Name NATHANIEL R. GABONADA JR.

Date Performed January 30, 2014

Subject ME56 (MECHANICAL ENGINEERING LABORATORY II ) Due Date March 13, 2014

Instructor DIOMEDES T. GABULE JR. Date Submitted March 13, 2014

PHYSICAL STUDY OF A HIGH PRESSURE PUMP

Exercise No. 5

I. OBJECTIVES

1. Discuss the principle of pumping liquids using high-pressure pumps.

2. Identify the parts of high-pressure pumps.
3. Enumerate the functions of the different parts of the high-pressure pumps.
4. Discuss the factors required in pumping liquids using high-pressure pumps.
5. Discuss the formulas in determining the power required to pump liquid using high-pressure
pumps.

II. THEORY

1. Principle of pumping liquids using high-pressure pumps.

Pumps come in a variety of sizes for a wide range of applications. They can be classified according to their
basic operating principle as dynamic or displacement pumps.

The pump head contains the suction/ discharge valve sets. The pressurised medium produced by
each individual plunger flows to a common high pressure discharge connection. The pump head valve
housing is not subjected to alternating stress.

Pumps are used widely in industry to provide cooling and lubrication services, to transfer fluids for
processing, and to provide the motive force in hydraulic systems. In fact, most manufacturing plants,
commercial buildings, and municipalities rely on pumping systems for their daily operation.

Pumps are essential to the daily operation of many facilities. This tends to promote the practice of
sizing pumps conservatively to ensure that the needs of the system will be met under all conditions. Intent
on ensuring that the pumps are large enough to meet system needs, engineers often overlook the cost of
oversizing pumps and err on the side of safety by adding more pump capacity. Unfortunately, this practice
results in higher-than-necessary system operating and maintenance costs. In addition, oversized pumps
typically require more frequent maintenance than properly sized pumps. Excess flow energy increases the
wear and tear on system components, resulting in valve damage, piping stress, and excess system operation
noise.

In contrast, positive displacement pumps have a fixed displacement volume. Consequently, the flow rates
they generate are directly proportional to their speed. The pressures they generate are determined by the
system’s resistance to this flow. Positive displacement pumps have operating advantages that make them
more practical for certain applications. These pumps are typically more appropriate for situations in which
the following apply:
The working fluid is highly viscous
■ the system requires high-pressure, low-flow pump performance
■ the pump must be self-priming
■ the working fluid must not experience high shear forces
■ the flow must be metered or precisely controlled
■ Pump efficiency is highly valued.
A disadvantage is that positive displacement pumps typically require more system safeguards, such
as relief valves. A positive displacement pump can potentially over pressurize system piping and
components.
Spectra’s Pearson Pump was developed to be used as the high pressure feed water pump in small
Reverse Osmosis desalination systems where the best possible energy efficiency is required. In
conventional Reverse Osmosis systems the high pressure needed in the membranes is created and regulated
by a back pressure regulating valve in the high pressure concentrate (brine) discharge line. All of the
potential energy in the high pressure concentrate is lost in the back pressure regulator, and the power
required to produce that energy is wasted.

The Spectra Pearson pump is a positive displacement three cylinder reciprocating high pressure pump
with the same motors and crankcases used in conventional RO system feed pumps. The Pearson Pump head
delivers water to the membranes in the same way as conventional feed pumps but is capable of recovering
the energy in the concentrate. This is done by returning the concentrate to the Pearson pump at high
pressure, where it flows into the pump cylinders on the undersides of the pistons, transferring its energy to
the feed water being discharged to the membranes.

The energy recovered from the concentrate reduces the load on the pump motor, reducing the electrical
consumption dramatically. If the volume of the cylinder under the piston were the same as the volume of
the cylinder above the piston all of the water being discharged from the Pearson pump could return to the
pump and no pressure would be developed. However, part of the volume in the underside cylinder is taken
up by the ceramic plunger, reducing the space available for the returning concentrate. Because feed water is
being forced out of the cylinder by the upper side of the piston, and only a portion of that water will be able
to return to the underside, a “Hydraulic Lock” is created, and flow is only possible if the water displaced by
the plunger has somewhere else to go. Because the electric motor is forcing the piston upwards, and that
water has nowhere to go, pressure begins to build up. When the pressure rises high enough water will be
forced through the membrane as permeate and flow will begin.
2. Functions of the different parts of the high-pressure pumps.

