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MODULE 2
STEAM BOILERS, TURBINES& HYDRALIC PUMPS

Contents

1 Introduction to boilers, classification of boilers

2 Lancashire boiler, Babcock and Wilcox boiler
3 Introduction to Boiler mountings and accessories
4 Introduction to Hydraulic turbines, classification and specification of turbines
5 Principle and operation of Pelton wheel, Francis Turbine
6 Principle and operation of Kaplan Turbine compounding
7 Introduction to hydraulic Pumps classification of Pumps and Specifications
8 Reciprocating pump and centrifugal pump
Definition of boilers: Boiler is defined as a closed metallic vessel in which the water is heated
beyond the boiling state by the application of heat liberated by the combustion of fuels to convert
it into steam.

Function of a boiler: The function of the boiler is to supply the steam at the required constant
pressure either with its quality dry or as nearly as dry, or superheated. The steam can be supplied
from the boiler at a constant pressure by maintaining the steam generation rate and the steam
flow rate.

CLASSIFICATION OF BOILERS:

a. According to the circulation of water and hot gases

1. Fire Tube boilers:-In fire tube, boilers the hot flue gases produced by the combustion of
fuel passes through the tubes, which are surrounded by water.
Eg: - Cornish boilers, locomotive boilers, marine boilers and Lancashire boiler.

2. Water Tube boilers: - In water tube boilers water circulated inside the tubes, while the
hot gases produced by the combustion of fuels pass around the tubes.
Eg: - Babcock and Wilcox boiler, Stirling boilers…etc.

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b. According to the location of furnace

1. Internally fired boilers: - If the furnace is situated inside the boiler shell, the boiler is
called internally fired boilers. Most of the fire tube boilers are internally fired.
2. Externally fired boilers:-If the furnace is situated outside the boiler shell, the boiler is
called externally fired boilers. Water tube boilers are always externally fired.
c. According to the circulation of water
1. Natural circulation: - In these boilers, water is circulated by natural convection currents
that are set up due to the temperature difference.
2. Forced circulation: - water is circulated with the help of pump driven by a motor.
Forced circulation is used only in high pressure and high capacity boilers like La mont
boilers and Benson boilers, etc...
d. Based on heat source
1. Heat generated by combustion of fuel in solid, liquid or gaseous form
2. Heat generated by hot waste gases as byproducts of other chemical processes
3. Heat generated by Electrical energy
4. Heat generated by nuclear energy.
e. According to pressure of boiler:
1. High Pressure boiler
2. Low pressure boiler
f. Stationary and mobile boilers
1. Stationary Boilers: These are the boilers which are stationary and cannot be moved from
one place to another. Once they are installed, cannot be transported to other destination.
These boilers are used in power plants and in industrial
process works.
2. Mobile Boilers: these are the steam boilers which can be moved from one place to
another. Locomotive and marine boilers are mobile boilers.

BOILER MOUNTING & ACCESSORIES

Boiler Mountings:
The boiler parts which are essential for the safely performance of boiler, or in absence of which
the boiler cannot generates steam, known as boiler mountings.
1. Water level indicator: The water level indicator is used to check the water level inside
the boiler. It is used to correct working of boiler. It is mostly fitted in front of boiler. It
consist three cocks and a glass tube.
2. Pressure gauge: A pressure gauge is used to measure the pressure inside the boiler. It is
also fitted in front side of the boiler. Generally, Bourden type pressure gauge is used in
the boiler.
3. Safety valve: The safety valve is fitted on the drum. It prevents the explosion due to high
pressure in the boiler. It is generally two in number. The safety valve blow offs the steam
when the pressure inside the boiler exceeds the certain limit.

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4. Stop valve: This valve is used to control the flow of steam from the boiler to the steam
pipe. It opens When the steam require, it shut off when sufficient steam is the steam pipe.
5. Blow off cock: It is used to blow off mud and water whenever required. It is situated at
the bottom of the drum. It is use to empty the boiler, when required.
6. Feed check valve: It is a NRV (Non Return Valve). It regulates supply of water in drum,
by the feed pump. It is fitted to the drum slightly below the normal water level.
7. Grate: It is the space in furnace on which fuel is burn.

