ChE 203

More on Pumps

Contents
Basic Conversions Series and Parallel Configurations Reciprocating Pumps Rotary Pumps Rotary Lobe Pumps Pump Performance Centrifugal v/s PD pumps Liquid Ring Vacuum Pumps

Converting Head to Pressure

Converting head in meter to pressure in bar p = 0.0981 h (1) where h = head (m) p = pressure (bar) Converting head in meter to pressure in kg/cm2 p = 0.1 h (2) where h = head (m) p = pressure (kg/cm2) Converting head in feet to pressure in psi p = 0.434 h (3) where p = pressure (psi) h = head (ft) = specific gravity

Converting Pressure to Head

Since pressure gauges often are calibrated in pressure - psi or bar, it may be necessary with a conversion to head - feet or meter, common used in pump curves. Converting pressure in kg/cm2 to head in meter h = p 10 / (4) where
h = head (m) p = pressure (kg/cm2)

Converting pressure in bar to head in meter h = p 10.197 / (5) where

h = head (m) p = pressure (bar)

Converting pressure in psi to head in feet h = p 2.31 / (6) where

h = head (ft) p = pressure (psi)

Pumps in Serial - Heads Added

When pumps are arranged in series, their resulting pump performance curve is obtained by adding heads at the same flow rate. For two identical pumps the head will be twice the head of a single pump at the same flow rate.

Two Pumps in Series

Pumps in Parallel - Flow Rate Added

When pumps are arranged in parallel, their resulting performance curve is obtained by adding their flow rates at the same head. For two identical pumps the flow rate will be twice the flow rate of a single pump at the same head

Pump Types
Pumps Positive Displacement Centrifugal

Reciprocating

Rotary

Radial

Axial

Mixed Flow

Plunger/Piston

Lobe/Gear

Diaphragm

Vane

Gear

Screw

Reciprocating Pump Types

Single Acting piston pump discharge curve Simplex Double Acting piston pump discharge curve

Reciprocating Pumps Flow Characteristics

Pulsation Dampeners

A pulsation damper absorbs only that portion of piston displacement above mean flow, and then stores it momentarily before discharging it during the portion of the cycle below mean flow (on the suction stroke).

Why?

Reduce high pressure fluctuations in the piping system that can either overpressure or fatigue components in the piping system Attenuate the frequency of the pressure pulsations produced by the pump Eliminate relief-valve chatter Provide relatively steady flow if large variations cannot be tolerated by the process Reduce acceleration head and friction losses to maximize NPSHA when installed as a suction stabilizer in the suction piping Reduce pump brake horsepower Minimize check valve wear

Dampener Working Principle

Half way through the pistons forward travel (discharge stroke), fluid velocity between the discharge check valve and the pulsation damper begins to decay. The corresponding drop in pressure causes the membrane inside the damper to expand, since the internal gas pre-charge pressure is now higher than the line pressure. The (stored) fluid now being displaced by the pulsation damper maintains velocity downstream of the damper thereby reducing, if not eliminating, any downstream pulsations. A pulsation damper removes pulses only from the line downstream of the damper not upstream. Discharge damper installations to be made as close to pump discharge nozzles as possible. In an application of a damper for suction stabilization (reduction of acceleration head losses) it is the velocity gradient between the supply vessel and the suction nozzle that is minimized.

Bladder Type Pulsation Dampener

Single liquid connection at one end of the metal housing A gas-charging valve at the other end with the bladder between. The gas volume acts as a spring, compressing and expanding to meet liquid system pressure changes. Shown: charging valve, bladder in the middle of the bottle, the antiextrusion button, the port, Gas/liquid phases.

The charging must be made with atmospheric pressure at the liquid port. The pre-charge should be set between 50 percent and 70 percent of the system pressure.

Diaphragm Pumps

Wilden T2 - 25 mm (1") Metal Pump

FLOW RATE

Rubber/TPE 133 lpm (35 gpm)

Teflon 95 lpm (25 gpm)

MAX PRESSURE
8.6 bar (125 psig)

MAX. SOLIDS PASSAGE

3.2 mm (1/8")

MAX. SUCTION LIFT

(wet): Rubber/TPE 9.5 m (31.0') Teflon 9.5 m (31.0') (dry): Rubber/TPE 5.2 m (17.0') Teflon 1.8 m (6.0')

SPECIFICATIONS
Height: 279 mm (11.0") Width: 268 mm (10.5") Depth: 184 mm (7.3") Air Inlet: 6 mm (1/4" FNPT) Liquid Inlet: 25 mm (1") Liquid Outlet: 19 mm (3/4")

Flow Curve

To pump 394 lpm against a discharge pressure head of 1.4 bar requires 4.1 bar and 102 Nm3/hr air consumption. Dot on chart represents the plotted intersection and the circled numbers are the air pressure and volume figures.

