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PUMPS TECHNOLOGY

GENERAL COURSE
9/6/2012

FOR ENGINEERS
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INTRODUCTION
PUMPS DEFINATION PUMPS HISTORY PUMPS APPLICATIONS PUMPS TERMINOLGY

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MAIN TOPICS
PUMPS CLASSIFICATION PUMPS APPLICATION MAJOR COMPONENTS OF CENERIFUGAL & RECIPROCATING PUMPS CALCULATION & PERFORMANCE OPERATION & TROUBLESHOOTING

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PUMPS
Pumps are machines that are used to move liquids from one place to anther through pipelines. Pumps handle all kinds of liquids. Pumping rates can vary from a few gallons to a million/day
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Pumps are made of different materials in different sizes and shapes Pumps are the second common machine in the world Pumps are used in all power plant
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Pumps applications
Examples of pumps application in power plants:
Boiler circulation Feed water Fuel oil Chemical Feed Condensate Circulation water Vacuum

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THEORY OF PUMPS
Pump Head Static Suction Lift Static Section Head Total Static Head Static Discharge Head Cavitations Net Positive Suction Head
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A) Pump Heads
Hss & Hsd : represent the pressure heads at suction and discharge ports of the pump if the flow rate is zero Hss= h1+Pa/y Hsd= h2+Pb/y Hst=hsd - hss

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PUMPS TERMES

Fig. a Suction Lift Showing Static Heads in a Pumping System Where the Pump is Located Above the Suction Tank. (Static Suction Head)
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PUMPS TERMS

Fig. b Suction Head Showing Static Heads in a Pumping System Where the Pump is Located Below the Suction Tank. (Static Suction Head)
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Suction Head
Suction Head A Suction Head exists when the liquid is taken from an open to atmosphere tank where the liquid level is above the centerline of the pump suction, commonly known as a Flooded Suction.

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Suction Lift
Suction Lift exists when the liquid is taken from an open to atmosphere tank where the liquid level is below the centerline of the pump suction

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Pump Heads
Pump suction head (hs) Hs represents the pressure head at the pump suction nozzle

Hs= Pa/y+h1-v2/2g-hLs hL=f(L/D)v2/2g

F=friction factor D=diameter V=velocity L= length of pipe up to the point required

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Pump Heads
Pump delivery head (hd) The pump delivery head represents the pressure head at the pump discharge nozzle (d) Hd= Pb/y+h2-v2/2g+hLd

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Head Total Dynamic

Total Dynamic Head (TDH) = Elevation (ft) + Friction (ft)

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Atmospheric Pressure
The Pressure of the Atmosphere on the Earth

Atmospheric Pressure at Sea Level

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Absolute Pressure
Absolute Pressure is the sum of the available atmospheric pressure and the gage pressure in the pumping system Absolute Pressure (PSIA) = Gauge Pressure + Atmospheric Pressure Absolute Pressure = 150 PSIG (Gauge Pressure) + 14.7 PSI (Atmospheric Pressure) = 164.7 PSIA
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Pump capacity
Capacity (Q) is normally expressed in gallons per minute (gpm). Since liquids are essentially incompressible, there is a direct relationship between the capacity in a pipe and the velocity of flow. This relationship is as follows: Q=A*V Where A = area of pipe or conduit in square feet. V = velocity of flow in feet per second.

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PUMPS CLASSIFICATION
Dynamic pump
Displacement

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CENTRIFUGAL CLASSIFICATION

RADIALL

CENTRIFUGAL AXIAL FLOW MIXED FLOW

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Centrifugal Pumps are classified into three general categories:

CENTRIFUGAL PUMPS

RADIAL FLOW

MIXED FLOW

AXIAL FLOW

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Axial Flow - a centrifugal pump in which the pressure is developed by the propelling or lifting action of the vanes of the impeller on the liquid.