Boiler Accessories:
Those parts, which are used to increase efficiency of a boiler and boilers, can perform safely
without these parts are known as boiler accessories. These parts are as follow.
1. Feed pump: Feed pump is use to pump the water in boiler for continuous working. The
feed pump is run by the electricity or by an steam turbine. The steam use to drive the
turbine taken by the boiler itself, which increase the boiler efficiency.
2. Super heater: The steam generate by the boiler is saturated steam. If this steam is use in
turbine, it may cause corrosion. So the steam is superheated before taken out for process
work. This is done by super heater.
3. Economizer: Economizer is use to preheat water before it enter into boiler drum. The
economizer uses the heat of flue gases to preheat the water. The flue gases coming out
from boiler, first passes through economizer and then to atmosphere. It increases the
efficiency of boiler.
4. Air preheated: Air preheats is use to preheat the air. The exhaust gases of boiler preheat
it. Therefore, it also increases efficiency of boiler. The heated air enters into boiler.
5. Steam separator: it is used to separate the water particles are present in the steam before
enters the turbine or engines.
6. Steam trap: it is used to drain off the condensed water accumulated in the steam pipes
and steam separator without allowing the escape of high-pressure steam from it.

LANCASHIRE BOILER
Lancashire boiler is the most commonly used boiler in the Sugar and Cotton industries.
Lancashire is a horizontal, stationary fire tube boiler. Sir William Fairbairn invents this boiler in
the year 1844.The flue gases flows through the fire tube, situated inside the boiler shell, so it is a
fire tube boiler. This boiler generates low-pressure steam. It an internally fired boiler because the
furnace is placed inside the boiler.

Principle of Lancashire Boiler:

This boiler works on the basic principle of heat ex-changer. The flue gases flow through the
tubes and the water flows through shell in a shell and tube type heat ex-changer. The heat is
transfer from flue gases to the water through convection. It is a natural circulation boiler, which
uses natural current to flow the water inside the boiler.

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Construction:
This boiler is similar a shell and tube type heat ex-changer. It consist a large drum of diameter up
to 4-6 meter and length up to 9-10 meter. This drum consist two-fire tube of diameter up to 40%
of the diameter of shell. The water drum is placed over the bricks works. Three spaces create
between the drum and the bricks, one is at bottom and two are in sides as shown in figure. Flue
gases passes through the fire tubes and side and bottom space. The water level inside the drum is
always above the side channels of flue gases, so more heat transfer to the water. The drum is half
filled with water and the upper half space for steam. The Furnace is located at one end of the fire
tubes inside the boiler. The low brick is situated at the grates (space where fuel burns) which
does not allow to un-burned fuel and ash to flow in fire tubes. The boiler also consist other
necessary mountings and accessories like economizer, super heater, safety valve, pressure gauge,
water gauge, etc. to perform better.

Working:
The Lancashire boiler is a shell and tube type heat ex-changer. The fuel is burn at the grate. The
water is pumped into the shell through the economizer, which increases the temperature of water.
Now the shell is half filled with water. The fire tube is fully immersed into the water. The fuel is
charged at the grate, which produces flue gases. These flue gases first passes through the fire
tube from one end to another. This fire tubes transfer 80-90% of total heat to the water. The
backward flue gases passes from the bottom passage where it transfer 8-10% heat to water. The
remaining flue gases passes from the side passage where it transfer 6-8% of heat to water. The
brick is the lower conductor of heat, so work as heat insulator. The steam produces in drum shell
it taken out from the upper side where it flows through super heater if required. So the steam
produce is taken by out for process work

Advantage:
1. This boiler is easy to clean and inspect.
2. It is more reliable and can generate large amount of steam.
3. It required less maintenance.
4. This boiler is a natural circulation boiler so lower electricity consumption than
other boilers.
5. It can easily operate.
6. It can easily meet with load requirement.
7. Lancashire boiler has high thermal efficiency about 80-90%.

