Waviness, and Lay). ASME PTC 8.2—Centrifugal Pumps. ASTM§ A36—Standard Specification for Carbon Structural Steel. ASTM A47—Standard Specification for Ferritic Malleable Iron Castings. ASTM A48—Standard Specification for Gray Iron Castings. ASTM A53—Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless. ASTM A194—Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both. ASTM A276—Standard Specification for Stainless Steel Bars and Shapes.

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AWWA E103-07

ASTM A283—Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates. ASTM A536—Standard Specification for Ductile Iron Castings. ASTM B16—Standard Specification for Free-Cutting, Brass Rod, Bar, and Shapes for use in Screw Machines. ASTM B505—Standard Specification for Copper-Base Alloy Continuous Castings. ASTM B584—Standard Specification for Copper Alloy Sand Castings for General Applications. AWWA M11—Steel Water Pipe—A Guide for Design and Installation. MSS* SP-55—Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components–Visual Method for Evaluation of Surface Irregularities. NSF/ANSI 61—Drinking Water System Components—Health Effects. SSPC†-SP2—Hand Tool Cleaning. SSPC-SP6—Commercial Blast Cleaning.

SECTION 3:

DEFINITIONS

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The following definitions shall apply in this standard. Definitions of pump components are included in Sec. 4.3. 1. Allowable operating range: Flow range at specified speeds with the impeller supplied, as limited by cavitation, heating, vibration, noise, shaft deflection, fatigue, and other similar criteria. This range is to be specified by the manufacturer. 2. Atmospheric head (hatm ): Local atmospheric pressure expressed in ft (m). 3. Best efficiency point (BEP): The rate of flow and corresponding head condition at which maximum pump efficiency is achieved. 4. Bowl assembly efficiency (ηba ): This is the efficiency obtained from the bowl assembly, excluding hydraulic and mechanical losses within other pump components.

* Manufacturers Standardization Society, 127 Park St., N.E., Vienna, VA 22180. † SSPC: The Society for Protective Coatings, 40 24th Street, 6th Floor, Pittsburgh, PA 15222.

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 5

5. Bowl assembly input power (Pba ): The power delivered to the bowl assembly shaft, expressed in hp (kW). 6. Condition point, normal: The point at which the pump will normally operate. It may be the same as the rated condition point. 7. Condition point, rated: The rate of flow, head, net positive suction head required (NPSHR), and speed of the pump, as specified by the purchaser. 8. Condition point, specified: Synonymous with rated condition point. 9. Cosmetic defect: A blemish that has no effect on the ability of the component to meet the structural design and test requirements of this standard. Should the blemish or the activity of plugging, welding, grinding, or repairing of the blemish cause the component to fail these requirements, the blemish shall be considered a structural defect. 10. Datum: A horizontal plane that serves as the reference for head measurements taken during test. Vertical pumps are usually tested in an open pit with the suction flooded. The datum is then the eye of the first stage impeller. Optional tests can be performed with the pump mounted in a suction can. Irrespective of pump mounting, the pump’s datum is maintained at the eye of the first stage impeller. For horizontal pump units, the pump’s datum shall be referenced from the centerline of the shaft. For vertical double-suction pumps, the pump’s datum shall be referenced from the center of the first/lowest impeller. 11. Electric motor input power (Pmot ): The electrical input power to the motor, expressed in hp (kW). 12. Elevation head (Z): The potential energy of the liquid because of its elevation relative to datum level, measured to the center of the pressure gauge or liquid level. 13. Field test pressure: The maximum static test pressure used for leak testing a closed pumping system in the field if the pumps are not isolated. Generally 125 percent of the maximum allowable casing working pressure. Where mechanical seals are used, this pressure may be limited by the pressure-containing capabilities of the seal. Note: See definition for maximum allowable casing working pressure. Consideration may limit the field-test pressure of the pump to 125 percent of the maximum allowable casing working pressure on the suction side of double-casing cantype pumps and certain other pump types.

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6

AWWA E103-07

14. Friction head (hf ): The hydraulic energy required to overcome frictional resistance of a piping system to liquid flow, expressed in ft (m). 15. Gauge head (hg ): The energy of the liquid because of its pressure relative to atmospheric pressure, as determined by a pressure gauge or other pressuremeasuring device. Gauge head is positive when the reading is above atmospheric pressure and negative when below. Gauge head is measured in ft (m). 16. Head (h): The expression of the energy content of the liquid referred to any arbitrary datum. It is expressed in units of energy per unit weight of liquid. The measuring unit for head is ft (m) of liquid. 17. Manufacturer: The party that manufactures, fabricates, or produces materials or products. 18. Maximum allowable casing working pressure: The highest pressure at the specified pumping temperature for which the pump casing is designed. This pressure shall be equal to or greater than the maximum discharge pressure. In the case of double-casing can pumps, the maximum allowable casing working pressure on the suction side may be different from that on the discharge side. Maximum allowable casing working pressure is expressed in psi (kPa). 19. Maximum discharge pressure: The highest discharge pressure to which the pump will be subjected during operation, which is expressed in psi (kPa). 20. Maximum suction pressure: The highest suction pressure to which the pump will be subjected during operation. 21. Net positive suction head available (NPSHA): The total suction head in ft (m) of water absolute, determined at the first-stage impeller datum, less the absolute vapor pressure of the water in ft (m): NPSHA = hsa – hvp

(Eq 1)

hsa = Total suction head absolute = hatm + hs

(Eq 2)

NPSHA = hatm + hs – hvp

(Eq 3)

Where: or

In can pumps, NPSHA is often determined at the suction flange. Since NPSHR is determined at the first-stage impeller, the NPSHA value must be adjusted to the first stage impeller by adding the difference in elevation and subtracting the losses in the can.

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 7

this is the ratio of the power imparted to the liquid (Pw ) by the pump to the power supplied to the motor (Pmot ); that is, the ratio of the water horsepower to the power input to the motor, expressed in percent. 24. Pump efficiency (hp): The ratio of the pump output power (Pw ) to the pump input power (Pp ); that is, the ratio of the water horsepower to the brake horsepower, expressed in percent. 25. Pump input power (Pp ): The power needed to drive the complete pump assembly, including bowl assembly input power, line-shaft power loss, stuffing box loss, and thrust-bearing loss. With pumps that have built-in thrust bearing, the power delivered to the pump shaft coupling is equal to the pump input power. With pumps that rely on the driver thrust-bearing, the thrust bearing loss shall be added to the power delivered to the pump shaft. It is also called brake horsepower (bhp). Pump input power is expressed in hp (kW). 26. Pump output power (Pw ): The power imparted to the liquid by the pump. It is also called water horsepower, and is expressed in hp (kW). 27. Pump total discharge head (hd ): The sum of the discharge gauge head (hgd) measured after the discharge elbow, plus the velocity head (hvd) at the point of gauge attachment, plus the elevation (Zd ) from the discharge gauge centerline to the pump datum. Pump total discharge head is measured in ft (m). hd = hgd + hvd + Zd

(Eq 4)

28. Pump total head (H): The measure of energy increase per unit weight of the liquid, imparted to the liquid by the pump, expressed as the difference between the total discharge head and the total suction head. Total head is normally specified for pumping applications, since the complete characteristics of a system determine the total head required. 29. Purchaser: The person, company, or organization that purchases products, materials, or work to be performed. 30. Rate of flow (capacity) (Q ): The total volume throughput per unit of time at the suction inlet. It includes both water and any dissolved or entrained gases existing at the stated operating conditions. Rate of flow is measured in gpm (m3/hr).

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22. Net positive suction head required (NPSHR): The percent loss in total head to the first stage of the pump at a specific rate of flow. 23. Overall efficiency (hOA ): Also referred to as wire-to-water efficiency,

AWWA E103-07

31. Shutoff: The condition of zero flow when no water is flowing from the pump during pump operation. 32. Single-plane balancing (also called static balancing): Correction of residual imbalance to a specified maximum limit by removing or adding weight in one correction plane only. Can be accomplished statically using balance rails or by spinning. 33. Speed (n): The number of revolutions of the shaft in a given unit of time. Speed is expressed as rpm. 34. Static suction lift (ls ): A hydraulic pressure below atmospheric at the intake port of the pump, expressed in ft (m). 35. Structural defect: A flaw that causes the component to fail the structural design or test requirements of this standard. This includes, but is not limited to, imperfections that result in leakage through the walls of a casting, and failure to meet the minimum wall-thickness requirement. 36. Submerged suction: When the centerline of the pump inlet is below the level of the liquid in the supply source. 37. Total suction head (hs ), closed suction: For closed suction installations, the pump suction nozzle may be located either above or below water level. The total suction head (hs ), referred to the eye of the first-stage impeller, is the algebraic sum of the suction gauge head (hgs ), plus the velocity head (hvs ) at point of gauge attachment, plus the elevation (Zs ) from the suction gauge centerline (or manometer zero) to the pump datum: hs = hgs + hvs + Zs

(Eq 5)

The elevation (Zs ) is positive when the suction gauge is located above the datum and negative when below. 38. Total suction head (hs ), open suction: For open suction (wet pit) installations, the first-stage impeller of the bowl assembly is submerged in a pit. The submergence in ft (m) of water (Zw ). Total suction head is measured in ft (m). The average velocity head of the flow in the pit is small enough to be neglected: hs = Zw

(Eq 6)

Where: Zw =

Vertical distance in ft (m) from free water surface to

datum.

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8

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 9

39. Two-plane balancing (also called dynamic balancing): Correction of residual imbalance to a specified limit by removing or adding weight in two correction planes. Accomplished by spinning on appropriate balancing machines. 40. Velocity head (hv ): The kinetic energy of the liquid at a given crosssection. Velocity head is measured in ft (m). Velocity head is expressed by the following equation: 2 (Eq 7) hv = v 2g

Where: v = rate of flow divided by the cross-section area at the point of gauge connection. Average velocity is expressed in ft/sec (m/sec). g = 32.2 ft/sec2 (9.81 m/sec2). 41. Vertical pump bowl assembly total head (Hba ): The sum of gauge head (hgd) measured at a gauge connection located on the column pipe downstream from the bowl assembly, plus the velocity head (hv ) at point of gauge connection, plus the vertical distance (Zd ) from datum to the pressure gauge centerline, minus the submergence Zw, which is the vertical distance from datum to the water level, plus the friction loss between the bowl exit and point of gauge connection and in the suction pipe and strainer, if used (hf ). These friction losses are usually very small. Bowl assembly total head is measured in ft (m). Hba = hgd + hv + Zd – Zw + hf

(Eq 8)

42. Working pressure (pd ): The maximum discharge pressure that occurs in the pump when it is operated at rated speed and suction pressure for the given application. Working pressure is expressed in psi (kPa).

SECTION 4: Sec. 4.1

REQUIREMENTS

Materials 4.1.1 Regulations. Materials shall comply with the requirements of the Safe Drinking Water Act and other federal, state or provincial, and local requirements. 4.1.2 Coatings, lubricants, and temporary corrosion prevention compounds. These materials shall comply with NSF/ANSI 61 when applied to surfaces that include, but are not limited to, interior pump surfaces, interior pump column

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AWWA E103-07

surfaces, and the exterior surfaces of pumps or pump components (usually vertical pump columns) immersed in water. 4.1.3 Pump components. Part names, item numbers, and definitions shown on Tables 1 through 3 are copied from ANSI/HI 1.1–1.2, Horizontal Pumps, and ANSI/HI 2.1–2.2, Vertical Pumps. Item numbers refer to pump component locations as shown on drawings located in the referenced ANSI/HI standards and shown in appendix A. If a component does not have an item number, it is defined in this standard and not the ANSI/HI standard. Materials listed are requirements for pumps meeting this standard. If no material is listed, manufacturers may provide their standard material, unless requirements are described in subsequent sections of this standard or in the purchaser’s documents. The following are abbreviations used in the tables and elsewhere in this standard: CRM: corrosion-resistant material. CA: copper alloy. Additional requirements for materials are also defined in Sec. 4.1.4. 4.1.3.1 Alternative materials. Materials shown in Tables 1 through 3 are suitable for most applications with water meeting the conditions described in Sec. 1.1.1. However, materials shown may not be appropriate for all applications, water quality, and jurisdictions. 1. Cost. Water may not be as aggressive as described in Sec. 1.1.1, or a long service life may not be required. In this case, lower-cost materials such as cast- or ductile-iron impellers may be appropriate. 2. Water quality. Some waters promote dealloying corrosion of some copper alloys in the form of dezincification or dealuminization, particularly when the material is exposed to water at high velocity. In this case, appropriate copper alloys, cast iron, ductile iron, or stainless steel may be required instead of the listed materials. 3. Regulatory requirements. Materials selected for components shown in Tables 1 through 3, which are in contact with the pumped fluid, do not have a lead content in excess of 1 percent except for bearings, which may contain as much as 8 percent. Specific materials or alternative materials may be required to meet regulatory requirements in some jurisdictions. As noted in Sec. III.B.1.1.2 in the foreword, purchasers can specify alternative materials or limit manufacturer’s choices of material listed in this standard. 4.1.4 Physical and chemical properties. Materials shall conform to the requirements of this subsection (see Table 4).

