Elements of Mechanical Engineering-18ME15/25

MODULE-2
Steam Boilers (Steam Generators)
Steam Boilers:- An Introduction
A steam boiler is a closed vessel made of steel, whose main function is to transfer heat
produced by the combustion of fuels to water and to generate steam which in turn is used in
steam engines and steam turbines for power generation.
The steam boilers are used in thermal power plants for power generation, in chemical
industries, in textile industries, in sericulture industries and in locomotives etc.
Classification of Steam Boilers:-
The classification of steam boilers can be done in many ways as follows:
1. According to the relative position of the hot flue gases and water in the boiler.
a) Fire tube or smoke tube boilers
b) Water tube boilers
a) Fire tube boilers:- In fire tube boilers the products of combustion of fuel (i.e., flue gases)
circulate inside the flue tubes (or fire tubes) and the water surrounds the flue tubes to get
the heat from the flue gases.
b) Water tube boilers:- In water tube boilers the water flows inside the tubes and the flue
gases surrounds these water tubes to transfer the heat to the water
2. According to the location of the furnace (combustion chambers)
a) Externally fired boilers
b) Internally fired boilers
a) Externally fired boilers:- The furnace is located outside the boiler drum.
b) Internally fired boilers:- The furnace is located within the boiler drum or inside the flue
tubes.
3. According to the position of the main boiler drum or boiler shell.
a) Vertical boilers
b) Horizontal boilers
4. According to the number of tubes used
a) Single tube boilers
b) Multi tubular boilers
5. According to the method of circulation of water
a) Natural circulation boilers
b) Forced circulation boilers
6. According to the pressure of steam generated
a) High pressure boilers
b) Low pressure boilers
7. According to the use of boilers
a) Stationary boilers
b) Locomotive boilers
c) Marine boilers
d) Portable boilers

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Babcock & Wilcox Boiler (Water Tube Boiler):-

D – Steam and water drum T.P – Steam pipe G – Grate

S – Super heater H1 – Uptake header B – Baffle
H2 – Downtake header W – Water tube E – Damper
M – Mid box V – Stop valve R – Door
It is a water tube, stationary, externally fired, natural circulation, low pressure and
horizontal boiler.
Construction
It consists of a steel water drum (main boiler drum). The main boiler drum is connected
to a set of water tubes through the uptake headers and down take headers. Each row of water
tubes is connected with two headers (i.e., uptake and down take headers) and there are plenty of
such rows of water tubes.
The water tubes set is supported on fire brick wall and fire brick baffle.
Each of the water tube is provided with a cap for the purpose of cleaning the tube. A mud
box is proved with each down take header and the mud and other precipitates that settles down is
removed at regular intervals. On the furnace side, there is a slow moving automatic chain grate
stoker on which the coal is spread from the hopper. A fire brick baffle causes the hot gases to
move upwards and then downwards and again upwards before leaving the chimney. The dampers
are provided at the furnace site and the chimney site to regulate the air flow rate into the furnace
and the flue gases out of the boiler. The boiler is supported on the fire brick walls on all the four
sides. The boiler drum is also provided with feed water pipelines, steel valves and safety valves.
Working Principle
The water from the main boiler drum enters into the water tubes through the down take
headers where it is heated up by hot flue gases resulting from the combustion of coal in the
furnace. The hot water in the down take header being lighter rises up through the water tubes and
reaches uptake header. While passing through the water tubes, being still lighter, from the uptake
header enters into the boiler drum through the tubes that connect uptake header and the boiler
drum.