Disadvantages:
1. This boiler required more floor space.
2. This boiler has leakage problem.
3. It requires more time to generate steam.
4. It cannot generate high-pressure steam if required.
5. Grates are situated at the inlet of fire tube, which has small diameter. So the grate area is
limited in this boiler.
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BABCOCK & WILCOX BOILER

Babcock and Wilcox boiler is a natural circulation, externally fired medium pressure, stationary
horizontal water tube boiler in which water is flow in the inclined tubes. The furnace is located
outside of the drum.

Main Parts:
Babcock and Wilcox is a stationary water tube boiler. It has inclined tubes which are inclined at
10 to 15 degree, which are inclined to maintain natural circulation of water from drum to tubes
and steam from tubes to drum. The main parts of this boiler are as follow.
1. Steam separator drum:
2. This drum is situated upside of the boiler. Water and steam placed together in larger
diameter drum. The one-half of the drum is filled with water and the other half is
remaining for steam.
3. Water tubes: Water tubes are situated bottom side of the drum. Water flows from the
drum to the tubes.
4. Uptake header: Steam separator drum and water tubes are connected by the two tubes.
One is known as uptake header and the other one is known as down take header. The
steam from the water tubes to the drum flow by the uptake header.
5. Down take header: The water flows form the drum to the water tubes through down take
header. When the steam flows by uptake header to the drum, at the same time water flows
from drum to the water tubes by down take header which maintains the flow of water.
6. Grate: The place in the furnace, where the fuel is placed and burn known as grate.
7. Furnace: The furnace is the place where the fuel burns. This is situated at the down side
of the water tubes. When the fuel burns, the flue gases generate. This gases flow upper
side and passes through water tube, which heat the water and convert it into steam.
8. Super heater: Super heater is situated upper side of the water tube. One end of super
heater is connected to the drum and other end is for process work. Steam flows from the
drum to the super heater, where it heated by the flue gases and send for the process work.
9. Baffles: Baffles are provided between the water tubes. The main function of baffles is to
divert the flue gases, so it flows more than one time through the tube and more heat is
transfer.

Other mounting like safety valve, blow off valve, fuel door, inspection door, mud box, feed
valve, stop valve, pressure gauge etc. are also provided for safely working of boiler.

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Working:

Babcock and Wilcox boiler is a high pressure, natural circulate, water tube boiler. The working
of this boiler is as follow.
First water is filled in the water drum through feed pump. The drum is half filled with
water and the upper half is for steam. First flue is fired at the grate. The flue gases generate by
burning of fuel. These gases start flowing from one end to another end of boiler. The flue gases
passes by the water tubes and exchange heat with water. The baffles are provided in the way,
which deflects the flue gases before escaping from the chimney. Due to this deflection, the flue
gases pass more than one time through water tubes, which cause more heat transfer. The water
flows from the drum to the water tube through down take header. The water tube nearer to the
furnace heated more than the other, so the density of water decrease in this tube which causes the
flow of steam from tube to drum through uptake header. At the same time the water from the
drum enters into the tubes through down take header. The circulation of water from drum to
tubes and again tubes to drum is natural; due to density difference. The steam separates in the
drum at the upper half. This is saturated steam. This steam sends to the super heater through
steam pipe. The steam is heated again by the flue gases in the super heater and taken out for
process work. The flue gases send to the atmosphere from the super heater. This
process repeat until sufficient amount of steam generates. This boiler can generate 20 ton steam
per hour.

Advantages:
1. The steam generation rate is higher about 20 ton per hour at pressure 10 to 20 bars.
2. The tubes can be replaced easily.
3. The boiler can expand and contract freely.