A typical pump has hundreds of parts. No matter how simple or complex some pumps are, their major
parts are designed to perform specific functions regardless of their sizes and shapes.  The major parts are:

 casing
 impeller
 shaft
 seal
 bearing
 coupling

Casing
The casing (or case) contains the liquid and acts as a pressure containment vessel that directs the flow of
liquid in and out of the pump. In most cases the casing includes the suction and discharge nozzles of the
pump that connect it to the external piping. In some vertical pumps the casing may be referred to
as bowl, and in some small pumps them may it call housing.

Impeller
The impeller is a vaned-disk (or disc) mounted on the shaft. Its function is to increase the pressure of the
liquid by means of its rotating action. The impeller may be of open, semi-open, or enclosed type, and
may have anywhere between two to ten vanes. It may also be of single, or double, suction design.

Shaft
The shaft is usually the longest part of a pump and is made of one piece. Its  function is to transmit the
input power from the driver into the impeller. In a close-coupled pump, the motor has an extended length
of shaft that acts as the pump shaft. In some vertical pumps, the so-called line shaft pump, the shaft may
be supplied in more than one piece of ten Feet sections depending on the pump bowl setting below the
ground surface.

Seal
A pump may be provided with one of two types of sealing elements - packing rings or mechanical seal.
The sealing elements prevents the leakage of the pumped liquid into the atmosphere.

Bearings
The functions of the bearings are to support the weight of the shaft (rotor) assembly, to carry the
hydraulic loads acting on the shaft, and to keep the pump shaft aligned to the shaft of the driver.

Coupling
The function of a coupling is to connect the pump shaft and the driver shaft, and to transmit the input
power from the driver into the pump.

A centrifugal pump has two main components:

1. A rotating component comprised of an impeller and a shaft.

2. A stationary component comprised of a casing, casing cover, and bearings.

Seal Chamber and Stuffing Box

Seal chamber and Stuffing box both refer to a chamber, either integral with or separate from the pump
case housing that forms the region between the shaft and casing where sealing media are installed. 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 at the point where the shaft passes out through the pump pressure casing.

Gland: The gland is a very important part of the seal chamber or the stuffing box. It gives the packing’s
or the mechanical seal the desired fit on the shaft sleeve. It can be easily adjusted in axial direction. The
gland comprises of the seal flush, quench, cooling, drain, and vent connection ports as per the standard
codes like API 682.

Throat Bushing: The bottom or inside end of the chamber is provided with a stationary device called
throat bushing that forms a restrictive close clearance around the sleeve (or shaft) between the seal and
the impeller.

Throttle bushing refers to a device that forms a restrictive close clearance around the sleeve (or shaft) at
the outboard end of a mechanical seal gland.

Internal circulating device refers to device located in the seal chamber to circulate seal chamber fluid
through a cooler or barrier/buffer fluid reservoir. Usually it is referred to as a pumping ring.

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.

 Rotating Components

1. Impeller
The impeller is the main rotating part that provides the centrifugal acceleration to the fluid. They are
often classified in many ways.

Based on major direction of flow in reference to the axis of rotation

 Radial flow
 Axial flow
 Mixed flow

Based on suction type

 Single-suction: Liquid inlet on one side.
 Double-suction: Liquid inlet to the impeller symmetrically from both sides.

Based on mechanical construction

 Closed: Shrouds or sidewall enclosing the vanes.
 Open: No shrouds or wall to enclose the vanes.
 Semi-open or vortex type.

2. 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.

Shaft Sleeve: 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.
 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.