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10

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

11

Table 1. Pump (horizontal or vertical) parts, materials, and definitions Item No.

Part Name

Materials List by AWWA

Definition

Cast Iron Steel 4

Base plate

23

A member on which the pump and its driver are mounted.

Bushing, stuffing box

63

A replaceable sleeve or ring placed in the end of the stuffing box opposite the gland.

CA 3

Coupling half, driver

42

The coupling half mounted on the driver shaft.

Steel 4

Coupling half, pump

44

The coupling half mounted on the pump shaft.

Steel 4

Deflector

40

A flange or collar around a shaft and rotating with it to prevent passage of liquid, grease, oil, or heat along the shaft.

Steel 4 Rubber

Gasket

73

Resilient material used to seal joints between parts to prevent leakage.

Gland

17

A follower that compresses packing in a stuffing box or retains the stationary element of a mechanical seal.

Guard, coupling

131

A protective shield over a shaft coupling.

Cast Iron Stainless Steel 2 CA 4 Steel

Impeller

2

A bladed member of the rotating assembly of the pump, which imparts the principal force to the liquid. Also called a propeller for axial flow pumps.

CA 1, 2, or 3 Stainless Steel 1 or 2

Key, impeller

32

A parallel-sided piece used to prevent the impeller from rotating relative to the shaft.

Stainless Steel 1, 2, 3, or 4

Packing

13

A pliable lubricated material used to provide a seal around that portion of the shaft located in the stuffing box.

Pressure bolting

Ring, bowl (or case)

213

Fasteners used to assemble pump components, which can be pressurized. Use Stainless Steel 5 or 6 for pressure bolting that is wetted. Steel 5 can be used for non-wetted bolting.

Stainless Steel 5 or 6

A stationary replaceable ring to protect the bowl (or case) at the running fit with the impeller ring or the impeller.

CA 3 Stainless Steel 3 or 4 CA 3 Stainless Steel 3 or 4

Ring, Impeller

8

Provides water seal at impeller.

Ring, lantern

29

Spaces out packing to allow for injection of lubricant.

Seal, mechanical, rotating element

80

A device flexibly mounted on the shaft in or on the stuffing box having a smooth, flat sealing face held against the stationary sealing face.

Seal, mechanical, stationary element

65

A subassembly consisting of one or more parts mounted in or on a stuffing box and having a smooth flat sealing face.

Spacer, coupling

88

A cylindrical piece used to provide axial space for the removal of the rotating assembly or mechanical seal without removing the driver.

Steel 3

Strainer

209

A device used to prevent large objects from entering the pump.

Steel 4

CA 4 PTFE

(Part name, item number, and definition courtesy of Hydraulic Institute) Table continued next page. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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12 AWWA E103-07

Table 1. Pump (horizontal or vertical) parts, materials, and definitions (continued) Part Name Stuffing box

Item No.

Definition

Materials List by AWWA

83

A portion of the casing through which the shaft extends, and in which packing or a mechanical seal is placed to prevent or minimize leakage.

Cast Iron

Table 2. Horizontal pump parts, materials, and definitions Part Name

Item No.

Materials List by AWWA

Definition

Cast Iron Steel

Base

53

A pedestal to support a pump.

Bearing, inboard

16

The bearing nearest the coupling of a double suction pump, but farthest from the coupling of an end suction pump.

Bearing, outboard

18

The bearing most distant from the coupling of a double suction pump, but nearest to the coupling of an end suction pump.

Bracket, bearing

125

Detachable bracket that contains a bearing.

Bushing, bearing

39

The removable portion of a sleeve bearing in contact with the journal.

Bushing, interstage diaphragm

113

A tubular-shaped replaceable piece mounted in the interstage diaphragm.

Bushing, pressure reducing

117

A replaceable piece used to reduce the liquid pressure at the stuffing box by throttling the flow.

Bushing, throttle, auxiliary

171

A stationary ring or sleeve placed in the gland of a mechanical seal subassembly to restrict leakage in the event of seal failure.

Cap, bearing, inboard

41

The removable upper portion of the inboard bearing housing.

Cap, bearing, outboard

43

The removable upper portion of the outboard bearing housing.

Casing

1

The portion of the pump that includes the impeller chamber and volute or diff user.

Collar, shaft

68

A ring used on a shaft to establish a shoulder for a ball bearing.

Collar, thrust

72

A circular collar mounted on a shaft to absorb the unbalanced axial thrust in the pump.

Coupling, oil pump

120

A means of connecting the driver shaft to the oil pump shaft.

Coupling, shaft

70

A mechanism used to transmit power from the drive shaft to the pump shaft, or to connect two pieces of shaft.

Cover, bearing end

123

A plate closing the tachometer port in the end of the outboard bearing housing.

Cover, bearing, inboard

35

An enclosing plate for either end of an inboard bearing of double suction or multistage pumps, or for the impeller end of the bearing of end suction pumps.

Cover, bearing, outboard

37

An enclosing plate for either end of the outboard bearing of double suction or multistage pumps, or for the coupling end of the bearing of end suction pumps.

Cast Iron

Cover, oil bearing A lid or plate over an oil filler hole or inspection hole in a 45 cap bearing cap. (Part name, item number, and definition courtesy of Hydraulic Institute) Table continued next page. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

13

Table 2. Horizontal pump parts, materials, and definitions (continued) Definition

Cover, suction

9

A removable piece, with which the inlet nozzle may be integral, used to enclose the suction side of the casing of end suction pumps.

Diff user

5

A piece, adjacent to the impeller exit, which has multiple passages of increasing area for converting velocity to pressure.

Elbow, suction

57

A curved water passage, usually 90 degrees, attached to the pump inlet.

Frame

19

A member of an end suction pump to which are assembled the liquid end and rotating element.

Gasket, impeller screw

28

Resilient material used to seal joint between hub of impeller and the impeller screw.

Gasket, shaft sleeve

38

Resilient material used to provide a seal between the shaft sleeve and the impeller.

Gauge, sight, oil

143

A device for the visual determination of the oil level.

Gland, stuffing box, auxiliary

133

A follower provided for compression of packing in an auxiliary stuffing box.

Guard, coupling

131

A protective shield over a shaft coupling.

Housing, bearing

99

A body in which the bearing is mounted.

Journal, thrustbearing

74

A removable cylindrical piece mounted on the shaft and which turns in the bearing. It may have an integral thrust collar.

Key, bearing journal

76

A parallel-sided piece used for preventing the bearing journal from rotating relative to the shaft.

Key, coupling

46

A parallel-sided piece used to prevent the shaft from turning in a coupling half.

Locknut, bearing

22

A fastener that positions an anti-friction bearing on the shaft.

Locknut, coupling

50

A fastener holding a coupling half in position on a tapered shaft.

Lockwasher

69

A device to prevent loosening of a nut.

Nut, impeller

24

A threaded piece used to fasten the impeller on the shaft.

Nut, shaft-adjusting

66

A threaded piece for altering the axial position of the rotating assembly.

Nut, shaft sleeve

20

A threaded piece used to locate the shaft sleeve on the shaft.

Retainer, grease

51

A contact seal or cover to retain grease.

Ring, balancing

115

The stationary number of a hydraulic balancing device.

Ring, casing

7

A stationary replaceable ring to protect the casing at the running fit with the impeller ring or the impeller.

Seal

89

A device to prevent the flow of a liquid or gas into or out of a cavity.

Shaft

6

The cylindrical member on which the impeller is mounted and through which power is transmitted to the impeller.

Shim

67

A piece of material that is placed between two members to adjust their position.

Sleeve, shaft

14

A cylindrical piece fitted over the shaft to protect the shaft through the stuffing box, and which may also serve to locate the impeller on the shaft.

Materials List by AWWA

Cast Iron

(Part name, item number, and definition courtesy of Hydraulic Institute)

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Item No.

Part Name

14

AWWA E103-07

Table 3. Vertical pump parts, materials, and definitions Item No.

Definition

MaterialsList by AWWA

Adapter, tube

195

A cylindrical piece used to connect discharge case to enclosing tube.

Steel 3

Barrel or can, suction

205

A receptacle for conveying the liquid to the pump.

Steel 4

Bearing, line shaft enclosed

103

A bearing that also serves to couple portions of the shaft enclosing tube.

CA 4

Bearing, sleeve

39

A replaceable, cylindrical bearing secured within a stationary member.

Bell, suction

55

A flared tubular section for directing the flow of liquid into the pump.

Cast Iron

Bowl, intermediate

199

An enclosure within which the impeller rotates, and which serves as a guide for the flow from one impeller to the next.

Cast Iron

Case, discharge

197

Aid flow from bowl to pump column.

Cast Iron

Case, suction

203

A device used to receive the liquid and guide it to the first impeller.

Cast Iron

Collar, protecting

64

A rotating member for preventing the entrance of contaminating material.

CA 2 or 3

Collet, impeller lock

84

A tapered collar used to secure the impeller to the pump shaft.

Coupling, column pipe

191

A threaded sleeve used to couple sections of column pipe.

Coupling shaft

70

A mechanism used to transmit over from the line shaft to the pump shaft, or to connect two pieces of shaft.

Steel 3 Stainless Steel 3

Elbow

57

A curved water passage, usually 90 degrees, attached to the pump inlet or discharge.

Cast Iron, Steel

Elbow, discharge

105

An elbow in an axial flow, mixed flow, or turbine pump by which the liquid leaves the pump.

Cast Iron

Flange, top column

189

A device used to couple column to discharge head.

Cast Iron Steel 4

Head, surface discharge

187

A support for driver and pump column, and a means by which the liquid leaves the pump.

Cast Iron Steel 4

Lubricator

77

A device for applying a lubricant to the point of use.

Nut, shaft-adjusting

66

A threaded piece for altering the axial position of the rotating assembly.

Nut, tube

183

A device for sealing and locking the shaft-enclosing tube.

Cast Iron

Pedestal, driver

81

A metal support for the driver of a vertical pump.

Cast Iron Steel 4

Pipe, column

101

A vertical pipe by which the pumping element is suspended.

Steel 2

Pipe, suction

211

A device for conveying the liquid to the pump’s suction.

Steel 2

Plate, tension, tube

185

A device for maintaining tension on shaft-enclosing tube.

Cast Iron CA 4

Rubber CA 3

Steel 3 Stainless Steel 4 Cast Iron Ductile Iron Steel 3

CA4 Steel 4 Ductile Iron

(Part name, item number, and definition courtesy of Hydraulic Institute) Table continued next page.

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Part Name

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

15

Table 3. Vertical pump parts, materials, and definitions (continued) Item No.

Part Name

Definition

Shaft, head

10

The upper shaft in a vertical pump that transmits power from the driver to the line shaft.

Shaft, line

12

The shaft that transmits power from the head shaft or driver to the pump shaft.

Shaft, pump

6

The shaft on which the impeller is mounted and through which power is transmitted to the impeller.

Sole plate

129

A metal pad, usually imbedded in concrete, on which the pump base is mounted.