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4. It is easy to repair maintenance and cleaning.
5. It drought loss is low compared to other boiler.
6. The overall efficiency of this boiler is high.
Difference between Fire Tube Boiler and Water Tube Boiler
Fire Tube Boiler
1. Hot flue gases flow inside the tube
and the water outside the tube.
2. This boiler pressure is limited up to
20 bar. These boilers are generally
low or medium pressure boiler.
3. Fire tube boiler have lower rate of
steam production compare to water
tube.
4. These boilers are almost internally
fired. Furnace is placed at the one
end of fire tube.
5. It is suitable for the production work
like sugar mill, textile industries.
6. Risk of explosion is lower due to
low pressure.
7. This boiler occupies large floor
space.
8. It required less skill to operate.
9. It is difficult to repair and cleaning.
10. It required large shell diameter
because the fire tube situated inside
the shell.
11. This boiler is difficult to construct.
12. The efficiency of fire tube boiler is
less compare to water tube. It will
increase by using other accessories.
13. The maintenance of this boiler is
costly. It is required regular
inspection.
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Water Tube Boiler
Water flows inside the tube and the flue
gases outside the tube.
This boiler pressure is up to 70-100 bar.
So these boilers are generally high
pressure boiler
It has higher rate of steam production.
These boilers are generally externally
fired.
It is suitable for large power plant.
Risk of explosion is higher due to high-
pressure boiler.
It occupies less floor space compare to
fire tube boiler.
It required a skilled operator.
It is easily clean and repairable due to
externally fired.
It required small shell diameter.
This is simple in construction.
This boiler is more efficient.
This boiler is easy to maintain.
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14. The treatment of water is not The water flows through small diameter
necessary. tube. So water is treated before entering
into the tube otherwise it will jam the
tube.
15. Example Lancashire boiler Example Babcock and Wilcox boiler

HYDRAULIC TURBINES:

Introduction and Classification

Hydraulic turbines are Machines, which convert hydraulic energy in to mechanical energy. Uses
the energy and kinetic energy of water and rotate the rotor by dynamic action of water.

Classification of Hydraulic turbines:

1. Based on type of energy at inlet to the turbine:
i. Impulse Turbine: The energy is in the form of kinetic form. e.g: Pelton wheel,
Turbo wheel.
ii. Reaction Turbine: The energy is in both Kinetic and Pressure form. e.g:
Tubular, Bulb, Propeller, Francis turbine.
2. Based on direction of flow of water through the runner:
i. Tangential flow: water flows in a direction tangential to path of rotational,
i.e. Perpendicular to both axial and radial directions.
ii. Radial outward flow e.g: Forneyron turbine.
iii. Axial flow: Water flows parallel to the axis of the turbine. e.g: Girard,
Jonval, Kaplan turbine.
iv. Mixed flow: Water enters radially at outer periphery and leaves axially. e.g :
Modern Francis turbine.
3. Based on the head under which turbine works:
i. High head, impulse turbine. e.g : Pelton turbine.
ii. Medium head, reaction turbine. e.g : Francis turbine.
iii. Low head, reaction turbine. e.g : Kaplan turbine, propeller turbine.
4. Based on the specific speed of the turbine:
i. Low specific speed, impulse turbine. e.g : Pelton wheel.
ii. Medium specific speed, reaction turbine. e.g : Francis wheel.
iii. High specific speed, reaction turbine. e.g : Kaplan and Propeller turbine.
5. Based on the name of the originator:
i. Impulse turbine – Pelton wheel,.
ii. Reaction turbine – Forneyron, Jonval, Francis, Dubs, Deriaze, Thomson kalpan,
Barker, Moody, Nagler, Bell.

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PELTON WHEEL TURBINE

Pelton wheel is a tangential flow impulse turbine, used for high heads and small quantity of
water flow. Figure shows the schematic diagram of a Pelton wheel. The Pelton wheel
consists of the following parts: nozzle with spear head, shaft, rotor, buckets, casing, and
tailrace.