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Water continues to circulate from the drum into down take header, through the water
tubes, through the uptake header and again to the boiler drum, till it is converted into steam. The
steam so generated will be collected above the water surface in the drum and later enters into the
super heater tubes. The steam while passing through the super heater tubes, will be further heated
up and gets converted into super heated steam. The super heated steam will be next taken from
the steam valve and is supplied to the steam engines or steam turbines.
The circulation of water is brought about by differential temperature called thermo siphon
principle.
Babcock and Wilcox boilers can generate steam up to a pressure of about 15-20 Kgf/cm2.
Lancashire Boiler (Fire Tube Boiler):-
Construction
Lancashire boiler consists of a cylindrical shell (main drum) of 2 to 3m in diameter and
length is of about 8-9m. This cylindrical shell in turn has two internal fire tubes having diameter
approximately 0.4 times that of the cylindrical shell. The cylindrical shell (main boiler drum) is
set in fire brick wall construction forming additional flue gas passages called external flues (i.e.
bottom flue and side flue). A part of the heating surface of the main boiler drum is on the
external flue. A fire grate is provided at the front end of the boiler, inside each fire tube. At the
end of the fire grate a fire brick arch is provided to prevent the passage of ash into the interior of
the fire tubes. Each tube has one opening called fire hole through which coal is introduced on to
the fire grate.

H – Fire hole, G – Grate, B – Fire bridge,

T – Furnace tube BF – Bottom flue E–Mounting for safety valve,
P – Steam collecting pipe M – Manhole L – Low water safety vale,
SF – Side flue CF – Chimney flue D – Damper,
F – Blow – off valve
Lancashire boiler is a stationary, fire tube, internally fired, horizontal, natural circulation
and low pressure boiler.
Working Principle
The hot flue gases resulting from the combustion of fuel, passes into the interior of the
flue tubes towards the rear end of the boiler. While passing through the fire tube, the flue gases

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transfer their heat to the water in the main boiler drum. At the rear end of the boiler, the flue
gases, after transferring a part of their heat to the water in the main boiler drum move down and
enter into the bottom flue. The flue gases next passes through the bottom flue and again reaches
the front end of the boiler. While passing through the bottom flue the flue gases again transfers
their heat to the water inside the drum through the bottom surface of the drum. At the front end,
the flue gases divide and flow into the side flues. The flue gases while passing through the side
flues transfer the remaining part of the heat to the water inside the drum. The flue gases also
transfer their heat through the super heater tubes provided in the side tubes. The flue gases next
move to the rear end of the boiler and enter into a common main flue which leads them to the
chimney at the rear end of the boiler.
The Lancashire boiler is generally constructed for normal working pressures up to 15
2
kgf/cm .
Boiler Mountings and Accessories:-
Boiler mountings and accessories are used in all boiler installations for the safe and
efficient working of the boilers.
Boiler Mountings:-
Boiler mountings are the safety devices used on the boilers to prevent the possible
hazards such as explosion of boiler drum and overheating of boiler drum, due to excessive steam
pressure or when the water level inside the boiler drum falls below the safe level.
The following are some of the boiler mountings that are commonly used.
1. Water level indicator (water gauge)
2. Pressure gauge (steam gauge)
3. Fusible plug
4. Safety valves
5. Stop valve
6. Feed check valve
7. Blow off cock
1. Water Level Indicator
The function of the water level indicator is to indicate the water level inside the main
boiler drum, so that when the level falls below the safe limit, the feed water can be supplied into
the boiler drum.
2. Pressure Gauge (or Steam Gauge)
The function of a pressure gauge is to indicate the steam pressure inside the boiler drum.
It is usually fitted onto the top of the boiler drum.
3. Fusible Plug
The function of the fusible plug is to put off the fire in the furnace in case when the level
of water inside the boiler drum falls below the safe limit.
4. Safety Valves
Are the safety devices used on the boilers to prevent the hazards resulting from the steam
pressure when it exceeds the normal working pressure.

