Centpump 012508 PDF

PRODUCT TRAINING
FUNDAMENTALS OF
CENTRIFUGAL PUMPS
1
Fundamentals of Centrifugal
Pumps
A centrifugal pump is a mechanical device that
converts energy to hydraulic work
Energy is supplied by a driver such as an electric
motor, turbine, or engine
Hydraulic work is the movement of a liquid mass
through a distance
This presentation is limited to centrifugal pump
types only
Sundyne pumps are a special design that will not be
covered in this presentation
2
Pumps
Just Say NO!!!!!

3
Pumps
The work takes place at an impeller which
accelerates the liquid by whirling it through
the impeller thus adding centrifugal force
and hence acceleration
4
Pumps
When an object is
spun around in a
circle it is accelerated
outward by
centrifugal force
5
Pumps
When liquid is spun
around in a circle, it
accelerates outward
from the center of the
circle due to
centrifugal force
6
Pumps
An impeller has vanes
which are blades that Vanes
push the liquid through
the impeller. The center
of the impeller where the
liquid enters the impeller
is called the eye
Eye
7
Pumps
To obtain useful
work, the impeller is Discharge
contained in a casing
which directs the
accelerated fluid
along a desired path
8
Pumps
Pump Impeller and Shaft
9
Pumps
Pump Impeller and Shaft

