Advanced Hydraulic Course

Lorenzo Pozos C. April-2017

 Pump Hydraulic Design

Introduction to Pump Hydraulics Design &

Performance Modification
The Physics of Impeller Head Generation
Velocity Triangles
Similarity Laws and Pump Scaling
Modifying Pump Performance
Influence of major impeller hydraulic parameters
Influence of major volute hydraulic design
parameters
Theoretical Head vs Actual Head
Impeller Velocity Triangles & Theoretical Head
Impeller Exit Velocity Triangle Flow Deviation
Theoretical Head vs Actual Head
Pump Head
Dimensionless Parameters
Change Diameter & Speed Affinity Laws
Change Diameter & Speed Affinity Laws
Matching a Pump to Its Duty
Matching a Pump to Its Duty
Impeller Design: Number of Vanes, z
Impeller Design: Exit Width B2
Impeller Discharge Vane Under File (U/F)
Impeller Under File (U/F)
Impeller Discharge Vane U/F
Volute Lip Cutback-Increase Nozzle Area
Volute Lip Cutback-Increase Nozzle Area
Effects of Increase Nozzle Area
 Nozzle Inserts To Achieve Broad
Hydraulic Range in Single Pump Case
ABILITY GET ANY OF THE
PERFORMANCES IN ONE PUMP
CASE
DIFFICULT DUE TO RANGE OF
PERFORMANCE AND LIMITED
SPACE TO WORK WITH.
THIS WOULD HAVE BEEN AN
IN-EFFICIENT MANUAL
MODIFICATION
BECAUSE THE LIPS EXTEND
PAST
THE SPLIT LINE.
Introduction to Cavitation & Impeller Inlet Desig Design

Introduction to pump cavitation

Inlet velocity triangle and incidence
Incipient cavitation versus 3% head breakdown
Influence of blade leading edge design on
cavitation
Cavitation Erosion
Specifying NPSH Margin
Cavitation What is it?
Cavitation What are the Consequences?
Evaluation of Cavitation Erosion
Cavitation Erosion on Volute & Diffuser Inlet
Impeller Inlet Velocity Triangle
Inlet Incidence (i1) Local Pressure
Suppression
Impeller Inlet Vane Pressure Suppression
Cavitation and Relative Flow Rate, Q/QSF
Affecting Pump NPSHR Performance
Protecting Against Cavitation Erosion
What to Avoid This!
Assessing Risk of Cavitation Erosion
Assessing Risk of Cavitation Erosion
 Radial Impeller Hydraulic Design
Procedure to establish hydraulic design
1.Establish operating conditions.
2.Decide on best efficiency point (BEP), either at right or left of operating
conditions.
If BEP is not specified by customer or if several operating conditions are
required use judgement in relationship to run-out how minimum flow
and rated flow.
3.Decide on RPM, direct-drive or driven through or gear.
4.Calculate conditions for full-diameter impeller. Use customer specifications
for future or required head or capacity increase.
5.Calculate specific speed (Ns). If multistage pump calculate Ns for different
number of stages in form of tabulation.
 Radial Impeller Hydraulic Design
6.Decide on proper number of stages. Too low Ns will result in lower
efficiency, large impeller diameter and low ratio of L/D (stiff pump: good
for dry-run conditions). Higher number of stages or higher Ns will result
in better efficiency, but the becomes longer with a high ratio of L/D. In
addition, overall length requirements by the customer has to be
considered.
7.Calculate suction specific speed (Nss). Use 1/2 Q for double suction
impeller.
8.Specify the required slope or rise to shut-off.
9.Look for about six tested pumps with the same Ns, Nss as calculated and
required rise to shut-off as models.
The Ns of the model should be within +-5% of the calculated Ns and by
applying the Affinity Law changed to the required Ns
(Trimming/Extending of impeller diameter).
 Radial Impeller Hydraulic Design
The models have to be as close in size to the new impeller as possible. Some
should be larger and some should be smaller.
The eye of impeller (Nss) can be calculated using different models with the
same number of vanes.
Use the model factor formulas to establish the size factors. This size factor
applies to all dimensions, the vane angles and number of vanes remain the
same.
10.Average out the factored dimensions, vane angles, number of vanes and
areas of the six tested models to achieve the basies for the design of the new
impeller and volute.
11.Lay out the impeller vanes accordingly and establish the impeller outlet area.
12.Calculate the throat area of the new volute by averaging. The throat areas of
the six tested pumps are multiplied by the square of their corresponding size
factors.
13.Calculate the area ratio of impeller outlet area to volute throat area.
14.According to Anderson, this area ratio should coincide with the calculated
Ns.
 Radial Impeller Hydraulic Design
15.Use Anderson curves to establish head and capacity coefficient. The
Anderson curves are the result of many tested pumps.
Use head and capacity coefficient to calculate the expected head and
capacity of B.E.P. If these values agree with the required conditions ( at
full diameter) stay with the discharge portion(outlet area) of the impeller
lay out.
16.Reduce the factored throat area of the volute by about 5%. This is a
precaution because in case the first full diameter test shows that the
B.E.P. is not exactly at the desired capacity, it is easier to open up the throat
area by grinding, than reducing it by welding.
17.The six tested models could have had a light or heavy duty shaft because
of:
Low or high number of stages,
Low or high strength of materia,
Low or high brake horse power(BHP) per stage, because of lower or higher
specific gravity of the pumped liquid.
Therefore a check of the factored impeller eye diameter and area has to be
done.
 Radial Impeller Hydraulic Design
Using the Bunjes Method(established from many tests), the optimum eye
diameter and area can be established in relationship to the required NPSH
or Nss.
Remember , low NPSHR values or high Nss might cause recirculation in the
eye of the impeller and the limit for the continuos minimum flow would
have to be establish at a higher value otherwise the reliability of the pump
would be reduced.
In the most cases the factored eye diameter and area will be very close to
the optimum, because some of six tested model pumps had a light and
others a heavy duty shaft.
18.Small changes to the factored impeller dimensions can be considered as
Fine-tunning to achieve the optimum efficiency, reliability and
availability of the pump.
19.New pattern will be manufactured in accordance to the new final layout
drawings.
 Radial Impeller Hydraulic Design
20.This described method is much more efficient in all areas of pump
performance, than using an existing impeller and extend the diameter in
the hope to achieve the performance required by the customer.
Extended impeller are almight for normal duty pumps.
For heavy duty and high energy pumps with good efficiency and optimum
reliability and availability to perform a new impeller pattern is the way
to go.
There is no mismatch involved. Extended impellers will produce most
likely the required head capacity conditions, but the impeller eye is still
designed for the original conditions.
The result is mismatch of flow and impeller angles, prewirl, discharge
recirculation, increase in vibration and noise level and loss of reliability
and availability to perform.
21.To apply Factoring Law, see procedure into separated pages.
New pump curve
red color
 New pump technical data 3x4x7.5-1 OHH
3520 RPM speed 3550 RPM speed