Tube, shaft-enclosing

85

A cylinder used to protect the drive shaft and to provide a means for mounting bearings.

Umbrella, suction

95

A formed piece attached to the suction bowl to reduce disturbance at pump inlet and reduce submergence required.

MaterialsList by AWWA Steel 1 Stainless Steel 3 or 4 Steel 1 Stainless Steel 3 or 4 Steel 1 Stainless Steel 3 or 4 Cast Iron, Steel 4 Steel 2 Cast Iron Steel 4

(Part name, item number, and definition courtesy of Hydraulic Institute)

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16 AWWA E103-07

Table 4. Materials Material

Type

ASTM Designation ASTM A48, Class 30

Copper Alloy

Type 1 (aluminum bronze)

ASTM B148 or 505 alloys 952, 953, 954, 955 956, or 958

Type 2 (silicon bronze)

ASTM B584 alloy 876

Type 3

ASTM B505, B584 alloy 903, 907

Type 4

Alloys listed for “Type 3,” plus alloys 836, 838, 844, 932

Type 5 (for fasteners)

ASTM B16

Ductile Iron

ASTM A536 Gr. 65-45-12

Malleable Iron

ASTM A47

Steel

Stainless Steel

Sec. 4.2

Type 1

ASTM A108, Gr. 1045

Type 2

ASTM A53 Gr. A, A120

Type 3

ASTM A108 Gr. 213, 1113, 1144, 1020

Type 4

ASTM A36, A283

Type 5 (for fasteners)

ASTM A307

Type 1

ASTM A276, Type 304, ASTM A351, Type CF3

Type 2

ASTM A276, Type 316, ASTM A351, Type CF8

Type 3

ASTM A276, Type 410

Type 4

ASTM A582, Type 416

Type 5 (for fasteners)

ASTM A193 (or A194), Gr. 8 (304 SS), ASTM F593 (31655)

Type 6 (for fasteners)

ASTM A193 (or A194), Gr. 8M (316 SS), ASTM F593 (31655)

General Design: Common to Horizontal and Vertical Pumps 4.2.1 Construction requirements. 4.2.1.1 Corrosion allowance. Iron and steel components subject to corrosion or erosion shall have an allowance of ¹⁄ in. (3.2 mm). 4.2.1.2 Machined joints. Component parts that are assembled together shall have machined joints. Mating faces of bowls, bells, and casings shall allow the parallelism of the assembled joint to be gauged. Components that require accurate alignment when reassembled shall be designed with shoulders and rabbeted fits. 4.2.1.3 Threading. Metric fine and UNF thread shall not be used. 4.2.1.4 Wrench clearances. Adequate clearance shall be provided at bolt locations to permit use of socket or box wrenches. 4.2.1.5 Structural defects. Components shall be free from structural defects. 4.2.1.6 Casting finish. Castings shall be sound and generally free from porosity, hot tears, shrink holes, blow holes, cracks, scale, blisters, and similar defects. Surfaces of castings shall be cleaned by sandblasting, shot blasting, chemical cleaning, or any other standard method to meet the visual requirements of MSS-SP-55.

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Cast Iron

Mold parting fins and remains of gates and risers shall be chipped, filed, or ground flush. The finish on casting surfaces located in water passages shall be free of slags, burrs, sharp edges and other defects, which reduce efficiency or render the surface unsuitable for required coatings. 4.2.1.7 Flanges. 4.2.1.7.1 Suction and discharge nozzles shall be supplied with flange dimensions conforming to ASME B16.1 Class 125 cast iron, including bolt circle, number, and size of bolt holes. Flanges shall be flat-faced with the minimum thickness and diameter specified in ANSI Class 125. Flanges 12 in. (305 mm) and smaller subject to a pressure exceeding 200 psig (1,400 kPa), and flanges larger than 14 in. (360 mm) subject to a pressure exceeding 150 psig (1,030 kPa), shall conform to ASME B16.1, Class 250 cast iron dimensions. 4.2.1.7.2 Steel flanges for suction and discharge nozzles shall conform to ANSI/AWWA C207. Flange class shall be suitable for continuous service at the maximum required pressure rating. 4.2.1.8 Impellers. 4.2.1.8.1 Impellers shall be cast in one piece. 4.2.1.8.2 Impellers having lengths greater than half of the outside diameters shall receive a dynamic balance to Grade G6.3 of ISO 1940 as a minimum. Impellers having lengths equal to or less than half of the outside diameters shall receive a static balance to Grade G6.3 of ISO 1940 as a minimum. 4.2.1.8.3 Enclosed impellers shall have radial wear surfaces on the front (eye-side) and, when balance holes are provided, on the back (hub-side) as well. Enclosed impellers larger than 10 in. (250 mm) in diameter shall have replaceable wear rings at wear surfaces or shall be designed to be machined to allow future ring installation. Hardness of the impeller or impeller wear rings shall be a minimum of 50 BHN (Brinell Harness Number) less than that of the casing or casing wear rings, unless nongalling metals or galling clearances are used. 4.2.1.9 Stuffing box. 4.2.1.9.1 The stuffing box shall accommodate five rings of packing, sized from ³⁄ in. (9.5 mm) to ¹⁄7 in. (3.6 mm) of the shaft diameter, including any sleeve, plus a lantern ring or a mechanical seal, split or solid, balanced or unbalanced, with or without a throat bushing. 4.2.1.9.2 Construction details.

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 17

AWWA E103-07

4.2.1.9.2.1 Packing or mechanical seals shall be replaceable without a requirement to remove the driver. 4.2.1.9.2.2 Glands shall be held in place by a minimum of two bolts having a minimum diameter of ³⁄ in. (9.5 mm). Bolts shall be of corrosion-resistant material (CRM) compatible with the gland. 4.2.1.9.3 Packing details. 4.2.1.9.3.1 Provide an extra ring of packing and delete the lantern ring if pumped fluid is clear and the pressure at the upstream face of the packing exceeds 10 psig (70 kPa). 4.2.1.9.3.2 Cooling and lubricating water shall be supplied to the stuffing box from an external source or from a connection to the pump discharge volute (horizontal pumps only). Connecting piping, fittings, and valves shall be of CRM and shall include a throttling valve. Provide a minimum ¼ in. (6.3 mm) NPT connection for an external source. 4.2.1.9.4 Mechanical seal details. 4.2.1.9.5 Maximum stuffing box leakage. 1. Mechanical seal: 2 drops per min. 2. Packing: 90 drops per min. 4.2.1.9.6 Packing shall not contain asbestos.

Sec. 4.3

General Design: Horizontal Pumps 4.3.1 Casing. 1. Casing shall be designed to produce a smooth flow with gradual changes in velocity. 2. Suction and discharge nozzles shall be integrally cast into casing. 3. Casing shall be constructed to permit examination of impellers and other interior parts without disturbing suction and discharge piping. 4. Casing shall include the means to facilitate disassembly without requiring the use of wedges or prying elements, such as provision of tapped holes for jackscrews. 5. Casings shall be designed and constructed complete with integral supports that are adequate to withstand hydrostatic and dynamic forces generated by the operation of the pump. Design of support connections between the casing and the base shall consider the hydrostatic and dynamic forces between the pump and connecting piping systems based on installation, in accordance with the recommendation of ANSI/HI 1.4.

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18

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

19

6. A ½-in. (12.7-mm) NPT minimum opening to facilitate draining of the casing shall be provided. 7. When enclosed impellers are used, the casing shall be provided with replaceable wear rings, which are held in place by rabbet-fit and locked with screws, pins, anaerobic adhesives, or tack welded at three or more points.

Sec. 4.4

General Design: Vertical Pumps 4.4.1 Discharge head assembly. 4.4.1.1 Head. Head shall be an iron casting or a steel fabrication. It shall be designed to mount the driver and support the pump column. Design shall consider the dynamic forces and vibrations transmitted both by the driver and by the pump. Openings covered by removable corrosion-resistant screens shall be provided for access to any seals, packing, tension device, or line-shaft couplings. 4.4.1.2 Discharge elbow. The discharge elbow may be located on the discharge head assembly (usual for above-grade discharge) or on the pump column (usual for below-grade discharge). If located on a cast discharge head, it shall be an integral part of the discharge head casting. Fabricated elbows 12 in. (305 mm) and larger shall be of the segmented design, using a minimum of three sections. The discharge end of the elbow shall be flanged or plain end. Plain ends shall have a minimum of three thrust lugs equally placed and of sufficient height to allow installation of a sleeve coupling in accordance with AWWA M11. Note that thrust rods, which are not included in this standard, should be designed to limit axial deflection to 0.005 in. (0.13 mm) when subject to the maximum pressure that occurs in the pipe adjacent to the thrust rods at any time during operation. 4.4.1.3 Sole plate. An opening in the plate shall allow removal of components below the sole plate. 4.4.1.4 Tension nut. For pumps with an enclosed line shaft, a tubing tension nut shall be installed in the head to allow tension to be placed on the shaft enclosing tube. Provision shall be made for sealing off the thread at the tension nut. 4.4.1.5 Line-shaft lubrication system. 4.4.1.5.1 Enclosed line-shaft pumps shall be provided with a manually operated sight-feed drip lubricator and an oil reservoir. Food-grade oil approved by the FDA shall be used. Pressurized lubrication systems using food-grade oil, water, or grease may be used instead of drip lubricators. 4.4.1.5.2 Open line-shaft pumps shall have fittings to allow prelubricating water to impinge on the line shaft. 4.4.2 Column assembly.

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20

AWWA E103-07

4.4.2.1 Column pipe. Except for the top and bottom column sections on water-lubricated open line-shaft pumps, column pipe shall be furnished in interchangeable sections having a maximum length of 10 ft (3 m). Column pipe over 12 in. (300 mm) in diameter shall be flanged. The length of the top and bottom connections on open line shaft water-lubricated pumps shall not exceed 10 ft (3 m). 4.4.2.1.1 On enclosed line-shaft columns, the ends of each section of the pipe may be faced parallel and machined with threads to permit ends to butt, or they may be fixed with ASME B1.20.1 standard tapered pipe threads. 4.4.2.1.2 On open line-shaft columns, the ends of each section of column pipe shall be faced parallel, and the threads machined or flanged so that the ends will butt against the bearing retainer shoulder to ensure proper alignment and to secure the bearing retainers when assembled. 4.4.2.2 Line shaft. Line shafts shall not be less than 1 in. (25.4 mm) in diameter. Line shaft may be threaded up to 2 ⁄ in. (75 mm) diameter. The thread will be designed to tighten during normal pump operation. Larger than 2 ⁄ in. (75 mm) diameter will be keyed construction. The line shaft shall have a surface finish at bearing locations not to exceed 40 Ra per ANSI B46.1. The shaft shall be furnished in interchangeable sections having a length not to exceed 20 ft (6 m) for an enclosed line shaft and 10 ft (3 m) for an open line shaft. They shall be straightened to within 0.005 in. (0.13 mm) total indicator reading per 10-ft (3-m) section. The butting faces shall be machined with center relief and square to the axis of the shaft. The maximum permissible error in the axial alignment of the thread axis with the axis of the shaft shall be 0.002 in. per 6 in. (0.05 mm per 150 mm). The minimum size of the shaft shall be determined by the following formula for steady loads of diffuser-type pumps with the shaft in tension because of hydraulic thrust plus suspended weight:

or

2

2

2 P E2 S = ; 2F2 E + ; 321,000 rD rD 3

or P=

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; FD E + ; 396,000P E 8 2rn

2 nD 3 S 2 - ; 2F2 E 321,000 rD

(Eq 9)

(Eq 10)

(Eq 11)

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D 3 = 16 rS

Where: D = shaft diameter at the root of the threads or the minimum diameter of any undercut (in.) S = combined shear stress (psi) F = total axial load acting on the shaft, including hydraulic thrust plus the weight of the shaft and all rotating parts supported by it (lb) P = power transmitted by the shaft (hp) n = rotational speed of the shaft (rpm) Note: in. × 25.4 = mm; lb × 0.454 = kg; psi × 6.895 = kPa; hp × 0.746 = kW; rpm × 0.0167 = rps. The maximum combined shear stress S shall not exceed 30 percent of the elastic limit in tension, or be more than 18 percent of the ultimate tensile strength of the material used. 4.4.2.3 Shaft couplings. The maximum combined shear stress, determined by the following formula, shall not exceed 20 percent of the elastic limit in tension, nor be more than 12 percent of the ultimate tensile strength of the coupling material used. S= =