with Pressure Casing
10
Pumps
Pump Impeller
and Shaft with
Pressure Casing
and Cover
11
Pumps
Adjustment
Process
Fluid
Packing
Stuffingbox
Cover
12
Pumps -Impellers
Pumps-Impellers
Impeller Design
The impeller is the most important part of the
pump since it is where the work is taking
place. Furthermore, the impeller plays an
important role in the design of other pump
components. It has a direct effect on the seal
cavity pressure for example
13
Pumps -Impellers
Pumps-Impellers
Many different types of Vanes
impeller styles are used.
Most, but not all, have vanes
that curve away from the
flow path so that the liquid
is in contact with the
impeller longer. These are
referred to as reverse
curve vane impellers
Eye
14
Pumps -Impellers
Pumps-Impellers
Impeller vanes may be
enclosed by shrouds.
In general impellers with
shrouds are slightly less
efficient due to the drag
of the liquid on the
shroud
15
Pumps -Impellers
Pumps-Impellers
Therefore many
impellers have no
shrouds. They are called
open impellers. Note
that the bottom impeller
is partially shrouded
due to a shroud area
around the impeller eye
16
Pumps -Impellers
Pumps-Impellers
Some impeller designs
may also have a shroud
only on one side of the
impeller. They are also
said to be partially
shrouded or semi-open
or semi-closed
17
Pumps -Impellers
Pumps-Impellers
Shrouds are generally used on larger impellers to
help support the vanes and maintain the
impeller shape under extreme pressure and
temperature conditions. They also have the
disadvantage of limiting the particle size that can
pass through the impeller
18
Pumps -Impellers
Pumps-Impellers
There are two different impeller
types used in the process industry.
They differ by the type of flow
through the impeller. The most
common type is a radial flow
impeller where the liquid makes a
90o turn as it passes through the
impeller
19
Pumps -Impellers
Pumps-Impellers
In a turbine type impeller, the liquid
also makes a turn as it passes through
the pump, but less than 90o. These are
most often found in diffuser type
pumps which relates to the casing
design and will be discussed later.
Since the liquid makes less of a turn, a
turbine style impeller may be slightly
more efficient than a similar radial
flow impeller
20
Pumps -Impellers
Pumps-Impellers
The impeller has a direct relationship to
pump performance. The design of the
impeller is the single most important factor
in determining the flow rate and liquid
pressure that a pump can generate
21
Pumps -Impellers
Pumps-Impellers
The Master Pumps & Power catalog is an
excellent reference resource for most
pump application problems. It should be a
part of every engineers library. It is free to
all of our customers
22
Pumps -Impellers
Pumps-Impellers
Flow through an impeller is determined
primarily by three factors
Vane width
Number of vanes
Impeller speed
23
Pumps -Impellers
Pumps-Impellers
A wide vane impeller
will move more liquid
per unit time than a
narrow vane impeller.
The flow is directly
proportional to the
vane width
24
Pumps -Impellers
Pumps-Impellers
Flow (Q) through an
impeller is also
directly related to the
impeller speed. The
more times an
impeller rotates per
unit time the more
fluid is will move
25
Pumps -Impellers
Pumps-Impellers
Finally the flow
through a pump is
somewhat related to
the number of vanes
although it is not
directly proportional.
More vanes will move
more fluid
26
Pumps -Impellers
Pumps-Impellers
An impeller creates
head by
accelerating the fluid
to a given velocity.
As it spins, the fluid is
accelerated outward
by centrifugal force
27
Pumps -Impellers
Pumps-Impellers
The fluid exits the
impeller at a given
velocity. Therefore it
will rise to a given height
in a column based on the
exit speed regardless of
the weight of the fluid
28
Pumps -Impellers
Pumps-Impellers
Therefore a centrifugal pump is said to be a
constant head device. At a given speed it will
accelerate a liquid to a given velocity regardless
of the weight of the liquid.
A heavier liquid would require more
horsepower and the discharge pressure would
be higher, but it would rise in a column no
higher than a light liquid
29
Pumps -Impellers
Pumps-Impellers
This phenomenon is based on simple laws of
physics
(V2 = 2 AS) where V is the velocity, A is the
acceleration of gravity, and S is the height
Note that this formula makes no
consideration of weight
30
Pumps -Impellers
Pumps-Impellers
If fluids are pushed up a
column to the same The formulae for this
height, the pressure at relationship are as follows
the bottom of the hd. ft. =
column would be (psi X 2.31) / sp. gr.
different for fluids of psi =
different weight. (hd ft. / 2.31) x sp. gr.
31
Pumps -Impellers
Pumps-Impellers
To illustrate, a pressure gauge
at the bottom of a 231 ft. high
column filled with water
would read 100 psi. If the
column was filled with butane
231 ft.
having a specific gravity of
only .5, the gauge would read
50 psi
32
Pumps -NPSH
Pumps-NPSH
In order for the pump to move fluid, the system
must be able to push fluid into the pump as fast
as the pump can push it out.
Therefore there must be a certain minimum
required suction pressure for each pump based on
the pump flow
This pressure is expressed in head feet and is
referred to as NPSH -net positive suction head
33
Pumps -NPSH
Pumps-NPSH
NPSH is expressed in two ways
NPSHA is the net positive suction head available
from the system
NPSHR is the net positive suction head required by
the pump at a particular flow
NPSHA must always be greater than NPSHR or
damage to the pump will occur due to cavitation
34
Pumps -NPSH
Pumps-NPSH
Cavitation is the flashing of the liquid at the
pump impeller eye caused by the pump
lowering the pressure in the eye area as it
accelerates fluid across the impeller
The damage occurs when the flashed gas is
compressed back to a liquid as it gains
pressure while traveling through the impeller
35
Pumps -NPSH
Pumps-NPSH
Cavitation causes pump problems in two areas
Severe cavitation can erode the pump
impeller resulting in decrease performance
and vibration due to imbalance
Cavitation normally results in substantially
higher vibration in the entire pump
36
Pumps -NPSH
Pumps-NPSH
NPSH is the total suction head in feet
of liquid (absolute at the pump
centerline or impeller eye) less the
absolute vapor pressure (in feet ) of
the liquid being pumped
37
Pumps -NPSH
Pumps-NPSH
NPSHA is the NPSH available at the pump suction nozzle and
depends on the suction system design. It must always be equal
to or greater than the NPSHR
NPSHR is the NPSH required by the pump for stable operation.
It is determined by the pump manufacturer and is dependent on
many factors including the type of impeller inlet, impeller design,
pump flow, rotational speed, nature of the liquid, etc. It is
usually plotted on the characteristic pump performance curved
supplied by the pump manufacturer
38
Pumps -NPSH
Pumps-NPSH
NPSHA is a difficult calculation. It will require
the help of a process engineer from the plant
NPSHA can be determined by direct field
measurement if the vapor pressure is known. A
method for this calculation is presented later
39
Pumps -NPSH
Pumps-NPSH
NPSHA Example for Suction Lift
*Assume vapor pressure
of water @ 80 F = .5psia
or 1.2 feet = hvpa
*Assume atmospheric
pressure @ sea level
or 34.0 feet = ha Height = hst Atmospheric
*Assume pipe losses = 15 feet Pressure = ha
3.5 feet = hfs
*NPSHA = ha - hvpa - hst - hfs
*NPSHA = 34 - 1.2 - 15 - 3.5 =
14.3 feet
40
Pumps -NPSH
Pumps-NPSH
*Assume vapor pressure
Atmospheric Pressure = ha of water @ 80 F = .5psia
or 1.2 feet = hvpa
*Assume atmospheric
pressure @ sea level
or 34.0 feet = ha
*Assume pipe losses =
3.5 feet = hfs
Height = hst *NPSHA = ha - hvpa + hst - hfs
15 feet *NPSHA = 34 - 1.2 + 15 - 3.5 =
44.3 feet
NPSHA Example
for Flooded Suction
41
Pumps -NPSH
Pumps-NPSH
Simple Method to Determine NPSHA