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5. Stop Valve
It is the largest valve fitted to the highest part of the shell by means of flange. The main
functions of this valve are,
a) To control the flow of steam from the boiler to the main steam pipe
b) To shut off the steam completely when required
6. Feed Check Valve
It is a non return valve, used to regulate the supply of water which is pumped into the
boiler drum by the feed pump.
7. Blow Off Cock
The main functions of blow off cock are,
a) To empty the boiler whenever required
b) To discharge the mud, scale or sediments which are which are accumulated at the bottom
of the boiler
Boiler Accessories:-
Boiler accessories are the devices used in the boiler installation to improve the overall
efficiency of the boiler by improving the furnace efficiency and quality of the steam generated.
The following are the commonly used boiler accessories,
1. Super heater 2. Economiser 3. Air pre heater
4. Steam separator 5. Steam trap 6. Feed pump
1. Super Heater
The function of the super heater is to remove the last traces of moisture from the wet
steam coming out of the boiler and to increase its temperature sufficiently above the saturation
temperature.
2. Economiser
Economiser is a device used to pre heat the feed water supplied to the boiler drum by
making use of heat content in the flue gases.
3. Air Pre Heater
Air pre heater is a device used to pre heat the air supplied to the combustion chamber (in
furnace) by making use of the last traces of heat contained in the flue gases.
4. Steam Separator
A steam separator is used to separate the water particles from the steam. These water
particles in the steam (wet steam) produces many disadvantages such as corrosion of engine parts
and turbine blades. Steam separators are therefore used to separate the water particles from the
wet steam before it is being supplied to the steam engines or steam turbines.
5. Steam Trap
The object of a steam trap is to automatically drain away the condensed steam from steam
jackets and steam separators without allowing any steam to escape.
6. Feed Pump
It is used to deliver water to the boiler. It is usually a double acting type reciprocating
pump.

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Hydraulic Turbines
Hydraulic turbines convert hydraulic energy into mechanical energy. This mechanical
energy is used for running electric generator which produces electrical energy. The electric
energy obtained from hydraulic energy is called Hydro-electric power.
The hydro-electric power installations depend upon water source at high elevation.
Generally a dam is built across a flowing river so that water is collected behind the obstruction
and water level is raised. The stored water acts as reservoir, providing sufficient head to drive
the turbines in a power house located downstream of the dam.
In order to supply water at constant head irrespective of the water level in the dam, an
additional reservoir called forebay may be built at a short distance downstream of the dam. From
the forebay water is carried to the power house in channels, tunnels or large diameter pipes called
penstocks. At the end of the penstock the hydraulic turbine is installed. The potential energy of
water is utilized to produce mechanical shaft work at the turbine and water is finally discharged
to the tailrace.

Classification of Hydraulic Turbines:-

1. According to the type of energy at inlet
a) Impulse turbine b) Reaction turbine
2. According to the direction of flow through the runner
a) Tangential flow turbine
b) Radial flow turbine
c) Axial flow turbine
d) Mixed flow turbine
3. According to the head available at the inlet of the turbine
a) High head turbine
b) Medium head turbine
c) Low head turbine
4. According to the specific speed of the turbine
a) Low specific speed turbine
b) Medium specific speed turbine
c) High specific speed turbine
At the inlet of the turbine if the entire available energy is only kinetic energy, the turbine
is called impulse turbine. Also as water flows over the vanes, the pressure is atmospheric from
inlet to outlet.
Example: Pelton wheel, Banki turbine
At the inlet of the turbine if the available energy is kinetic energy and pressure energy,
the turbine is called reaction turbine. As water flows through the runner, the water is under
pressure and pressure energy goes on changing to kinetic energy. The runner is completely
enclosed in an airtight casing and the runner and casing are completely filled with water.
Example: Francis turbine, Kaplan turbine, Propeller turbine

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If water flows along the tangent of the runner, the turbine is called tangential flow
turbine. Example: Pelton wheel.
If the water flows parallel to the axis of rotation of the runner, the turbine is called axial
flow turbine. Example: Kaplan turbine, Propeller turbine.
If the water flows in the radial direction through the runner, the turbine is called radial
flow turbine. Example: Francis turbine.
Pelton wheel is a high head turbine, Francis turbine is a medium head turbine and Kaplan
turbine is a low head turbine.
Pelton wheel is a low specific speed turbine, Francis turbine is a medium specific speed
turbine and Kaplan turbine is a high specific speed turbine.