Installation

Discharge regulation
Limiting the volume and/or pressure of the air supply to the pump. An air regulator is used to regulate air pressure. A needle valve is used to regulate volume. Throttling the pump discharge by partially closing a valve in the discharge line of the pump. This action increases friction loss which reduces flow rate (control the pump from a remote location). When the pump discharge pressure equals or exceeds the air supply pressure, the pump will stop; no bypass or pressure relief valve is needed, and pump damage will not occur. The pump has reached a deadhead situation and can be restarted by reducing the fluid discharge pressure or increasing the air inlet pressure.

Surge Dampening

As the reciprocating pump begins its stroke, the liquid discharge pressure increases and flexes the diaphragm inward, accumulating fluid in the liquid chamber. When the pump redirects its motion, the liquid discharge pressure decreases allowing the diaphragm to flex outward displacing the fluid into the discharge line A compressed air line attached to the air side of the air regulator body sets and maintains pressure on the air side of the diaphragm.

Efficiency of Reciprocating Pump

There are only two efficiency losses Volumetric and Mechanical. Volumetric efficiency loss is induced by slippage through valves, ratio of liquid chamber volume at end of stroke to plunger/piston displacement volume, and liquid compressibility. Mechanical efficiency loss occurs while overcoming mechanical friction in bearing and speed reduction. The overall efficiency of a reciprocating pump unit is generally above 85 percent throughout its full operating range.

Rotary Pumps

 Advantages Two moving parts One stuffing box Positive suction, non-pulsating discharge Ideal for high viscosity liquids Constant and even discharge regardless of varying pressure conditions Low NPSH required Easy to maintain

Internal Gear Pumps

Disadvantages
Low speeds usually required Medium pressure One bearing runs in pumped product Overhung load on shaft bearing
Internal gear pumps are ideal for high-viscosity liquids, but they are damaged when pumping large solids.

External Gear Pumps

Advantages High speed Medium pressure No overhung bearing loads Relatively quiet Design lens itself to use of a wide variety of materials Disadvantages Four bushings in liquid area Four stuffing boxes No solids allowed

External gear pumps (shown is a double pump) are typically used for high-pressure applications such as hydraulics

Lobe Pumps
Advantages Pass medium solids High acceptance Little galling (frictional wear) possibility Disadvantages Timing gears More space required May require factory service to repair Two seals

Lobes in lobe pumps do not make contact, because they are driven by external timing gears

Sliding Vane Pumps

Advantages Medium capacity Medium speed Thin liquids Sometimes preferred for solvents, LPG Can run dry for short periods Can have one seal or stuffing box Develops good vacuum Disadvantages Can have two stuffing boxes Medium pressure Complex housing Not suitable for high viscosity Not good with abrasives
Vane pumps have better dry priming capability than other positive displacement pumps.

Rotary Pump Applications

Pump Selection Guide Abrasives Internal Gear External Gear Lobe Vane G P G P Thin Liquids G G A E Viscous E G E A Solids P P E P Dry Prime A A A G Diff. Pressure G E G A

E = Excellent, G = Good, A = Average, P = Poor

Rotary Lobe Pumps

Attributes include:
Gentle transfer of delicate suspended solids. Bi-directional operation. Compact size with high performance and low energy input. Ability to pump shear sensitive media. Easy maintenance.

EOU Dryer Feed Pump

FEED PUMPS 61P1, 62 P1, 63 P1
Make
Impeller Dia Motor Make Motor rating Motor rpm Rated rpm Fluid Sp Gr Fluid temperature

SRU2/018/HS with AINSI B16.5 Flange

Trilobe Siemens 1.5kW/2 HP 1420 rpm 200 RPM 1.3 30 C

H= Vertical orientation S= SS shaft

Shanti Gear Box

Coupling Guard Plain Base Frame

Type F20-YU and 2 HP ND 90L

SS 304 SS 304

Pump System Design

Confirm the Net Positive Suction Head requirements of the pump (NPSHr) are met by the system, as this is crucial for ensuring the smooth operation of the pump and preventing cavitation. Avoid suction lifts and manifold/common suction lines for two pumps running in parallel, as this may cause vibration or cavitation. Protect the pump against blockage from hard solid objects e.g. nuts, bolts etc. Also protect the pump from accidental operation against a closed valve by using one of the following methods: - relief valves, pressure switch, and current limiting device.

Slip

Slip is the fluid lost by leakage through the pump clearances. The direction of slip will be from the high pressure to the low pressure side of the pump i.e. from pump outlet to pump inlet.

Factors Affecting Slip

The amount of slip is dependent upon Pressure Clearance Viscosity.