62F @

n ^ D 2 - d 2h

2

G +>

^321,000P h H n ^ D 3 - d 3h

2

(Eq 12)

Where: S = combined shear stress (psi) F = total axial load acting on the shaft, including hydraulic thrust plus the weight of the shaft and all rotating parts supported by it (lb) D = outside diameter of the coupling (in.) d = inside diameter of the coupling at the root of the threads (in.) P = power transmitted by the shaft (hp) n = rotational speed of the shaft (rpm) Note: in. × 25.4 = mm; lb × 0.454 = kg; psi × 6.895 = kPa; hp × 0.746 = kW; rpm × 0.0167 = rps. 4.4.2.4 Line-shaft bearings. 4.4.2.4.1 For enclosed line shafts, the shaft bearings, which are also integral enclosing tube couplings, shall be spaced not more than 5 ft (1.5 m) apart. The

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 21

22

AWWA E103-07

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maximum angle error of the thread axis to the bore axis shall be within 0.001 in. per in. (0.001 mm per mm) of thread length. The concentricity of the bore to the threads shall be within 0.005 in. (0.13 mm) total indicator reading. The bearings must contain one or more lubricant grooves, or a separate bypass hole that will readily allow the lubricant to flow through and lubricate the bearings below. 4.4.2.4.2 For open line shafts, the shaft bearings shall be designed to be lubricated by the liquid pumped. They shall be mounted in bearing retainers that shall be held in position in the column couplings by means of the butted ends of the column pipes. The bearings shall be spaced at intervals of not more than 10 ft (3 m). The shaft shall be provided with a noncorroding wearing surface at the location of each guide bearing. Shafts passing through stuffing boxes shall be stainless steel or fitted with a stainless steel sleeve. 4.4.2.5 Shaft-enclosing tube. The shaft-enclosing tube shall be made of Schedule 80 steel pipe in interchangeable sections not more than 10 ft (3 m) in length. The ends of the enclosing tube shall be square with the axis and shall butt to ensure accurate alignment. The maximum angle error of the thread axis relative to the bore axis shall be 0.001 in. per in. (0.001 mm per mm) of thread length. The enclosing tube shall be supported in the column pipe by stabilizers. 4.4.3 Bowl assembly. 4.4.3.1 General. 4.4.3.1.1 Major components shall be designed with shoulders and rabbeted fits to ensure accurate alignment during repeated disassembly and reassembly. Mating faces of bowls, bells, and cases shall be fully machined to allow the parallelism of the assembled joint to be gauged. 4.4.3.1.2 Bowl, discharge case, and suction case/bell shall be constructed as one-piece castings, or fabricated from carbon steel plate. 4.4.3.1.3 Similar bowls and the discharge case shall be designed for the maximum discharge pressure of the bowl assembly. 4.4.3.1.4 Adequate clearance shall be provided at bolt locations to permit the use of socket or box wrenches. 4.4.3.2 Suction bells and suction cases. 4.4.3.2.1 Suction cases shall be used when suction pipes are required for submergence in well applications. Suction bells are preferred for open-pit applications. 4.4.3.2.2 Suction case connections shall be threaded or flanged to accommodate the connections on the bowl and suction pipe. The suction case

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 23

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inlet connection shall be a nominal pipe size, which is larger in diameter than the impeller eye diameter. 4.4.3.2.3 Suction cases and bells shall have a grease-packed CA bearing with a grease fitting and be protected from sand intrusion. Alternative designs (i.e., water-lubricated rubber bearings) may be used if stated in the purchase documents. 4.4.3.2.4 Suction strainer. Strainers may be cone-type or basket-type and shall have a net inlet area equal to at least three times the impeller inlet area. The maximum opening shall not be more than 75 percent of the maximum opening of the water passage through the bowl or impeller. 4.4.3.3 Intermediate bowls. 4.4.3.3.1 Bowl connections shall be threaded or flanged for bowl sizes 8 in. (200 mm) and smaller. Bowl connections shall be flanged for sizes greater than 8 in. (200 mm). 4.4.3.4 Discharge cases. 4.4.3.4.1 Discharge cases for enclosed line-shaft construction shall have two bearings with bypass ports between them. 4.4.3.4.2 Discharge case connections shall be threaded and/or flanged design to accommodate the connections on the bowl and column pipe. 4.4.3.5 Impellers. 4.4.3.5.1 Impellers shall meet the requirements stated in Sec. 4.2.1.8. 4.4.3.5.2 Impellers shall be enclosed or semi-open configuration. 4.4.3.5.3 Impellers shall be attached to the shaft with either impeller lock collets or keys and thrust-ring retainers. Keys and thrust-ring retainers shall be used exclusively for shaft diameters 2.50 in. (64 mm) and larger. 4.4.3.5.4 Minimum diametrical running clearances of radial wear surfaces shall be 1.5 times the clearance of the bowl bearings employed, 0.002 times the diameter of the wear surface, or 0.010 in. (0.25 mm), whichever is greater. With the agreement of the purchaser, replaceable wear rings of special gall-resistant materials may be employed that would permit reduced running clearances. For materials with high galling tendencies, such as 300 series stainless steels, 0.005 in. shall be added to the above minimum clearances. 4.4.3.6 Pump shafts. The shaft shall have a surface finish not to exceed 40 Ra per ASME B46.1. The straightness of the shaft shall be 0.0005 in. (0.012 mm) per foot of length or better. Bowl shaft stress calculations and limitations shall be in accordance with the line-shaft requirements of this standard.

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24 AWWA E103-07

4.4.3.7 Bowl bearings. Bowl bearings shall be cylindrical sleeve type and shall be force-fitted to their larger components (bowls) with ASME B4.1, Class FN1 interference or greater. One bearing shall be located in each bowl and in the suction bell or suction case so that impellers, including the first-stage impellers, are between bearings. The discharge cases may have one or two bearings.

Coatings 4.5.1 Extent. Ferrous surfaces (except stainless steel) shall receive a factory-applied coating. Other surfaces shall not be coated. 4.5.2 Materials. 4.5.2.1 Bearing housings. Internal surfaces of oil lubricated bearing housings shall be coated with an oil-soluble rust preventive. 4.5.2.2 Machined surfaces. Machined surfaces shall be coated with an NSF/ANSI 61-certified rust preventive. 4.5.2.3 Surfaces not in contact with water. Surfaces not in contact with the water shall be primed with one coat of paint. 4.5.2.4 Surfaces in contact with water. Interior surfaces of pump casings shall be coated with materials meeting the requirements of ANSI/AWWA C550. Interior surfaces of vertical pump discharge heads and interior and exterior surfaces of columns shall be coated with materials meeting the requirements of ANSI/ AWWA C550 or ANSI/AWWA C210. Products shall be formulated from materials certified as suitable for contact with drinking water by an accredited certification organization in accordance with NSF/ANSI 61 on the date of the purchase order. 4.5.3 Surface preparation surfaces. Surfaces to be coated shall be cleaned prior to coating. The cleaning and surface preparation shall meet or exceed the coating manufacturer requirements for the selected coating. As a minimum, the following surface cleaning shall be done: 4.5.3.1 Exterior surfaces. Exterior surfaces not in contact with the water surfaces shall be cleaned to meet the requirements of SSPC-SP2. 4.5.3.2 Other surfaces. Other surfaces shall be cleaned to meet the requirements of SSPC-SP6. 4.5.4 Application. 4.5.4.1 Application of coatings. The application method and conditions for coatings (i.e., surface temperature, humidity restrictions, mixing instructions, pot life, wet and dry film thickness, etc.) shall meet the coating manufacturer’s requirements for the coating being applied. 4.5.4.2 Noncoated surfaces. Surfaces not to be coated or cleaned shall be

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Sec. 4.5

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 25

protected from contamination and damage. Metalwork shall not be welded after coating unless the coating can be inspected and repaired. 4.5.4.3 Coatings shall be applied after hydrostatic testing for leakage, and at such time that subsequent welding and assembly procedures will not damage the coating.

SECTION 5: Sec. 5.1

VERIFICATION

Factory Tests 5.1.1 General. Pumps shall receive a hydrostatic test in accordance with the applicable ANSI/HI Standard. 5.1.2 Horizontal pumps. The assembled pump shall be tested in accordance with the requirements of ANSI/HI 1.6. 5.1.3 Vertical pumps. The bowl assembly and discharge head shall be tested in accordance with the requirements of ANSI/HI 2.6.

Submittals 5.2.1 General. Following are minimum submittal requirements required for each pump prior to delivery. 5.2.2 Anticipated performance data. For horizontal pumps, performance shall be measured from the suction to the discharge. For vertical pumps, performance shall be measured from the inlet to the outlet of the bowl assembly. Data shall include 1. Operating speed. 2. Head versus capacity curve from shutoff to runout. 3. NPSHR curve for the operating range. 4. BHP requirements from shutoff to runout. 5. Specific speed. 6. Suction specific speed. 7. Efficiency from shutoff to runout. 5.2.3 Mechanical. 1. Maximum allowable casing discharge pressure. 2. Maximum allowable casing suction pressure (for horizontal pumps only). 3. Weight of the pump or bowl assembly.

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Sec. 5.2

26 AWWA E103-07

SECTION 6: MARKING, PREPARATION FOR SHIPMENT, AND AFFIDAVIT Sec. 6.1

Marking 6.1.1 Pump nameplate. A corrosion-resistant nameplate containing the following information shall be permanently affi xed to the pump: 1. Manufacturer’s name. 2. Year of manufacture. 3. Identifying serial number. 4. Model. 5. Design flow. 6. Design head. 7. Rotational speed. 8. Maximum casing or bowl assembly allowable pressure.

Sec. 6.2

Preparation for Shipment The manufacturer shall carefully prepare the pump for shipment to minimize the likelihood of damage during shipment. Cavities shall be drained of water. Equipment shall be properly supported and securely attached to skids. Openings shall be covered in a manner to protect both the opening and interior.

Sec. 6.3

Affidavit of Compliance

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When requested, the manufacturer shall provide an affidavit that materials and work provided conform to the applicable requirements of this standard and the purchaser, and that required tests have been performed and test requirements have been met.

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Appendix A Pump Cross-Sections This appendix is for information only and is not a part of ANSI/AWWA E103.

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This appendix is not part of this standard, but is presented to help the user identify specific part numbers of several types of pumps. Item numbers shown on the drawings that follow correspond to the numbers of the components or parts described in Tables 1–3 of this standard. The drawings contained in this appendix have been provided courtesy of the Hydraulic Institute, 9 Sylvan Way, Parsippany, NJ 07054-3802, www.pumps.org, and are contained in the following standards: Fig. A.1, A.2, A.3, and A.4 are contained in American National Standard for Centrifugal Pumps for Nomenclature and Definitions, ANSI/HI 1.1–1.2-2000. Fig. A.5 is contained in American National Standard for Vertical Pumps for Nomenclature and Definitions, ANSI/HI 2.1–2.2-2000.

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28 AWWA E103-07

1

Casing

2

Impeller

6

Shaft, pump

11

Cover, seal chamber

14

Sleeve, shaft

16

Bearing, inboard

17

Gland

18

Bearing, outboard

33

Cap, bearing, outboard

40

Deflector

42

Coupling half, driver

44

Coupling half, pump

47

Seal, bearing cover, inboard

49

Seal, bearing cover, outboard

73

Gasket

81

Pedestal, driver

88

Spacer, coupling

89

Seal

99

Housing, bearing

Courtesy of Hydraulic Institute, www.Pumps.org, Parsippany, NJ 07054.

