Pumps and Pumping Systems

Pumps are generally used on ships to circulate or move various liquids via piping arrangements from point to
point in a system, from one vessel to another or from a vessel to shore, the main function being to circulate
or supply liquid at pressure. The two storage facilities or tanks may be at different heights or there may be
great distances between them so the pump used may need to create pressure to raise the liquid through the
height or overcome the distance between the facilities. This is achieved by converting the kinetic energy or
static head energy to pressure. There may be various losses through the system and these losses need to
be accommodated for during the design phase of the pumping system. The system is largely governed by
▪ medium to be pumped (corrosive, viscosity, temperature range)
▪ pressure/head to be overcome
▪ volume or quantity of liquid required
The latter two factors will determine the speed of rotation, impeller dimensions, number of impellers, whether
the pump should be single or double entry and whether (in the case of centrifugal pumps) it should be
horizontally or vertically installed.
Suction head refers to the distance the fluid must travel to the pump entry point and this may either be
below or above the entry point. Negative head refers to the suction point being below the pump eye height
or datum and positive head is when the suction point is higher than the entry point (eye) of the pump. The
term flooded suction may also used as for this as the pump chamber may remain permanently filled with
fluid. This method could be used when boiling water is to be pumped to ensure that no steam gets
trapped inside the chamber that may result in cavitation.

Page 1 of 13
Pump Categories
Pumps used on board ships can be divided into two main categories viz Positive displacement and ,
Centrifugal. A third type referred to as Axial Flow is also used. The positive displacement type can be further
subdivided into reciprocating and rotary.

Reciprocating : involves a piston or plunger sliding inside a cylinder. The main difference between the
piston and plunger type is the length of the ram inside the cylinder. The reciprocating motion is obtained
through a crank or cam mechanism connected to an electric motor. Steam or compressed air may also be
used. It is also common to have springs fitted to assist with the quick return of the piston. The pump can be
either single acting (suction and discharge occurs only on alternate strokes) or double acting (when suction
and discharge is obtained on each stroke) so double the volume is effectively pumped. These pumps are
generally used for delivering smaller quantities of water, oil or fuel at higher pressures, although when used
as stripping pumps and driven by compressed air, they are relatively fast acting. The diagram below shows
the arrangement of a double acting pump.

The system consists of two inlet valves and two discharge valves with each of the inlets connected to a
common suction line and the discharges connected to a common discharge line. As the piston moves
downwards, the inlet valve (No. 2) opens allowing water into the chamber behind the piston and the
discharge valve (No.3) is forced open so that any water below the piston is forced into the discharge line.
As the piston reaches the lower end of its stroke and begins its’ upward movement, the inlet valve (No. 2) is
forced close and the discharge valve (No. 3) closes by the suction created. The water above the piston now
forces the discharge valve (No. 4) open and the water leaves the chamber simultaneously allowing water
into the chamber through suction valve (No. 1) which opens due to the suction created by the piston moving
upwards. As the piston reaches the upper end of its’ stroke and changes direction the cycle repeats itself.
An air vessel or accumulator is usually fitted to the discharge line to dampen pressure variations or water
hammer effect. The air vessel allows the air trapped above the water in the accumulator to be compressed
and expand as the pressure varies with each stroke. These types of pumps have relief valves fitted to
prevent damage if the pump is run with a closed discharge valve. They are also self-priming i.e. they should
not require purging or venting.
Page 2 of 13
Rotary : involves a rotation action using gears, screws, flexible rubber impellors, scrolls, vanes or lobes.
They are used for delivering larger quantities than reciprocating pumps at medium to high pressures. The
starting procedure for this type of pump is similar to the reciprocating pump and a safety relief valve is also
fitted to the system for protection. Following are diagrams of the various pumps in use.

Screw Pump
In the screw pump, the timing of the screws is important and the screws should be carefully matched when
assembling this type of pump as incorrect timing of rotation may seriously damage the screws. It consists of
meshed screws with one acting as the driving screw. The other screw is driven and is merely there to force
liquid from the suction side between the screws and out the discharge side as the two screws mesh. They
may especially be used as fuel transfer pumps. There rotational speed is high and they are coupled directly
to electric motors.

