Operation Department ACWA POWER PLANT ZARQA

Contents
Table of Figures .......................................................................... 3
Introduction: .............................................................................. 4
What is a pump ? ...................................................................... 5
Classification of pumps .............................................................................................................................................. 5
Comparisons between the two types : .................................................................................................................... 6

Dynamic Pump .......................................................................... 7

The Operation of centrifugal pump .......................................................................................................................... 9
Types of centrifugal pumps : .................................................................................................................................... 10
Construction of impellers .......................................................................................................................................... 11

Cavitation ................................................................................ 12
Net Positive Suction Head (NPSH) ........................................................................................................................... 13
NPSHA ................................................................................................................................................ 13

Head–flow characteristics ...................................................... 14

Mechanical Seal ..................................................................... 15
BASIC FUNCTIONS OF MECHANICAL SEALS ............................................................................................................ 15
MECHANICAL SEAL COMPONENTS : ....................................................................................................................... 15

Positive Displacement Pumps ................................................ 16

Positive displacement pumps can be classified by the type of motion ............................................................ 16
Gear Pump ................................................................................................................................................................. 16
1-External Gear Pump ....................................................................................................................... 16
2- Internal Gear Pump ...................................................................................................................... 18
3- Lobe Pump .................................................................................................................................... 19
4- Gerotor Pump................................................................................................................................ 20
5- vane ............................................................................................................................................... 21
PISTON PUMP .............................................................................................................................................................. 22
1- Axial Piston Pump (Bent-Axis Design) ........................................................................................... 22
2 -In-Line Piston Pump (Swash Plate Design) ................................................................................... 23

Reference : .............................................................................. 25

EYAD N. MASOUD 1
Operation Department ACWA POWER PLANT ZARQA

Prepared by: Eng. Eyad N. Masoud

Supervised by: Eng. Salah Al-Momani

EYAD N. MASOUD 2
Operation Department ACWA POWER PLANT ZARQA

Table of Figures

Figure 1 : al-Jazari's hydropowered saqiya chain pump device. ............................................................................. 4

Figure 2 : Classification of Pumps. ................................................................................................................................. 5
Figure 3 :Classification of Dynamic Pumps. ................................................................................................................. 7
Figure 4 : CONSTRUCTION features of a centrifugal pump. ...................................................................................... 8
Figure 5 : construction features of a centrifugal pump. ............................................................................................ 8
Figure 6 :Pressure versus flow curve .............................................................................................................................. 9
Figure 7 :Vertical pump and horizontal pump .......................................................................................................... 10
Figure 8 :Multistage pump ........................................................................................................................................... 10
Figure 9 : Types of impellers ......................................................................................................................................... 11
Figure 10 :Suction pressure falling below vapor pressure causes bubble formation............................................ 12
Figure 11 :Pump design characteristic curves ........................................................................................................... 14
Figure 12 :External Gear Pump .................................................................................................................................... 17
Figure 13 :FLOW VERSUS PRESSURE CURVE ................................................................................................................. 17
Figure 14 :Internal Gear Pump .................................................................................................................................... 18
Figure 15 :Operation of the lobe pump ..................................................................................................................... 19
Figure 16 : Operation of the Gerotor pump .............................................................................................................. 20
Figure 17: Vane pump .................................................................................................................................................. 21
Figure 18 :Volumetric displacement changes .......................................................................................................... 22
Figure 19 :Axial Piston Pump (Bent-Axis Design) ........................................................................................................ 23
Figure 20 : In-line design piston pump. ....................................................................................................................... 24
Figure 21: Swash plate causes pistons to reciprocate ............................................................................................. 24

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Operation Department ACWA POWER PLANT ZARQA

Introduction:

Arab and Pumps:

The transfer of liquids against gravity existed from a lot of time ago . A
pump is one such device that expends energy to raise, transport, or
compress liquids. The earliest known pump devices go back a few
thousand years. One such early pumps devices that created by
Arabian inventor Al-Jazari are 1- Saqiya chain pumps 2- Double-action
suction pump with valves and reciprocating piston motion 3- Water
supply system

Al-Jazari

ARAB AND
MECHANICAL
ENGINEERING

Fig (1) : SAQIYA CHAIN PUMP DEVICE.

F IGURE 1 : AL -JAZARI ' S HYDROPOWERED

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What is a pump ?
A pump, which is the heart of a system , converts mechanical energy into hydraulic
energy . The mechanical energy is delivered to the pump via a prime mover such as an
electric motor. Due to Mechanical Action the pump then pushes the fluid into system

Classification of pumps:
There are two classifications of pumps as identified :

1- Dynamic Pumps (Kinetic) :

This type is generally used for low-pressure , high-volume flow application , Because they
are not cable of withstanding high pressure , this type of pumps is primarily used for
transporting fluids from one location to another , the most common types of dynamic
pumps are centrifugal and the axial flow propeller pumps .

