Pumps

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Introduction

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 Introduction
 A pump is a mechanical device which can transfer
rotational energy (mechanical energy) of the
machine to the potential or kinetic energy of the
liquid.

 A pump may be defined as machine when driven

from some external source (electric motor,
turbine or an engine) transfer/lifts liquid or semi-
solid fluid from one place to another.

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Introduction

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 Classification
Dynamic Positive displacement

Centrifugal Peripheral Reciprocating Rotary

Axial Mixed Radial Special

high Piston Plunger Gear Screw
head

Diaphragm
Vane Lobe

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Pumps Application range

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 Reciprocating pump
• A reciprocating pump is a positive displacement machine
• It traps a fixed volume of liquid at near-suction conditions,
compresses it to discharge pressure, and pushes it out the discharge
nozzle
• The basic principle involved is that a plunger or piston will displace
a quantity of liquid equal to its swept volume.

In Figure, plunger A is lowered into the container, displacing liquid

which flows into container B

Plunge
In a reciprocating pump, reciprocating r
motion is accomplished by a piston or
plunger, or diaphragm.
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 Reciprocating pump
Figure depicts the suction stroke of a plunger pump. When the
plunger moves away from the head end of the cylinder, the
discharge check valve is held closed by the higher pressure in
the discharge pipe compared to the lower pressure in the liquid
cylinder. This lower pressure in the liquid cylinder also causes
the suction valve to be opened by the higher pressure in the
suction line. Fluid then flows into the cylinder until the plunger
reaches the end of its travel.

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 Reciprocating pump
Figure depicts the discharge stroke of a plunger pump. As the
plunger moves toward the head end, the increasing pressure in
the cylinder closes the suction valve. The pressure in the
cylinder continues to rise until it exceeds the pressure in the
discharge line and the discharge valve opens, releasing the
volume of fluid displaced by the plunger.

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Reciprocating pump

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 Rotary pump
Rotary pumps are positive displacement pumps, but unlike
reciprocating pumps, have relatively steady, non-pulsating flow.
Rotation of the rotor(s) within the casing traps pockets of liquid
at suction conditions, elevates the fluid pressure, and then
pushes the fluid out the discharge.
 Can handle debris
 Used to raise the level of
wastewater
 Abrasive material will
damage the seal between
screw and the housing
 Grain augers use the same
principle
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 Rotary pump
 Gear Pump
 fluid is trapped between gear
teeth and the housing
 Two-lobe Rotary Pump
 (gear pump with two “teeth” on
each gear)
 same principle as gear pump
 fewer chambers - more extreme
pulsation

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 Rotary Pump
 Disadvantages
 precise machining
 abrasives wear surfaces rapidly
 pulsating output
 Uses
 vacuum pumps
 air compressors
 hydraulic fluid pumps
 food handling
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 Peristaltic Pump
 Fluid only contacts tubing
 Tubing ID and roller velocity
with respect to the tubing
determine flow rate
 Tubing eventually fails from
fatigue and abrasion
 Fluid may leak past roller at
high pressures
 Viscous fluids may be pumped
more slowly 14
 Centrifugal Pump
• Centrifugal pump is a machine consisting of a set of rotating
vanes enclosed within housing or casing.
• Centrifugal pump convert energy of a prime mover (a electric
motor or turbine) first into velocity or kinetic energy and then
into pressure energy of a fluid that is being pumped.

• The energy changes occur by virtue of two main parts of the

pump:

i. Impeller - is the rotating part that converts driver energy

into the kinetic energy

ii. Volute or diffuser-is the stationary part that converts the

kinetic energy into pressure energy.
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 Centrifugal Pump
• The process liquid enters the suction nozzle and then into eye
(center) of a revolving device known as an impeller. When the
impeller rotates, it spins the liquid sitting in the cavities
between the vanes outward and provides centrifugal
acceleration. As liquid leaves the eye of the impeller a low-
pressure area is created causing more liquid to flow toward
the inlet. Because the impeller blades are curved, the fluid is
pushed in a tangential and radial direction by the centrifugal
force.

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 Centrifugal Pump
• The faster the impeller the faster the liquid moves .
• Centrifugal force pushes the liquid outward from the eye and
enters the casing . Thus liquid velocity decreases & its pressure
increases.

• The head (pressure in terms of height of liquid) developed is

approximately equal to the velocity energy at the periphery of
the impeller expressed by the following well-known formula:

where:
H = Total Head developed in feet
v = Velocity at periphery of impleller in ft/s
g = Acceleration due to gravity = 32.2 ft/s2
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 Components of
Centrifugal Pump

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 Components of
Centrifugal Pump
A centrifugal pump has two main components:
1. Stationary Components:
i. Casings: A Casing is provided for housing the
impeller & supporting the bearings provided with
the shaft. Also casing has a provision for
connecting with suction & discharge pipe liens.
Casing are three types:
• Volute Casings
• Volute with vortex or whirlpool casing
•Diffuser or turbine casing

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 Components of
Centrifugal Pump
Volute casings:
• A volute is a curved funnel increasing in area to the
discharge port. As the area of the cross-section increases,
the volute reduces the speed of the liquid and increases
the pressure of the liquid.