Figure A.1

Separately coupled, single-stage, inline, flexible coupling pump with overhung impeller

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 29

1

Casing

46

Key, coupling

2

Impeller

66

Nut, shaft adjusting

6

Shaft, pump

70

Coupling, shaft

7

Ring, casing

73

Gasket

8

Ring, impeller

81

Pedestal, driver

11

Cover, seal chamber

86

Ring, thrust, split

24

Nut, impeller

89

Seal

27

Ring, cover

117

32

Key, impeller

Bushing, pressure reducing

Courtesy of Hydraulic Institute, www.Pumps.org, Parsippany, NJ 07054.

Figure A.2

Separately coupled, single-stage, inline, rigid coupling pump with overhung impeller

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AWWA E103-07

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30

1

Casing

27

Ring, stuffing-box cover

2

Impeller

28

Gasket, impeller screw

6

Shaft, pump

29

Ring, lantern

9

Cover, suction

32

Key, impeller

13

Packing

35

Cover, bearing, inboard

14

Sleeve, shaft

37

Cover, bearing, outboard

16

Bearing, inboard

38

Gasket, shaft sleeve

17

Gland

40

Deflector

18

Bearing, outboard

47

Seal, bearing cover, inboard

19

Frame

49

Seal, bearing cover, outboard

22

Locknut, bearing

69

Lockwasher

24

Nut, impeller

73

Gasket

25

Ring, suction cover

78

Spacer, bearing

Courtesy of Hydraulic Institute, www.Pumps.org, Parsippany, NJ 07054.

Figure A.3

Separately coupled, single-stage, frame-mounted pump with overhung impeller

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 31

1A Casing, lower half

22

Locknut

1B

31

Housing, bearing inboard

2

Impeller

32

Key, impeller

6

Shaft

33

Housing, bearing outboard

7

Ring, casing

35

Cover, bearing inboard

8

Ring, impeller

37

Cover, bearing outboard

14

Sleeve, shaft

40

Deflector

16

Bearing, inboard

65

Seal, mechanical stationary element

18

Bearing, outboard

80

Seal, mechanical rotating element

20

Nut, shaft sleeve

123

Cover, bearing end

Courtesy of Hydraulic Institute, www.Pumps.org, Parsippany, NJ 07054.

Figure A.4

Separately coupled, single-stage, axial (horizontal) split-case pump with impeller between bearings

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Casing, upper half

32 AWWA E103-07

2 Impeller 6 Shaft, pump 8 Ring, impeller 10 Shaft, head 12 Shaft, line 13 Packing 17 Gland 29 Ring, lantern 39 Bushing, bearing 40 Deflector 55 Bell, suction 63 Bushing, stuffing-box 64 Collar, protecting 66 Nut, shaft-adjusting 70 Coupling, shaft 77 Lubricator 79 Bracket, lubricator 83 Stuffing-box 84 Collet, impeller lock 85 Tube, shaft-enclosing 101 Pipe, column 103 Bearing, lineshaft, enclosing 183 Nut, tubing 185 Plate, tension, tube 187 Head, surface discharge 189 Flange, top column 191 Coupling, column pipe 193 Retainer, bearing, open line shaft 197 Case, discharge 199 Bowl, intermediate

Semi-open impeller open lineshaft hollow shaft driver

203 Case, suction 209 Strainer (optional) Enclosed impeller enclosed lineshaft hollow shaft driver

211 Pipe, suction

Courtesy of Hydraulic Institute, www.Pumps.org, Parsippany, NJ 07054.

Figure A.5

Deep-well pumps

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Appendix B Field Testing of Pumps This appendix is for information only and is not a part of ANSI/AWWA E103.

PURPOSE OF FIELD TESTS

A field test gives an indication of the performance of a pump when it is operating under actual field conditions. Such a test indicates the operation of the pump assembly, the vibration and noise levels, and the operation of the driver and control equipment. Additionally, on vertical turbine pumps, the test indicates the friction loss in the column pipe and discharge elbow, the bearing losses in the line-shaft assembly, the well or system characteristics, and the air content or sand content of the water. Although these items are important, they are normally judged on a qualitative basis, as compared to what is considered to be good engineering practice, unless specific requirements are provided by the purchaser. The purpose of this appendix is to establish a guide for the quantitative evaluation of the hydraulic performance of the complete pumping unit as installed in the field. Field tests are sometimes used as acceptance tests. When this is done, the accuracy of the test obtainable under field conditions with the specific test equipment employed should be taken into account. Data to help determine the best possible accuracy obtainable with various instruments are included in this standard. Under most conditions, it is recommended that acceptance of the pump should be based on tests made in a laboratory, where accurate instruments used under controlled conditions permit precise measurements. It is also recommended that field tests be used as an overall indication of pump performance, and as a guide to show when the pump or well requires service. Field performance tests (in addition to the factory test) are usually run to ensure that the pump is properly installed and that there are not unanticipated field conditions that impede performance. If there are discrepancies between factory performance and field performance, they need to be understood, evaluated, and if necessary dealt with. Possible explanations may include 1. Incorrect rotation of pump. 2. Incorrect impellers or bowl assemblies may have been shipped. 3. Improper installation: There may be leaks in the column joints

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SECTION B.1:

34 AWWA E103-07

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(vertical pumps) or blockage of internal components. 4. Motor full load rpm may be lower than anticipated because of bearing binding or electrical problems. 5. Submerged or surface vortices may be forming in the sump. 6. Field equipment, including level and pressure gauges and flow meters, may be faulty, improperly calibrated, or improperly located. 7. The factory test report may be incorrect. 8. Air may be present in the water or be introduced through suction piping, packing, or seals. 9. The piping arrangement may produce a prerotation or nonuniform velocity at the inlet (suction) to the pump. 10. Setting of semi-open impellers on vertical line-shaft pumps may be incorrect. 11. The NPSH margin, equal to NPSHA minus NPSHR, is 5 ft or less, causing cavitation. 12. Ensure balanced voltage is supplied to the motor and within 5 percent of rated motor nameplate voltage if efficiency and load discrepancies are observed. It is desirable to field test new or reconditioned pumps to provide a comparison for future tests. Thus, pump wear and changing operating conditions may be indicated. Periodic tests should be made using the same procedure and an accurate record kept to give a complete and comparable history, and as a guide to determine if an internal inspection or repair is required.

SECTION B.2:

ACCURACY OF FIELD TESTING

The accuracy with which a field test can be made depends on the instruments used in the test, the proper installation of the instruments, and the skill of the test personnel. If accurate field tests are required, it is necessary to design the complete pump installation with this in mind and to provide for the use of the most accurate calibrated instruments. It should be recognized that environmental conditions in a well or the design of a sump can significantly affect field performance and also affect the results of field tests. Table B.1 gives an indication of the best possible accuracy that can be expected for the various instruments that may be used for a field test. The values

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 35

given assume that each instrument is properly installed, is the correct size for the values to be measured, and is used by experienced engineers. A method of estimating the probable combined accuracy that will be obtained with the instruments selected is illustrated in the following examples: Table B.1. Limits of accuracy of pump test measuring devices in field use

Capacity

Head

Power Input

Measuring Device Venturi meter Nozzle Pitot tube Orifice Disc Piston Volume or weight tank Propeller meter Magnetic meter

Calibrated Limit of Accuracy (percent) ± 0.75 ± 1.00 ± 1.50 ± 1.25 ± 2.00 ± 0.25 ± 1.00 ± 4.00 ± 1.00

Electric sounding line Air line Liquid manometer (3- to 5-in. deflections) Liquid manometer (over 5-in. deflections) Bourdon gauge, 5-in. minimum dial ¼ to ½ full scale ⅝ to ¾ full scale Over ¾ scale

± 0.25 ± 0.50 ± 0.75 ± 0.50 ± 1.00 ± 0.75 ± 0.50

Watt-hour meter and stopwatch Portable recording watt meter Test type precision watt meter ¼ to ½ full scale ⅝ to ¾ full scale Over ¾ scale Clamp-on ammeter

± 0.75 ± 0.50 ± 0.25 ± 4.00

Speed

Revolution counter and stopwatch Hand-held tachometer Stroboscope Automatic counter and stopwatch

± 1.25 ± 1.25 ± 1.50 ± 0.50

Voltage

Test meter ¼ to ½ full scale ⅝ to ¾ full scale Over ¾ scale Rectifier voltmeter

± 1.00 ± 0.75 ± 0.50 ± 5.00

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± 1.50 ± 1.50

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Test Variable

36

AWWA E103-07

Example 1 Vertical turbine pump Pump conditions: head, 500 ft (152 m); setting, 450 ft (137 m). Instrumentation is shown in the following chart. First, the head accuracy is weighted. Weighted accuracy of the electric sounding line is ⁴⁵⁰⁄₅₀₀ × 0.25 = 0.225 percent; weighted accuracy of the bourdon gauge is ⁵⁰⁄₅₀₀ × 0.50 = 0.050 percent; and the sum, or weighted-average head accuracy, is 0.275 percent. The combined accuracy of the efficiency (Ac) is the square root of the quantity of the square of the weighted-average head accuracy, plus the square of the venturi-meter accuracy, plus the square of the watt-meter accuracy. Pump speed and voltage are not necessary in determining efficiency, so the values for the tachometer and the voltage meter are not included under the radical. Line Number (Field test report form)* 3 7 14 19 22 16

Instrument Electronic sounding line Bourdon gauge, 5-in. (130-mm) dial, ¾ scale Venturi meter Watt meter, over ¾ scale Hand-held tachometer Voltage meter, over ¾ full scale

Accuracy† percent ± 0.25 ± 0.75 ± 0.75 ± 0.25 ± 1.25 ± 0.50

Ac = 0.275 2 + 0.75 2 + 0.25 2 0.700 = = ± 0.84 percent

(Eq B.1)

Example 2 Vertical turbine pump Pump conditions: head, 500 ft (152 m); setting, 450 ft (137 m). Instrumentation is shown in the chart below. Line Number (Field test report form)* 3 7 14 19 22 16

Instrument Air line Bourdon gauge, 5-in. (130-mm) dial, ½ scale Pitot tube Watt-hour meter and stopwatch Stroboscope Rectifier voltmeter

Accuracy† percent ± 0.50 ± 1.00 ± 1.50 ± 1.50 ± 1.50 ± 5.00

*From Figure B.6. †From Table B.1.

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*From Figure B.6. †From Table B.1.

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 37

The head accuracy is weighted in the same way as in Example 1. Air line: 450 ft (137 m) 0.5 percent 0.45 percent # = 500 ft (152 m)

(Eq B.2)

Bourdon gauge: (Eq B.3)

50 ft (15 m) # 1.0 percent = 0.10 percent 500 ft (152 m)

Weighted-average head accuracy: 0.45 + 0.10 = 0.55 percent The combined accuracy of the efficiency (Ac) is the square root of the quantity of the square of the weighted-average head accuracy, plus the square of the pitot-tube accuracy, plus the square of the watt-hour meter accuracy. Ac = 0.55 2 + 1.5 2 + 1.5 2 = 4.8 = ± 2.19 percent

(Eq B.4)

Example 3 Vertical turbine pump Pump conditions: head 500 ft (152 m); setting, 20 ft (6 m). Instrumentation is shown in the chart below. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

Line Number (Field test report form)* 3 7 14 19 22 15

Instrument Air line Bourdon gauge, 5-in. (130-mm) dial, full scale Venturi meter Watt meter over ¾ scale Automatic counter and stopwatch Voltage test meter, full scale

Accuracy† percent ± 0.50 ± 0.75 ± 0.75 ± 0.25 ± 0.50 ± 0.50

*From Figure B.6. †From Table B.1.