The Pelton Wheel:-

Break Nozzle
Casing

Runner

Shaft

Buckets
Conical Needle

Tailrace
Main Nozzle

Fig 2-5

The Pelton wheel is an impulse type of turbine mainly used for very high head of water.
Here water from the dam is made to flow through a pipe line, then through a guide mechanism
and finally through a nozzle. On such a process, the entire available energy is converted into
kinetic energy with the help of the nozzle which is kept close to the runner to minimize losses.
The jet of water from the nozzle hits the buckets fitted to the outer periphery of the runner,
transfers energy to the runner and leaves with a low velocity. The pressure of water both
entering and leaving is atmospheric.
The main components of the Pelton wheel are nozzle, runner and buckets, casing and break
nozzle.
1. Nozzle
It guides water to flow at the designed direction and also regulates the flow of water. The
water emerges from the nozzle in the form of high velocity jet impinges on the buckets. A
conical needle (spear) inside the nozzle operates in the axial direction to control the quantity of
water. The nozzle is kept very close to the runner buckets to minimize losses.

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2. Runner and Buckets

The runner of a Pelton wheel consists of a circular disc mounted to a horizontal shaft. On
the periphery of the disc, number of buckets are fitted uniformly. The surface of the buckets is
made very smooth to minimize losses.
The buckets are made of cast iron for very low heads and of stainless steel, bronze and
other alloys for high heads. The buckets are generally bolted to the runner disc since few may
require early replacement due to damage.
3. Casing
The casing of a Pelton wheel does not perform any hydraulic function but it is necessary
to avoid accidents and to prevent splashing of water. The casing leads water to the tailrace. It
may be fabricated or casted.
4. Break Nozzle
Whenever the turbine has to be stopped, the main nozzle is completely closed. The
runner goes on revolving for a considerable time due to its inertia before it comes to rest. In
order to bring the runner to rest in a short period, a nozzle is provided such that it will direct a jet
of water on the back of the buckets. It acts as a brake for reducing the speed of the runner.

Francis Turbine:-
The Francis turbine is a reaction turbine and the runner should be enclosed in an airtight
casing since water is always under a pressure other than atmospheric. The energy of water at the
rotor inlet is partly kinetic and partly potential. Francis turbines have the advantage of working
at high speeds even for low heads below 200 meters.
The Francis turbine consists of a spiral casing (scroll casing,) the inlet of which is
connected to the penstock. Uniform distribution of water around the runner circumference is
obtained by using a spiral casing. The casing is generally provided with stay vanes to give
enough strength to the casing to withstand high pressure.
WATER FROM PENSTOCK

RUNNER

SHAFT

RUNNER BLADES
SPIRAL CASING

GUIDE BLADES

Fig 2-6

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The water is guided to the runner by a number of guide vanes placed on the periphery of a
stationery circular ring. The guide vanes can be set at any desired angle for the speed regulation
and to direct water in the desired direction. The water passes through the runner, transfers energy
and then enters into a draft tube, the exit of which is immersed below the tailrace level. The
length of the runner depends on the specific speed.
The runner may be casted or fabricated. For large output cast steel or stainless steel may
be used.

