YOURAPPIJEI'ON T

ore often than not, operatorsofprocess facilities and pumpmanufacturers to fail achievethe intendedgoal of a centrifi:gal pumping system. Rather than optimizing the process, lengtheningthe run time, increasing reliability, and lowering rnaintenance costs, engineers end up frustrated when the pump fails. However,nost failures can be attributed to a single major flaw in how a pumpapplication was approached: systemwas not. the initially analyzed completely accuand rately enoughto consider of the all needed hydraulicandmechanical fits. Rer,-ersing situaiion is not diffithe cult. The use of a few weil established application guidelines for analyzing process conditions, well asthe interas 'relationship betweenhydrauiic and mecha:rical will assure fit, reiiable, efficient operation of process pumps (Table, 80I By remembering pg. some of the basics, and establishing pata tern ofanalysis, plantengineer any can achievehighly successfi.rl installations of centrifugal pumps.And by taking stepsto relay defgilsdinformation to the pumpmanufacturer, userscaa end rest assured that the pumpthey select will be the pumptheyneed. Defrning flow paths Systemcurvesmust be developed for all potentialflow paths.These curves relate the total headto the flow rate, They take into account static head, the pressure head,and friction head.fhe static headand pressure headcomponentsremainconstant the frictional as head increases with the flow rate. In most systems, thereis a control va1ve, which is adjusted addor remove to frictional head,therebyloweriogthe flow rate. Curvesare drawn for both open and shutpositions ofthe valve. Fromthe system curve, moves one to the pump performancecurve. lhis
7E CHEMICAL ENGINEERING /JANUARY1998

GET TO KNOW ^,.y,$iffi&r

pumps, theone sketchshows interCentrifugal like the shownbelow, themost are action of the elements commonly usedpumpin the ofthe system curvewith the process chemical industries pumpcurve.Thepumpoperatesat theiatersecfion ofthe pumpcurveandsystem curve. Thesystem curvecon trols the flow rate through the pump. Many handbooks are available that offertheoryantltips on the propercomposition of system andpumpcuryes. The next pla.oning step thecreation is ofa systemsketchthat incorporates flowpathsof the the system.This diagram graphically describesthe piping arrangement,pump placement,andrelated object asother such pumpsup- or downsfoeam control and valves.AII availableinfomration con- be definedfor all flow conditions,with gl; pressure cerning drops, viscosities, spe- adequate margiasspecified. Many en-!::l cific gravitiesandtemperatures should gineers forgetthat NPSHis not " it"tir i . bedenoted. condition. Rather, it is dynamic,andi,,,il In addition,the minimum flow, nor- must accountfor vaporizationof liquid i:l.r'l mal flow and ratedflow would be con- insidethe pump. i.ii sidered.Theminimumflow is the lowThe pressure iiquid in a centrifu-: of est flow ratc that the pump will see galpurnpdropsasit flowsfromthe suc-| under any operatingconditions.This tion flange,throughthe suctionnozzlet, flow rate is a process parameter, and andto the impeller.This pressure drop ; shouldnot be con-firsed the mini- is the fi:nction of many factors,includ- r with mal flow of the centrifugaipumpitself. ing designgeometry, rotationalspeed, ; Theratedflowrefersto the flow rate at flowrate,andfrictionallosses. curvej A which the pumpsandother equipment that showsthe minimrrmDressure rein the system shouid capable op- quired to prevent vaporizationanybe of eratiagin a like-new condition. in Unless where the pumpversus flowrate : the otherwise stated the process-designthroughthe pumpcanbegenerated in foi report, assume rated flow is 110 any pump-impeller the combination. The percent the normal of flow.This avoids NPSHris ihe minimumheaddescribed #n .,i, oversizing thepump. of by the curvefor any givenflow rate. .i'j.i, The differencebetween the actual tr; NPSHavs. NPSH. pressure, head,of the liquid avail- s, or The Net PositiveSuctionHead Avail- ableandthe vaporpressure that liq- ' of St able (NPSIQ versusthe Net Positive uid is called the MSH". When the : f"t. (NPSHT) SuctionHeadRequired is must NPSHa greaterthan or equalto the

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rs, with any ena static r.ic,and ,fli, I :ntrifu:hesucnozzle re drop includspeed, \ curve ure re, anY,wrate tedfor r. The cribed actual availat liqr the :o the