Working: In operation, water from the reservoir (dam) having potential energy flows through
the penstock and enters the nozzle. As water flows through the nozzle, the potential energy of
water is completely converted into kinetic energy in the nozzle. The high velocity jet of water
issuing from the nozzle impinges on the curved blades fixed around the runner wheel. The
impulse force due to the high velocity jet of water sets the runner wheel into rotary motion.
Hence, the shaft coupled to the runner wheel also rotates thereby doing useful work. Thus,
the potential energy of the water is converted into mechanical work. After performing work,
the water freely discharges to the tailrace. The work produced at the output shaft is used to
drive a generator to produce electricity the electricity is then transmitted to a substation
where transformers increase voltage to allow transmission to homes, office, and factories.

Advantages:

1. Simple in construction and easy maintenance

2. To drive more power multiple jets (2 to 6) Pelton wheel may be used.

Disadvantages:
1. A lot of head loss occurs when the river discharge is low.

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FRANCIS TURBINE

Francis turbine is a mixed flow reaction turbine used for medium heads. It was the first
Hydraulic turbine with radial flow, designed by American scientist James Francis. Figure shows
the front and top views of a Francis turbine. Francis turbine consists of the following parts: spiral
casing (volute), runner, shaft, guide blade (fixed blade), guide wheel, moving blade (runner
blade).

Working:
In operation, water from the reservoir (dam) flows through the penstock and enters the spiral
casing. As the water flows through the tapered spiral casing, a part of its potential energy is
converted into kinetic energy. Water flows through the guide blades, is deflected and then flows
radially inwards to the outer periphery (outer diameter) of the runner. The water then moves over
the moving blades in the radial direction and is finally discharged to the tailrace axially from the
centre of the runner via a draft tube. During its flow over the runner blades, the blade passages
act as nozzle, and the remaining part of the potential energy is converted into kinetic energy. It is
important to note at this point, that the jet of water does not impinge on the runner. In fact, they
are leaving the runner at high velocity. Therefore, the momentum is converted into force as in the
case of impulse turbine. Since the water leaves the blades at high velocity, there is a reaction
force on the runner. This force sets the runner into rotary motion. Hence, the shaft connected to
the runner also rotates thereby doing useful work. The shaft in turn drives the generator to
produce electricity.
Advantages:

1) No head loss occurs even at low discharge of water.

Disadvantages:

1) Eddy losses are more

2) Since the spiral casing is grounded, runner is not easily accessible. Hence dismantling is
difficult.

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KAPLAN TURBINE
The Kaplan turbine is a low head reaction turbine in which water flows axially, Figure
shows the rotor and front view of a Kaplan turbine. Kaplan turbine consists of the following
parts: guide vanes, runner vanes, shaft, spiral casing, tailrace, hub, and blade.

Working:
Kaplan turbine is an axial flow reaction turbine and is used where large quantity of water is
available at low heads. The turbine consists of a hub or boss fixed to a vertical shaft. The
runner blades attached to the hub are adjustable, and can be turned about their axis to take
care of change of load. The runner has only 4 to 8 blades. Similar to Francis turbine, Kaplan
turbine also has a ring of fixed guide blades at the inlet to the turbine. The inlet is a scroll
shaped tube surrounding the fixed blades. In operation, water from the reservoir flows
through the penstock and enters the spiral casing. A part of the potential energy of water is
converted into kinetic energy in the spiral casing.

The water then moves through the guide blades (fixed blades), gets deflected and then flows
axially through the runner blades as shown in figure. During its flow over the runner blades,
the blade passages act as nozzle, and the remaining part of the potential energy is converted
into kinetic energy. The water leaves the runner blades at high velocity, and as a result, a
reaction force is set up causing the runner to rotate at high speeds. Hence, the shaft
connected to the runner also rotates thereby doing useful work. The shaft in turn drives the
generator to produce electricity. The water discharging at the centre of the runner enters the
draft tube whose end is immersed into the tailrace as in Francis turbine.

Advantages:

1) Simple in construction and requires less space.

