Pump is a mechanical device, used to transfer igud from one place to another with required flow rate & Pressure. Pump transfers rotational energy ige mechanical energy OF He TT EM the fluid as potential & kinetic energy. A fluid only flows if there is a presse difference. function ofthe pump is to create this pressure difference for transporting offic. Pump Classification: iston/Plunger : Reciprocating isplacement- iaphragm tary. ‘Single Rotor a Mutiple Rotors Open Impeller ee Stage Centrifugal Pump- Multi Stage Dynamic-| ®*@iaVAxialMixed flow) _Closed Impeller special effect Reciprocating Pump Working Principle: A chamber is filled with liquid, on which pressure is imparted, The liquid is then forced outward through reciprocating action of moving element and consequently increases the pressure of the liquid. Constructional Description: The major segments of reciprocating pump are- 1. Liquid end 2. Power end Liquid end segment consists of: - Cylinder - Piston or plunger - Piston ring = Valves - Stuffing box ~ Manifold Cylinder: Its the major pressure retaining part and usually contains liquid end components. Piston: A piston is cylindrical dise, mounted on a rod (called piston rod) used to transmit the force that develops the pressure to the liquid. Piston ring: Piston rings serve as seal and minimize leakage, Valves: The valves of a reciprocating pump are simply check valves. They are o} - Taal pressure only. The function of valves is to control the flow ofthe liad 4 Stuffing box: The stuffing box of a pump consists ofthe box, lower and upper bushing, packi and gland. The function of stuffing box is o seal around the reciprocating piston rod pce Manifold: These are the chambers where liquid is dispersed or collected for uniform distributio (flow) before or after passing through the cylinder. form distribution Liner: A cylindrical sleeve to absorb wear fom the sealing element, which is fas cylinder by an interference ft or by bolting ened to thea Power end segment consists of: ~ Crankshaft ~ Connecting rod ~ Crosshead and pin : “Boning Pi Crosshead guide Crankshaft It drives the connecting rods and absorbs the loads from the rods and driver. It is made of ductile iron, cast steel and forged steel. Connecting rod ate ra The connecting rod transmits vom rod transmits the power from the crankshaft 10 the crosshead. The crankshaft moves in pare rotary mation, {he reciprocating motion. osshead in pure Crosshead and pin The crosshead pin is driven by the connecting rod, transmit some pumps, the pin is locked in the crosshead. On others, 1 rod and rotates in the crosshead. The crosshead absorbs the transmits it to the extension. .e to the crosshead. On ‘eked in the connecting fad pin and tting the fore the pin is lo force from the crossbe: Crosshead guide: Crosshead guide is the surface on which the crosshead reciprocates Bearing Bearing supports the crankshaft and absorbs all of the loads imposed on the erankshaft. Bearings used in reciprocating pumps are of the sleeve type, roller type, or, in smaller pumps, ball type. ROTARY PUMP Working Principle: Rotary pumps are positive displacement pumps in which the main pumpinig action is caused by relative movement between the rotating and stationary element of the pump. The rotary pump continuously scoops the liquid from the pump chamber. {ZB sweriow ror Constructional Deseription: 1p consists of the following main parts. Rotary pum| ~ Casing or Housing ~ Suction & Discharge ports oe — DISCHARGE LINE = Seal - Bearing Casing or Housing: The casing is that part of the pump, which surrounds the boundaries of the pumping chamber. The pumping chamber is generally defined as all the space inside the pump that may contain the pumped fluid while the pump is operating, Suction & Discharge ports: Fluids enter the pumping chamber through one or more suction ports and leave through one or more discharge ports. Rotor: Rotor is the specific part of the rotating assembly, which rotates in the pumping chamber Rotors may be given specific names in specific types of rotary pumps, i. gears, screws, etc, Shaft: Most rotary pumps have driven shaft, which accepts driving torque from a power source. Ir Two type of seals are generally used in rotary pump, i.c-static and moving seal Seal Bearing supports the rotor and absorbs all of the loads imposed on the rotor. Bearing:Working p Centrifugal rotatin ple: asses through & 2 impel AP OPerates by increasing the velocity of the fd 9s i pee outward BY contr aga Re iad first comes in atthe center ofthe impeller HSM OT ros its Mud With