: Mechenical frt fit Mechanical in reiation to hydraulic for must be considered axial demands placed andradial loads,with emphasis on satisfactoryseal and bearing life. =P!H.-Ht.H--rp Radiaihydraulicloadsare createdas a result ofthe desip ofthe casingthat with tne lfeSn :nctrea.ses pr:rnpacsurrounds the impeller. AnY unbal practiceis to esbablish tv. normal.:-- ... ... impeller, "-i' Affectthe anOdd-foiceserbrited operating eon&iiionr; lhen * 'at :the ] are Axial load.s creiiidoi ana Uearings. margmm accommG a reasonable atedby the impeller when the suction in iricrease pumpany anticipated pressure either higher or lower than is capacilv. However, this .quicklY pressure.The thrust creatmospheric ofcaPacaddition to therepeated forceon the an atedplaces unbalanced process designmovesfrom as the the imPeller. areaof hub,or nose, and to , to user,to contractor, Radialloadsare taken into.account manufacturer.As a result a area the by sizing volutecross-sectional makingit vulpirrnp*uy beoversized, suchthat, at designflow, the fluid venrirableto surging,recirculation,cavilocity is nearly constant at all points noise, and vibration. across volutearea.Whenselecting the On the othersideof the coin,the unimpellers, choose styles with blunt cavof rrestimation NPSH"cancause vanetips or a wideradial gap,ifradial to damage the impeller.This ocmaybeproblematic. loads turs "r a result ofthe vibration caused bY Axial thrust canbe caused a variare filled with liqsomeimpellers ety of factorsinside the pump' These and otherswith gas. Pitting and iiid factorsinclude the location of the imofthe internal parts cansigniferosion peller relative to the stationary wall licantly lower pump lilb. A pump operofthe walls. roughness andthe surface i,ating with insuffinen:t NPSHa will To correctaxial thrust, impellers may bften pumpin sp'url's' be adjustedaxidly to maintain the corprediction. bY the . Proper Mffi. -manufacturer In the across vanes. adis alsa vital to proper than the mjnimal flow rate basedonly rect clearance ps-$e dition,impellersmay bemountedbackrise. in general, on temperature Itpo*p'operation- Otherwise rntrained the pumpenergylevel decreases, mini- to-back, or a double suction impeller j.air or gasmn causecavitation,.inp+Under ideal condiFor may be selected. p"tfottoanceand, ultimately, mud- IIow rate tendsto decrease. i..nent of Headlossdueto fric- example, pumps with high suction tions, the hydraulic axial forcesacting iiimpeller damage. t'tion anil fluid acceleration must be speed,and the resulting low MSH., 0n one side of the impeller balance are likely to have recirculationcavita- those on the other, and there is no carefirllyonsidered. tion in the inpeller idet. Therefore, thrust. Another alternative is to itni. theseimpeller designsrequire higher arrangethe impellersin seriesso that Minimalflow i*,::.' from oneend flow movesprogressively $i Operatinga centrifugal prunp at iess minimumflows. consid- of the pumpto the other. when tips point Some to remember or $, ttran the design best-efrciency '.fi;, 138t, flov rate increases potential eringminimum flow rate include: the .",'J' problens. it sometimes is 1. Assr:meno purnp is designedto Flow considerations However, for must be utilized .:*i, ""..tt"ty to adjustthe flow rate to sat- operatefor longer than about 15 min Flow controlsystems ',:i flow control within the so as to assure BEPflow conditions.But before this below isfv Drocess rangeofthe specoperating ,;' is done, a pump manufacturer'5mini- 2. Provide rninimum-flow byPass acceptable : mal flow requiement mu-stbe defined pipingfor high-energ/pumps ified pump.Properuse of flow control 'i such as flow control valves that reducethe mini- systems, to satisfy the system Iloln' and NPSH 3.Corrections rateis mum flows in the handling of hYdro- and flow meters, will ensure the shouldbeusedcarefirlly.These work done to calcuiate the NPSH carbons for attempt to accouat the and minimum flow rate will not be corrections are that many hydmcarbons com- wasted.In addition,correctcontrolof fact the dangersof dry runof the fluid beingpurnped. ald the load on posed fractionsthat vaporizeat dif- flow will avoid ferent temperatures.However,if the ning a pump. ihe impeller. Key perforrrance requirements are I The prsper rrinimun ftow require- corrections beingusedfor recirculaspeproveuseless. particularlyfluid characteristics, 6ent for most centrifi4PJ PurtrPs tion streams,they rnay i_. should6s fa-sedprimarily on the hy- Cavitationthat occurs duringthe recir- cificgravityandtemperature mustbe to origin andis clearly defined and communicated ..f.T' draulic desig:r: When calculated in culationis of a mechanical of selection the pump vendor.Proper related ,.- sucha way,theflow rateis oftenhigher not totally temperature
the purrrp "vill not cavitalce. is giren bl ilre puneploanufrrc, based ort lheil testir6 N?St{a be.calcullaiedunng

