Performance Characteristics Key Design Parameters Calculation Method Specification Data Sheet Selection Guidelines Control Systems Typical Operating Problems
Pumps and Pumping Systems Positive Displacement Reciprocating Rotary
Kinetic or Centrifugal Radial Axial
Categories and Types Pumps and Pumping Systems Selection Guidelines 1820m 30.5m 227m 3 /h 2.3m 3 /h Pumps and Pumping Systems Positive Displacement Pumps Pumps and Pumping Systems Centrifugal Pumps 1.Casing, volute 2. Impeller, vanes, vane tips, backplate, frontplate (shroud), back vanes, pressure equalising passages 3. Back cover parallel to Plane of the impeller intake 4. Stuffing Box - Gland/mechanical seal housing, packing/lantern ring 5. Pump shaft 6. Pump casing 7. Bearing housing 8. Bearings 9. Bearing seals 8 9 Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Positive displacement Pumps are Constant Volume Pumps
Centrifugal Pumps are Constant Head Pumps Pumps and Pumping Systems Centrifugal Pumps Effect of Fluid Density on Pressure with Constant Head 9.8 bar 11.8 bar 7.4 bar 1 0 0 m
Water SG=1.0 1 0 0 m
Brine SG=1.2 1 0 0 m
Gasoline SG=0.75 P = gh: g = 9.81 m/s 2 Pumps and Pumping Systems Centrifugal Pumps Pump Head Calculation: Example 1 Calculate the total differential head for the following pumping system: 3 m
2 0 m
3m of 10 pipe 45m of 8 pipe 8 gate valve 8 check valve 1.8 bar 340 m 3 /h capacity Hydrocarbon, sg = 1, = 0.9cP Pumps and Pumping Systems Centrifugal Pumps Pump Head Calculation: Example 1 Discharge head:
Static head = 20m Pressure head = 280/(9.81x1) = 28.5 m
Friction: for 8 line, flow = 340 m 3 /h:
u = 340/3600/((/4)*0.203 2 ) = 2.9m/s
Re = 1000 x 2.9 x 0.203/0.0009 = 6.5 x 10 5
/d = 0.0018/7.98 = 0.00023
f = 0.016
P/100m = 0.016 x 100 x 1000 x 2.9 2 /(2 x 0.203) = 33.1 kPa/100m
Pumps and Pumping Systems Centrifugal Pumps Pump Head Calculation: Example 1 Length of 8 pipe = 45m 3 x 8 elbows = 3 x 20.2ft = 60.6ft = 18.5m 1 x gate valve = 4.5 ft = 1.4 m 1 x check valve = 50 ft = 15.2m Exit loss = 20 ft = 6.1m Total = = 86.2m
P friction = 86.2/100 x 33.1 = 28.5 kPa h friction = 28.5/(9.81 x 1) = 2.9 m, add 20% safety for pump h friction = 1.2 * 2.9 = 3.5 m
Total Discharge head = 3.5 + 20 + 28.5 = 52 m
Pumps and Pumping Systems Centrifugal Pumps Pump Head Calculation: Example 1 Suction head:
Static head = -3m Pressure head = 100/(9.81x1) = 10.2 m
Friction: for 10 line, flow = 340 m 3 /h:
u = 340/3600/((/4)*0.255 2 ) = 1.85m/s
Re = 1000 x 1.85 x 0.255/0.0009 = 5.2 x 10 5
/d = 0.0018/10.02 = 0.00018
f = 0.015
P/100m = 0.015 x 100 x 1000 x 1.85 2 /(2 x 0.255) = 10.1 kPa/100m
Pumps and Pumping Systems Centrifugal Pumps Pump Head Calculation: Example 1 Length of 10 pipe = 3m 1 x 10 elbows = 26ft = 8m Entrance loss = 15 ft = 4.6m Total = = 15.6m
P friction = 15.6/100 x 10.1 = 1.6 kPa h friction = 1.6/(9.81 x 1) = 0.16 m, add 20% safety for pump h friction = 1.2 * 0.16 = 0.2 m
Total Suction head = -3 + 10.2 0.2 = 7 m
Total differential head = 52 7 = 45 m
Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Centrifugal Pumps Pumps and Pumping Systems Centrifugal Pumps For similar conditions of flow (ie the same efficiency): Capacity is directly proportional to speed Head is directly proportional to the square of speed & Power is directly proportional to the cube of speed Pumps and Pumping Systems Centrifugal Pumps This translates into the corresponding formulae (for variations in speed with impeller diameter remaining constant) :
Q2 = Q1 x (N2 N1) H2 = H1 x (N2 N1) 2 and P2 = P1 x (N2 N1) 3
However, the above formulae can also be used to determine the relationship between impeller Diameter and flow, Head and Power by substituting speed (N) with Impeller Diameter (D), keeping Speed constant. Results in this case are approximate as these formulae are analogous to the Affinity Laws above.