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38

AWWA E103-07

Weighted head accuracy is Air line:

(Eq B.5) 20 ft (6 m) # 0.50 percent = 0.02 percent 500 ft (152 m)

Bourdon gauge:

(Eq B.6)

480 ft (146 m) 0.50 percent 0.42 percent # = 500 ft (152 m)

Weighted-average head accuracy:

0.02 + 0.48 = 0.50 percent

The combined accuracy of the efficiency is Ac = 0.5 2 + .75 2 + 0.25 2 = 1.06 = ± 1.03 percent

(Eq B.7)

(Eq B.8)

The recommended procedure for conducting pump acceptance tests is outlined in Sec. B.5 of this standard. It will be apparent that if the accuracy of all instrumentation is not taken into account, the final result will appear more accurate than it actually is. Individual errors in reading the instruments are not accounted for, so the final combined accuracy may be considered an optimistic figure at best. Example 4 Horizontal pump Pump conditions: total head, 500 ft (152 m), suction head, 20 ft (6 m), discharge head, 520 ft (158 m). Instrumentation is shown in the chart below: Line Number (Field test report form)* 6 7 14 19 22 16

Instrument Bourdon gauge, 5-in. (130-mm) dial, ½ scale Bourdon gauge, 5-in. (130-mm) dial, ¾ scale Venturi meter Watt meter over ¾ scale Hand-held tachometer Voltage meter, ¾ full scale

Accuracy† percent ± 1.00 ± 0.75 ± 0.75 ± 0.25 ± 1.25 ± 0.50

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--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

*From Figure B.6. †From Table B.1.

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 39

First, the head accuracy needs to be weighted between both the suction gauge and discharge gauge. Suction bourdon gauge: (Eq B.9) 20 ft (6 m) # 1 percent = 0.04 percent 520 ft (158 m)

Discharge bourdon gauge:

(Eq B.10)

500 ft (152 m) 0.75 percent 0.72 percent # = 520 ft (158 m)

Weighted-average head accuracy:

0.04 + 0.72 = 0.76 percent

The combined accuracy of the efficiency is Ac = (0.76) 2 + (0.75) 2 + (0.25) 2 = ± 1.10 percent

(Eq B.12)

DEFINITIONS AND SYMBOLS

1. Datum: The elevation of the surface from which the weight of the pump is supported. This is normally the elevation of the underside of the discharge head or head base plate. 2. Driver efficiency (Ed ): The ratio of the driver output to the driver input, expressed in percent. 3. Driver power input: The power input to the driver, expressed in horsepower. In a line-shaft vertical turbine pump powered by an electric motor, driver power input is equivalent to kilowatt input measured at the motor conduit box divided by 0.746. In a submersible vertical turbine pump, it is equivalent to kilowatt input measured at the conduit box on the discharge head divided by 0.746. No satisfactory evaluation of this term for engine-driven pumps is available. 4. Head above datum (ha ): The head measured above the datum, expressed in feet (meters) of liquid, plus the velocity head at the point of pressure measurement. 5. Head below datum (hb ): The vertical distance, in feet (meters), from the datum to the pumping level. 6. Overall efficiency (E): The ratio of pump output, in horsepower, to motor power input. 7. Pump output, in horsepower (hp ) [water hb (WHP)]: Calculated from

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--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

SECTION B.3:

(Eq B.11)

40

AWWA E103-07

the following expression: hp =

QH # specific gravity of liquid pumped 3,960

(Eq. B.13)

Where: Q = rate of flow, in gallons per minute H = pump total head, in feet 8. Pump speed of rotation (n): This is expressed in revolutions per minute (rpm) or revolutions per second (rps). The speed of submersible motors cannot be measured conveniently in field testing. 9. Pump total head (H): The sum of the heads above and below datum (ha + hb ). 10. Rate of flow (Q ): Flow expressed in gallons per minute (cubic meters per hour). 11. Velocity head (hvs or hvd ): The kinetic energy per unit weight of the liquid at the point of measurement, expressed in feet (meters) of liquid. Using the average velocity in feet per second (meters per second) at the point of measurement, it is calculated from the following expression: hv = v 2/ 2g

(Eq. B.14)

Where: v = g =

SECTION B.4: --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

Sec. B.4.1

velocity, in ft/sec (m/sec) 32.2 ft/sec2 (9.81 m/sec2)

INSTRUMENTATION

General 1. Measuring instrument placement. Figures B.1, B.2, B.3, and B.4 show the placement of instruments and the dimensions for four types of pump installation. Figure B.5 shows piping requirements for orifices, flow nozzles, and venturi tubes. 2. Clamp-on electrical measuring devices. Except for rough checks on motor loading, these devices are deemed not acceptable for pump field tests.

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 41

Note: Numbers in parentheses refer to item numbers in report form (Figure B.6). Minimum dimensions are the lengths of straight pipe required in Figure B.5 for the particular type of capacity-measuring device used.

Figure B.1 Field-test diagram for line-shaft vertical turbine well pumps

Note: Numbers in parentheses refer to item numbers in report form (Figure B.6). Minimum dimensions are the lengths of straight pipe required in Figure B.5 for the particular type of capacity-measuring device used.

Figure B.2 Field-test diagram for vertical turbine pumps for booster service

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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AWWA E103-07

Note: Numbers in parentheses refer to item numbers in report form (Figure B.6). Minimum dimensions are the lengths of straight pipe required in Figure B.5 for the particular type of capacity-measuring device used.

Figure B.3 Field-test diagram for horizontal split-case pump

Note: Numbers in parentheses refer to item numbers in report form (Figure B.6). Minimum dimensions are the lengths of straight pipe required in Figure B.5 for the particular type of capacity-measuring device used.

Figure B.4 Field-test diagram for end-suction pumps

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42

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

43

Figure B.5 Pipe requirements for orifice, flow nozzles, and venturi tubes Figure continued next page. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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44 AWWA E103-07

Figure B.5

Pipe requirements for orifice, flow nozzle, and venturi tubes (continued)

Reprinted from ASME PTC 19.5;4-1959, by permission of The American Society of Mechanical Engineers. All rights reserved.

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

Sec. B.4.2

45

Evaluation of various methods of flow measurement

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

1. General evaluation. It is impossible to extend flow measurement beyond that corresponding to the system head, which equals the pump total head, unless the head above datum can be lowered for the test. More often than not, this is not feasible, so the only portion of the pump characteristic that can be measured in a field test is the region of rates of flow lower than the design rate. It is also possible that the design rate cannot be reached if the method of flow measurement introduces friction head loss, thereby raising the system head. Substantial head losses are, indeed, incurred by introducing orifice plates and flow nozzles into the system. In some cases this may reduce their usefulness. The friction head loss introduced by insertion of a pitot-static tube, on the other hand, can generally be neglected. Venturis also introduce very low losses, but because of their weight and length they are somewhat more expensive to employ in field tests (unless they are a permanent part of the installation). 2. Flow measurement by volume or weight. The accuracy of volumetric measurement depends on the accuracy of tank dimensional measurements and differences in liquid level. The derivation of rate of flow depends on the accuracy of time measurement of the period of flow. It is recommended that the minimum change in liquid level during any test run not be less than 2 ft (0.6 m). The duration of any test run shall not be less than one min when the tank is filled from an open discharge pipe. A submerged entrance into the tank will cause an increase in the system head as the tank fills and will result in a nonlinear change in rate of flow. Correlation of rate of flow with weight is seldom feasible, except for extremely small flow. 3. Head above datum (ha ). This quantity can be measured by means of a calibrated bourdon-tube gauge (reading converted to feet of liquid), plus the distance from the datum to the centerline of the gauge plus velocity head. When the head above datum is quite low, it may be measured with manometers, using mercury or the liquid being pumped as a manometer fluid. The choice of manometer fluid should produce manometer deflections of at least 6 in. (150 mm). 4. Head below datum (hb ). This distance can be measured by steel tape, electric sounder, or the air-line gauge method. The elevation of the pumping water level is determined electrically by measuring the length below datum of waterproof insulated wire terminating in a shielded electrode that completes the circuit through a magneto or dry cell to an indicating lamp, bell, or meter on touching the water surface. The elevation of the pumping water level can be

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46

AWWA E103-07

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

determined by the air-line gauge method, by subtracting the calibrated bourdontube gauge reading (converted to feet of liquid) from the known length of airtight tubing (open at the bottom) that has been pumped full of air to the maximum gauge reading that can be attained. The air-line gauge length must exceed the head below datum. In the airline gauge method, the gauge accuracy tolerance must be included (dependent on gauge quality and the portion of the gauge range in use), unless the gauge is calibrated before and after the test. 5. Pitot-static tube. These instruments, available in several forms, correlate velocity head with rate of flow. Velocity head distribution in pipe flow is nonuniform, and for acceptable accuracy, a multiple-point traverse of the pipe cross-section is mandatory. Pitot-static tube designs using a series of impact holes, each transmitting different velocity pressures to a common cavity within the tube, produce internal circulation. Pitot-static tubes cannot be presumed to measure average velocity head, unless the velocity profile in the pipe flow under test agrees exactly with that prevailing in the pipe in which the instrument was calibrated. Consequently, these devices are not deemed acceptable. Complete details on construction, formulas, and use of acceptable types have been published. 6. Thin-plate square-edged orifice. The orifice plate correlates static head difference, measured upstream and downstream, with rate of flow. Data on dimensions, limitations, installation effects, and formulas have been published (Fluid Meters—Their Theory and Application. Report ASME Res. Comm. on Fluid Meters, American Society of Mechanical Engineers, New York). 7. Venturis and flow nozzles. These devices are based on the same principle as the orifice plate, but introduce somewhat less head loss in a flow system.

Sec. B.4.3

Other Considerations 1. Power measurement. Although not impossible, it is generally considered impractical to attempt to measure pump power input by means of a transmission dynamometer in field tests. The most frequently encountered alternative is that of measuring driver power input, which is then multiplied by the driver efficiency. The derived pump power input obtained by this method is subject to the accuracy tolerance on the driver efficiency. Since the only pump driver on which power input measurements of the requisite degree of accuracy can be made is the direct-drive electric motor, this standard deals with the measurement of electric power only. 2. Portable watt meters. Used with or without portable current and

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 47

potential transformer(s), portable watt meters are available in varying degrees of precision. They may be used with the manufacturer’s statement of accuracy tolerance if they are in good condition. 3. Pump-speed measurement. Hand-held tachometers are the preferred method of obtaining speed, which is read directly at revolutions per minute or revolutions per second. 4. Watt-hour meters. These devices measure total energy, but may be used for measuring power by introducing the time factor in the following formula: driver power input = 4.826 KMR t

(Eq B.15)

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

Where: K = M = R = t =

disc constant, representing watt-hours per revolution. product of current and potential transformer ratios (if not used, omit from formula). total revolutions of watt-hour meter disc. time for total revolutions of disc, in sec.

The duration of this measurement shall not be less than one min. Commercial watt-hour meter power measurements are expected to be within 0.5 percent, unless specifically calibrated and used with a calibration chart. In this case, the stated accuracy of the calibration shall prevail.

SECTION B.5: Sec. B.5.1

TEST PROCEDURE

Preliminary agreement The contractual obligations of the several parties involved should be clarified to the point of mutual agreement before the start of testing. The following points for hydraulic performance are among those that may be considered desirable: 1. Rate of flow with specified tolerance. 2. Pump total head with specified tolerance. 3. Driver power input with specified tolerance. 4. Pump speed with specified tolerance. 5. Overall efficiency with specified tolerance. 6. Stipulation of hydraulic performance tolerance on field tests must take strict account of the accuracy limitations inherent in field testing. Choice of

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48

AWWA E103-07

instrumentation and installation effects shall be considered to avoid an unrealistic tolerance requirement. The following points for mechanical performance are also desirable: 1. Acceptable vibration limits specifying point of measurement and maximum total indicator reading in mils (mm). 2. Noise-level limits above specified ambient noise level, also specifying location at which noise level is to be measured.

Sec. B.5.2

Instrumentation Choice, installation location, accuracy tolerances, and requirements for calibration curves shall be mutually agreed on.

Sec. B.5.3

Time limits The effect of wear caused by abrasive material in the liquid being pumped makes it mandatory that field tests, if conducted for the purpose of acceptance, be concluded as soon as possible after installation. Wear varies within wide limits, so as much preliminary information as is possible to obtain shall be made available to contracting parties, for the purpose of agreement on the time of test, or allowances that shall be made for undue wear before the test is run.

