BASICS OF PUMPS &

COMPRESSORS,TYPES OF
PUMPS & COMPRESSORS

By
HITESH GUPTA
MNM

5/26/2019 1
Types of Rotary Equipments

 Pumps
 Compressors
 Steam Turbines
 Gas Turbines
 Gear-Boxes
 Cooling Tower fans / ID Fans / FD fans
 Agitators / Mixers
5/26/2019 2
 Introduction of Pumps
 As per the law of conservation of
energy “Energy can neither be created
nor destroyed but it can be transformed
from one form to another“.
 The instrument or equipment used for
the conversion is defined as
“MACHINE”.

5/26/2019 3
 What is a pump?
 A Pump is a contrivance which converts
Mechanical Energy into Hydraulic
Energy.
 The term Pump has been initially
developed based on its principle of
action i.e., sucking of water.

5/26/2019 4
 Principle of Pump
 Present day pumps mostly used are
based on the principle of turbines.
 In a turbine, energy of liquid is
converted into mechanical energy
whereas in pumps, the principle is
reversed. This principle is called “Roto-
dynamic Action”.

5/26/2019 5
 Classification of Pumps
 In general, pumps can be classified into
two groups:-
 Positive displacement Pumps .

 Rotodynamic Pumps .

 There are other pumps also, such as Jet

Pumps, Hydraulic Ram etc. , operated
on different principles.

5/26/2019 6
 TYPE OF PUMP
 DYNAMIC TYPE

 DISPLACEMENT TYPE

5/26/2019 7
 DYNAMIC TYPE

 Energy is added continuously to

increase fluid velocity in the machine
and subsequently velocity reduction
produces increase in pressure.

 Example: Centrifugal pump

5/26/2019 8
 DISPLACEMENT TYPE

 Energy is periodically added by

application of force to a movable
boundary resulting in direct increase in
pressure.
Example:
 Reciprocating pump

 Screw pump

 Rotary pump

5/26/2019 9
 CENTRIFUGAL PUMPS
 It is the machine that moves fluid by
spinning it with a rotating impeller in a
casing that has a central inlet and a
tangential outlet. The path of the fluid
is an increasing spiral from the inlet at
the center to the outlet tangent to the
annulus.

5/26/2019 10
 CENTRIFUGAL PUMPS
 Useful work comes from the pump
when some of the spinning fluid flows
from the casing tangential outlet into
the pipe system.

 Head (pressure) is controlled by rpm,

impeller diameter and flow rate.

5/26/2019 11
 Classification of Centrifugal Pumps

Types Classification
based on

Volute Casing
Diffuser Casing
Radial Flow Impeller
Mixed Flow Impeller
Axial Flow Impeller

5/26/2019 12
 Classification of Centrifugal Pumps
Each of the above types can be further classified in
many ways detailed below:

Single stage / multistage based on number of

impellers mounted on the shaft.

Single suction or double suction depending on the

number of liquid entry path.

Axially split or radial split casing.

Vertical/ Horizontal pumps.

5/26/2019 13
 Type of Pumps - Centrifugal Pumps

 Single stage
Pumps
 Used normally
for medium
pressure & flow.

5/26/2019 14
Cross-section of a simple CF Pump

Bearings

Mechanical Seal
/ Gland Packing

Impeller

5/26/2019 15
Cross-section of a simple CF Pump

5/26/2019 16
Type of Pumps - Centrifugal Pumps

Double stage Radially split pump

•Used in HC services
with Medium flow &
pressure.

5/26/2019 17
 Type of Pumps - Centrifugal Pumps

Double stage Radially split pump Mechanical Seal

Radial bearing
Mechanical Seal

Thrust Bearing

Ist Stage
Impeller
IInd Stage
Impeller
5/26/2019 18
 Type of Pumps - Centrifugal Pumps
 Multistage Pumps

5/26/2019 19
Type of Pumps - Centrifugal Pumps

Multistage Centrifugal Pump

5/26/2019 20
 MULTISTAGE PUMPS
 If a larger head is required more impellers
are to be fitted in series, so that the
discharge from the first impeller is guided into
the inlet of the second impeller. This is
repeated with the third impeller and so on
until the required head is reached. Each
impeller will increase the pressure by the
same amount.
 A pump of this type is called a multi-stage
pump.