2- Positive Displacement Pumps

This type is universally used for fluid power system , a positive displacement pump ejects a fixed amount of
fluid into the hydraulic system . such a pump is capable of overcoming the pressure resulting from the
Mechanical loads on the system as well as the resistance to flow due to friction .

F IGURE 2 : CLASSIFICATION OF P UMPS .

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Comparisons between the two types :

Characteristic Positive Displacement dynamic

Flow rate Low High

Pressure rise High Low

Self Priming Yes no

Outlet stream Pulsing Steady

Work with high viscosity Yes No

fluids

Stated with Discharge valve closed Discharge valve open

It should be understood that pumps do not pump pressure. instead, they produced fluid
flow. The resistance to this flow, produced by the system, is what determines the pressure.
For example, if a positive displacement pump has its discharge line open to the
atmosphere, there will be flow, but there will be no discharge pressure above
atmospheric because there is essentially no resistance to flow. However, if the discharge
line is blocked then we have theoretically infinite resistance to flow. Hence, there is no
place for fluid to go. their pressure will therefore rise until some component breaks unless
pressure relief is provided. This is the reason a pressure relief valve is needed when a
positive displacement pump is used. When the pressure reaches a set value, the relief
valve will open to allow flow back to the oil tank.

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Dynamic Pump

The two most common types of dynamic pumps are the centrifugal (impeller) and axial
(propeller) pumps as shown in fig .3 , these pumps are typically used for low-pressure ,
high-volume flow applications , also , since there is a great deal of clearance between
the rotating and stationary elements , dynamic pumps are not-self priming unlike positive
displacement pumps . Priming is required . Priming is the prefilling of the pump housing
and inlet pipe with fluid so that the pump can initially draw in the fluid and pump it
efficiently

F IGURE 3 :CLASSIFICATION
Fig (3):OF DYNAMIC P UMPS .

Axial flow Pumps Centrifugal Pumps

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Figure 4 and 5 show the construction features of a centrifugal pump, the most commonly
used type of dynamic pump

F IGURE 4 : CONSTRUCTION FEATURES OF A CENTRIFUGAL PUMP .

Fig (4-A):

The centrifugal pump has a simple construction, essentially comprising a volute (1) and an
impeller (2). The impeller is mounted on a shaft (5), which is supported by bearings (7)
assembled in a bearing housing (6). A drive coupling is mounted on the free end of the
shaft.

F IGURE 5 : CONSTRUCTIONFig (4-B): OF A CENTRIFUGAL PUMP .

FEATURES

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The Operation of centrifugal pump.

The prime mover, which is usually an electrical motor, steam turbine, or an IC engine,
transmits the torque through the coupling.
The fluid enters at the center of the impeller and is picked up by the rotating impeller. As
the fluid rotates with the impeller, the centrifugal force causes the fluid to move radially
outward. This causes the fluid to flow through the outlet discharge port of the housing .
Although dynamic pumps provide smooth continuous flow (when a demand exists), their
output flow rate is reduced as resistance to flow is increased. This is shown for centrifugal
pumps in Figure 5, where pump pressure is plotted versus pump flow. The maximum
pressure is called the shutoff head because an external circuit valve is closed, which shuts
off the flow. As the external resistance decreases due to the valve being opened, the
flow increases at the expense of reduced pressure .

F IGURE 6 :P RESSURE VERSUS FLOW CURVE

Fig (5):
flow curve

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Types of centrifugal pumps :

Centrifugal pumps can be categorized in various ways. Some of the main types are on
the following basis :

1- Orientation of the pump shaft axis

This refers to the plane on which the shaft axis of the pump is placed. It is either horizontal
or vertical as shown in Figure

F IGURE 7 :VERTICAL
Fig (6): AND HORIZONTAL PUMP
PUMP

2- Number of stages

This refers to the number of sets of impellers and diffusers in a pump. A set forms a stage
and it is usually single, dual, or multiple (more than two) stages Figure

F IGURE 8 :M
FigULTISTAGE
(7): PUMP

flow curve

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Construction of impellers

There are three types of construction seen in an impeller. These are based on the
presence or absence of the impeller covers and shrouds. The three types Figure 8 are:

1. Closed (Pumps with closed type impellers and wear rings on both sides have a higher
efficiency.)

2. Semi-open ( preferred when the liquid used may contain suspended particles or fibers )

3. Open

F IGURE 9 :Fig (8):OF IMPELLERS

TYPES
flow curve

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Cavitation
when the liquid is sucked in the pump inlet, the pressure acting on the
liquid surface drops. Under conditions, when the reduced pressure
approaches the vapor pressure of the liquid (at that temperature), it
causes the liquid to vaporize (see Figure 9). As these vapor bubbles
travel further into the impeller, the pressure rises again causing the
bubbles to collapse

Cavitation in
Pumps

F IGURE 10 :SUCTION PRESSURE FALLING BELOW VAPOR PRESSURE CAUSES BUBBLE FORMAT ION

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Operation Department ACWA POWER PLANT ZARQA

Net Positive Suction Head (NPSH)

NPSH is the minimum requirement to perform its duties. what happens in the suction side
of the pump, including what goes on in the eye of the impeller , unsuitable NPSH created
conditions for cavitation in the pump .