3. Different factors required in pumping liquids using centrifugal pumps.

A pump is always connected to a system where it must circulate or lift fluid. The energy added to the
fluid by the pump is partly lost as friction in the pipe system or used to increase the head. Regulated pumps
adjust to the system by changing the rotational speed. The regulation of speed is especially used in heating
systems where the need for heat depends on the ambient temperature, and in water supply systems where the
demand for water varies with the consumer opening and closing the tap.

A. Single pump in a system

A system characteristic is described by a parabola due to an increase in friction loss related to the flow
squared. The system characteristic is described by a steep parabola if the resistance in the system is high. The
parabola flattens when the resistance decreases. Changing the settings of the valves in the system changes the
characteristics.

B. Pumps operated in parallel

In systems with large variations in flow and a request for constant pressure, two or more pumps can be
connected in parallel. This is often seen in larger supply systems or larger circulation systems such as central
heating systems or district heating installations.

Parallel-connected pumps are also used when regulation is required or if an auxiliary pump or standby
pump is needed. When operating the pumps, it is possible to regulate between one or more pumps at the same
time. A no return valve is therefore always mounted on the discharge line to prevent backflow through the
pump not operating.

C. Pumps operated in series

Centrifugal pumps are rarely connected in serial, but a multi-stage pump can be considered as a serial
connection of single-stage pumps. However, single stages in multistage pumps cannot be uncoupled. If one
of the pumps in a serial connection is not operating, it causes a considerable resistance to the system. To
avoid this, a bypass with a non-return valve could be build-in. The head at a given flow for a serial-connected
pump is found by adding the single heads vertically.

D. Regulation of pumps
It is not always possible to find a pump that matches the requested performance exactly. A number of
methods makes it possible to regulate the pump performance and thereby achieve the requested performance.
The most common methods are:

1. Throttle regulation, also known as expansion regulation

2. Bypass regulation through a bypass valve
3. Start/stop regulation
4. Regulation of speed

a. Throttle regulation
Installing a throttle valve in serial with the pump it can change the system characteristic. The resistance
in the entire system can be regulated by changing the valve settings and thereby adjusting the flow as needed.
A lower power consumption can sometimes be achieved by installing a throttle valve. However, it depends
on the power curve and thus the specific speed of the pump. Regulation by means of a throttle valve is best
suited for pumps with a relative high pressure compared to flow of low pumps

b. Regulation with bypass valve

A bypass valve is a regulation valve installed parallel to the pump. The bypass valve guide part of the
flow back to the suction line and consequently reduces the head. With a bypass valve, the pump delivers a
specific flow even though the system is completely cut off. Like the throttle valve, it is possible to reduce the
 power consumption in some case. Bypass regulation is an advantage for pumps with low head compared to
flow of high pumps.

c. Start/stop regulation
In systems with varying pump requirements, it can be an advantage to use a number of smaller parallel-
connected pumps instead of one larger pump. The pumps can then be started and stopped depending on the
load and a better adjustment to the requirements can be achieved.

d. Speed control
When the pump speed is regulated, the QH, power and NPSH curves are changed. The conversion in
speed is made by means of the affinity equations.

Proportional-pressure control
Proportional-pressure control strives to keep the pump head proportional to the flow. This is done by
changing the speed in relation to the current flow. Regulation can be performed up to a maximum speed,
from that point the curve will follow this speed. The proportional curve is an approximate system
characteristic as where the needed flow and head can be delivered at varying needs.

Proportional pressure regulation is used in closed systems such as heating systems. The differential
pressure, is kept almost constant despite changes in the heat consumption. The result is a low energy
consumption by the pump and a small risk of noise from valves.

Constant-pressure control
A constant differential pressure, independent of flow, can be kept by means of constant-pressure control.
In the QH diagram the pump curve for constant-pressure control is a horizontal line. Constant-pressure
control is an advantage in many water supply systems where changes in the consumption at a tapping point
must not affect the pressure at other tapping points in the system.