Gear Pump
It consists of two meshing gears in a close fitting casing. As the wheels turn, they trap liquid between the
teeth and as each tooth leaves its corresponding space, a partial vacuum is created allowing the liquid to
flow into the space. The liquid is then carried around in the space at the periphery between the gear and
casing, entering at the inlet port and as that space approaches the outlet port, the liquid is discharged.
The pump efficiency is dependent on the fine clearances between the gearwheel sides and the casing end
covers. They are not suited for liquids containing grit or dirt as this causes rapid wearing. They are common
for lubricating oils and fuels.

Page 3 of 13
Rotary Vane Pump
In this pump the rotor is eccentric and the moving blades/vanes may be spring loaded. As the rotor turns
and the space between rotor and casing ring increases the liquid enters at the inlet between the space
formed between the blades. As it turns the blades move further out, radially and increases the size of the
liquid chambers. The trapped liquid is carried around to the outlet/discharge and as the space decreases the
liquid trapped inside the chambers is forced out at the discharge outlet under presure.

Scroll Pump
This is more commonly referred to as a mono pump. It consists of a non ferrous/stainless steel rotor working
inside a hard rubber stator. It is motor driven through an articulated shaft. The rotor is formed like a single
start thread and the stator as a matching double start thread. As the rotor turns it slides off the stator thread
at the top while talking liquid into the space formed at the bottom. The liquid is forced along the screw length
from the suction end and out at the other end. It can be used to pump almost any medium but the suction
should be kept flooded at all times or primed before operation. It is particularly suited to high viscosity liquids.

Page 4 of 13
Flexible Impeller (Jabsco) Pump (Not used on large ships)
This pump consists of a synthetic rubber rotor with integrated flexible rubber vanes that follow the contours
of the casing as it rotates. As in the gear pump, liquid enters the casing between the spaces of the vanes
and is carried around until the liquid reaches the discharge. The casing is fitted with an eccentric cam or flat
section inside that causes the flexible vanes to bend and so force the trapped liquid to be discharged at the
outlet. Though this pump is positive displacement, it must be primed/vented prior to starting. If it is to remain
idle for a length of time the impellor should be removed. It is generally used for cooling of smaller engines
and is directly coupled to the engine via a gearing and shaft arrangement.

Positive displacement pumps during operation have fixed volumes on the suction and discharge strokes
alternately and do not necessarily require priming. They also build pressure continuously once started,
hence the need for safety relief valves or bursting discs to avoid overpressure of the pipelines in the event of
shut valves in the discharge line.

Axial Flow : These pumps use a screw propeller to axially accelerate the liquid through passages and
guide vanes arranged in a manner to convert the kinetic energy or velocity of the water to pressure head.
The pump shaft is coupled to the drive motor through a flexible coupling and it operates at high speeds. It
requires less power to drive the motor that is generally smaller when compared to an equivalent centrifugal
pump. It is used where large volumes of water are required at low to moderate pressure.

Page 5 of 13
Centrifugal pumps: These pumps may be confused due to rotation but are not positive displacement.
Instead make use of the principle of centrifugal force. They use impellors turning at high speed to increase
the speed of the liquid entering the chamber through the central eye. The chamber or casing has a
special shape referred to as a volute that assists in converting the kinetic energy of the water to pressure
head. In some cases the pump may have a diffuser ring in place of the volute that assists in converting the
kinetic energy to static pressure head. These pumps are used where very large volumes are required at low
to moderate pressures and can be either single stage (one impellor) or multistage (two or more). Multistage
pumps generally being used in order to increase the output pressure of a system. The impellor used may
also vary and could be either open, semi-open or closed (shrouded).
Centrifugal pumps usually require priming before operation. This means that all air should be purged from
the volute chamber or casing before starting. Priming is usually carried out using a sea suction line and air is
purged from the chamber through a cock on the highest point of the casing. Priming is extremely important
where the suction head is negative as the chamber must be completely filled before starting. The direction of
rotation is also important as they only deliver in one direction. Priming may not be necessary with a positive
suction head.