2) Eddy losses are almost eliminated.
Disadvantages:

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1) Cavitations are likely to occur due to high velocity flow of water.
Difference between impulse water turbine and reaction water turbine:
Sl. Impulse Turbine
No
1 In impulse turbine all hydraulic energy is
converted into kinetic energy by a nozzle
and it is is the jet so produced which strikes
the runner blades.
2 The velocity of jet which changes, the
pressure throughout remaining atmosphere.
3 Watertight casing is not necessary. Casing
has no hydraulic function to perform. It
only serves to prevent splashing and guide
water to the tailrace.
4 Water is admitted only in the form of jets.
There may be one or more jets striking
equal number of buckets simultaneously.
5 The turbine does not run full and air has a
free access to the bucket.
6 The turbine is always installed above the
tail race and there is no draft tube used.
7 Flow regulation is done by means of a
needle valve fitted into the nozzle.
8 Example of impulse turbine is Pelton
wheel.
9 Impulse turbine has more hydraulic
efficiency.
10 Impulse turbine operates at high water
heads.
11 Water flow is tangential direction to the
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Reaction Turbine
In reaction turbine, only some amount of the
available energy is converted into kinetic
energy before the fluid enters the runner.
Both pressure and velocity changes as fluid
passes through a runner. Pressure at inlet is
much higher than at outlet.
The runner must be enclosed within a
watertight casing.
Water is admitted over the entire
circumference of the runner.
Water completely fills at the passages
between the blades and while flowing
between inlet and outlet sections does work
on the blades.
Reaction turbine is generally connected to
the tail race through a draft tube which is a
gradually expanding passage. It may be
installed below or above the tail race.
The flow regulation in reaction turbine is
carried out by means of a guide-vane
assembly. Other component parts are scroll
casing, stay ring runner and the draft tub.
Examples of reaction turbine are Francis
turbine, Kaplan and Propeller Turbine,
Deriaz Turbine, Tubular Turbine, etc.
Reaction turbines have relatively less
efficiency.
Reaction turbine operates at low and
medium heads.
Water flows in radial and axial direction to
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turbine wheel. turbine wheel.

12 Needs low discharge of water. Needs medium and high discharge of water.
13 Degree of reaction is zero. Degree of reaction is more than zero and
less than or equal to one.
14 Impulse turbine involves less maintenance Reaction turbine involves more
work. maintenance work.

HYDRAULIC PUMP

Hydraulic pumps are used in hydraulic drive systems and can be hydrostatic or hydrodynamic. A
hydraulic pump is a mechanical source of power that converts mechanical power into hydraulic
energy (hydrostatic energy i.e. flow, pressure). It generates flow with enough power to overcome
pressure induced by the load at the pump outlet. When a hydraulic pump operates, it creates a
vacuum at the pump inlet, which forces liquid from the reservoir into the inlet line to the pump
and by mechanical action delivers this liquid to the pump outlet and forces it into the hydraulic
system.

CLASSIFICATION OF PUMPS

1. Centrifugal pumps: are used to transport fluids by the conversion of rotational kinetic
energy to the hydrodynamic energy of the fluid flow.
2. Reciprocating pump: is a positive displacement pump where certain volume of liquid is
collected in enclosed volume and is discharged using pressure to the required
application. Reciprocating pumps are more suitable for low volumes of flow at high
pressures.

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3. Rotary pumps: are positive displacement pumps whereby a “moving chamber” is

formed between a pair of rotating elements (rotors) or between a single rotor and
the pump housing.

1. CENTRIFUGAL PUMP
Centrifugal pump is a hydraulic machine, which converts mechanical energy into
hydraulic energy (i.e. pressure energy) by the use of centrifugal force acting on the fluid. The
flow of liquid takes place in radial outward direction, which is reverse of the inward radial
flow reaction turbine. It is used in different areas where fluid is needed to raised from low level
to high level.

Working Principle
It works on the principle of forced vortex flow. The forced vortex flow means when a
certain mass of fluid or liquid is allowed to rotate by an external torque than there is a rise in
pressure head of the rotating liquid takes place. This rise in pressure head is used to deliver water
from one location to another. It is centrifugal force acting on the fluid that makes it to flow
within the casing. The rise in the pressure head of the rotating liquid at any point is directly
proportional to the square of the tangential velocity of the rotating liquid.