5/26/2019 21
 MULTISTAGE PUMPS
 All the impellers are keyed to the same shaft and
usually all impellers and diffusers of one pump are
identical.
 This has the advantage of reducing the labor in
manufacturer and stocking spares of maintenance.
 The discharge from each diffuser is either
circumferential or radial, this is collected by vanes
attached to the casing which direct, the liquid into
the edge of the next impeller.
 The last diffuser will discharge into the delivery
pipe.

5/26/2019 22
 Type of Pumps - Centrifugal Pumps
 Multistage pumps
 Used in Boiler feed
applications & other
HC applications
where flow &
pressure
requirement is high.

5/26/2019 23
 Type of Pumps - Centrifugal Pumps

Axially split pumps

Mostly used in CW applications
where High flow & low
pressure is required.

5/26/2019 24
 DOUBLE SUCTION PUMP

5/26/2019 25
 Types of Pumps – Vertical Pumps

Used in CBD, Molten

Sulphur, Condensate
Extraction
applications

5/26/2019 26
 Vertical Pumps

5/26/2019 27
 Net positive suction head:
 Net positive suction head:
 NPSH=Head corresponding to absolute
pressure on free surface of liquid+
Suction head –Frictional loss- vapour
pressure at PT.
 NPSHA=NPSHR+0.6 m

5/26/2019 28
 Cavitation
 The formation and subsequent collapse
of vapor filled cavities in a liquid due to
dynamic action are called cavitation.

 NPSH is the minimum suction head

required for a pump to prevent
cavitation.

5/26/2019 29
Performance Curves of Centrifugal Pumps

5/26/2019 30
 Centrifugal pump
 Pump efficiency=
 Mechechical eff x Volumetric eff x
Hydraulic eff.

5/26/2019 31
 CONSTRUCTION OF A CENTRIFUGAL
PUMP
 A Centrifugal pump essentially consists of an impeller
with vanes, surrounded invariably by a volute casing.
The impeller is mounted firmly on a shaft, which is
supported by two supports- one ball bearing and
another bush bearing. Both these supports are kept
in a housing called bracket or housing. At the other
end of the shaft a coupling is fitted to get the drive
from the prime mover such as electric motor or IC
engine or Turbine. The impeller rotates with close
tolerance inside the casing.

5/26/2019 32
 CONSTRUCTION OF A CENTRIFUGAL
PUMP
 The casing has connections for suctions and delivery
pipes. Liquid enters from the suction pipe to the
impeller at the center called EYE OF THE IMPELLER.
 Due to the rotation of the impeller by the prime
mover, a centrifugal force is imparted on the liquid
by the impeller vane, there by the liquid flows
towards the outer periphery.
 While flowing, the mechanical energy from the shaft
is converted to hydraulic energy at the impeller and
hence the liquid leaves impeller with higher hydraulic
energy.
 This energy consists of three forms - potential
energy, kinetic energy & pressure energy.

5/26/2019 33
 CONSTRUCTION OF A CENTRIFUGAL
PUMP
 The purpose of the casing is to convert these three forms of
energy into any other form of Hydraulic energy which is
required at the end use. A delivery pipe connected at the out let
of the casing takes away the liquid to the place where it is used.
 There are some more arrangements provided in centrifugal
pumps:
 Stuffing box arrangement is provided to avoid leakage of the
liquid from impeller area to outside atmosphere through the
clearance in bush bearing support.
 Balancing holes are provided to reduce axial load on the
bearing, as other wise higher capacity ball bearing are to be
provided
 In heavy duties pumps or in high speeds pumps two ball
bearing supports, supports along with bush bearing support
are provided to give more rigidity to the system.

5/26/2019 34
 Main features of centrifugal pump
 Simple in construction
 No direct contact of parts always through
fluid entangled in the close clearance
between moving and stationary parts
 Small floor space
 Lesser weight of pump per unit quantity
pumped
 Low initial and maintenance cost
 Easy maintenance

5/26/2019 35
 Main features of centrifugal pump
 Continuous Flow
 Quiet in Operation
 Less wear & tear of parts since there is no
direct contact of parts and no valves or no
reciprocating motion and
 High speed of rotation

5/26/2019 36
 ROTARY PUMPS
 Rotary pump is a positive displacement pump
employing rotary motion.
 Gear and Vane pumps are of the rotary type.
 A gear-type pump is a rotary, positive displacement
pump. Most hydraulic systems use rotary pumps of
the gear-type.
 The screw type rotary pump is also a positive
displacement pump but it is constructed differently
than the gear pumps.
 Screw type pumps are used as transfer pumps
because of their large capacities.

