Pumps & their
types
Objective
Pump & their types Positive Displacement
Pump(PDP).
PDP protections.
Dynamic pump (Centrifugal pump) & its operation.
Centrifugal pump parts.
Suction, Discharge, Total Head and Pressure &
head relation.
NPSH with NPSHa & NPSHr.
Centrifugal pump Efficiency.
Pros of Centrifugal Pump.
Problem & Remedy.
Centrifugal pump protections.
Pump & types
•IT IS A DEVICE WHICH USED TO DISPLACE A LIQUID.
•PUMPS ARE CLASSIFIED BY TWO TYPES,
Dynamic
Centrifugal
Positive Displacement Pumps
PDP has an expanding cavity on suction side and
a decreasing cavity on discharge side. Volume is
constant in each cycle of operation.
1. Reciprocating
2. Rotary (Screw & Gear)
Reciprocating Pump
Suction and discharge valves are mounted in the head of
cylinder. In suction stroke plunger retracts and the suction
valves open causing fluid enters into the cylinder while in
forward stroke the plunger pushes the liquid out to discharge
valve.
Rotary Pump
It operates as a rotating screw/ gear traps the liquid in the suction
side of pump casing and forces it to discharge side of the casing.
pros
Self-priming capability & producing a high suction lift.
Con
It operates at low speed due to close clearances. Otherwise, high
velocity liquid would increased clearances, resulting slippage.
Slippage is leakage of fluid from the discharge of the pump back to
its suction.
Screw Pump
A single screw rotates in a cylindrical cavity, thereby moving the
material along the screw's spindle. (OWS)
2-Screws pump
One screw has a right-handed thread and other screw has a left-
handed thread. One shaft is the driving shaft which drives the
other shaft through a set of herringbone timing gears. These gears
serve to maintain clearances between the screws.
3-Screw Pump (Pressurizing pump)
Center screw is used to drive the two outer idler rotors. As the
screws rotate in opposite directions, the pumped liquid moves
align the screws spindles.
That used to pump high pressure viscous fluids like lubricating,
hydraulic, or fuel oil.
Positive displacement pump protection
Relief valve fitted on their discharge side to protect the
pump & piping from over pressurization. E.g. if the pump
discharge valve is shut during pump operation or if clogged
strainer blocks system flow.
Suction line must full with fluid otherwise it will take air.
Gear pump clearances must be minimum to protect
slippage problem.
Centrifugal Pump
Rotating impeller used to increase P and Q of a fluid.
In radial flow fluid enters along the axial plane and exits at right
angles to the shaft (radially). Gives higher pressures and lower flow
rates. It consume more power as flow increases due to resistance.
In axial flow impeller pushes the liquid in a direction parallel to the
pump shaft. Fluid is "lifted" by the action of impeller. It gives low
pressure but high flow rate. Consume less power as flow increases.
(CW fan)
In mixed flow pumps borrow characteristics from both radial & axial
flow pumps. Fluid accelerated & lifted and exits the impeller
somewhere between 0-90 degrees from the axial direction. Operate at
higher pressures & delivering higher discharges. (CWP)
Pump Operational Description
Fluid (suction line) Pump casing (channel)
Impeller (Vanes gives rotary motion) Volute (reduce
velocity & increase pressure) Discharge nozzle.
Pump has small drain & vent fittings to remove gases.
Centrifugal Pump Parts
Wearing rings are replaceable rings which
attached to impeller & pump casing to allow a
small running clearance between themselves
without causing wear of impeller or pump casing
material. Pump efficiency increases by minimizing
liquid leak through this clearance.
Shaft transmits torque during starting &
operation. Also supporting impeller & other rotating
parts.
Pump shafts are usually protected from erosion,
corrosion, and wear by renewable shaft sleeve.
Impeller main rotating part that provides the
centrifugal acceleration to the fluid.
Coupling
Couplings used to connect motor
with pump and transmit torque to the
impeller.
Rigid Flexible
Casing (Volute) reduces velocity of
liquid & increases its pressure. Elastomeric Non-
(rubber/pol Elastomeric
ymer) (metallic)
Bearing (Anti-friction, Plain) bearing
housing encloses bearings mounted on
the shaft. Bearings keep the shaft or
rotor in correct alignment with the
stationary parts under the action of
radial and thrust loads.
Stuffing box seal the shaft (Gland Packing, pusher, lantern ring &
sleeve). Pump suction may be under a vacuum so that outward
leakage is impossible or fluid may be too hot to provide adequate
cooling of the packing. In these conditions lantern ring is used.