Parts of Pump
1. Impeller
2. Casing
3. Suction pipe with a foot valve and strainer
4. Delivery pipe
1. Impeller
It is the rotating part of the pump. The impeller is mounted on a shaft and the shaft of impeller is
again connected with the shaft of an electric motor. It is rotated by the motor and consists of
series of backward curved blades.

2. Casing
It is an airtight passage, which surrounds the impeller. The design of the casing is done in such a
way that it is capable of converting the kinetic energy of the water discharging from the outlet of
the impeller into pressure energy before it leaves the casing and enters into the delivery pipe.
Commonly three types of casing are used in centrifugal pump and these are

(i). Volute Casing: It is a spiral type of casing in which the area of flow increases gradually. The
increase in area of flow decreases the velocity and increases the pressure of the liquid that flows
through the casing.

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(ii). Vortex Casing: In vortex casing, a circular chamber is introduced in between the impeller
and casing. This is done in order to prevent the loss of energy due to formation of eddies. The
efficiency of the vortex casing is more than that of the volute casing.

Suction Pipe with Foot Valve and Strainer

A pipe whose one end is connected with the inlet of the impeller and the other end is dipped into
the sump of water is called suction pipe. The suction pipe consists of a foot valve and strainer at
its lower end. The foot valve is a one-way valve that opens in the upward direction. The strainer
is used to filter the unwanted particle present in the water to prevent the centrifugal pump from
blockage.

Delivery Pipe
It is a pipe whose one end is connected to the outlet of the pump and other end is connected to
the required height where water is to be delivered.

Advantages:
1. Centrifugal pumps do not have any leakage issue.
2. They are able to pump hazardous as well as sensitive fluids.
3. There is also no problem of heat transfer as the space between the motor and chamber is
sufficiently large.
4. There is no loss of power due to friction and they are very simple in structure and easy in
handling.
Disadvantages:
1. Magnetic resonance in centrifugal pump results in small loss of energy.
2. The risk of the clogging of pipe may arise due to particle attractive nature of magnetic
drive.
3. Vibrations due to surrounding atmosphere can damage these pumps.
4. The risk of cavitations is always there.

Applications:
1. These pumps are used in buildings for pumping the regular water.
2. They are used in the fire protection related services.

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3. Centrifugal pumps are used to transfer lactose and other drugs in pharmaceutical
industry.
4. They are also used in coolant recirculation, refrigerants.
5. These pumps are used in sprinkling, irrigation, drainage.

CAVITATION
Simply defined, cavitation is the formation of bubbles or cavities in liquid, developed in
areas of relatively low pressure around an impeller. The imploding or collapsing of these bubbles
triggers intense shockwaves inside the pump, causing significant damage to the impeller and/or
the pump housing.
If left untreated, pump cavitation can cause:
Failure of pump housing
Destruction of impeller
Excessive vibration - leading to premature seal and bearing failure
Higher than necessary power consumption
Decreased flow and/or pressure

PRIMING
Priming is the process in which the impeller of a centrifugal pump will get fully sub merged
in liquid without any air trap inside. This is especially required when there is a first start up. It is
always advisable to start the pump only after primping.
For Centrifugal Pump, priming is required only when the elevation of liquid in the
suction tank is less than the elevation of the pump. Centrifugal pump cannot suck the
liquid, but it pushes the liquid. Liquid enter in the suction of centrifugal pump by the
energy it possess (atmospheric pressure in the suction tank).

Let us consider the atmospheric pressure as 1 atm, then maximum lift generated by
centrifugal pump will be (1* 101.325)/9.81 = 10.3m (theoretical). If we want to "lift"
water from elevation more than 10.3 m, even if we try to prime the centrifugal pump, it
will not work.

Usually, to lift the water centrifugal pump push the liquid and due to pressure difference,
liquid enter in the suction side provided suction line is completely filled with liquid
(primed). During the startup of the pump if air pocket are present at the suction side, then
pump will push the air and it will not generate enough momentum. As a result suction air
will try to expand and it will block the liquid from entering into the centrifugal pump. In
addition, if pump is allowed to run in this condition for longer duration, it will overheat
the system and eventually pump will fail. So to avoid all these problems we do the
priming operation.