Pump Characteristic and System Curve

Pump Performance Curve

Net Positive Inlet Pressure (NPIP)

NPIPA = Pa +/- Pz - Pf - Pvp Pha where NPIPA = net positive suction head available, kPa Pa = absolute pressure working on the fluid in the suction vessel or sump, kPa Pvp = vapor pressure of the fluid being pumped at the pumping temperature, kPa Pz = static height above (+) or below (-) centerline of the cylinder, kPa Pf = piping friction loss, m(based on equivalent length) kPa Pha = acceleration head, m (based on actual length) kPa NPIP Required (NPIPR) is a function of pump type, speed and viscosity of fluid pumped. NPIPA must always be greater than NPIPR to prevent cavitation. NPIPR values published by manufacturers are expressed in kPa units.

NPIP- Rotary Pumps

Rotary pumps are often selected to move liquids with a low vapor pressure point, or fluids with a lot of entrained bubbles. NPIP required (NPSH) is difficult to test and is established at the point where Cavitation noise is heard. A 5% reduction in capacity at constant differential pressure and speed A 5% reduction in power consumption at constant differential pressure and speed.

Flow Regulation
Discharge throttling Not Possible Suction throttling Not possible Recycle control Efficient method of control for PD pumps. The flow rate constant, the power requirement is roughly proportional to discharge pressure. The effect of recycle is to drop the discharge pressure, it results in reductions in power requirement. Power wasted is in proportion to discharge pressure times recycle flow. Speed Control Stroke Adjustment

Centrifugal Versus Positive Displacement Effect of Viscosity

Comparison
Parameter Optimum Flow and Pressure Applications Maximum Flow Rate Low Flow Rate Capability Maximum Pressure Requires Relief Valve Smooth or Pulsating Flow Variable or Constant Flow Self-priming Space Considerations Costs Centrifugal Pumps Medium/High Capacity, Low/Medium Pressure 20000+ m3/h No 400+ kg/cm2 No Smooth Variable No Requires Less Space Lower Initial Lower Maintenance Higher Power Suitable for a wide range including clean, clear, nonabrasive fluids to fluids with abrasive, high-solid content. Not suitable for high viscosity fluids Lower tolerance for entrained gases Reciprocating Pumps Low Capacity, High Pressure 2000+ m3/h Yes 7000+ kg/cm2 Yes Pulsating Constant Yes Requires More Space Higher Initial Higher Maintenance Lower Power Suitable for clean, clear, nonabrasive fluids. Specially-fitted pumps suitable for abrasiveslurry service. Suitable for high viscosity fluids Higher tolerance for entrained gases Rotary Pumps Low/Medium Capacity, Low/Medium Pressure 2000+ m3/h Yes 250+ kg/cm2 Yes Smooth Constant Yes Requires Less Space Lower Initial Lower Maintenance Lower Power Requires clean, clear, nonabrasive fluid due to close tolerances Optimum performance with high viscosity fluids Higher tolerance for entrained gases

Fluid Handling

Liquid Ring Vacuum pumps

Operating Principle
An impeller (A) is mounted eccentric to a round pump body (B) and enclosed between two endplates. As the body is partially filled with service liquid before operation, the impeller rotation creates a liquid ring (C) concentric to the body by the action of centrifugal force. As the cavities pass the suction port, the volume of liquid within them reduces, and this in-turn creates a negative pressure. This acts as the pumps suction, drawing more gas from the vessel to be evacuated. As the impeller continues to rotate, these cavities become filled with the liquid ring, and the entrained gas is compressed. As rotation continues past the discharge port, all gas and some service liquid is forced out of the pump. The liquid ring can be regenerated through the use of a separator (D).

Design Data
Inlet pressure, usually expressed in mm Hga Inlet temperature Mass flow rate, usually expressed in kg/hr and the molecular weight of fluid components Vapor pressure data for each fluid component Seal fluid data, if other than water: specific gravity, specific Heat, viscosity, thermal conductivity, molecular weight and vapor pressure data Temperature of the seal fluid or cooling water Discharge pressure, usually expressed in kg/cm2

How To Avoid Cavitation

Use a colder seal fluid. Use a seal fluid with a lower vapor pressure. The seal fluid should be compatible with the process gas mixture and the materials of construction. Increase the inlet operating pressure beyond the range of cavitation. Check the loading and operating pressure. If the load is less than design, a vacuum relief valve or air bleed valve can be used to introduce additional load so the pump will be able to operate closer to the design pressure. Install a booster upstream of the liquid ring vacuum pump to compress and raise the absolute pressure of the vacuum pump suction. An ejector works by using pressure energy of the motive to increase the velocity of the entrained gas load. This produces a higher absolute pressure at the outlet of the ejector. Increase the throughput of seal fluid, if possible.