5/26/2019 37
 ROTARY PUMPS
 There are a variety of rotary pumps available
such as Gear Pumps (Internal and External),
Vane pumps (single vane, multi-vane, sliding
type, eccentric rotor type), Lobe pumps (two
lobes, three lobes), Metering pumps or
dosage pumps, radial piston and axial piston
pumps etc.
 These pumps are used mostly for controlled
smaller amount of flow conditions.

5/26/2019 38
 ROTARY PUMPS
 The main features of rotary positive displacement
pumps are:
 Positive displacement
 Slow and medium speed
 Self priming
 Fairly constant discharge
 Less vibration
 Wt. per unit flow is lower when compared to reciprocating
type
 Because of less number of parts in contact with each other,
lower friction (hydraulic and mechanical), higher efficiency.

5/26/2019 39
 RECIPROCATING AND PLUNGER
PUMPS
 A reciprocating pump ,primarily, consists of a
piston or a plunger inside a close fitting
cylinder.
 The piston moves forward and backward
inside cylinder with the help of crankshaft
and connecting rod mechanism.
 The crankshaft is driven by means of a prime
mover.

5/26/2019 40
Types of Pumps – Reciprocating
Pumps
 Positive
displacement pumps
 Plunger pumps
 Diaphragm pumps

5/26/2019 41
 Reciprocating Pumps - Main Parts

 Suction / discharge
valves
 Plunger
 Liquid head
 Gears
 Gland Packing

5/26/2019 42
 Reciprocating Pumps
 These pumps are used mainly for feeding
small boilers, gasoline pumping, fuel oil
pumping, sprinkling, irrigation jobs etc.,
where high delivery pressure and low
capacity conditions exist.
 Reciprocating pumps are either single acting
or double acting and both reciprocating and
plunger pumps are run in parallel (many
pumps are operated in one crankshaft) to
increase the quantity at the same pressure.

5/26/2019 43
 DIAPHRAGM PUMPS
 The pumping action of a diaphragm
pump is similar to a single acting
reciprocating pump.
 For handling chemicals or other
corrosive fluids, pumps should be either
lined or manufactured of stainless steel
or other corrosion resistant metals.

5/26/2019 44
 DIAPHRAGM PUMPS
 Most diaphragm pumps are operated
mechanically, but some are air operated. Air
operated pumps can be operated by either
compressed air or vacuum air, depending on
the pump .
 Because of their simple construction these
pumps are used for metering, transferring, or
as sump pumps. Also, they can handle fluids,
slurries, or sewage.

5/26/2019 45
 GEAR PUMPS
 Gear pumps, some times called external gear
pumps, are probably the most common type
of rotary pumps used for industrial
applications.
 The material being pumped is drawn through
the space between the rotors and the pumps
casing by the gear teeth and forced out of
the discharge port. The fluid is prevented
from flowing back to the suction side of the
pump by the meshing of the gears.

5/26/2019 46
 Types of Pumps – Gear Pumps
 Positive
Displacement Pump.
 Used in low flow,
high pressure
applications
 Mostly used in Lube
oil applications

5/26/2019 47
 SCREW PUMPS
 Screw pumps are a special type of rotary positive
displacement pump in which the flow through the
pumping elements is truly axial.
 The liquid is carried between screw threads on one or
more rotors and is displaced axially as the screws
rotate and mesh. In all other rotary pumps the liquid
is forced to travel in circumferential manner, thus
giving the screw pumps with its unique axial flow
pattern and low internal velocities a number of
advantages in many application areas where liquid
agitation or churning is objectionable.

5/26/2019 48
 Types of Pumps – Screw Pumps
 Commonly used in Lube oil, high viscous
fluids like Bitumen, Furnace Oil applications
 Single screw pump
 Double screw pump
 Triple Screw Pump

5/26/2019 49
 Screw Pumps
 The screw pump can handle liquids in a range of viscosity from
molasses to gasoline , as well as synthetic liquids in a pressure
range of 3.5 to 350 kg/cm2 and flows up to 1300 L/min.
 Because of the relatively low inertia of the rotating parts ,
pumps are capable of operating at higher speeds than other
rotary or reciprocating pumps of comparable displacement.
Some turbine attached lubricating oil pumps operate at 10,000
rpm and even higher.
 Screw pumps, like other rotary positive displacement pumps,
are self-priming and have a delivery flow characteristic which is
essentially independent of pressure.