• These casings can convert only a small amount of velocity

head into pressure head and a large amount of velocity
head is lost in eddies, thus produce comparatively low
heads.

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 Components of
Centrifugal Pump
Vortex or whirlpool casing:
• Like volute casing with a circular vortex or whirlpool
chamber between the impeller & the volute.
• Vortex chamber converts some of the kinetic energy into
potential energy with slight loss by friction.
• More efficient than volute casing or volute pump.

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 Components of
Centrifugal Pump
Diffuser or turbine casing:
• In this system the impeller is surrounded by a series of stationary
guide vanes or by a diffuser ring with guide vanes which by their
divergence furnish gradually expanding passages for the liquid to
follow after leaving the impeller.
• In this process direction of flow is changed and velocity head is
converted to pressure head before the liquid enters the volute.
• Velocity head of the liquid leaving the impeller is completely
converted into pressure than in the volute type
• Under variable conditions of speed and discharge the efficiency of
the pump goes down since the diffuser is generally designed for one
rate of discharge at a given impeller speed.
• Costlier than volute pump
• Pumps having diffuser type casing are commonly known as Turbine
pumps.
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 Components of
Centrifugal Pump
ii. Casing Wear rings- act as the seal between the
casing and the impeller to restrict leakage of high
pressure liquid back to the pump suction.

iii. Suction and Discharge Nozzles.

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 Components of
Centrifugal Pump
iv. Seal Chamber and Stuffing Box:
When the sealing is achieved by means of a mechanical seal, the
chamber is commonly referred to as a Seal Chamber.

When the sealing is achieved by means of packing, the chamber is

referred to as a Stuffing Box.
Both the seal chamber and the stuffing box have the primary function
of protecting the pump against leakage from the gap between the
pump casing and the shaft.
The seal chambers and stuffing boxes are also provided with cooling
or heating arrangement for proper temperature control.

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 Components of
Centrifugal Pump
v. Glands
The gland is a very important part of the seal chamber or
the stuffing box. It gives the packings or the mechanical
seal the desired fit on the shaft sleeve. It can be easily
adjusted in axial direction.
vi. Bearing Housing
The bearing housing encloses the bearings mounted on the
shaft. The bearings keep the shaft or rotor in correct
alignment with the stationary parts under the action of
radial and transverse loads. The bearing house also
includes an oil reservoir for lubrication, constant level
oiler, jacket for cooling by circulating cooling water.

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 Components of
Centrifugal Pump
2. Rotating Components
i. Impeller
ii.Impeller wearing ring
iii. Shaft
iv. Shaft sleeve
v.Couplings

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 Impeller
• It is the main part of pump assembly fitted with a
series of backward vanes (or blades). The function
of the impeller is to force the liquid into a rotary
motion by centrifugal force.
• On the basis of construction can be classified as:
i. Closed or shrouded impeller: contains two
shrouds (or side walls) in which plain or curved
vanes are inserted.
ii. Semi-open impeller: Vanes are fixed on one
shroud only.
iii. Open type impeller: Vanes are directly fixed on
the web. There is no shroud. 27
Impeller

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 Shaft
The basic purpose of a centrifugal pump shaft is to
transmit the torques encountered when starting and
during operation while supporting the impeller and
other rotating parts. It must do this job with a
deflection less than the minimum clearance between
the rotating and stationary parts.

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 Shaft sleeves
Pump shafts are usually protected from erosion, corrosion, and
wear at the seal chambers, leakage joints, internal bearings,
and in the waterways by renewable sleeves. Unless otherwise
specified, a shaft sleeve of wear, corrosion, and erosion-
resistant material shall be provided to protect the shaft. The
sleeve shall be sealed at one end. The shaft sleeve assembly
shall extend beyond the outer face of the seal gland plate.
(Leakage between the shaft and the sleeve should not be
confused with leakage through the mechanical seal).
.

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 Coupling
Couplings can compensate for axial growth of the shaft
and transmit torque to the impeller.
Shaft couplings can be broadly classified into two
groups: rigid and flexible.
Rigid couplings are used in applications where there is
absolutely no possibility or room for any misalignment.
Flexible shaft couplings are more prone to selection,
installation and maintenance errors. Flexible shaft
couplings can be divided into two basic groups:
elastomeric and non-elastomeric.
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 Axial flow pump
• An axial flow pump is one in which the fluid enters parallel to
the axis of rotation and leaves in the axial tangential plane.
• Axial flow pumps are normally designed for conditions where
low head high flows

Axial flow pumps are sometimes called propeller pumps because

they operate essentially the same as the propeller of a boat.

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Axial flow pump

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 Radial flow pump
Radial flow pumps are those where the fluid enters
the impeller in a direction parallel with the axis of
rotation and leaves the impeller in the radial
tangential plane.
Radial flow pumps operate at higher pressures and lower flow
rates than axial and mixed flow pumps.