Toggtlhe most fromo centrifugol pump,you hqve lo kh6wollofits insond outs:,:+,

1 J C H E M I C A E N G I N E E R I N/G A N U A R Y 9 9 8 L

79

REFORT . FEATITRE

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x'a} design, of mar.erutks rsmg,tqid;igq and horseporrer _tfi lependent on ry* : the fluid chir:at**rhf;l*'i:. .

andthenwor}rngtowardthepiperac\ 3.'Excessiveloads to pr''np flanges during piping fabricamust be avoided tion by using temporarybracesald as supports required PipingDe^sigtr* long vibrations, resonant 4. To prevent sta'rd:nfi;*io,uld be apEngineering be supported'at'ui piper14sishould, pUJato piphg iesgn" rsifir'^rnqidera-tion equaldistances m pssfi*lesnfigy savings, siven 5. Carein the alignmentof piping com' that will ana Jliminatim of ta:bu-'bnce during ini' ponentsmust be exercised or adverseiyaffeli pu4, llrerformance Ual fabrication,to prevent problems be pumplife. Pariicularatientionmust later giventhe suctionPiPing. generous of expansionjoints use to remmber that the of pipe strarn ancl selectron ol the 6.The It is important that exin andloops pipingwill ensure below correct base design.If the PumP minimumFessuremwtnot droP on loadswill not beimposed the installed, vibration may cessive ofthe liquid at the not securely the vaporpressure to eventuallycausedamage the shaft pump pumpingtemperature'hessure drops that can of because and seals.If the base itself is not 7.The pipingfabricationerror throughoutthe system occur pmduce the largest piping strain is or resistance frictionwiththe piping,fit- properlytreated,it will needreplacenonparallelflangefaces.Caremust be All tingsandothercomponen-ts. ofthese ment or repair, which will result in takento avoidsuchsituations no changes fluid Pressuemust be ac- pumpdowntime. There are many base selections - The first aspect of installation is for counted in orderto pmperlysizethe today'Beyond to the engineer its punp:arnd driver to meetthe design foundationcreation.If a new founda- available the material of construction'us3rs is qm-r',r,ilfrionsi, pressnre changes' tion ofpouredconcrete used,anchor The the need for leveling and for oa:lsnkl"led eachbranchin bolts shouldbe checked rechecked must consider dvuul&be; vent holes, welding, continuous properplacement and projection. screws, for dierchalP tbe suciionand PiPing. and safetycorners rounded and drainpans, that Alsorernember the baseplate clrop Xhepressure, dlueto resistance oPtions. shouldnot be installeduntil flexiblenounting things,in- soleplates or frictitmihperibornrnany of 10 diYs have elaPsed tyBeof pipe being " -ioi*.tcludingthss'iit*aartr your manufacturer d-*he pipe'sinte- from the time when the foundation You and rsu.ghniess ifate used, developedto satisfy was Documentation poured,if normal concrete the ^r:icn'surfiae; leng*of the pipe and was guidelinesshould be re the design riiid:rctexibtics of the fluid. Today, used. About 85Voof the concrete are shrinkage should have occurred bY viewed by operations and mainiepipingsystems manysmoo:th-finish nanceprior to new installations and ofun listed fcr clean-in-place that time. availahle, when repair of existinginstallations.When' Grouting is vitaily important or utaitary use. are to evlr changes the process consid' of the Cbnsider piacement pipinge1e- securinga pump.The grout forns the and founda- ered. the reasonsfor selectionof a baseplate bond between in mentscarefirlly.The turbulence the iven pump must be reviewed. This iiquid entering the PurrP can often tion. Tbe forces and moments eornt.. that unnecessary Problems position- ated by the pumP and simplybyproper becontroiled will not be introducedto the process first bY the For ingofthepiping. exanple, place- equipmentare absorbed Any equipmentadditions must not ment of an elbowjoint parallel to the grout. Therefore,grout plays an imofpres= "uiutiu"iy impact the systemskeich the pumpshaft,directlybefore pump,is portantpart in the dissipation Ail for developed the process. marruto conducive spiralflowandunbaianced iure and vibration created bY the literature should be saved facturey's flow can pump. To facilitate good bondiag beflowdistribution.Thb unequal t part of the documentation. vihation,highaxial.- i*".tt th" foundation, baseplate and as excessive resultil Roberts Edited bv Sandra grout, a1lthe surfacesthat will noise carlieavitation. thrust loads, into contact with grout should suctibngriping,calculaWhensizing' to rated basedioa,rthe flow sand-blasted a near-whitefinish, References: tionsshould$e "CentrJ-firgal -*s;;;ffit," states Dufour. J., and Nelson, W., New Y6rk, Pulnf The suction unlessthe grout manufacturer N.Y' vahae'and the t\P-S'Ita McGrd*-l*u, is 1993. h*, iines shodd not, be smaiilerthan the otherwise.Oncethe grout - cured, "Centrifugal Punps ---D".-ig lnbanoff, V., and Ross,R., for the cavi- check baseplate voids bub nszzle".?o pumpsuetiion' Blrevent Htu' "ita epplication," 2nd ed., Grif, not in the grout. If any are found,drill a should ton. Tex., 1992. iine suct'ion veloeitjes tati-on, void i$ exceed fils ualess'ihs*isi a substan- hole at that location and fiIl the of *raig]xf p{u:isr,nediately usilg a groutgun. tial iengLh F:l pump Author iolan is the nationai accogi m3'tt"I-r.,. Whenpiping up a cen.trifi-r.g:atr of u,pst'rearn the.pump. Yillianr,{. be "itr A.R. wil(b,v & Sons, Lnc. @:O- B-otr": should considered: fotrlowing ;the Ploni: 303-7?9-1lj;*: pipiag to the PumP fr5b. tj*to, Col{nno-i; WiUIey in lgbr ' ' 1. Never connect Fax:30&:l79LZ7i;). He rar'red Funp installation m the pump industry for 25 ye.f)* ; ' Having rmrked Proper atteniisn nust be given to prior to grouting Tolan has been involved in prmp- design' appltg'.q .. that Z. fne piping systemshouldbe fabri- tion. reliabiliry improvement and sales. lie hor:i. procedr-ues purnp inslallation B.S. and M.S. degreesin mechanical engtneeflns:: guaranteeproper grouting,reduction catedby stariing at the purnpflanges
e r l D