NPSHA is the total suction head in feet of liquid (absolute at
the pump centerline or impeller eye) less the absolute vapor
pressure (in feet) of the liquid being pumped
Measure the suction pressure and convert to feet of head
(must be absolute not atmospheric)
Determine the vapor pressure of the liquid and convert to
feet of head
Subtract the vapor pressure from the suction pressure
42
Pumps-Performance Curves
Pumps-Performance
A pump manufacturer will supply a curve for
every pump purchased which graphically
represents the expected pump performance
For most applications, a copy of the pump curve
is required information for properly selecting a
sealing system and flush plan
43
Pumps-Performance
NPSHR
Head
Efficiency
BHP
Flow, GPM 44
Pumps -Performance Curves
Pumps-Performance
Contents
What pump curves represent
How to read pump curves
45
Pumps-Performance
A Pump Curve
NPSHR
Head
Efficiency
BHP
Flow, GPM 46
Pumps-Performance
Summary of Pump Curve Info
Graphical representation of performance
Head
BHP
Efficiency
NPSHR
47
Pumps-Performance
Summary of Pump Curve Info
Graphical representation of performance
Contains more than performance data
speed
stages
may have info about liquid
impeller, case patterns
wear ring clearances
48
Pumps-Performance
Actual Sample Curve

Pricebook Curve 49
Pumps-Performance
Actual Sample Curve -Job Curve 50

Pumps-Performance
How Pump Curves are Made
P2
P1
Flow Meter
Pump
51
Pumps-Performance
Test Data
Flow P2 - P1 BHP
0 311 20
400 291 117
800 234 156
960 195 163
Pressure in PSIG
52
Pumps-Performance
Convert Pressure to Feet of Head
Head = 2.31 (P2-P1) / S.G.
Head is in Feet!
53
Pumps-Performance
Compute Efficiency
Efficiency = Theoretical Horsepower
divided by Actual Horsepower
Convert to Percent
54
Pumps-Performance
Test Data
Flow Head BHP Efficiency
0 718 20 ***
400 672 117 58%
800 540 156 70%
960 450 163 67%
Now in feet
55
Pumps-Performance
Head Portion of Pump Curve
800
700
600
500
TDH
400
300
200
100
0
0 200 400 600 800 1000 1200
Flow, GPM
56
Pumps-Performance
BHP Portion of Pump Curve
180
160
140
120
BHP
100
80
60
40
20
0
0 200 400 600 800 1000 1200
Flow, GPM
57
Pumps-Performance
Efficiency Portion of Pump Curve
80
70
60
50
Eff
40
30
20
10
0
0 200 400 600 800 1000 1200
Flow, GPM
58
Pumps-Performance
NPSH
NetPositive Suction Head

NPSHR: Required
NPSHA: Available
59
Pumps-Performance
NPSH
Net Positive Suction Head