-Q= 430 gpm - Q= 404.73 gpm

-H= 195 ft - H= 172.75 ft
-NPSHR= 12.5 ft - NPSHR= 11.07 ft
-Ns= 1399 - Ns= 1498.8
-Nss= 10980 - Nss= 11767.93
-Eff= 76 % - Eff= 75.6 %
-Eff hyd= 79.8% - Eff hyd= 79.47 %
-Slope to shut off= 15.2% - Slope to shut off= 15.73 %
-No. vanes= 5 - No. Vanes= 5
-outside diam= 7.50 - Outside diam= 7.00
-Eye diam= 3.75 - Eye diam= 3.75
-B2= 0.600 - B2= 0.600
-BHP= 27.86 -BHP= 23.35
 Model
pump
curve A
blue color
 Model pump technical data 3x2x6 D-800
3550 RPM speed 3550 RPM speed

-Q= 322 gpm - Q= 350 gpm

-H= 153 ft - H= 176.57 ft
-NPSHR= 15 ft - NPSHR= 17.39 ft
-Ns= 1464 - Ns= 1371
-Nss= 8358 - Nss= 7799
-Eff= 77 % - Eff= 77.5 %
-Eff hyd= 80.7% - Eff hyd= 81.15 %
-Slope to shut off= 20.3% - Slope to shut off= 21.5 %
-No. vanes= 5 - No. Vanes= 5
-outside diam= 6.50 - Outside diam= 7.00
-Eye diam= 3.19 - Eye diam= 3.194
-B2= 0.520 - B2= 0.560
-BHP= 16.15 - BHP= 20.13
Model pump curve B red color
 Model pump technical data 3HPX7A
3540 RPM speed 3550 RPM speed

-Q= 340 gpm - Q= 340.96 gpm

-H= 156 ft - H= 156.88 ft
-NPSHR= 11.7 ft - NPSHR= 11.76 ft
-Ns= 1479 - Ns= 1478.78
-Nss= 10318 - Nss= 10322.25
-Eff= 69 % - Eff= 69.1 %
-Eff hyd= 73.5% - Eff hyd= 73.65 %
-Slope to shut off= 22% - Slope to shut off= 21.1 %
-No. vanes= 5 - No. Vanes= 5
-outside diam= 7.05 - Outside diam= 7.00
-Eye diam= 3.309 - Eye diam= 3.309
-B2= 0.559 - B2= 0.559
-BHP= 19.4 - BHP= 19.54
Model pump curveC
 Model pump technical data 2x4x7N 3700
3550 RPM speed

-Q= 362 gpm

-H= 175 ft
-NPSHR= 10 ft
-Ns= 1404
-Nss= 12011
-Eff= 73 %
-Eff hyd= 77.16%
-Slope to shut off= 17.6%
-No. vanes= 5
-outside diam= 7.00
-Eye diam= 3.413
-B2= 0.560
-BHP= 21.9
Factored features calculation
Hydraulic Calculations
Apply the size
factor f
 New pump
factored curve
Impeller Design Guidelines
Efficiency Correction
Estimation of total efficiency
Formulas for refiguring pump performance with
impeller diameter or speed change
Impeller Trim correction
Percent head rise
Head constant
Capacity constant
Impeller eye diameter/outside diameter ratio
 Recommended
minimum
impeller vane and
shroud thickness
for casting
Area between vanes/eye area ratio
Suggested standard for vane number
Predicting efficiency on both sides of BEP
Impeller Proportions
 References
- Centrifugal Pumps Design and Application, Val S. Lobanoff, Robert R. Ross
- Centrifugal Pumps and Blowers , Austin H. Church
- Centrifugal Pump Design and Performance , David Japikse, William D.
Marscher, Rymond B. Furst
- Centrifugal and Axial Flow Pumps, A. J. Stepanoff ph D.
- Pump Handbook Fourth Edition, Igor J. Karassik, Joseph P. Messina, Paul
Cooper, Charles C. Heald
- Centrifugal Pumps, Johann Glich
- The Interaction Between Geometry and Performance of a Centrifugal
pump, B. Neumann.
- Pamphlets from Worthington Pumps, Goulds Pumps, Flowserve Pumps
and Sulzer Pumps.