For Reciprocating pump, during suction phase, piston moves backward and forms a low
pressure zone in the pump. This pressure difference between suction & tank is large

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enough that it will pull the liquid, even if air pocket is present in the suction line. So we
need not have priming operation. These are called self-priming devices

2. RECIPROCATING PUMP
Reciprocating pump is a positive displacement pump where certain volume of liquid is collected
in enclosed volume and is discharged using pressure to the required application. Reciprocating
pumps are more suitable for low volumes of flow at high pressures.

Main Parts or Component of Reciprocating Pump:

1. Suction Pipe
2. Suction Valve
3. Delivery Pipe
4. Delivery Valve
5. Cylinder
6. Piston and Piston Rod
7. Crank and Connecting Rod
8. Strainer
9. Air Vessel

Suction Pipe:
It is used to suck the water from the water reservoir to the cylinder. It connects the inlet of the
pump with the water tank.

Suction Valve: The suction valve is a non-return valve which means only one directional flow is
possible in this type of valve. This is placed between the suction pipe inlet and the cylinder.
During suction of liquid, it is opened and during discharge, it is closed.

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Delivery Pipe:
It is a pipe, which is used to deliver the water from the cylinder to the desired location.
It connects the outlet of the pump to the tank where the water is to be delivered.
Delivery Valve:
Delivery valve also non-return valve placed between the cylinder and delivery pipe outlet. It is in
a closed position during suction and in opened position during discharging of liquid.
Cylinder:
A hollow cylinder made of steel alloy or cast iron. An arrangement of piston and piston rod is
inside this cylinder.
Piston and Piston Rod:
A piston is a solid type cylinder part, which moves backward and forwards inside the hollow
cylinder, to perform suction and delivery of liquid. Piston rod helps the piston to its linear
motion.
Crank and Connecting Rod:
Crank is a solid circular disc, which is connected to the power source like motor, engine etc, for
its rotation. Connecting rod connects the crank to the piston; as a result, the rotational motion of
crank is converted into linear motion of the piston.
Strainer:
A strainer is provided at the end of the suction pipe to prevent the entrance of solids from a water
source into the cylinder.
Air Vessel:
Air vessels are connected to both suction and delivery pipes to eliminate the frictional head and
to give uniform discharge rate.
WORKING
When crank starts rotating, the piston moves in the cylinder. When a crank is at A, the piston is
at the extreme left position in the cylinder. As the crank is rotating from A to C,(θ=0º to
180º) the piston is moving towards the right in the cylinder. The movement of the piston towards
the right creates a partial vacuum in the cylinder. However, on the surface of the liquid in the
sump atmospheric pressure is acting, which is more than the pressure inside the cylinder.
Thus, the liquid is forced into the suction pipe from the sump. This liquid opens the suction valve
and enters into the cylinder.
When a crank is rotating from C to A (θ=180º to 360º), the piston from extreme right position
starts moving toward left in the cylinder. The movement of the piston towards the left increases
the pressure of the liquid inside the cylinder more than the atmospheric pressure.

SPECIFICATION OF HYDRAULIC PUMPS

1. Maximum Discharge Pressure: The maximum pressure the pump is designed to generate
2. Maximum Discharge Flow: The maximum flow the pump is designed to generate. This
value is dependent on the system or pressure head the pump must enter.
3. Discharge Size: Size of the pump discharge or outlet connection

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4. Temperature of the media being pumped.

5. Pump Type: ( Hand / Foot Pumps, Testing / Calibration Pumps, Booster Pumps, Positive
Displacement Pumps ,Gear Pumps ,Piston / Plunger Pumps,) Rotary Vane Pumps)
6. Power Source :( None, Pump Only AC Powered DC Powered Air / Pneumatic Gasoline /
Diesel Engine, Hydraulic, Manual)
7. Housing Material :( Aluminum, Cast Iron, Plastic, Stainless Steel)

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