Inspection and preliminary operation Contracting parties shall make as complete an inspection as possible of the installation to determine compliance with installation requirements, and to correct connection of the instrumentation. On satisfactory completion of this requirement, the pump shall be started. The pump, as well as the instrumentation, should be checked immediately for any evidence of malfunction. An immediate check of pumping water level shall be made, followed periodically by additional checks until the level has stabilized to the satisfaction of the parties. Any evidence of cascading within the well or the presence of gas or abrasive material shall also be collected at this time. A preliminary check of the test values can then be made for stability of reading, and a final check can be made on any possible malfunction.

Sec. B.5.5

Recording The recording of test data may take any convenient form and shall include make, type, size, and serial number of pump and driver; date of test; duration of run; description of instrumentation used; instrument constants or multipliers; other basic physical constants or formulas used that are not specifically listed in this standard; liquid temperature at pump discharge and pump submergence; and the instrument readings. Additional data or remarks may also be included by mutual

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--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

Sec. B.5.4

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

49

agreement. Copies of test data and accompanying instrument calibration curves shall be made available to the contracting parties. If several test runs are made at different rates of flow, a performance curve can be drawn and shall become a part of the recorded data. An example of a satisfactory field test report form is shown in Figure B.6.

Sec. B.5.6

Test observations Since at least two persons will generally be present during a field acceptance test, the duties of making test observations may be distributed among those present. It may be preferable, if the instrument locations permit, to record each reading as a matter of mutual agreement. The practice of making simultaneous and instantaneous readings of all instruments must be avoided. For example, the transient response of a bourdon-tube gauge is much faster than that of a mercury manometer. The recommended procedure is to make a continuous observation of at least one min of the instrumentation showing rate (or instantaneous values). During the prescribed observation period (if possible), the totaling instruments are read against time to determine rate. With some experience, it is possible to observe rate (instantaneous reading) instruments, mentally rejecting random fluctuations, and selecting the value that represents that prevailing most of the time during the observation period. It should be mentioned that the use of linear scales for nonlinear values (inch scales on differential manometers recording velocity head pressure from a pitotstatic tube, for example) may cause error in the process of obtaining a time-weighted average, if the fluctuation is appreciable. Notwithstanding any skill that may be obtained with experience, it must be recognized that a considerable observational error can still exist. If possible, readings should be repeated and different observers should be employed to ensure complete agreement among the parties. It is difficult to evaluate the effect of fluctuating readings because of the highly variable damping that may be present with some types of instrumentation. It is not recommended that any devices be used to increase damping of instrument readings, as it is occasionally possible for some of these methods to superimpose a rectifying effect or asymmetrical response on the instrument reading when subjected to dynamic fluctuations. It is desirable that the contracting parties agree in advance of the test on minimum (or maximum) scale readings of instruments and on the magnitude of fluctuation that may be acceptable, although fluctuations in readings occasionally reflect system response and cannot be readily controlled.

--`,`,`,`,``,,,,,,,`,````,,``-`

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50

AWWA E103-07

Expected Accuracy of Field Test Measurement Instrument Accuracy Accuracy Squared Head above datum — Head below datum — Weighted-average head accuracy* Capacity Power Sum of accuracy squared Combined accuracy * Average is weighted according to the proportion of head above datum and head below datum to total head: <^Accuracy of hbh # c hb mF + <^Accuracy of hah # c ha mF = weighted average head accuracy H H

Test Readings and Calculations All readings except No. 1 are taken when pumping.

No. 1 2 3 4 5 6

Symbol

hb Zs Zd hgs

Head below datum when not pumping Drawdown Head below datum Datum to center line suction gauge Datum to center line discharge gauge Suction pressure head reading

7

hgd

Discharge pressure head reading

8 9 10 11 12 13 14 15 16

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

17 18 19 20 21 22 23 24 25 26

hvs hvd ha h Q

Units

Suction pressure head above datum =(4)+(6) Discharge pressure head above datum =(5)+(7) Velocity head in suction pipe* Velocity head in discharge pipe* Head above datum* = [(11)+(9)]–[(10)+(8)] Total head* = (3)+(12) Capacity Current Line A Current Line B Current Line C Voltage Phase AB Voltage Phase BC Voltage Phase AC Revolutions of watt-hour meter disc (constant) Time Watt meter reading Electrical input* from (17) and (18) or 19 Horsepower input* = (16)/0.746 Pump speed Pump output = (13) × (14) × sp gr/3,960 Pump efficiency* = (23)/(21) Motor efficiency* (source) Overall field efficiency* = (24) × (25)

1

2

ft (m) ft (m) ft (m) ft (m) ft (m) ft or psi (m or kg/cm2) ft or psi (m or kg/cm2) ft (m) ft (m) ft (m) ft (m) ft (m) ft (m) gpm (m3/h) amps amps amps V V V sec kW hp rpm hp† percent percent percent

* Calculated † Results will be in horsepower only if head measurements are in feet of liquid (hp × 0.746 = kW).

Figure B.6 Expected accuracy of field test

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3

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 51

Pump Field-Test Report Test No. _______________________________________ Date ____________________________ Owner: Name __________________________ Address _________________________ Pump: Location ________________ Type _____________Size ________Stages ________________ Make ___________________________ Serial No. ___________________________________ Motor: Make ___________________________ Serial No. ___________________________________ Rated hp: _________ rpm _________vss ___________ vhs ___________ subm ___________ Power Supply: Nominal Voltage __________________ Frequency ___________________________________ Suction Size: ___________________________________ Discharge Size _______________________________ Column: Pipe Size ________________________ Shaft Size ___________________________________ or Length _______________________ Test Conducted by: ______________________________ Witnessed by ________________________________ Pump Serial No _________________________________ Test Date ___________________________________ --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

Test Instruments Head Below Datum Measured With (if applicable) __________________________________________________ Length Air Line (if used)________________________________________________________ Suction Pressure: Make Gauge __________________ Size Face ______________Serial No. ________________ Gauge Calibration: Date_____________ by _________________Chart No. _____________ Manometer Fluid _________________ Specific Gravity ______________________________ Discharge Pressure: Make Gauge __________________ Size Face ______________Serial No. ________________ Gauge Calibration: Date_____________ by _________________Chart No. _____________ Manometer Fluid _________________ Specific Gravity ______________________________ Measured Pipe Inside Diameter at Pressure Tap: Suction___________________Discharge __________________ Type Capacity-Measuring Device Used ___________________________________________________________ Size ____________________________ Make ______________________________________ Serial No. ___________________________________________________________________ Calibration: Date _________________ by _________________Chart No. _____________ _________________ft Downstream From _______________ (Valve, Elbow, or Other Fixture) _________________ft Downstream From _______________ (Valve, Elbow, or Other Fixture) Measured Diameter of Pipe at Instrument __________________________________________ Condition of Pipe Upstream: Excellent __________Good ____________Poor ____________ Type and Make of Power-Measuring Device Used__________________________________________________ Watt-Hour Meter Disc Constant _____________________No._________________________ Watt Meter Multiplier______________________________No._________________________ Current Transformers Ratio _________________________No._________________________ Potential Transformers Ratio ________________________No._________________________ Calibration of Meter _______________________________Chart No. ___________________ Date _______________________________ by _____________________________________ Voltmeter: Type ________________________________Serial No. _______________________________ Ammeter: Type _______________________________ Serial No. _______________________________ Speed-Measuring Device ______________________________________________________________________________

Figure B.7 Pump field-test report

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52

AWWA E103-07

Sec. B.5.7

Adjustment of field-test results Occasionally the pump-driver speeds will deviate slightly from the nominal value on which the pump performance guarantee is based. In such cases, the application of the following hydraulic affinity relationships should be made to adjust the test values to the design operating speed: Q = Qt(n/nt )

(Eq B.16)

H = Ht(n/nt )2

(Eq B.17)

P = Pt(n/nt )3

(Eq B.18)

Where: Q = pump capacity, gpm (m3/hr) t n nt H P

Sec. B.5.8

= = = = =

indicated test values design operating speed, rpm test operating speed, rpm head, ft (m) power, hp (kW)

Evaluation of accuracy tolerances Observation errors do not necessarily follow the law of probability. If agreement on instrument readings cannot be reached before recording, the arithmetic average shall be used. Instrumentation accuracy tolerances for individual measurements are given in Table A.1. The value of the overall efficiency is calculated from the head, capacity, and driver power input measurements. It must be recognized that, in the extreme case, the accuracy tolerance on overall efficiency could be as large as the sum of the accuracy tolerances of these three measurements. It will be assumed that the most probable value of the overall efficiency accuracy tolerance is the square root of the sum of the squares of the individual tolerances. In the computation of test data, the final values obtained from head, capacity, driver power input, overall efficiency, and pump speed shall be shown with the appropriate tolerance following each value.

--`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`-

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Appendix C Suggested Data Form for the Purchase of Horizontal Pumps This appendix is for information only and is not a part of ANSI/AWWA E103. Horizontal Pump Data Sheet 1.

Purchaser ______________________________________________________________________________

2.

Address ________________________________________________________________________________

3.

Installation Site __________________________________________________________________________

4.

Job Reference Number _______________________Item No. _____________________________________

5.

No. Required ______________________________Date Required _________________________________

6.

Prime Mover: Electric motor _________________Engine _______________________________________

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Other________________________ 7.

Prime Mover Data: Motor:

Voltage _________Frequency _________Phase _________ rpm _________

Engine (type): Gas ____________ Gasoline __________ Diesel ________ Other ________ Maximum operating rpm _____________________________________________________ 8.

Driver:

Horizontal solid-shaft motor drive ______________________________________________ Horizontal hollow-shaft right-angle gear drive _____________________________________ Horizontal hollow-shaft belted drive _____________________________________________ Combination drive __________________________________________________________ Speed:

Variable__________________________ Constant __________________________

Other _____________________________________________________________________ 9.

Bearing lubrication required: Oil __________________________Other_____________________________

10. Discharge nozzle position: Suction nozzle position:

Horizontal ____________________Vertical ___________________________ Horizontal

Vertical ___________________________________________

If below base:

Distance from datum to centerline of Flange ________ ft (m)*

11. Type of Pump: Horizontal Split Case _____________________No. of Stages ________________________ Radial or Vertical Split Case ________________________________________________________________ End Suction ____________________________________________________________________________ 12. Type of Seal: Packing____________Single inside mechanical seal ______________ Other _____________ 13. Other requirements a. ANSI/NSF 61 Certification ( Y / N ) b. Certificate of Compliance ( Y / N )

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54

AWWA E103-07

Horizontal Pump Operating Conditions 14. Design rate of flow _____________________________________________________________gpm (m3/hr) 15. Datum elevation ___________________________________________________ ft (m) (Datum c/l of pump) 16. Pumping level below datum at design rate of flow __________________________________________ ft (m) 17. Total head above datum (static plus system friction) at design rate of flow ________________________ ft (m) 18. Total pump head at design rate of flow ___________________________________________________ ft (m) 19. Suction Pressure:

Minimum ________________________________________________________ ft (m) Maximum ________________________________________________________ ft (m)

20. Operating Range:

Minimum total pump head ___________________________________________ ft (m) Maximum total pump head ___________________________________________ ft (m)

21. Other operating conditions_________________________________________________________________

Description of Installation 22. Type of installation: Horizontal ________________________Vertical____________________________ 23. Other conditions: ________________________________________________________________________ 24. Special materials required to resist corrosion and/or erosion: _______________________________________ ______________________________________________________________________________________

Connections and Accessories 25. Discharge flange: ______________________________________________________in. (mm), 125-lb ANSI 26. Strainer required:

Yes ________ No _________

27. Lubricant:

Oil ________ Water _______

26. Gauge required:

Yes ________ No _________

Pumps are to be furnished in accordance with ANSI/AWWA E103 with the following exceptions: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________

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______________________________________________________________________________________

Appendix D Suggested Data Form for the Purchase of Vertical Line-Shaft Pumps This appendix is for information only and is not a part of ANSI/AWWA E103. Vertical Pump Data Sheet 1.

Purchaser ______________________________________________________________________________

2.

Address ________________________________________________________________________________

3.

Installation Site __________________________________________________________________________

4.

Job Reference Number _______________________Item No. _____________________________________

5.