NPSHR: Required
NPSHA: Available
NPSH = Actual Pressure - Vapor

Pressure, then convert to feet of head
60
Pumps-Performance
NPSH Required
Determined during pump test
Throttling suction to pump
Hot water
Based on 3% head loss-reduce NPSHA

until 3% loss in produced head is observed
Based on water
61
Pumps-Performance
Test Data
Flow Full Head 3% Loss
0 718 - 22 = 696
400 672 - 20 = 652
800 540 - 16 = 524
960 450 - 14 = 436
62
Pumps-Performance
NPSHR Portion of Pump Curve
35
30
25
NPSHR
20
15
10
5
0
0 200 400 600 800 1000 1200
Flow, GPM
63
Pumps-Performance
35
30
R
H
25
S
P
NPSH
N
20
15
10
5
0
0 200 400 600 800 1000 1200
800
700
600
H
TDH 500
D
T
400
300
200
100
0
0 200 400 600 800 1000 1200
80
70
EFF 60
50
ff
E
40
30
20
10
0
0 200 400 600 800 1000 1200
180
160
140
HP
120
BHP
B
100
80
60
40
20
0
0 200 400 600 800 1000 1200
Flow, GPM
FLOW IN GPM 64
Pumps-Performance
A Pump Curve
NPSHR
Head
Operating Point
Efficiency
BEP
BHP
65
Flow, GPM
Pumps-Performance
The pump manufacturer will normally show the
point on the curve where the pump is expected
to operate
BEP is the best efficiency point taken at the
highest point of the efficiency curve
At BEP the pump normally operates the most stably
Operation below BEP can result in mechanical and
hydraulic problems
66
Pumps-Performance
Summary of Pump Curve Information

Graphicalrepresentation of
performance
Contains more than performance data
67
Pumps-Impeller Effect
Pumps-Impeller
Balance Holes
68
Pumps-Impeller
Effect of back wear rings
and balance holes
Pressure at O.D. of
impeller breaks down
across back wear ring
Balance holes bleed
pressure back to suction
Seal chamber at same
pressure as balance holes
69
Pumps-Impeller
Impeller with PumpoutVanes

70
Pumps-Impeller
Effect of pump out
vanes
Vane O.D. is the same as
the impeller O.D. and is
turning at the same speed
Therefore vane puts up
same head as impeller
Therefore back of
impeller at shaft is at same
pressure as front
71
Pumps-Impeller
Impeller with no back wear

rings or pumpout vanes 72
Pumps-Impeller
Effect of no back wear
rings or pump out vanes
Pressure at impeller
O.D. is present
behind entire impeller
Seal chamber at
discharge pressure
73
Pumps-Pump Case Design
Pumps-Pump
If a higher pressure
differential is required
across the pump the
designer has several
options. Two would
be to:
Increase the pump
speed-the flow would
also increase
Increase the impeller
O.D.
74
Pumps-Pump
In most cases neither is practical
There is a practical limit to the impeller diameter.
Beyond that limit it would be difficult to control
the tolerances to ensure proper fit and balance.
The hardware would be prohibitively expensive
There is also a practical limit to the shaft speed.
Not only would balance be critical, but the
bearing and lubrication system would be complex
and expensive
75
Pumps-Pump
The third option is simpler. To achieve high
differential head without the expense more than one
stage or impeller are used. Multistage pumps come
in many varieties
Multistage volute
Split case
Double case
Multistage diffuser
Vertical
Horizontal
76
Pumps-Pump
To understand multistage pump design, it is first
essential to know that there are in general two
different ways that the pump case directs the
flow from the impeller to the discharge nozzle
Volute pattern
Diffuser pattern
77
Pumps-Pump
Volute Pump
One or two passages in
the pump case guide the
fluid from the impeller to
the pump discharge or the
next stage
Single volute pumps can
result in excessive
hydraulic load on the
impeller and shaft
78
Pumps-Pump
Single Volute Double Suction Pump 79

Pumps-Pump
Diffuser Pump
A multipassage diffuser
or bowl assembly
surrounds the entire
impeller O.D. and guides
the fluid to the discharge
nozzle or next stage
through multiple paths
80
Pumps-Pump
Diffuser Pumps
Note that the Byron Jackson design incorporates a
mixed flow impeller
The fluid does not make a full 90o turn in the impeller.
Since it is not a radial flow impeller, it is termed a mixed
flow impeller
Not all turbine pumps are mixed flow. Some are
furnished with radial flow impellers such as the
horizontal diffuser pump shown previously
81
Pumps-Pump
Multistage Volute Split Case 82