NPSH takes into consideration

1- The suction piping and connections.

2- The elevation of the liquid in suction side.
3- The absolute pressure of the fluid in the suction piping.
4- The velocity of the fluid.
5- The temperature of the fluid.

NPSHR NPSH

Net Positive Suction Head Required

It is the energy in the liquid required to overcome the friction losses from the suction nozzle
to the eye of the impeller without causing vaporization.
NPSHA

Net Positive Suction Head Available

his is the energy in the fluid at the suction connection of the pump over and above the
liquid’s vapor pressure. It is a characteristic of the system.

NPSHa > NPSHr

During pump operation, NPSHa should be always greater than the NPSHr as a general guide
the NPSHa should be a minimum 10% or 1 meter above the NPSHr, whichever is greater

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Operation Department ACWA POWER PLANT ZARQA

Head–flow characteristics

One of the most important characteristics of a pump is its capacity; that is, the amount of
fluid it moves per unit time. The capacity of a centrifugal pump decreases as the pressure
at the pump discharge increases.
When the discharge valve is completely closed, the head developed by the pump is
called the shut-off head. At this point, the pump will obviously not deliver any liquid. This is
also the maximum head any pump can develop. The shut-off
head is represented as Hso .
Now, if the discharge valve is opened completely and the flow is
directed into the atmosphere, the pump discharges at maximum
capacity.
The shape of the H–Q curve as seen in the graphs in Figure 10 is
dependent on the specific speed or the shape of the blades of
the impeller.
Performance and Characteristics

F IGURE 11 :P UMP DESIGN

Fig (10):
CHARACTERISTIC CURVES

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Mechanical Seal

BASIC FUNCTIONS OF MECHANICAL SEALS

Mechanical seal is one of the technique to seal the gap formed between a rotary shaft
and a stationary stuffing box. This situation is mostly commonly encountered in centrifugal
pumps. Mechanical seals are used to prevent leakage of gases and liquids in rotating
shaft applications that exceeds the capabilities of radial lip shaft seals and packing

Mechanical seals can withstand high operating pressure, temperature and shaft speeds
and give longer life with less leakage than packing and radial lip seals .

MECHANICAL SEAL COMPONENTS :

The Basic components in a mechanical seals include the following :

- Secondary static seals, O-rings

-Static seal or stationary component Mechanical seal

-Seal for the rotating component to the shaft.

-A spring member; metal bellows, multiple spring or single spring

-Other hardware such as gland rings, compression rings, collars, shaft sleeves, etc.

FFig (11):
IGURE 12Mechanical
:MECHANICALseal
SEAL

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Operation Department ACWA POWER PLANT ZARQA

Positive Displacement Pumps

This type of pump ejects a fixed quantity of fluid per revolution of the pump shaft. As a
result, pump output flow, neglecting changes in the small internal leakage, is constant
and not dependent on system pressure. This makes them particularly well suited for fluid
power systems . A pressure relief valve is used to protect the pump against overpressure
by diverting pump flow back to the hydraulic tank, where the fluid is stored for system use.

Positive displacement pumps can be classified by the type of motion

The motion may be either rotary or reciprocating .

1- Gear pumps
1- External gear pumps
2- Internal gear pumps
3- Lobe pumps
4- Screw pumps
2- Vane pumps
1- Unbalanced vane pumps (fixed or variable displacement)
2- Balanced vane pumps (fixed displacement only)

3- Piston pumps (fixed or variable displacement)

1- Axial design
2- Radial design

Gear Pump

1-External Gear Pump

the operation of an external gear pump, which develops flow by carrying fluid between
the teeth of two meshing gears. One of the gears is connected to a drive shaft
connected to the prime mover. The second gear is driven as it meshes with the driver
gear

External Gear Pump

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Fig
F IGURE 12 :E (12): GEAR P UMP
XTERNAL

F IGURE 13 :FLOW VERSUS PRESSURE CURVE

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2- Internal Gear Pump

This design consists of an internal gear, a regular spur gear, a crescent-shaped seal, and
an external housing. As power is applied to either gear, the motion of the gears draws
fluid from the reservoir and forces it around both sides of the crescent seal, which acts as
a seal between the suction and discharge ports. When the teeth mesh on the side
opposite to the crescent seal, the fluid is forced to enter the discharge port of the pump.