No. Required ______________________________Date Required _________________________________

6.

Prime Mover: Electric motor _________________Engine _______________________________________ Other________________________

7.

Prime Mover Data: Motor:

Voltage _________Frequency _________Phase _________ rpm _________

Engine (type desired): Gas ______ Gasoline __________Diesel _________Other________ Maximum operating rpm _____________________________________________________ 8.

Driver:

Vertical solid-shaft motor drive _________________________________________________ Vertical hollow-shaft right-angle gear drive ________________________________________ Vertical hollow-shaft belted drive _______________________________________________ Combination drive __________________________________________________________ Speed:

Variable__________________________ Constant __________________________

Other _____________________________________________________________________ 9.

Line-shaft lubrication required: Open ______________________ Enclosed __________________________

10. Line-shaft lubrication required: Oil ________________________Water _____________________________ 11. Type of discharge:

Surface _____________________Below Base ________________________

If below base: Distance from datum to centerline of discharge tee ________________ ft(m)* 12. Other requirements a. ANSI/NSF 61 Certification ( Y / N ) b. Certificate of Compliance ( Y / N )

Vertical Pump Operating Conditions 13. Design rate of flow _____________________________________________________________gpm (m3/hr) 14. Datum elevation _____________________________________________ ft (m) (Datum c/l of stage impeller) 15. Pumping level below datum at design rate of flow __________________________________________ ft (m) 16. Total head above datum (static plus system friction) at design rate of flow ________________________ ft (m) 17. Total pump head at design rate of flow (line 14 plus line 15) __________________________________ ft (m)

* See datum definition in Section 3. --`,`,`,`,``,,,,,,,`,````,,``-`-`,,`,,`,`,,`---

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56

AWWA E103-07

18. Operating Range:

Minimum total pump head ___________________________________________ ft (m) Maximum total pump head ___________________________________________ ft (m)

19. Other operating conditions_________________________________________________________________ 20. Overall length (datum to inlet of pump suction case - _______) ____________________________________ 21. Length of suction pipe required _____________________________________________________________

Description of Installation 22. Type of installation: Well __________Can ___________Sump ___________Other____________________ 23. Minimum inside diameter of well or casing to pump setting ________________________________in. (mm) 24. Maximum permissible outside diameter of pump _________________________________________in. (mm) 25. Total depth of well/case or sump _______________________________________________________ ft (m) Note: A well is considered straight if a 20-ft (6-m) long cylinder equal to the maximum permissible outside diameter of the pump will not bind when lowered to a depth equal to the pump setting. 26. Static water level below datum _________________________________________________________ ft (m) 27. Sand in water: (After 15 min pumping interval) Concentration -ppm (mg/L) __________________________ 28. Gas in water: (type, if known) Concentration -ppm (mg/L) ________________________________________ 29. Other conditions: ________________________________________________________________________ 30. Special materials required to resist corrosion and/or erosion: _______________________________________

Connections and Accessories 31. Discharge flange: ______________________________________________________in. (mm), 125-lb ANSI 32. Companion flange required: Yes _________No __________ __________________in. (mm), 125-lb ANSI 33. Column Pipe:

Threaded sleeve coupling ________________Flanged ____________________

34. Column Pipe:

Diameter ___________________________ in. (mm) Thickness ___________________________ in. (mm)

35. Shaft Size:

Diameter ______________ in. (mm)

Coupling Threaded _______________________ Keyed _______________________

37. Strainer required:

Yes ________No _______

38. Lubricator required:

Yes ________No _______Voltate _______________Frequency ____________

39. Prelube water tank required: Yes ________ No _______Capacity______________ Gallons ______________ 40. Automatic lubrication controls required:

Time delay relay ________Float switch ___________

41. Air line and gauge required: Yes ________No _______ Pumps are to be furnished in accordance with ANSI/AWWA E103 with the following exceptions: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________

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36. Enclosing tube (if used) nominal pipe size: ___________

Appendix E Engineering Information and Recommendations This appendix is for information only and is not a part of ANSI/AWWA E103.

SECTION E.1: COMMON FOR HORIZONTAL AND VERTICAL PUMPS Sec. E.1.1 Engineering Information Information not currently available.

Sec. E.1.2 Recommendations Recommendations not currently available.

SECTION E.2:

HORIZONTAL PUMPS

Sec. E.2.1 Engineering Information Information not currently available.

Sec. E.2.2 Recommendations

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E.2.2.1. Wear ring clearances. Wearing rings are fitted in the casing and sometimes on the impeller. These wearing rings provide a close running clearance, to reduce the quantity of liquid leaking from the high-pressure side to the suction side. These rings depend on the liquid in the pump for lubrication. They will eventually wear so that the clearance becomes greater and more liquid recirculates back to the suction. This rate of wear depends on the character of the liquid pumped. Figure E.1 shows recommended clearances between the fixed and rotating surfaces. These clearances are for dissimilar metals that have a low tendency to gall. However, wear rings that are of the same material must have more clearance than recommended.

SECTION E.3:

VERTICAL PUMPS

Sec. E.3.1 Engineering Information E.3.1.1. Diameters and weights of standard steel discharge column pipe are 57 Copyright American Water Works Association Provided by IHS under license with AWWA No reproduction or networking permitted without license from IHS

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58

AWWA E103-07

shown in Table E.1. Heavier- and lighter-weight pipe is available. E.3.1.2 Friction loss charts. E.3.1.2.1 Discharge head. Figure E.2 can be used as a general design guide. Friction loss will vary depending on the design of the discharge elbow, shaft or enclosing tube size, and column size. E.3.1.2.2 Column. The column friction chart (Figure E.3) can be used as a design guide to determine the loss of head because of column friction. This chart was compiled from head loss data where the flow is between the inside diameter of the column pipe and the outside diameter of the shaft-enclosing tube or, in the case of open line-shafting, the outside diameter of the shaft itself. E.3.1.2.3 Mechanical friction. The mechanical friction chart (Figure E.4) can be used to determine the added horsepower required to overcome the mechanical friction in rotating the line shaft. The chart was compiled from test data submitted by representative turbine-pump manufacturers. Variations in designs used by individual manufacturers may affect the figures slightly. Added horsepower will also be required to overcome the mechanical friction at the shaft seal (packing or mechanical) and in the motor thrust bearing. The values of these losses can be obtained from the pump manufacturer.

E.3.2.1. Drivers. E.3.2.1.1 Rotation. Shaft rotation may be counterclockwise or clockwise when viewed from the driven end. E.3.2.1.2 Thrust bearing. Provide a thrust bearing of ample capacity to carry the weight of rotating parts plus the hydraulic thrust at operating conditions. For anti-friction bearings, the bearings shall be of such capacity that the AFBMA (Anti-Friction Bearing Manufacturers Association, 1101 Connecticut Ave. N.W., Suite 70, Washington, DC 20036) calculated rating life (L10) should be based on the duty cycle but not less than 8,800 hr when operating at the design point. If the design and operating conditions are such that upthrust can occur, provisions should be made to accommodate the upthrust. Minimum upthrust capacity of roller bearings should be equal to one quarter of the downthrust capacity. E.3.2.1.3 Ratchets. For pumps having a setting of 50 ft (15 m) or more, anon-reverse ratchet should be provided in the motor to protect line-shaft bearings and prevent motor overspeed in reverse when the pump is shut down and water empties from the column. E.3.2.1.4 Steady bushing. For vertical hollow-shaft motors used on

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Sec. E.3.2 Recommendations

59

pumps equipped with mechanical seals, and also for pumps with packed stuffing boxes operating at speeds greater than 2,900 rpm, a steady bushing should be provided. E.3.2.2. Prelubrication. Prelubrication of line-shaft bearings for waterlubricated open line-shaft pumps having settings greater than 50 ft (15 m) should be provided. Bearing should be thoroughly wetted before pump startup. E.3.2.3. Seals. E.3.2.3.1 Mechanical seals. Mechanical seals should be considered for pressurized can pumps to avoid seal leakage during periods in which the pump is not operating. E.3.2.4. Column pipe corrosion. It may be advisable not to apply a coating to threaded column pipe exposed to waters having high conductivity levels. The higher electrical potentials in this water are attracted to uncoated surfaces to concentrate corrosion. Uncoated pipe provides a much larger surface area for the electrical potentials to dissipate, and eliminates the concentration at the uncoated threaded surfaces of the column pipe joints. Most product-lubricated pumps have bronze bearing retainers, which are located in the center of the threaded pipe coupling where the threaded column pipe ends are located. The bronze alloy is more cathodic than the adjoining sacrificial steel-column pipe. This results in electrolysis at the interface of the two dissimilar materials, and accelerated corrosion of the steel pipe threads. Dissimilar materials also add to the rate of corrosion when elevated conductivity and higher concentrations of chlorides in the water exist.

Nominal diametrical clearance (in.)

0.044 0.040 0.036 0.032 0.028 0.024 0.020 0.016 0.012 0.008

Case ring inner diameter (in.)

Figure E.1

Horizontal pump nominal impeller-ring diametrical clearance (1 in. = 25.4 mm)

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HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS

60 AWWA E103-07

Table E.1.

Diameters and weights of standard discharge column pipe sizes

Nominal Size (ID) in. (mm) 2½ (65) 3 (75) 4 (100) 5 (125) 6 (150) 8 (200) 10 (255) 12 (305) 14* (355) 16* (405)

OD in.

(mm)

2.875

(73.0)

3.500

(88.9)

4.500

(114.3)

5.563

(141.3)

6.625

(168.3)

8.625

(219.1)

10.750

(273.0)

12.750

(323.8)

14.000

(355.6)

16.000

(406.4)

Weight (Plain Ends) lb/ft (kg/m) 5.79 (8.62) 7.58 (11.28) 10.79 (16.06) 14.62 (21.76) 18.97 (28.23) 24.70 (36.76) 34.24 (50.96) 43.77 (65.14) 54.57 (81.21) 62.58 (93.13)

Head loss (ft)

Head loss (m)

* OD

Conversion factors:

Figure E.2

,

,

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,

in. × 25.40 = mm ft × 0.3048 = m

Friction loss in discharge heads

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Head loss—ft/100 ft (m/100 m) of column

HORIZONTAL AND VERTICAL LINE-SHAFT PUMPS 61

,

,

,

,

,

Capacity (gpm)

NOTE: Friction loss determined by laboratory tests on new pipe (C = 140). Diagonals are labeled to show nominal diameters (in inches) of outer pipe column and inner shaft-enclosing tube, or if an open shaft, the shaft itself. For the outer pipe columns, the calculations used in constructing the chart were based on inside diameters, which are close to the nominal sizes for pipe up to and including 12 in. (for example, 10 in. Sch 30 pipe = 10 ⅕ in. ID). For pipe sizes in 12 in. and larger, the diameters shown are equivalent to the outside diameter of pipe with ⅜-in. wall thickness (for example, 16 in. = 15 ¼ in. ID). For the inner columns (shaft-enclosing tubes), the calculations were based on the outside diameters of standard or extra-heavy pipe. Thus, “8 × 2” on the chart is actually 8.071 × 2 ⅜, and “16 × 3” is 15 ¼ × 3 ½. Conversion factors:

Figure E.3

1 ft = 0.30 m 1 in. = 25.40 mm

Friction loss for standard pipe column

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62

AWWA E103-07

Mechanical friction per 100 ft of line shaft (hp)

Shaft diameter (mm)

Note: 0.746 hp = 1 kW 1 in. = 25.4 mm

Shaft diameter (in.) NOTE: The chart shows values for enclosed shaft with oil or water lubrication and drip feed, or for open shaft with water lubrication. For enclosed shaft with flooded tube, read two times the value of friction shown on the chart.

Figure E.4

Mechanical friction in line shafts

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AWWA is the authoritative resource for knowledge, information and advocacy to improve the quality and supply of water in North America and beyond. AWWA is the largest organization of water professionals in the world. AWWA advances public health, safety and welfare by uniting the efforts of the full spectrum of the entire water community. Through our collective strength we become better stewards of water for the greatest good of the people and the environment.

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1P-3.6M-45103-7/08-JP

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