Pumps-Seal Cavity Pressure
Pumps-Seal
Most multistage volute type pumps have front and back
wear rings.
Therefore the seal cavity pressures would be as
follows:
One end-suction
The other end-discharge pressure of one of the stages unless

some measures are taken to reduce the pressure
Most multistage volute pumps will have several taps
on the pump case where various pressures are available
for the flush source
83
Pumps-Pump
Multistage Volute Double Case 84

Pumps-Seal
Most multistage double case volute type pumps have
front and back wear rings.
Therefore the seal cavity pressures would be as
follows:
One end-suction
The other end-discharge pressure of one of the stages

unless some measures are taken to reduce the pressure
Only pump discharge pressure is available for a flush
source
85
Pumps-Seal
Many of these pumps as well as other multistage
designs will have some provision for reducing the
pressure in the seal chamber at the high pressure end
Balance line
Close clearance bushing
86
Pumps-Seal
A balance line will typically bleed the high pressure seal
chamber to about suction plus 70% of one stage
differential
Depends on the bushing wear
Also depends on the allowable flow in the
balance line which represents pump
inefficiency
87
Pumps-Seal
Dont assume
Check to see if the
balance line exists
Measure the seal
cavity pressure
The following slide
illustrates a balance
line-they are not Confucius say - When you
always so visible assume you make a donkey
out of u and me
88
Pumps-Pump
Multistage Volute
with Balance Line 89
Pumps-Pump
Multistage Diffuser Horizontal 90

Pumps-Seal
Multistage Diffuser Horizontal
Since all the impellers face and pump the same
direction the seal cavity pressures are as follows
One end-suction
The other end-full discharge unless some measure

is taken
91
Pumps-Seal
Measure taken to reduce seal cavity pressure on high
pressure end
Balance drum (piston)
Balance disc
Both are similar to balance lines and close clearance

bushings
92
Pumps-Seal
Balance drum (piston)
Balance disc
Both have additional function in that they are

part of the mechanism to reduce the load on the
pump thrust bearing
Both are very complex and extremely precise
mechanical devices
93
Pumps-Pump
Byron Jackson
Sumpmaster
Multistage Diffuser Vertical 94

Pumps-Pump
Byron Jackson VLT

(Very Large Turbine)
Process Pump with Case
Multistage Diffuser Vertical 95

Pumps-Seal
Vertical Turbine Pumps
Note that the sumpmaster is shown without a
mechanical seal. This is typical for low pressures
but many of these pump styles do have
mechanical seals
Since all the impellers are pumping in the same
direction and the seal sits in the discharge head of
the pump, the seal cavity is at discharge pressure
unless measures are taken
96
Pumps-Seal
Measures taken depend on the pump seal cavity
construction
Internal seal head-the seal actually sits in the pump
discharge flow-it can only be at pump discharge pressure
External seal or packing head-a close clearance bushing
and balance line arrangement are used to reduce the
pressure to suction plus 70% of one stage. Again you
must measure to be sure
97
Pumps-Seal
Measures taken depend on the pump seal cavity
construction
Internal packing head-the seal chamber is a
separate piece but sits in the discharge flow-
usually some provision is made to reduce the
pressure in the packing or seal area
98
Pumps-Seal
Internal
Seal Head
99
Pumps-Seal
External
Seal Head
100
Pumps-Seal
Internal
Packing
Head
101
Pumps-Pump
There are three typical styles of pump
construction
Overhung: an example follows
Double-ended: several examples have been given
similar to the previous slides and the slide
following the overhung pump
Vertical: many variations exist
Turbine style-an example is the previous slide
Process with and without a bearing bracket-examples

will follow
102
Pumps-Pump
Typical end Suction

(Overhung) Process Pump 103
Pumps-Pump
Many pumps use a double suction impeller
design which is a single impeller with two inlets
High flow
Low NPSHA
Since a double suction impeller must be radial

flow, they are all in volute type cases almost
without exception
104
Pumps-Seal
Double Suction Pumps
In a single stage double suction pump the seal or
seals sit in the impeller eye
The only pressure they can see is suction
There are limited choices to dealing with

inadequate vapor suppression margin for these
pumps
Close clearance throat bushing with plan 11 or 32
flush
Cooling
105
Pumps-Pump
Double Suction Radially Split 106