al force. When rotation takes place, de to centrifugal foree the mre i bieh velocity to outward direction. ‘Then the i fauid enters the casing with decreases velocity as easing the area and inereasing pressure Constructional Description: A centrifugal pump has the following major parts. ~ Impeller ~ Casing + Shait - Shafi sleeve tulfing box - Bearing als - Coupling impeller Impeller is the bladed member of a rotating assembly of the pump. Impeller imparts the principal force to the liquid to be pumped. Impellers are classified according to the m: © 10 axis of rotation. Thus a ecntrifugal pump may have. Radial flow impellers - Axial flow impellers Mixed flow impellers. which combine radial & axial flow principles fajor direction of flow in Impellers are further classified as = Single suction, with a single inlet on one side Double suction, with water flowing to the impeller symmetrically from both sides Casing i euides liquid to the impeller, collects liquid from the impeller and slows (diffuses) it to a usable velocity and thus converts the kinetic energy of the liquid to potential energy. It is primary clement of pressure boundary. ‘There are two types of casing, ic = Volute casing - Concentric casing Shaft Th. basic function of a shaft is to transmit the torque encountered in starting & during operation while supporting the impeller & other rotating pasts. In shor, it ean be said that shaft drives and ppellers are mounted on the shaft, It is a media to transler mechanical supports the impeller. Inj energy (rpm) to total energy of the liquid. Shaft Sleeves ; Sleeves protect the pump shaft from erosion, corrosion & wears at stuffing boxes, leakage joints jnternal bearings and in the waterways. The most common shaft sleeve function is to protect the shalt from wears at a stuffing box. Stuffing Box Stutling boxes have primary function of protecting the pump against leakage at the point where the shaft passes out through the pump casing. Ifthe pump handles a suction lift int whe the interior stuffing box end is below atmospheric, the stuffing box function ae prevent sit Jeakuse into the pump. If the pressure is above atmospheric, the function is to. pr ST eee ut of the. pump. For general pumps, a stuffing box usually takes the Ton tne (cinuirieal shape that accommodates number of packing rings around the shaft or aia ot aBearing sent {t gives the chance to move shaft freely. The function of bearing in © the shaft or rotor in correct alignment with the stationary parts under the Ss transverse load. Bearing that give radial positioning to the rotor are 100 those that locate the rotor axially area called thrust bearings. In most APF bearings actually serve both as thrust & radial bearings. All types of bearines centrifugal pumps, Seals Q : f seals are Ieseals the opening where the shaft passes through the pressure boundary. Two TYPES © used in centrifugal pump, i.e- Stuffing box seals & Lip type oil seals. Coupling Gs Centrifugal pumps are connected to their driver through couplings. The principal purpows © coupling is to transmit rotary motion and torque from one piece of equipment to another. Coupling may perform other, secondary functions, such as accommodating misalignment between shafts, transmitting axial thrust loads from one machine to another and maintaining precise alignment between connected shaft. Operational Characteristics of Pump: Pump is used to transfer liquid from on place to another with required flow rate & Pressure. Specific category pump is used depending on liquid properties, flow rate & Pressure. Centrifugal Pump can be used for high flow rate & intermediate pressure of solid content liquids. High pressure & intermediate flow rate of clean fluid can handle reciprocating pump. Rotary pump is used for viscous fluid. Pump charactei ree Ee ame te | Ri | Head 300-6000 psi. | Upto 100 psi | Upto30psi_ | Upto600 psi | UP Oe Capacity Up 1 200,000 Up o 6,000 | Up wl }00,000 Up to 500 Up to 500 gal/min gal/min gal/min “gal/min gal/min Liquid | Clean or diny | High solids Abrasive Viscous Clean | property am atents | — — i he most important operating parameters of the pump are the capacity (Q), head (H), power (P) and efficiency (n). The power required of a pump, head developed by a pump & its efficiency vary with the capacity. : : wee The speed (n) & the impeller diameter (d) influence the pump parameter. Capacity (Q) the volume of liquid per unit time delivered by the pump. The pump capacity (Q) is re eeanding units of capacity of the pump are liter/sec, m’/sec, Head (I) qui The fae head (H) represents the net work done on a unit weight of liquid in passing from the inlet or suction flange (s) to discharge flange (4). Itis given by — [=Hy—He= (P+ V228 +Z)s- (P+? 