That is hollow ring which receives relatively cool, clean liquid from
either discharge of the pump or from an external source and
distributes the liquid uniformly around the shaft to provide
lubrication and cooling or seal the joint between the shaft and
packing against leakage of air into the pump in the event the pump
suction pressure is less than that of the atmosphere. Gland is a very
important part of the stuffing box. It can be easily adjusted in axial
direction. It provides sealing of shaft in the stuffing box.
Sometime packing material is not adequate for sealing a pumps
shaft. Mechanical seal used where we need 100 % sealing like
(expensive & dangerous liquid). It consist of two basic parts,
rotating element (soft face) attached to shaft and stationary
element (hard face) attached to pump casing. Both has a highly
polished sealing surface which prevents leakage along the shaft.
It provides sealing from 4-sides. (Sealing between shaft & sleeve
by O-ring, sealing of sleeve & soft face by O-ring, hard face by O-
ring & face to face sealing done by compression to soft face.
Precaution: Soft & hard face both are polished & un-necessarily
touching is not allowed. Also performed their fittings very
carefully.
Suction, Discharge, Total Head & Pressure
& head relation
Capacity liquid pushed by the pump. (m3/hr). It
varies with the changes in operation E.g. (FWP).
Capacity depends on a number of factors like:
(Liquid characteristics i.e. density, viscosity),
(Size of the pump inlet and outlet sections),
(Impeller size & speed), (Pump suction and
discharge temperature and pressure conditions).
Head measures the kinetic energy created by
the pump. It defines height of a liquid column
that the pump could create from the kinetic
energy imparted to the liquid. The main
reason for using head instead of pressure
to measure pump's energy because the pressure
from a pump will change if the specific gravity of
the liquid changes, but the head will not change.
Pressure to head conversion: depends on S.g
of liquid whose range from 0.5 (light
hydrocarbons) to 1.8 (sulfuric acid). This formula
helps in converting pump gauge pressures to
head. Pressure = (Head x
(0.433 PSI = 1 FT) S.g)/2.31,
Head = (Pressure x 2.31)/
Suction Head (hS): Head resulting from elevation of the
liquid relative to the pump center line. If the liquid level is
above pump centerline, hS is positive. If the liquid level is
below pump centerline, hS is negative. Negative hS
condition is commonly denoted as a “suction lift” condition.
Discharge Head (hd): It is the vertical distance in feet
between the pump centerline and the surface of the liquid in
the discharge tank.
Friction Head (hf): Head required to overcome the
resistance to flow in the pipe and fittings. It is depends on
the size, condition and type of pipe, number and type of
pipefitting, flow rate, and nature of the liquid.
Vapor Pressure Head (hvp): Pressure at which a liquid
and its vapor co-exist in equilibrium at a given temperature.
Value of hvp increases with rising temperature of liquid and
in effect, opposes the pressure on the liquid surface, which
cause liquid to flow into the pump suction i.e. it reduces the
suction pressure head.
Net Positive Suction Head
(NPSH): determine pressure of the liquid being pumped is adequate to avoid
cavitations.
NPSHr: It is + head in feet required at pump suction to overcome pressure
drops in pump (turbulence by impeller, velocity ↑ & pressure ↓ by centrifugal
force of impeller) & maintain liquid above its vapor pressure to avoid
cavitations. NPSHr value is not constant for given pump at all conditions. It
increase as flow rate & speed of pump (capacity) increases because velocity of
liquid increases.
NPSHa: Difference between total suction head and vapor pressure of liquid, in
feet, at suction flange. It make sure pump does not cavitate. It ↑ as fluid temp
↓ because vapor pressure ↓.
NPSHa > NPSHr at suction flange of pump to operate properly (at least 2 to 3
feet) to avoid head loss in suction pipe & in pump casing and pressure
decrease. NPSHa ↓ when elevation of pump ↑. At some level NPSHa will come
to 0 & fluid starts to evaporate.
Problems: If NPSHa > NPSHr many serious problems can result (reduction in
head & capacity or complete failure, excessive vibration if liquid & vapor
occurs, pitting and erosion on pump parts).
Atmp = 14.7 psi, Gage pressure =
open at sea level, static head = 5 ft,
Piping = 10 ft of 2 inch pipe plus one
90° long radius screwed elbow,
Pumping = 100 gpm at 68°F. fresh
water, specific gravity = 1, Vapor
pressure of 68°F. Water = 0.27 psia
from vapor chart. NPSHR = 9 ft.
