EFFICIENCY IMPROVEMENT IN PUMPS

By R G Padalkar, Manager
Corporate Research & Engineering Division
Kirloskar Brothers Limited, Pune

1.0 Introduction
Centrifugal pump is selected on the basis of discharge requirements and total
head of the system. While selecting operating speed there are certain
limitations from site conditions like available NPSH or available submergence
etc. It is recommended that the speed should be so selected that pump has
maximum achievable efficiency. As per Hydraulic Institute Standard
maximum efficiency can be achieved when the specific speed is around 2500
NsUS.

2.0 Pump Efficiency:

In case of centrifugal pumps efficiency of pump depends on hydraulic
efficiency, volumetric efficiency and mechanical efficiency.

Overall Efficiency = Hydraulic Efficiency x Volumetric Effi. x Mechanical

Efficiency.

To achieve maximum overall efficiency it is clear that we should achieve

maximum hydraulic efficiency, maximum volumetric efficiency and
maximum mechanical efficiency. For increasing efficiency it is essential to
reduce the respective losses.

2.1 Hydraulic Efficiency: The hydraulic efficiency depends, naturally,

very much upon the design and execution of the flow passages.
Nevertheless, if one considers only pumps of above average
performance and plots their hydraulic efficiency (at the design point)
versus capacity, the points arrange themselves in a narrow band. The
value of the hydraulic efficiency can be approximated by

in USCS units ηH = 1 - 0.8

Q0.25 Eq.(1)

In SI units ηH = 1 - 0.071
Q0.25

This equation is plotted in Fig.1. The specific speed has only a small
influence on the hydraulic efficiency. At Ns = 500, the hydraulic
efficiency seems to be about 2 points lower than at Ns = 2000 (Nsm =
 39). This possible variation has been neglected in Eq.(1) since it is not
greater than the scatter of the test data.

There are many pumps in service which have, because of mediocre

design or manufacture, hydraulic efficiencies 5 points lower than given
by Eq. 1. Even hydraulic efficiencies 10 points lower have been
tolerated in some cases, especially for small capacities.

2.2 As per the latest techniques used in Japan, the idea of Inverse Design
is gaining momentum. Inverse design is based on the comprehensive,
thorough and quantitative study of various losses and the methods to
reduce these losses. Change of materials, change of constructional
features, change of manufacturing methods and techniques are some of
the tools used in inverse design method.

This thinking can be very well applied to centrifugal pumps design.

Volumetric efficiency can be increased by reducing the leakage
through casing ring clearance by putting labyrinth (Fig.2) or by
reducing clearance itself. The definition of the volumetric efficiency
is given in Eq.(2).

Q
Eq.(2)
ηv = --------------------
Q + QL

To calculate the leakage flow, the details of the individual pump design
must be known. Standard methods can be found in the work done by
i) Pfleiderer ii) A J Stepanoff For an approximate prediction of nv at
the design point Fig.3 can be used. It shows the volumetric efficiency
as a function of specific speed and flow for pumps for normal
construction. For instance, for a pump handling 1000 gpm (227 m3/h)
at a specific speed of 2500 (Nsm = 48) Fig.3 estimates nv= 0.98. For
100 gpm (23 m3/h) at Ns = 500 (Nsm = 10), the estimate is nv 0.9.

2.3 Mechanical Losses: The mechanical losses can be calculated only

when the design details of bearings and seals are available . For an
approximate prediction of the ratio of mechanical power loss to water
power Fig. 4 can be used. It shows the general trend in that the
mechanical power loss relative to the water power increases with
decreasing specific speed and capacity.

2.4 Disk Friction: Disk friction losses can be reduced by increasing

surface finish of the impeller shrouds normally by machining.The outer
surfaces of a rotating impeller are subject to friction with the
surrounding fluid. There have been a number of attempts to predict
this power loss on the basis of tests with rotating disks i) K Pantell ii) J
W Daily & R.E.Nece. therefore the expression disk friction.
Pfleiderer writes on the basis of tests by Schultz-Grunow
 In USCS Units PDF =163 (10-17) N3D4(D+ 5e)
Eq.(3)

In SI units PDF =1149(10-25) N3D4 (D + 5e)

Valid for Re = w(D/2)2/ν = 7.0 (105). The disk friction power

increases approximately with the Re-0.2. Eq. 3 aims to account not
only for the friction on the two sides of the impeller but also for the
friction on the outer cylindrical surfaces of the shrouds (e is the sum of
the width of two shrouds).