2g 4Z) ~ (1) 1m in Eq.-I represents the discharge head (Hg) and the second, the suction first potential te The first potent fference is called the pump head; pump total head or total dynamic head @). head (H,). The differerC, + apr jg the pressure difference at The term “pay Of the Higuidl ona? filled the pressure head. Here and d is the density of the liquid Pressure head the surface Velocit) clocity/| , kinetic energy ravity in head, represents the kine 2” is the acceleration of BF 1 head, ¢ elevation head or potent Hlevation heaa/P, head/Potential head: ‘The term “2, called thi the chosen datum represents the poten Potential cnergy of a unit weight of liquid with respect t0 1 Power (P) :‘The © pump output is given as li cr if water is the liquid pumped Hise Le as liquid horsepower (Ihp) or as water horsepower if wate} Thp ~~ Qity/3960 Thp — QU y/882 11” is in fect and “y” is specific weight Whore “Q” is in gal/min ot fi'/sce, Efficieney ; 7 Te re ee ery elie Navid ecreoa divided by the power input 0 timp shal. The latter usually is called the break horsepower (bhp) iency may be expressed as a decimal or multiplied by 100 and expressed as percent Performance of a Centrifugal Pump: The theoretical maxi he theoretical maximum suction lift of a pump = 10.33/p meter or 33.9/p ft. But the practical maximum suction lift available (MSLA) is reduced by \d velocity head V7/2¢ @ ! riction losses involved in the suction piping system he eficet of the vapour pressure of the fluid at the temperature at which it is being pumped I cat poner» 12 heoretiel thea erect . oe Yon vane te imate = ue to circulating esa I treater” Ane | leas rection ue ttn Actus head Capacity (Q) Dace he various losses are usually identified as follows. (1) Mechanicat losses: ‘his is friction in bearings, in stuffing box ins packings and in similai imilar items. (2) Leakage losses: This is duc to leakage from the tip of the impeller impeller, back between the i and the'casing, to the impeller suction : ick between the impeller The velocity of the liquid in the space between two adjacent v. f anes o| This difference a velocity"produces a circulation of the liquid within th a circulation consumes power for no usefil purpose. 7 (3) Recirculation losse an impeller is different. pace between the vanes, and such (4) Hydraulic losses: These include a variety of losses, such as frict : one between the liquid & faces of the vanes and losses due to suddon change of dn liquid & ge of direction cte.Characteristic Curves of centrifugal pump: The graphical relationship of head, power & efficiency vs. capacity at constant speed are called characteristic curves of centrifugal pump. A centrifugal pump can give a flow rate from zero to maximum value during operation at any speed. In figure, a higher speed of rotation gives a higher capacity at the same pressure and requires more horse power to supply this . increased flow of liquid. The actual head tenet end wed developed by a pump is always less than ideal fw ouemetere i" aa pump relation. . nce of Cavitation: An important factor in satisfactory operation of a pump. is {98 = ‘The cavitation, both for the sake of good efficiency and for the prevention of impetie! Oey term cavitation refers to conditions within the pump where, owing to a local pressure CT the vapor pressure of the liquid at the corresponding temperature, cavities filled with wt vapors are formed; these cavities collapse as soon as the vapor bubbles reach the region o! ig) pressure on their way through the pump. Cavitation may affect in operation as; a) Noise & vibration, b) Impeller vane pitting & corrosion fatigue failure of metals and c) Drop in Head Vs. Capacity & Efficiency curves. Net Positive Suction Head (NPSH): ‘To avoid cavitation, the suction pressure must exceed the vapor pressure (P,) of the liquid at the corresponding temperature by a certain value, called the net positive suction head or NPSH. ‘The net positive suction head or NPSH jis the total suction head less the vapor pressure of the liquid expressed in feet or meters. The NPSH can be shown by the following relation NPSH jvsisnc“(Hus—Ps)s To avoid cavitation for smooth operation, NPSH vaistic2NPSHrepairement Where; Hy ~ (Patm | Pgs + Hes - Hp #2) He = Total suction head Pum = Atmospheric pressure, Py ~ Gage pressure Hy. = Suction velocity head, He P, = Vapor pressure of liquid at