Page 6 of 13
Water Hammer and Cavitation
These are the two main factors affecting pumping systems. Water hammer usually occurs in reciprocating
pumps and is caused by a sudden change in the speed at which the fluid is moving together with a
proportional change in pressure usually caused by:
1) The sudden closing of a valve or stop cock in a pipeline that causes the water inside that is still in
motion to slam against the valve setting up reflected waves that cause vibration of the pipes.
2) In reciprocating pumps, the colliding of water on successive strokes as the water from the two
delivery strokes meet.
This effect is overcome by making use of an accumulator or air vessel to smooth the flow. During delivery
the piston forces water into the air vessel compressing the air inside the vessel. On the suction stroke the
non-return valve prevents the water from falling back down the delivery pipe and the air, which is under
pressure continues to push the water up the pipe thereby maintaining continuity of flow.

Cavitation is the effect of vapour bubbles created and subsequently bursting while passing from the lower to
the higher pressure side of the impeller. Various factors may cause it but generally if the suction capability of
the pump is too low to accommodate the demand it will persist, causing damage to the impeller. Two main
causes are low suction volume and high temperatures of supply medium.

Advantages of Centrifugal Pumps over Reciprocating Pumps

Each of the pumps described would be suitably matched for the particular system but centrifugal pumps are
generally superseding reciprocating pumps as they are now capable of producing the similar pressures at
much larger volumes with the use of multi-staging systems. Rotary positive displacement pumps are still
widely used but the centrifugal pump has distinct advantages over this type and the reciprocating type as it is
possible to change the impeller material and casing material to accommodate any medium. The main
advantages are:
1) They are more compact so require less floor space.
2) Their initial cost is low and maintenance and operating costs are lower.
3) They are more adaptable (i.e. they can pump sandy, muddy or dirty fluids easily).
4) The construction is simple, robust and reliable.
5) It operates at high speed so can be coupled directly to a motor, without intermediate gearing.
6) Water hammer and shocks do not occur so there is reduced vibration if installed correctly.
7) Fluid delivery can be regulated without shutting off the pump.
8) They have no moving valves or sensitive parts as in the case of reciprocating pumps
9) They can withstand high heat variations and if suitable materials are used corrosive mediums are
easily accommodated.

Centrifugal pump systems are usually designed taking into account the various losses that would be
experienced due to friction at bearings, leaking glands, surfaces and material types for impeller and casing,
eddy currents, turbulence, hydraulic imbalance and clearances. Centrifugal pumps in particular should be
monitored and assessed regularly to determine their condition. Mountings and bearings should be checked
and the overall pump performance monitored. If it is affected or reduced, various checks can be made. Some
of the more common problems are listed below with possible causes.

Page 7 of 13
Pump fails to deliver liquid, losses pressure or fails to build pressure while running
1. Ensure the pump has been primed or vented
2. In the case of negative suction, the head may be too large to overcome.
3. Check on the speed and direction of rotation.
4. There may be leaks on the suction line.
5. Strainers may be blocked.
6. The impeller may be clogged.
7. The discharge valve may be closed.
8. Clearances may be too large at wear ring.
9. There may be no liquid in the supply tank.
10. Temperature of supply may be too high
11. Suction glands / seals may be leaking
12. Coupling may be stripped or bolts sheared

Pump vibrates
1. Check mounting bolts are tight.
2. Impeller may be clogged.
3. Bearings may be worn
4. Shaft may be bent
5. Clearance between wear ring and casing may be too large
6. Impeller may be damaged

Pump will not prime

1. Air may be entering the system through glands.
2. Joints at flanges may be damaged.
3. Bolts on casing or at flange connections may be loose.
4. Check that discharge / delivery valve is shut.
5. Check that filters at the float valve are free.
6. Check bilge suction valve

Pump overloads driving engine or motor

1. Speed may be too high
2. Pump may be pumping too much water for the rated speed due to the discharge head been lower
than the rated head.
3. Viscosity or specific gravity of the pumped liquid may be incorrect

If any of the above faults are experienced, the pump should be stopped and restarted using the usual start
up routine and if the pump capacity or output is reduced or falls all the above checks should be made and
the general arrangement checked before the pump is opened. At all costs, it should be ensured that there is
no electrical problem before commencing any disassembly of a pump. Mud boxes and strainers on pump
suction lines should regularly checked and cleared and bilges should be kept clear of debris. Priming of the
centrifugal pumps on a ship may be through a central priming system to ensure automatic priming of the
pumps.