Radial Flow - a centrifugal pump in which the pressure is developed wholly by centrifugal force. Mixed Flow - a centrifugal pump in which the pressure is developed partly by centrifugal force and partly by the lift of the vanes of the impeller on the liquid.
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CENTERIFUGAL PUMP
OPERATE ON THE PRINCIPLE OF CENTERIFUGAL FORCE DRIVEN BY
ELECTRIC MOTOR STEAM TURBINE GAS TURBINE

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Axial Flow

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Radial Flow Types

The flow parallel to the axis (the center line) of the shaft

Axial flow
Single stage
Multistage

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AXIAL FLOW
Axial flow pumps are propeller pump The arrangement of the pump is usually vertical Ability to operate at high speed Lift capacity, discharge and the head are low There are to type: single stage & multistage
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RADIAL FLOW
Flow at 9 0 angle to the center line of the shaft

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MIXED FLOW
Mixed flow pump is a pump that uses both axial-flow and radial flow components in one impeller The head developed by centrifugal force and partly by the lift of the impeller vanes on the liquid Is used mainly on low head high capacity.
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MAJOR COMPONENTS OF CENTERIFUGAL PUMP

SUCTION INLET IMPELLER SHAFT CASING(HOUSING) DISCHARGE OUTLET BEARINGS SEALS

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Centrifugal Pump Components

The two main components of a centrifugal pump are the impeller and the volute. The impeller produces liquid velocity and the volute forces the liquid to discharge from the pump converting velocity to pressure.
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CENTRIFUGAL PUMP

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CENTERIFUGAL PUMPS

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1. SUCTION INLET
Liquid enter the pump through the suction The side of flow entering is called UPSTREAM The discharge side is called the DOWNSTREAM The pipeline that carries the liquid is bolted or screwed the suction flange

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1)SUCTION INLET

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SUCTION NOZZLE
DIRECT FLOW
RADIAL AXIAL MIXED

SUCTION
SINGLE ENTERY
DOUBLE ENTERY

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2. IMPELLER & SHAFT

Impeller is the main part of a centrifugal pump. It move the liquid through the pump It is vary considerably in design It can be classified according to specific speed

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IMPELLER TYPES
There are three types, depend upon the pump size or type of liquid and required discharge pressure.
Open Partially open Enclosed

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IMPELLER

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IMPELLER CAVITATION

Cavitation : The formation and collapsing of bubbles inside the pump casing
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COLLAPSE OF VAPOR

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PARTS OF IMPELLER

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3. PUMP CASING
Centrifugal pump casing (Housing) encloses the rotating parts The suction and discharge nozzles are usually in the lower casing The upper have can be easily lifted for inspection There are many types of casing, ex. Volute and split.
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4. DISCHARGE OUTLET
The liquid leave the pump under pressure through the discharge outlet The discharge outlet is the downstream side of the pump The discharge flange is located at the large end of the volute.

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5. SEALS
All pumps developed pressure to pump the liquid. The pressurize liquid must be contained by a seal to prevent leakage around the drive shaft . There are many types of seals that are used in many types of pump. Ex
Wearing ring Packing Mechanical seal
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Wearing Rings
Centrifugal pumps contain rotating impellers within stationary pump casings. To allow the impeller to rotate freely within the pump casing, a small clearance is designed to be maintained between the impeller and the pump casing. To maximize the efficiency of a centrifugal pump, it is necessary to minimize the amount of liquid leaking through this clearance from the high pressure or discharge side of the pump back to the low pressure or suction side.
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Some wear or erosion will occur at the point where the impeller and the pump casing nearly come into contact This wear is due to the erosion caused by liquid leaking through this tight clearance and other causes. As wear occurs, the clearances become larger and the rate of leakage increases. Eventually, the leakage could become unacceptably large and maintenance would be required on the pump. To minimize the cost of pump maintenance, many centrifugal pumps are designed with wearing rings.
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STUFFING BOXES
In almost all centrifugal pumps, the rotating shaft that drives the impeller penetrates the pressure boundary of the pump casing. It is important that the pump is designed properly to control the amount of liquid that leaks along the shaft at the point that the shaft penetrates the pump casing. There are many dif ferent methods of sealing the shaft penetration of the pump casing. Factors considered when choosing a method include the pressure and temperature of the fluid being pum ped, the size of the pump, and the chemical and physical characteristics of the fluid being pumped. One of the simplest types of shaft seal is the stuffing box
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The stuffing box is a cylindrical space in the pump casing surrounding the shaft. Rings of packing material are placed in this space. Packing is material in the form of rings or strands that is placed in the stuffing box to form a seal to control the rate of leakage along the shaft. The packing rings are held in place by a gland. The gland is, in turn, held in place by studs with adjusting nuts. As the adjusting nuts are ti ghtened, they move the gland in and compress the packing. This axial compression c auses the packing to expand radially, forming a tight seal between the rotating shaft and the inside wall of the stuffing box.
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The high speed rotation of the shaft generat es a significant amount of heat as it rubs against the packing rings. If no lubrication and cooling are provided to the packing, the temperature of the packing increases to the point where damage occurs to the packing, the pump shaft, and possibly nearby pump b earings. Stuffing boxes are normally designed to allow a small amount of controll ed leakage along the shaft to provide lubrication and cooling to the packing. The leakage rate can be adjusted by tightening and loosening the packing gland
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CENERIFUGAL PUMP OPERATION