corresponding temperature, Suction line friction loss, Z= Suction elevation head, ‘To increase the NPSH the following attempt can be taken: 1) Increase the diameter of the suction 2) Reduce the length of the suction pipe, 3) Install a suction stabilizer, 4) Elevate the suction liquid level, 5) Sub-cool the liquid,cedure (SOP) Of Pump: « the plant bes 7 xerience unless can be a troublesome exP: probably more AL the start up #) Inspection p of centrifiyga 'gal pump one should follow ing sequenc’ Works before stanton follow the following sea In initial stage, fact Stage, factors to be considered in starting any centrifugal pump include Se ~ Alignment * Rotation Lubricants - Sight Gage glasses ~ Lube-oil system Pump Di ~ Pump exterior = Auxiliary piping Presiarta ~ Priming ~ Position of valve ii) Pre-start up check points ~ Cooling water must be circulating pump by hand Id be clos | ubrication system of all bearing points must be check Prime mover power should be checked Rotate the Level of liquid at suction side should be check ~ Discharge valve shoul All ow control valves should be set according to instructions - Pump should be warmed gradually by slowly circulating hot liquid through h the pump. iii) Start up procedures - Suction valve should be open & discharge valve should be closed Priming should be performed properly - Recirculation valve should be opened Venting the casi ~ Suction line should full of liquid = Barring with prime mover Direction of rotation should be check by ON-OFF switch When pump reached at normal operating speed. open the discharge valve slowly iv) Post start up cheekpoints = Process parameters Abnormal sound = Seal leakage Vemperature & vibration at all bearing points, = Motor ampere y) Check points during normal operation Bearing temperature [ube oil temperature & pressure - Seal leakage ~ Oil level at all bearing points - Driving side energy consumption - Suction and discharge pressure - Discharge flow vi) Shut down works Partially close the dischat \\s soon as the power is sree valve - Shut off the power off, close the discharge valve rapidly ion: ‘The recirculation or bypass connections should be cut in whenever th eat run at 20 percent or Kss STs rated capacity. Be sure the reirutated or by _ a figuid flows to a lower pressure area where it can release some of its heat before returning to th Jos there will be n0 possibilty of danger of the pumps overheating, The br news 0 the source of suction supply, but not directly to the pump sucrrone Bypass Opera pump. liquid is often returned t RacesSeries and Parallel Operation: Most pumping. installations include at f least two pumps; “one pump being generally operative and the other serving asa standby pump both pumps are used in = certain cases: Parallel Operation: a Iv is considered when the Now rate of @ pump is small; to increase the flow rate t more than the quantity of a single pump, a second pump will put into operation in parallel with the first eo Series Operation: Iti applied when the head of a pump is. low: to increase the head at required level, a second pump will be put into operation in series with the first . Selection of Pum; a particular application the selection of pump is influenced by the following factors; 2. System layout 3, Fluid characteristics | I, System requirements ments, 5. Material of construction 6. Type of service | 4, Code requi 7. Running speed System requirements Important points for system requirement are; 1a) Required capacity - Constant or variable. +b) Required length of time - Continuous or intermittent ) Range of system head variation ~ Wide or small System layout ; The system layout ean influence the decision on the choice of pump type. In peacral, centrifugal pumps require less floor space than the reciprocating pumps and vertical floor space than the horizontal pumps. pumps require less Fluid characteristics: Viscosity, density, volatility, chemicals stability and solids content are also important factors to be considered. Operating factors, such as type of service (continuous or intermittent, critical or ces (high of low), and intended life, will also influence the ‘Type of service: non-critical) running speed preferent de Code requirements Pump containing codes made up by controlling organization like API fulfill the additional ‘Heuniads of pump which influences over construction and pump rating sion. Material of construction | wrateTals are affected by both the pumped fluid and environment. Resistant to corrosion and art re two oF the more important material properties in this regard