The ratio of the disk friction power to water power, as a function of the
specific speed, can be derived

PDF = 1.38 (105) D + 5e

Eq.(4)
In USCS units ----- -----------------------
Pw N2 ψ 2.5 D
s

PDF = 51.8 D + 5e
In SI units ----- -------- ------------
Pw N2 ψ 2.5 D
sm

In view of the smaller value obtained below in “Impeller Disk Friction

Deduced from Maximum Efficiency”, it is recommended that only 70
to 80% of Eq.(4) be used.

Above specific speeds of 2000 (Nsm = 39) the disk friction power is
relatively small and can be approximated by

PDF
----- = 0.02
Pw

3.0 Efficiency enhancement:

3.1 Coating of Hydraulic Passages
Maximum achievable efficiency of a pump is normally decided by
certain standard charts available like Hydraulic Institute Standards
(Fig.5 ) or Sabini and Fraser charts (Fig.6) giving maximum achievable
efficiency against specific speed. The efficiencies given by Sabini and
Frazer are based upon certain conditions of i) hydraulic surface
roughness of impeller (Fig.7)and casing ii) Suction Specific Speed. If
 the surface is rough, then efficiency reduction can vary from 5 points
to 0.55 points depending upon specific speed (Fig.8 ) Also these charts
are applicable for pumps with suction specific speed upto 8500.
Higher efficiency can be achieved by coating the hydraulic passage
using special coating where boundary layer is suppressed and since the
coating is of hydrophobic nature the frictional losses are reduced to the
minimum (Fig.9) Such coatings are now available in the market.

3.2 Full diameter Impeller/Trimmed Impeller:

Any centrifugal pump design gives maximum efficiency at one

particular head and discharge when impeller and casing are matching
hydraulically. It is customary to cut down the impeller to meet lower
head and discharge. It should be noted that whenever impeller is cut
down or trimmed the compatibility of impeller and casing is lost.
Clearance between impeller and volute tongue increases and results in
reduction in efficiency. Substantial energy saving can be effected
particularly in large pumps if volute tongue is modified to suit new
impeller diameter. This may involve some additional cost as
investment from customer point of view but it is justified due to saving
in energy. (Fig.10) (Fig.11). It is advised that customer should check
from the pump manufacturer that he can modify the tongue in the
casing to increase the efficiency.

3.3 Operating range:

Nature of H-Q curve and Eff-Q curve has an effect on pump selection
from energy saving point of view. Whenever there is large variation of
total head in the operating range of a pump, it will be prudent to have
a pump having flatter efficiency curve so that the pump operates
consistently at higher efficiency throughout the range resulting in the
energy saving. (Fig.12 )

4.0 Computational Fluid Dynamics (CFD)

4.1 Advances in computational techniques have improved design

methodologies for pumps and pumping systems. The computational fluid
dynamics packages are now commercially available and could be used to
understand the fluid flow behaviour as it passes through complex rotating
blade passages. Achieving this understanding by using experimental
techniques is far more time consuming and requires special measurement
techniques such as laser doppler anemometry. The software packages are
capable of giving all the details like pressure variation, velocity vectors,
total pressure difference and many more physical quantities of interest to
designer in a relatively shorter time. Designer can use these tools to arrive
at a optimised design without experimenting on actual pumps.
 4.2 The sketches shown here demonstrate the use of CFD tools when used
with a view to improve efficiency of a pump. Existing design had
efficiency as per standards and it was thought appropriate to use it as a
test case. The impeller blade flow passage was analysed using CFD
package Tascflow. As was expected recirculation zones were traced
in flow passage. The blade passage was modified/redesigned and
crosschecked using CFD tools. The recirculation zones disappeared in
the modified design. The pump was fabricated and tested.
Comparative statement about efficiency improvement is presented in
the sketch.
( Fig.13, Fig.14 and Fig.15)

5.0 Conclusion:
Thus large energy savings are possible in the case of centrifugal pumps by
taking precaution during every stage such as design, selection, installation and
application to enhance pump efficiency and utilising the equipments in a
proper manner.
EFFICIENCY IMPROVEMENT IN PUMPS

By
R G Padalkar, Manager
Corporate Research & Engineering Division
Kirloskar Brothers Limited, Pune