Propeller Turbines and Kaplan Turbines:-

The propeller turbine consists of an axial flow runner with 4 to 6 blades of aerofoil shape.
The spiral casing and guide blades are similar to those in Francis turbine. In the propeller
turbine, the runner blades are fixed and non–adjustable. However in the Kaplan turbine, which is
a modification of the propeller turbine, the runner blades are adjustable and can be rotated about
pivots fixed to the boss of the runner. The blades can be adjusted automatically by a servo
mechanism so that at all loads the water enters without shock.
The Kaplan turbine is an axial flow reaction turbine in which the flow of water is parallel
to the shaft. This turbine is mainly used for very large quantity of water and for very small
heads. The runner of a Kaplan turbine looks like the propeller of ship.
Shaft
Guide Blades

Volute Casing

Draft Tube Runner Blade

Hub

Tail race

Fig 2-7

Water from the spiral casing flows over the guide vanes and then to the runner blades in
the axial direction. Water, after transferring energy to the runner is discharged to the tail race
through the draft tube. The runner of a Kaplan turbine has two main differences with that of
Francis turbine runner.
1. In Francis turbine runner water enters radially but in Kaplan turbine runner water enters
axially
2. In Francis turbine runner the number of blades are usually 16 to 24,but in Kaplan runner the
number of blades will be 3 to 8

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Hydraulic Pumps
A pump is a machine used to move liquid through a piping and to raise the pressure of the
liquid. It is a machine which converts mechanical energy into hydraulic energy [pressure energy].

Classification of Pump:-
Pumps can be classified into two categories
1. Positive displacement pump
It operates by forcing a fixed volume of fluid. It can be classified into two types:
a. Reciprocating Type: it moves the fluid using one or more oscillating pistons, plungers
and membranes (diaphragms) while valves restrict fluid motion to the desired direction.
Ex: piston pump, Diaphragm pump
b. Rotary Type: It moves the fluid by using rotating mechanisms that creates vacuum that
captures and draws in the liquid. Ex: Internal gear pump, Screw pump
2. Non-Positive displacement pump
In this pump, the volume of the liquid delivered for each cycle depends on the resistance
offered to flow. a non positive displacement pump can be classified as follows:
a. Centrifugal pump
b. Submersible pump

Specifications of Pump:-
The pumps are specified as follows:
1. Discharge size: Size of the pump
2. Horse power: Rate at which mechanical energy expended
3. Maximum discharge flow: Maximum flow the pump is designed to generate
4. Maximum discharge pressure: Maximum pressure the pump is designed to generate

What is a Reciprocating Pump?

Reciprocating pump is a positive displacement pump where certain volume of liquid is
collected in enclosed volume and is discharged using pressure to the required application.
Reciprocating pumps are more suitable for low volumes of flow at high pressures. Priming is not
required. Reciprocating pumps have low efficiency compared to centrifugal pumps.

Fig 2.8

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The main components of reciprocating pump are as follows:

1. Suction Pipe:
Suction pipe connects the source of liquid to the cylinder of the reciprocating pump. The
liquid is suck by this pipe from the source to the cylinder.
2. Suction Valve:
Suction valve is non-return valve which means only one directional flow is possible in
this type of valve. This is placed between suction pipe inlet and cylinder. During suction of liquid
it is opened and during discharge it is closed.

(a) Without Air Vessel

(b) With Air Vessel

Fig 2.9

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3. Delivery Pipe
Delivery pipe connects cylinder of pump to the outlet source. The liquid is delivered to
desired outlet location through this pipe.
4. Delivery Valve
Delivery valve also non-return valve placed between cylinder and delivery pipe outlet. It
is in closed position during suction and in opened position during discharging of liquid.
5. Cylinder
A hollow cylinder made of steel alloy or cast iron. Arrangement of piston and piston rod
is inside this cylinder. Suction and release of liquid is takes place in this so, both suction and
delivery pipes along with valves are connected to this cylinder.
6. Piston and Piston Rod
Piston is a solid type cylinder part which moves backward and forward inside the hollow
cylinder to perform suction and deliverance of liquid. Piston rod helps the piston to its linear
motion.
7. Crank and Connecting Rod
Crank is a solid circular disc which is connected to power source like motor, engine etc.
for its rotation. Connecting rod connects the crank to the piston as a result the rotational motion
of crank gets converted into linear motion of the piston.
8. Strainer
Strainer is provided at the end of suction pipe to prevent the entrance of solids from water
source into the cylinder.
9. Air Vessel
Air vessels are connected to both suction and delivery pipes to eliminate the frictional
head and to give uniform discharge rate.