Internal Gear Pump

F IGURE 14 :INTERNAL GEAR P UMP

Fig (13):

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3- Lobe Pump

This pump operates in a fashion similar to the external gear pump. But unlike the external
gear pump, both lobes are driven externally so that they do not actually contact each
other. Thus, they are quieter than other types of gear pumps. Due to the smaller number
of mating elements, the lobe pump output will have a somewhat greater amount of
pulsation, although its volumetric displacement is generally greater than that for other
types of gear pumps.

Lobe Pump

FIGURE 15 :OPERATION OF THE LOBE PUMP

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4- Gerotor Pump

operates very much like the internal gear pump. The inner gear rotor (Gerotor element) is
power-driven and draws the outer gear rotor around as they mesh together. This forms
inlet and discharge pumping chambers between the rotor lobes . The tips of the inner and
outer rotors make contact to seal the pumping chambers from each other. The inner gear
has one tooth less than the outer gear, and the volumetric displacement is determined by
the space formed by the extra tooth in the outer rotor .

Gerotor Pump

F IGURE 16 : OPERATION OF THE GEROTOR PUMP

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5- vane

The rotor, which contains radial slots, is splined to the drive shaft and rotates inside a cam
ring. Each slot contains a vane designed to mate with the surface of the cam ring as the
rotor turns. Centrifugal force keeps the vanes out against the surface of the cam ring.
During one-half revolution of rotor rotation, the volume increases between the rotor and
cam ring. The resulting volume expansion causes a reduction of pressure. This is the
suction process, which causes fluid to flow through the inlet port and fill the void. As the
rotor rotates through the second half revolution, the surface of the cam ring pushes the
vanes back into their slots, and the trapped volume is reduced. This positively ejects the
trapped fluid through the discharge port.

Vane Pump

F IGURE 17: VANE PUMP

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PISTON PUMP

A piston pump works on the principle that a reciprocating piston can draw in fluid when it
retracts in a cylinder bore and discharge it when it extends. The basic question is how to
mechanize a series of reciprocating pistons. There are two basic types of piston pumps.
One is the axial design, having pistons that are parallel to the axis of the cylinder block.
Axial piston pumps can be either of the bent axis configuration or of the swash plate
design. The second type of piston pump is the radial design, which has pistons arranged
radially in a cylinder block.

1- Axial Piston Pump (Bent-Axis Design)

axial piston pump (bent-axis type) that contains a cylinder block rotating with the drive
shaft. However, the centerline of the cylinder block is set at an offset angle relative to the
centerline of the drive shaft, The cylinder block contains a number of pistons arranged
along a circle. The piston rods are connected to the drive shaft flange by ball-and-socket
joints. The pistons are forced in and out of their bores as the distance between the drive
shaft flange and cylinder block changes. A universal link connects the block to the drive
shaft to provide alignment and positive drive.

The volumetric displacement of the pump varies with the offset angle q, as shown in
Figure 19. No flow is produced when the cylinder block centerline is parallel to the drive
shaft centerline. θ can vary from 0° to a maximum of about 30°. Fixed displacement units
are usually provided with 23° or 30° offset angles

Axial Piston Pump (Bent-

Axis Design)
F IGURE 18 :V OLUMETRIC DISPLACEMENT CHANGES

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F IGURE 19 :AXIAL P ISTON P UMP (B ENT-AXIS DESIGN )

2 -In-Line Piston Pump (Swash Plate Design)

Figure 20 provides a photograph and sketch illustrating the swash plate design in-line
piston pump. In this type, the cylinder block and drive shaft are located on the same
centerline. The pistons are connected to a shoe plate, which bears against an angled
swash plate. As the cylinder rotates (see Figure 21), the pistons reciprocate because the
piston shoes follow the angled surface of the swash plate. The outlet and inlet ports are
located in the valve plate so that the pistons pass the inlet as they are being pulled out
and pass the outlet as they are being forced back in.

In-Line Piston Pump

(Swash Plate Design)

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F IGURE 20 : IN-LINE DESIGN PISTON PUMP .

F IGURE 21: SWASH PLATE CAUSES PISTONS TO RECIPROCATE

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Reference :
1- uments.site/understanding-npsh-in-centrifugal-pumps.html?page=7

2- Fluid Power with Applications Anthony Esposito Seventh Edition

3- Practical Centrifugal Pumps Design, Operation and Maintenance Paresh Girdhar B. Eng
(Mech Eng), Senior Engineer for Girdhar and Associates

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