Q2 = Q1 x (D2 D1) H2 = H1 x (D2 D1) 2 and P2 = P1 x (D2 D1) 3 Pumps and Pumping Systems Centrifugal Pumps Design Parameters
Temperature Properties Capacity Head (TDH) Cavitation (NPSH) Horsepower Efficiency Pumps and Pumping Systems Centrifugal Pumps Liquid Properties
Specific Gravity Composition/Quality Vapour Pressure Viscosity Pumps and Pumping Systems Effect of Viscosity on Pump Performance Pumps and Pumping Systems Viscosity Correction Pumps and Pumping Systems Centrifugal Pumps Cavitation
NPSH = Net Positive Suction Head Available Required
Calculation NPSH Pumps and Pumping Systems Centrifugal Pumps Cavitation Formation of vapour bubbles in pump Occurs when pressure NPSH A falls below vapour pressure Reduces capacity and efficiency Eventually flow ceases Causes noise, vibration, erosion and pump failure if allowed to persist for a prolonged period of time Pumps and Pumping Systems Centrifugal Pumps Avoiding Cavitation Establish accurate range of flow for pump. If running speed higher than pump curve data multiply NPSH R at curve speed by speed ratio ( eg. NPSH R = 3.2 x (1800 / 1500) = 3.84 m) Avoid suction specific speeds of over 6750 (metric) or 11,000 (usgpm). If possible select a pump with rated flow within 10% of best efficiency point (BEP). Select for NPSH A 10% above NPSH R . Require witnessed pump tests over flow range for critical service applications. Dont accept model tests as a basis for larger pumps. Centrifugal Pumps Net Positive Suction Head Available (NPSH A )= Static Head + Head developed
NPSH A = hp s + h s hvp s hf s
hp s Pressure Head h s Static suction Head (@ min. supply level) hvp s Vapour pressure Head (@ max. pumping temperature) hf s Friction Head
p s h s
hf s hvp s NPSH Centrifugal Pumps NPSH Example The cooling water used for cooling of the reactor during the reaction is pumped from an open tank. Calculate the NPSHA for the pump given the following conditions: Temperature of Water = 30c, Density (r) @ 30C = 995.7 kg / m 3
Centrifugal Pumps NPSH Example 1 Using the formula: NPSHA = Hts Hvap
Where Hts = total static head = Atmospheric Pr (Ha) suction lift (Hs) friction losses (Hf) = Ha x 1000 2.6 (1 + 0.9 + 0.4 + 0.1) g x r = 101.325 x 1000 2.6 2.4 9.81 x 995.7 = 10.38 2.6 2.4 = 5.38m H vap = 4.241 x 1000 9.81 x 995.7 = 0.43m NPSH A = 5.38 0.43 = 4.95m
Add 10% safety factor for value specified to pump supplier: The NPSH required is thus 4.95/1.1 = 4.5 m Centrifugal Pumps NPSH Example 2 Water temperature - 125 C Density @ 125 C 939 kg/m 3
Vapour pr @ 125 C = 230 kPa (absolute) Gauge pr = 130 kPag Gravitational acceleration = g = 9.81 m/s^2 Suction head (Hs) = 4.0m max, 1.0m min Pipe friction loss = 1.1m Valve friction loss = 0.1m NPSH A = Hts - Hvap Hsmin = 1m max Centrifugal Pumps NPSH Example 2 H ts = Ha + Hs - Hf = (101.325 + 130) x 1000 + 1 (1.1 + 0.1) 9.81 x 939 = 25.1 + 1 1.2 = 24.9 m H vap = 230 x 1000 9.81 x 939 = 25.0 m NPSH A = 24.9 25.0 = -0.1 m
(as NPSH A is negative, the pump will start to cavitate when the tank level drops to minimum level) To solve this problem? Increase elevation of tank! Pumps and Pumping Systems Centrifugal Pumps Define Liquid Properties: SG, VP, Vis 1 Establish Flow Rates 1 : Normal & Design Calculate Net Suction Pressure Calculate NPSH Available Calculate Net Discharge Pressure at Normal Flow including Control Valve P 2 Calculate Differential Pressure & Head Select Efficiency: Calculate Power
1. At pumping temperature 2. Allow of total friction P at Normal Flow for control valve. Verify control valve P at Design Flow minimum 70 kPa Pump Calculation Method Pumps and Pumping Systems Centrifugal Reciprocating Rotary Pressure max, bar abs 350 1000 350 Temperature max, C 500 370 400 P max, kPa 200 1400 200 Capacity max, m 3 /h 3600 450 340 Viscocity max Pa.s 0.2 400 400 Efficiency, % range 5080 6090 40-85 Capacity Turndown H M M Relative Cost L H M
H = High, M = Medium, L = Low Pumps and Pumping Systems Cavitation / Low NPSH Low Suction Pressure High Discharge Pressure High SpGr/Viscocity Capacity Loss Driver Overload Typical Operating Problems