Working: When the power source is connected to crank, the crank will start rotating and
connecting rod also displaced along with crank. The piston connected to the connecting rod will
move in linear direction. If crank moves outwards then the piston moves towards its right and
create vacuum in the cylinder. This vacuum causes suction valve to open and liquid from the
source is forcibly sucked by the suction pipe into the cylinder. When the crank moves inwards or
towards the cylinder, the piston will move towards its left and compresses the liquid in the
cylinder. Now, the pressure makes the delivery valve to open and liquid will discharge through
delivery pipe. When piston reaches its extreme left position whole liquid present in the cylinder
is delivered through delivery valve.

Uses of Reciprocating Pump

1. Oil drilling operations
2. Pneumatic pressure systems
3. Light oil pumping
4. Feeding small boilers condensate return

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Centrifugal pump:-
Centrifugal pump is a hydraulic machine which converts mechanical energy into
hydraulic energy by the use of centrifugal force acting on the fluid. These are the most popular
and commonly used type of pumps for the transfer of fluids from low level to high level.
It is used in places like agriculture, municipal (water and wastewater plants), industrial,
power generation plants, petroleum, mining, chemical, pharmaceutical and many others.
When a certain mass of liquid is made to rotate by an external source, it is thrown away
from the centrifugal axis of rotation and a head is impressed which enables it to rise to a higher
level. Centrifugal Pumps can be used for viscous and non-viscous liquids and has higher
efficiency.

Fig 2.10
The Main parts of Centrifugal Pump are:
1. Impeller
It is a wheel or rotor which is provided with a series of backward curved blades or vanes.
It is mounded on the shaft which is coupled to an external source of energy which imparts the
liquid energy to the impeller there by making it to rotate.

Fig 2.11
Impellers are divided into 3 types,
 Open Impeller
 Semi enclosed Impeller
 Enclosed Impeller
2. Casing
It is a pipe which is connected at the upper end to the inlet of the pump to the centre of
impeller which is commonly known as eye. The double end reaction pump consists of two
suction pipe connected to the eye from both sides. The lower end dips into liquid in to lift. The
lower end is fitted in to foot valve and strainer.

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Commonly three types of casing are used in centrifugal pump,

 Volute Casing
 Vortex Casing
 Casing with Guide Blades
3. Delivery Pipe
It is a pipe which is connected at its lower end to the out let of the pump and it delivers
the liquid to the required height. Near the outlet of the pump on the delivery pipe, a valve is
provided which controls the flow from the pump into delivery pipe.
4. Suction Pipe with Foot Valve and Strainer
Suction pipe is connected with the inlet of the impeller and the other end is dipped into
the sump of water. At the water end, it consists of foot value and strainer. The foot valve is a one
way valve that opens in the upward direction. The strainer is used to filter the unwanted particle
present in the water to prevent the centrifugal pump from blockage.
Working: The first step in the operation of a centrifugal pump is priming. Priming is the
operation in which suction pipe casing of the pump and the position of fluid with the liquid
which is to be pumped so that all the air from the position of pump is driven out and no air is left.
The necessity of priming of a centrifugal pump is due to the fact that the pressure generated at the
centrifugal pump impeller is directly proportional to density of fluid that is in contact with it.

Fig 2.12
After the pump is primed the delivery valve is still kept closed and electric motor is
started to rotate the impeller. The delivery valve is kept closed in order to reduce valve is opened
the liquid is made to flow in an outward radial direction there by vanes of impeller at the outer

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circumference with high velocity at outer circumference due to centrifugal action vacuum is
created.
This cause liquid from sump to rush through suction pipe to eye of impeller thereby
replacing long discharge from center circumference of the impeller is utilized in lifting liquid to
required height through delivery pipe.