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LANTERN RING
The leakage rate can be adjusted by tightening and loosening the packing gland. Lantern Ring It is not always possible to use a standard stuffing box to seal the shaft of a centrifugal pump. The pump suction may be under a vacuum so that outward leakage is impossible or the fluid may be too hot to provide adequate cooling of the packing. These conditions require a modification to the standard stuffing box. One method of adequately cooling the packi ng under these conditions is to include a lantern ring.
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LANTERN RING
A lantern ring is a perforated hollow ring located near the center of the packing box that receives relatively cool, clean liquid from either the discharge of the pump or from an external source and distributes the liquid uniformly around the shaft to provide lubrication and cooling. The fluid entering the lantern ring can cool the shaft and packing, lubricate the packing, or seal the joint between the shaft and packing against leakage of air into the pump in the event the pump suction pressure is less than that of the atmosphere
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MECHANICAL SEAL
Is used in high pressure pumps Is used in chemical pumps and liquids such as gasoline, acids and ammonia. There are two types:
Rotating seal Stationary seal

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ADVANTAGES OF DISADVFUGAL PUMPSANTAGE OF CENTER

They are the least expensive of pump to build They have only one moving part. They do not need a lot of maintenance The main disadvantage is must be primed before they are started

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II. DISPLACEMENT PUMPS

Introduction Displacement pump types Reciprocating & Rotary Pumps
Major parts Describe the operation Advantages & Disadvantages Drawing symbol

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INTRODUCTION
Rotary &Reciprocating pumps are positive displacement pumps. Positive displacement pump can be classified by the type of motion of internal elements The motion may be either rotary or reciprocating

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Basic Types
GEAR

DISPLACEMENT

PISTON

VANE

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a) Rotary pumps

Rotary pumps

External

Internal

Lobe

Screw

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Major Parts of Rotary Pumps

The major parts of rotary pumps are the:
Suction Inlet Pumping Element/Drive shaft* Housing Discharge Outlet * The pumping elements in each of the four types are different.

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Gear pumps

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1)External pumps
The pumping element in external pump consist of two gear wheels inside the housing. One gear is driven by the motor (Drive gear) The driven gear connected directly to the drive shaft
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External Pumps Operation

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External Pumps Operation

From the figure :
Liquid enters the pump through the suction inlet. As the gears rotate, liquid is trapped between the gear teeth and the housing. In suction side, volume expand In discharge, volume decrease When the gear teeth mesh, the liquid is squeezed out through the discharge outlet
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2) Internal Gear Pumps

This design consist of internal spur gear and external housing. As a power is applied to either gear, the motion of the gears draws fluid from tank and forced it around both sides of the crescent seal (seal between S & D)
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3) Lobe Pumps
The pumping element in this pump consists of two close-fitting parts, which are called rotors. The lobe trap the liquid and carry it around to the discharge outlet.

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4)Screw pumps
Gear pumps use toothed gears turning inside a close tolerance housing to draw-in liquid and then squeezing it out ahead of them. Paddle steamers used the same principle of operation. These pumps are positive displacement pumps and anything drawn into them will be forced out. As a consequence they can generate very high discharge pressures. Materials of construction vary from metals of various types and hardness through to plastics of various types and hardness.
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Advantages & Disadvantages of Rotary pumps

High pressure capability (up to 10,000 psi) Small, compact size. High volumetric efficiency. Small change in efficiency through the design pressure range Great flexibility of performance. Only the disadvantage is the gear must fit close together.
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Reciprocating Pumps
Introduction Major Parts Pump Operation Main types Drawing Symbol Advantages & Disadvantages

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Introduction
Reciprocating pumps, like rotary pumps, are positive displacement pumps. Reciprocating means to move with a back and forth motion. The main parts are piston and cylinder The main types :
Axial design Radial design
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Major Components
Main Parts
Suction Inlet Valve Cylinder Piston Discharge Outlet Valve Housing
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Disadvantages
There are two main disadvantages of this type of pumps :

Expensive to repair Deliver liquid with pulses pressure

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