80

1998 / ENGINEE3INGJANUARY CHEMICAL

Pressure Loss Due to Friction

Flow is always accompanied by friction. This friction results in a loss ofenerry available for work. A general equation for pressure drop due to friction is the Darcy-Weisbachz (often referred to as simply the Darcy) equation. This equation can be rationally derived by dimensional analysis, with the exception of the friction factor, f-, which must be determined experimentally. Expressed in feet offluid this equation is: f- gO , = - ZL V z ttr EqlT-6

is the sum of the A Plvalues calculated for the individual segments. For gas applications the segmental length may be relatively short, as compared to liquid applications, since many gas applications involve compressible gases where gas densities vary with pressure.

Friction

Factor and Effect of Pipe Roughness

When the fluid flow is laminar (Re<2000), the friction factor has a direct relationship to the Reynolds number, such that:

f- = 64 /Re or fr = 16 /Re

Eq 17-8

Converting to pounds per square inch, the equation becomes:

Piperoughness no effecton the friction factorin laminar has flow. Substitution of the formula for Reynoldsnumber,Eq 17-4, into Eq 17-8,yields the following:

*'ap.=

Pll=t Y' (ta4)D(2e")

Eqrz-7

It shouldbe notedthat the Moodyfriction factors,f-, is usedin the equationsabove.Someequationsare shown in terms of the which is onefourth of f^ (f- = 4.0 fr).A Fanningfriction factor,f1, graph of both Fanning and Moody friction factors as a function in numberappears .f iS. i 7-?. of Reynolds equation is valid for both laminar and The Darcy-Weisbach with turbulent flow of any liquid, and may alsobe usedfor gases in certain restrictions.When using this equation,changes elevation, velocity,or density must be accountedfor by applying Berequation must be applied noulli's theorem.The Darcy-Weisbach to line segmentssufficiently short such that fluid density is essentially constantover that segment.The overall pressuredrop

'-=ff=(,,i)t,*)t+)
= APr o.ooo6ur#

Eq 17-9

This expressioncan then be substitutedfor the friction factor in Eq 17-7,resulting in the following formula for pressure lossin poundsper squareinch: Eq 17-10

law Eq 17-10is commonlyknown as Poiseuille's for laminar flow. When the flow is turbulent, the friction factor dependson the Reynoldsnumber and the relative roughnessofthe pipe,

FlG.17-2 FrictionFactorss

05 01

0.0r5

0.03 0.02 0.015

0.010 0.009 0.008 0.007 0.006 0.005

0.01 0.m8 006 Ralalivr Rouehnrss

0.002 0.00r 0 0000 0.m06 0.0001 0.0002 0.m01 0.00005

3 1 5 6 8 1 0 '?

3 1 5 6 8 Re

3 4 56 8

3 1 5 6 I

{ 56 Bl d

Rcynolds lumlcr - ?Y!'

i o.ooo,oos

't7-3

Revised (5-99)