Application of Centrifugal Pump

1. Oil & Energy – pumping crude oil, slurry, mud; used by refineries, power generation plants
2. Industrial & Fire Protection Industry – Heating and ventilation, boiler feed applications, air
conditioning, pressure boosting, fire protection sprinkler systems.
3. Waste Management, Agriculture & Manufacturing – Wastewater processing plants,
municipal industry, drainage, gas processing, irrigation, and flood protection
4. Pharmaceutical, Chemical & Food Industries – paints, hydrocarbons, petro-chemical,
cellulose, sugar refining, food and beverage production
5. Various industries (Manufacturing, Industrial, Chemicals, Pharmaceutical, Food
Production, Aerospace etc.) – for the purposes of cryogenics and refrigerants.

Comparison between Reciprocating Pump and Centrifugal Pump:-

Reciprocating Pump Centrifugal Pump
 Discharge of the fluid is non-continuous  It continuously discharges the fluid
 Used for pumping low viscous fluids  Used for pumping high viscous fluids
 Efficiency is low  Efficiency is high
 These does not require priming  Priming is required
 It uses piston cylinder device to  It uses impellers to transfer energy to
transfer energy to fluid fluid
 These are heavy in weight  These are light in weight
 Maintenance is high  Maintenance is low
 Occupies more space  Occupies less space
 Difficult to install  Easy to install
 Used in industries  Mostly used for domestic purposes

What is Pump Priming?

Priming is the process in which the impeller of a centrifugal pump will get fully sub
merged in liquid without any air or vapour trap inside. It is very essential step in start up of a
centrifugal pump but it is not required in reciprocating pump.
For a centrifugal pump to work properly, you need to fill it up with water. Fact is that
centrifugal pumps are not capable of pumping air or vapours. Pressure generated by centrifugal
pump is directly proportional to density of fluid. Since density of air is much less than that of
water, enough pressure is not generated to lift water. Therefore, all the air must be removed out
of a centrifugal pump which can be done by filling its impeller completely with water which in

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turn automatically removes air. Now, impeller is surrounded by high density fluid (water) due to
which required pressure will be generated. The pump will resume operation once the air or
vapour is removed. Most centrifugal pumps are incapable of pumping vapours or gases and
continuously doing so will damage the pump impeller.
The pumps can be primed by any of the following methods.
1. Manually: water is poured in the pump through funnel and air escapes through air vent
valve.
2. With vacuum pump: a small size reciprocating pump is used in priming.
3. With jet pump: water available at high head is allowed to flow through a nozzle.
4. With separator: air separator is provided on the delivery side of pump and bent suction
pipe portion at the inlet of the pump.

What is Pump Cavitation?

Cavitation is the formation and accumulation of bubbles around a pump impeller. When
each of these tiny bubbles collapses or bursts, it creates a high energy shock wave inside the
liquid.
In centrifugal pump, if the pressure at any point in a suction side falls below the vapour
pressure then water starts boiling. This causes the formation of saturated vapour bubbles. These
bubbles move at a very high velocity to high pressure side of the impeller blade and strike the
surface of the blade and collapse. In this way, more bubbles will be formed and collapse on the
surface of the blade as the pressure further decreases. This enables erosion and pitting forming
cavities on blades. This process takes places many thousand times. Also a considerable noise and
vibrations are produced. This phenomenon is known as cavitation.
Effects of Cavitation
1. Due sudden collapse of vapour bubbles, considerable noise and vibrations are produced.
2. Impeller surface gets damaged and the cavities are formed.
3. Efficiency of the pump reduces.
4. Loss of material due to pitting and consequent roughening of the surfaces.
Precautions
1. The pressure of the fluid flow should not fall below the vapour pressure. For water
should not be below 8.5m of water.
2. Impeller should be made of better cavitation resistant material such as stainless steel and
nickel steel.

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Prof. Ramesh B R, Dept. of Mech Engg., JIT, Davangere

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