Page 8 of 13
Ejectors and Eductors
This is also a pumping system with no mechanical moving parts on the system itself, although the motive
medium is provided through a pump. An ejector pump utilises a high pressure motive supply, either steam,
compressed air or sea water. The motive supply is directed through a converging / diverging nozzle and
reduces in pressure while simultaneously increasing in speed. At the centre point (throat) of the nozzle
where the change in diameter occurs a pipe is led to the required area to be pumped. As the motive medium
exits the nozzle at high speed, the pressure increases again at the diverging side creating a partial vacuum
and thus allowing liquid to be drawn into the nozzle from the bilge, tank or well. The advantages of this
system is that they are inexpensive, effective, maintenance free and generally highly reliable when
maintained correctly. They may be used for steering compartment bilges or hold bilges and are commonly
used on the bilge injection system for emergency bilge operation in which case the system is linked to the
main circulating pump, which is generally the largest pump on board.

The bilge injection system makes use of this principle and is an extremely important and common feature on
board any ship. Its’ main function is for use in the case of heavy flooding in machinery spaces. Initially, the
suction must be drawn from the main sea water line and once proper priming has been established and
pumping is underway, the suction would be changed over to draw water directly from the bilge. This ensures
that flooding to a large degree can be stemmed. The minimum diameter of the bilge injection valve should be
at least 2/3rds of the main sea water inlet.

Emergency Bilge Pump (Refer to diagram on next page)

This pump should not be confused with the injection system for the bilge. The function of this pump is to
ensure that any compartment or space is emptied or drained rapidly immediately adjacent to the damaged
compartment. This pump can work at normal rating even when it is completely submerged. It consists of a
standard centrifugal pump with an air pump either rotary or reciprocating to ensure self priming. The driving
motor is enclosed in an air bell that prevents water from entering so that even when flooded the air bell
covering the motor ensures the motor remains dry. The motor is commonly operated on a DC supply from
the ships emergency supply circuit as part of the essentials. The pump can be used as an emergency fire
pump as well.
Page 9 of 13
Bilge and Ballast System
The bilge and ballast systems perform different functions on board a ship but may be interconnected by
means of cross-over valves. It should be possible to pump bilges on older vessels, using any of the pumps in
the system however, on more modern vessels these systems are being separated. On small fishing vessels,
the system may consist of only one or two pumps where larger vessels may have five or more pumps to
cater for these two systems. Common names used to refer to these pumps would be bilge, fire, ballast,
general service, stripping, emergency bilge, main sea or raw water. The pumps servicing the bilge and
ballast system may be interconnected via cross-over valves.

Bilge system : is a system of pipes, valves and pumps arranged to allow draining or pumping of any water
in places where water should not be allowed to accumulate in machinery spaces or holds. The drains are in
the form of scuppers or wells leading from watertight compartments, refrigeration and cargo holds or
machinery spaces. The water is allowed to drain to the lowest point on the ship, referred to as the bilge, and
from this point it is then pumped overboard through a filtration system to meet the regulations regarding
discharge of oily water mixtures. All suction lines are fitted with strainers and in machinery spaces mud
boxes may be fitted. Water is pumped overboard through the O.W.S or to a bilge holding tank holding.

Ballast system : is the system of piping and tanks on board for controlling the stability and draft of a vessel.
Individual tanks and bilges have isolating valves but piping is generally connected to a common manifold that
may or may not require priming before operation. Non-return valves or one way cocks are fitted to prevent
flooding or the possibility of water entering dry spaces. The diagrams below show the general arrangement.
Page 10 of 13
 General Arrangement for a small fishing vessel

General Arrangement for a small coaster or container vessel

Page 11 of 13
Packing and Sealing
Where shafts of pumps or spindles of valves pass through holes in cast metal casings that carry fluids or
gases under pressure it is necessary to ensure that the gas or fluid inside the casing cannot leak out
between the shaft or spindle that is turning inside the hole and that undesired particles cannot enter the
system. Leaking may occur between the inner face of the hole and the shaft or spindle. However, the easy
running fit of a shaft or valve spindle must be maintained and to achieve this goal a “ stuffing box “ may be
used around the shaft or spindle. Systems that may use packing or sealing on board a ship are Fresh water,
Sea water, Lubricating Oil, Steam, refrigeration gas or hydraulic systems.