Static head = 5 ft,
Atmp=pressure x 2.31/sg = 14.7 x
2.31/1=34 ft,
Gage pressure=0,
Vapor pressure of 68°F. water converted to
head = pressure x 2.31/sg = 0.27x2.31/1 =
0.62 ft,
From friction charts:
100 gpm flowing through 2 inch pipe
shows a loss of 17.4 ft for each 100 ft of
pipe or 17.4/10 = 1.74 ft loss in the
piping
The K factor for one 2 inch elbow is 0.4
x 1.42 = 0.6 ft
Sum 1.74 + 0.6 = a total of 2.34 ft friction
loss in the pipe and fitting.
NPSHA (net positive suction head available)
= 34 + 5 + 0 - 0.62 - 2.34 = 36.04 ft. This
Atmp = 14.7 psi, Gage pressure = -20
inches of vacuum, static head = 5 ft,
Piping = 10 ft of 2 inch pipe plus one
90° long radius screwed elbow,
Pumping = 100 gpm. 68°F fresh water,
specific gravity = 1, Vapor pressure of
68°F water = 0.27 psia from the vapor
chart, NPSHR = 9 ft.
Static head = 5 ft,
Atmp = 14.7 psi x 2.31/sg = 34 ft,
Gage pressure = -20 inches of vacuum
converted to head
inches of mercury x 1.133 / specific gravity
= ft of liquid
-20 x 1.133 /1 = -22.7 ft of pressure head
absolute
Vapor pressure of 68°F. water converted to head
= pressure x 2.31/sg = 0.27 x 2.31/1 = 0.62 ft,
From friction charts:
100 gpm flowing through 2 inch pipe shows
a loss of 17.4 ft for each 100 ft of pipe or
17.4/10 = 1.74 ft loss in the piping
The K factor for one 2 inch elbow is 0.4 x
1.42 = 0.6 ft
Adding these two numbers together: (1.74 +
0.6) = a total of 2.34 ft friction loss in the pipe
and fitting.
NPSHA = 34 + 5 - 22.7 - 0.62 - 2.34 = 13.34 ft.
This is enough to stop cavitations.
Pump Efficiency
Efficiency decline over
time due to wear (e.g. ↑
clearances as impellers ↓
in size).
Also matching pipeline
play vital role. Pump
selection is done by
performance curve which
is between pressure head
and flow rate.
Best Efficiency point
pump does not
completely convert the
K.E to pressure energy.
Some of energy always
lost internal & external in
pump. Efficiency of pump
at the designed point is
normally maximum and
is called BEP.
Pros of Centrifugal Pump
PDP must not be operated against a closed valve on the discharge
side because it has no shut-off head like centrifugal pumps.
Otherwise the line bursts or the pump is severely damaged - or
both.
Displace huge amounts of liquid at a time.
It has a low initial & maintenance cost since all motion is rotary and
there are no sensitive parts such as the valves in a plunger pump.
Problem & Remedy
Pump must be prime
Pump becomes incapable of
pumping. otherwise it must be
located below the level of
source.
Cavitations occurs when
velocity of liquid increases
to the point where the Increase suction pressure
pressure drop reaches to by maintain pressure in the
pressure of vaporization. pump or alter the pump
design by installing larger
Vapor bubbles moving at piping to reduce friction
high speed, (severely pit, loss or by installing a foot
corrode impeller surfaces valve to reduce suction lift.
and pump casing). Suction For hot liquid use small dia
impeller.
pressure became low
(caused by high suction lift
or friction losses in the
suction piping).
Pump Protections
Discharge stop valve must be CLOSED before starting the pump. That
builds up an effective pressure head before distributing the liquid
downstream. After the pump is up to speed and discharge valve is
opened, the pump continues to maintain that pressure head unless
the operating conditions are altered.
Pump becomes dead-headed when operated with no flow through it,
E.g. with a closed discharge valve or against a seated check valve.
Impeller will churn the same volume of water as it rotates in the pump
casing. This will increase temperature of the liquid (due to friction) in
the pump casing to the point that it will flash to vapor. The vapor can
interrupt the cooling flow to the pump's packing and bearings, causing
excessive wear and heat. If the pump is run in this condition for a
significant amount of time, it will become damaged. That problem can
be removed by providing recirculation line from pump discharge line
back to pump's supply source.
Also protect from runout. That can lead a cavitations & also cause
overheating of the pump's motor due to excessive currents. One
method for ensuring that there is always adequate flow resistance at
the pump discharge to prevent excessive flow through the pump is to
place an orifice or a throttle valve immediately downstream of the
pump discharge. Properly designed piping systems are very important
to protect from runout.