5/26/2019 50
 Compressor
 The compressor is a machine which
compresses a gas from a pressure at
which it is available to a higher pressure
at which it is required for a process.

5/26/2019 51
 Categories of Compressor
 Positive Displacement Compressors

 Dynamic Compressors

5/26/2019 52
 Positive Displacement
Compressor
 It works on the principle of confining
the gas in a closed space and gradually
reducing the volume by the positive
displacement of a moving component
thereby increasing the pressure of the
gas.

5/26/2019 53
 Types of Positive Displacement
Compressor
 Reciprocating Compressors
 Diaphragm Compressors
 Rotary Sliding Vane Compressors
 Rotary Lobe Compressors

5/26/2019 54
 Dynamic Compressor
 It works on the principle of imparting
Kinetic energy to the gas by dynamic
action of rotating vanes of impellers
thus increasing the velocity which is
further converted into pressure by
means of diffusers.

5/26/2019 55
 Types of Dynamic Compressor
 Centrifugal Compressors

 Axial Compressors

5/26/2019 56
 Basic Principle Reciprocating
Compressor
Basic Principles
Compressor Cycle in the Pressure-Volume Diagram
next cycle
begins

Discharge

Pressure p
Expansion p,V-
Diagram
Compression

..... of the gas Volume V

in the cylinder
Suction 2.3

© Copyright 2008
5/26/2019 57
 Various Parts of a
Reciprocating Compressor Gas
Inlet
Compressor
Connecting Unloader
Crosshead Valve
Crankshaf Rod Crosshead
“Jamnut”
t Crosshead Crosshead
Pin Shoe Piston Rod

Crankcase Crankcase Crosshead Guide Distance Compressor

Lube Oil (Frame) (Frame Piece Cylinder
Pump Gas
Extension) Discharge
Cylinder
Support

58
 Compressor Cylinder Details Gas
Lube
Line
Valve
Cover
Inlet Inlet
Distance
Manifold Valve Cage
Crosshead Piece Piston Cylinder
Jamnut Bolting Rod Liner
Inlet
Valve
Piston

Piston Nut

Clearance
Pocket

Outer
Head
Scraper Partition Pressure Rider Discharge
Packing Packing Packing Band
Water Valve
Piston Gas
Oil Slinger Frame-end Jacket
Discharge
Ring
Head
Discharge
Manifold

59
 Crank Shaft

60
 Connecting Rod

61
 Cross Head

62
 Piston & Piston Rod Assembly

63
 DIFFERENT VALVES

64
 PACKING CASE ASSEMBLY
Main Pressure Packing Intermediate Packing

© Copyright 2008
65
 MAIN PRESSURE PACKING
Seals the inboard compression chamber to distance piece
in the area of the piston rod. Can be lube or non lube.
O-Rings Piston rod
Cups or Containers
Flange

Purge
inlet

Tie rods

Ring sets
Flange bolts

© Copyright 2008
and nuts Cooling

66
 INTERMEDIATE PACKING
Intermediate Packings seal the first distance piece
to the second distance piece in the area of the piston rod.
Usually they are not lubricated and not water cooled
Flange Ring sets

Flange bolts
and nuts Piston rod

Cups or
Containers

Purge (plugged)

© Copyright 2008
Tie rods

67
How centrifugal compressor work?

• A dynamic compressor using centrifugal

forces to produce air at constant pressures
with varying volumes.

• Work performed on the air by the rotating

impeller increases the pressure and velocity
with a subsequent drop in velocity through
the diffuser resulting in a further increase in
pressure.
• Typically the 2/3 of the pressure developed
occurs in the impeller area and 1/3 in the
diffuser area.
Centac Compressor of IR Make
Centac New Product
CENTAC Compressor Components
Demister
MOTOR

CV
BV CMC Panel
STG 3
ITV/IGV

STG 1
COOLER

STG 2
COOLER OIL HEATER

ADTs
CWin/out
SKID
Model – nomenclature

2CC – C 35 M X 3 EXT
Driver
Flow(cfm) X External Mounted
100 Coolers

Generation Stages

Frame Frequency
(50 Hz)
Simplicity By Design
 THANK YOU

5/26/2019 74