The stuffing box is sealed using packing material referred to as a gland. Packing creates a seal between the
two surfaces either moving or stationary. Various types may be used, generally they can be divided into two
main groups:
➢ Packing for reciprocating and/or rotating parts (dynamic sealing) and
➢ Packing between flange pipes (static sealing)
For packing to perform its’ function it must meet certain requirements, the most important being factors being
the correct material, suitable size and it must be correctly fitted

The incorrect choice of packing could result in fire, explosion or loss of life due to leaking of toxic vapours.
Factors that influence the choice of a packing or sealing material are the nature of the fluid or gas, the
temperature of the fluid, the pressure of fluid in the system and the environment in which the machine
operates
and the characteristics that should be applied to the material are:
➢ The strength of the material to be used
➢ The amount of elasticity the material possesses
➢ The materials resistance to chemicals
➢ The materials resistance to temperature (high or low)
➢ The coefficient of expansion of the material
➢ The thermal conductivity of the material
➢ The density of the material
➢ The frictional properties that the material possesses

Examples of where packing, sealing or insulation is fitted are rotating pump shafts, piston rods, valve stem
seals, propeller shafts, steam / exhaust pipes and joints between pipe flanges on pump systems.

On many pumps, “lantern rings” are used inside the stuffing boxes, especially where the stuffing box may be
subject to a partial vacuum. The lantern ring is a steel or brass ring that has a series of holes set into a
recess along it’s circumference. The stuffing box has a port leading through it to the lantern ring and water,
oil or grease is fed to the lantern ring ensuring a seal is maintained. The fluid or gas inside may contained
solid particles that could result in wear so the pressure to the lantern ring is maintained slightly higher than
that of the system to ensure the particles remain in the system and do not affect the shaft by accumulating in
the stuffing box.
Various types of materials are used for packing viz. hemp, cotton, asbestos, rubber and leather.

Page 12 of 13
Variable Delivery Pumps
The two most commonly used types are the radial piston type as in the Hele-Shaw pump and the axial
piston type as in the Swashplate type. Both of these pumps could be be used on the telemotor steering
system and make use of the principle of eccentricity to provide pressure. They each have two ports and
either of the ports could be inlet or discharge.

In the Hele-Shaw pump the pistons/plungers move radially i.e. in a direction towards and away from the
shaft at right angles. The shaft remains centred driven by a constant speed motor and the pistons or slippers
run in grooves on two circular floating rings. When the rings’ centres coincide with the shaft no pumping
action occurs but as the control rod linked to the telemotor moves, the rings move to an eccentric position
and one port then becomes suction while the other becomes a discharge port. As the floating lever is
centralized by the hunting rod the ports again align centrally with the shaft and no pumping takes place until
the next signal is received from the bridge. This type of pump has largely been discontinued due to the
complexity of its’ construction and has been superseded by the swash plate variable delivery pump.

The axial piston Swash plate pump pump is the preferred type when compared to the radial piston
heleshaw pump due to the complexity of the latter pumps design. In the swash plate variable delivery pump
the drive shaft carries a round concentric piston cylinder block keyed to the shaft which is driven through a
constant speed uni-directional motor. The block is free to slide axially along the shaft and consists of a
number of sleeves housing the concentric pistons. The free end of the pump has an end cover and two ports
for allowing the oil either in or out. The pistons are secured towards the driven end to the swash plate which
is a circular plate that does not rotate with the shaft and they are also free to move axially in the sleeves. The
pump rotates at constant speed and by angling the swash plate away from the vertical, the individual piston
strokes vary so the pump sucks through one of the ports and discharges through the other. When the swash
plate is angle in the opposite direction from the vertical, the ports alternate so that the oil flows in the
opposite direction. The angle of the swash plate is controlled through the floating lever which is in turn
operated through the link to the receiver arm

Page 13 of 13