• Also called Centrifugal Pump pumps

• broad range of applicable flows and heads
• higher heads can be achieved by increasing the
diameter or the rotational speed of the impeller

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 Mixed flow pump
• Mixed flow pumps, as the name suggests, function as a
compromise between radial and axial flow pumps

• fluid experiences both acceleration in radial and the axial

direction

• As a consequence mixed flow pumps operate at higher

pressures than axial flow pumps while delivering higher
discharges than radial flow pumps

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Mixed flow pump

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 Starting of
centrifugal pump
A typical starting sequence for a centrifugal pump is:
• Ensure that all valves in auxiliary sealing, cooling, and
flushing system piping are open, and that these systems are
functioning properly.
• Close discharge valve.
• Open suction valve.
• Vent gas from the pump and associated piping.
• Energize the driver.
• Open discharge valve slowly so that the flow increases gradually.

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Pumps performance

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 Pumps Selection
 Material Compatibility
 Solids
 Flow
 Head
 NPSHa
 Self priming requirment

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 Pumps performance
Effects of Changing Liquid Specific Gravity
Specific gravity (S.G.) has the following effects on pump
performance, assuming constant rpm and impeller diameter:
1. Flow rate (quantity) is unchanged by S.G. (although the flow
reading on a differential-pressure flow meter varies.)
2. Pressure varies directly with S.G. (Although pressure varies,
head is constant.)
3. Horsepower varies directly with S.G.

These relationships are important when converting a pump to

another service or if significant changes to fluid gravity are
anticipated. For example, converting from a light hydrocarbon
service to water service may significantly overload an existing
driver. 41
 Matching pumps to system
characteristics
 Good piping system design
◦ Match system characteristics to pump curve
 Trimming pump impellers
◦ To reduce flow
◦ To match partload requirments
 Pump control
◦ Two-speed pumping & motors
◦ Variable speed pumping
◦ Source distribution pumping

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 Matching pumps to system
characteristics
• Modulation of pump-piping systems
• Throttle volume flow by using a valve
• Change flow resistance – new system curve
• Also known as “riding on the curve”
• Turn water pumps on or off in sequence
• Sudden increase/drop in flow rate and head
• Vary the pump speed
• System operating point move along the system curve
• Requires the lowest pump power input
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 Matching pumps to system
characteristics
 Plant loop (at constant flow) (production loop)
◦ To protect evaporator from freezing, a fairly constant-
volume water flow is required
 Building loop (at variable flow)
◦ For saving energy at partload
◦ A differential pressure transmitter is often installed at
the farthest end from the pump
 Primary-secondary loop
◦ A short common pipe connects the 2 loops

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 Matching pumps to system
characteristics
Series and Parallel Operation
Often pumps are installed in series or in parallel with other pumps.
In parallel, the capacities at any given head are added; in series,
the heads at any given capacity are added.
Figures show series and parallel pumps curves, a system curve,
and the effect of operating one, two or three pumps in a system.
In both figures, the operating points for both pumps "A" and "B" are
the same only when one pump is operating.
For 2 or 3 pumps operating, the points are not the same because of
the pump curve shapes. Hence, due consideration should be given
to the pump curve shape when selecting pumps for series or
parallel operation.
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Matching pumps to system
characteristics

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Matching pumps to system
characteristics

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 Common problems
• Low Performance
• Cavitation
• Seal Leakage
• Bearings Failure
• Vibration
• Noise

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 Cavitation
The formation of vapor bubbles in the impeller suction eye due to fluid
flashing or boiling, with subsequent collapse of the bubbles as the pressure
rises, is called cavitation. Cavitation may cause vibration, pitting damage,
and impaired performance. Cavitation may or may not be serious
depending on the pump, HP/stage, impeller design, and the fluid being
pumped. In small pumps with low differential head per stage, the energy of
collapsing bubbles is much less than in larger, high-head-per-stage
pumps. Cavitation is more severe in a single-boiling point fluid (like water)
than with a mixture (like petroleum stocks) that have a broad boiling
range.

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 NPSH
NPSHA: is technically defined as the total suction pressure (in
psia) at the suction nozzle less the true vapor pressure of the liquid
(in psia) at the pumping temperature. For centrifugal pumps,
NPSHA is always expressed in feet of the liquid pumped. For
reciprocating pumps it includes the acceleration head. NPSHA
depends on the system characteristics, liquid properties and
operating conditions.
NPSHR: The minimum total suction absolute head, at the suction
nozzle minus the liquid vapor absolute pressure head, at flowing
temperature, required to avoid cavitation. For positive displacement
pumps it includes internal acceleration head and losses caused by
suction valves and effect of springs. It does not include system
acceleration head.
NPSHR depends on the pump characteristics and speed, liquid
properties and flow rate and is determined by vendor testing, 52

usually with water.

 NPSH
Calculation of NPSHA
NPSHA can be calculated as follows:
NPSHA = H + S - F – Vp
where: NPSHA = feet of head of the pumped liquid, at the
pump impeller-eye elevation and suction
flange face.
H = minimum absolute pressure on the
surface of liquid pumped, in feet of the liquid.
S = static head, or vertical distance between
the surface of the liquid and the center of the
impeller, in feet. S is negative (-) when the
pump is above liquid surface, and positive (+)
when the pump is below.
F = friction losses, in the suction pipe and 53
fittings, in feet of the liquid.