Pumps-Pump
Double Suction Axially Split 107

Pumps-Pump
Double Suction Overhung 108

Pumps-Pump
Vertical Process Pumps
In addition to those previously shown, there are a
class of pumps that are process pumps mounted in a
vertical configuration. They are almost always volute
single stage pumps. There are two styles
Rigid coupling-no bearing bracket
Flexible coupling with bearing bracket
109
Pumps-Pump
Vertical Inline
Process Pump with
Rigid coupling-
No bearing bracket
110
Pumps-Pump
Vertical Inline
Process Pump with
flexible coupling
and bearing bracket
111
Pumps-Seal
Since these pumps are process style pumps, the
seal cavity pressure can be at anything between
and including suction and discharge
The normal rules apply. It is necessary to know
the impeller and case construction to estimate
the seal cavity pressure
112
Pumps -Problem Constructions
Pumps-Problem
Some pump designs have inherent mechanical
problems because of their design and resultant
impeller and shaft loads
Vertical inline rigid coupling no bearing
bracket
Overhung double suction or two stage
Single volute
113
Pumps-Problem
Some pump designs have inherent mechanical
problems because of their design and resultant
impeller and shaft loads
Shaft deflection and vibration are common to
these designs
Something must be done to address the
mechanical situation
114
Pumps-Problem
Cureor eliminate problem pump
constructions
L3/D4 < or = 40
Vertical inline with rigid coupling
Two stage or double suction overhung
Internal sealed (glandless) pump designs

Something we havent discussed
No seal chamber or stuffingbox-similar to internal seal
arrangementfor vertical turbine pumps
115
Pumps-Problem
3 4
L /D < or = 40
L = distance in inches from center of radial
bearing to center of impeller
D = diameter of shaft in inches under the seal
sleeve
116
Pumps-Problem
3 4
L /D < or = 40 Solutions
Replace bearing bracket and stuffingbox with
7th edition upgrade
Modify existing pump with heavier shaft and
more robust bearings
Close clearance non galling wear rings and
throat bushing
117
Pumps-Problem
Vertical inline with rigid coupling
Fine for low horsepower (<25 H.P.) and low speed
(1750 rpm max.)
Above these parameters a 7th edition upgrade with
bearing bracket and flexible coupling should be
considered
Pumps with field renewable throat bushing such as
Union VLK and Goulds 3900 give better
performance
118
Pumps-Problem
Vertical inline with rigid coupling (continued)
Close clearance non galling wear rings and throat
bushing
Add external bearing assembly on top of seal flange
May require more first obstruction-add motor

spacer ring and lengthen pump shaft
May be oil mist or grease lubricated
119
Pumps-Problem
Two stage or double suction overhung, old API pumps with
large calculated shaft deflection, single volute pumps
Same problem as L3/D4 < or = 40
Replace bearing bracket and stuffingbox with 7th
edition upgrade
Modify existing pump with heavier shaft and more
robust bearings
Close clearance non galling wear rings and throat
bushing
120

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PRODUCT TRAINING

Just Say NO!!!!!

Pump Impeller and Shaft

Pump Impeller and Shaft

Simple Method to Determine NPSHA

may have info about liquid

impeller, case patterns

wear ring clearances

Actual Sample Curve

Actual Sample Curve -Job Curve 50

NetPositive Suction Head

Net Positive Suction Head

NPSH = Actual Pressure - Vapor

Based on 3% head loss-reduce NPSHA

Summary of Pump Curve Information

Impeller with PumpoutVanes

Impeller with no back wear

Single Volute Double Suction Pump 79

Multistage Volute Split Case 82

The other end-discharge pressure of one of the stages unless

Multistage Volute Double Case 84

The other end-discharge pressure of one of the stages

Multistage Diffuser Horizontal 90

The other end-full discharge unless some measure

Both are similar to balance lines and close clearance

Both have additional function in that they are

Multistage Diffuser Vertical 94

Byron Jackson VLT

Multistage Diffuser Vertical 95

Process with and without a bearing bracket-examples

Typical end Suction

Since a double suction impeller must be radial

There are limited choices to dealing with

Double Suction Radially Split 106

Double Suction Axially Split 107

Double Suction Overhung 108

Flexible coupling with bearing bracket

Two stage or double suction overhung

Internal sealed (glandless) pump designs

May require more first obstruction-add motor

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