4. Formulas in determining the power required to pump liquid using centrifugal pumps.
In dealing with the theory of hydraulic pumps, a number of assumptions will be made. At any point within
the blade passages the fluid velocity will in general have three components, one each in the axial, radial and
angular directions as shown in the figure below. The velocity may then be written as a function of the three
components.
V = f(r,θ,z)

Assumptions for the hydraulic pump theory to hold:

 There are an infinite number of blades so closely spaced that δV/δθ = 0. That is, there is no flow in the
blade passage in the tangential direction and Vθ = 0.
 The impeller blades are infinitely thin, thus allowing the pressure difference across them, which produces
torque, to be replaced by tangential forces that act on the fluid.
 The velocity variation across the width or depth of the impeller is zero and hence δV/δz=0.
 The analysis will be confined to conditions at the impeller inlet and outlet and to the anguilar momentum
change between these two stations. No account is taken of the condition of the fluid between these two
stations.
 It is assumed that at inlet the fluid is moving radially after entering the eye of the pump.
.
From Euler’s pump equation, the work done per second on the fluid per unit weight of fluid flowing is
 The water power or the power delivered to the fluid is,

Pw =ρ gQH

 The power required to drive the pump or the brakepower is,

Pb =ωT
• The pump efficiency, η, is

Pw ρ gQH
η= =
Pb ωT

5. APPARATUS/MATERIALS

1. Bond Paper
2. Drawing Pen
3. Straight Edge
4. High-pressure pump
5. Hand tools

6. SKETCH/DRAWING

1. Drawing of high-pressure pump examined indicating the different parts.

 7. OBSERVATIONS

In this activity, I observed the principles and operations of pumping liquids using centrifugal pumps, the
functions of the different parts of the centrifugal pumps, the factors required in pumping liquids using centrifugal
pumps and the formulas in determining the power required to pump liquid using centrifugal pumps.

I also observed as 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. This force acting inside the pump is the same one that keeps water inside a
bucket that is rotating at the end of a string.

Pumps provide the means for moving water through the system at usable working pressures. The operation and
maintenance of these pumps are some of the most important duties for many water utility operators. There are two basic
types of pumps used in water and wastewater systems.

Positive displacement pumps are used for low flow and high-pressure applications. High pressure water jet systems like
those used for well screen or sewer line cleaning use positive displacement pumps since pressures in excess of 2000 psi
are needed and the flows seldom exceed 100 gpm. Sludge pumps and chemical feed pumps are also likely to be positive
displacement pumps. Piston pumps, diaphragm pumps, and progressive cavity screw pumps are the most common types
of positive displacement pumps.
Another difference in centrifugal and positive displacement pumps has to do with how they react to changes in
discharge pressure. When the pressure that a centrifugal pump has to work against changes, the flow from the pump
changes. As the pressure increases, the flow from the pump will decrease, and when the pressure drops the flow will
increase. Positive displacement pumps do not react this way. The flow does not change when the discharge pressure
changes. This is the main reason that positive displacement pumps are used for chemical feeding and sludge pumping.
The operator knows that every time the pump strokes, it is pumping the same amount of fluid. This is important if
accurate records are to be kept of chemical dosages and pounds of solids that are moving through the system. The most
common positive-displacement pump is the reciprocating pump. These pumps are also called piston or diaphragm
pumps.

8. CONCLUSION

Based on this activity, I was able to determine the principles and operations of pumping liquids using
centrifugal pumps. I was able to identify the different parts of the centrifugal pumps. I was able to enumerate the
 functions of the different parts of the centrifugal pumps. I was able to determine the factors required in pumping
liquids using centrifugal pumps. I was able to define the formulas in determining the power required to pump liquid
using centrifugal pumps.

Therefore, the centrifugal pump is a machine that imparts energy to a liquid to increase its pressure and move
it from one point to another. It also emphasize the conditions and physical properties of the liquid, and, most
importantly, the flow rate, pressure, density and viscosity. The flow rate determines the capacity of the pump, and the
head depends on the density and viscosity of the liquid.

VII. RECOMMENDATIONS

In using centrifugal pumps, I recommend to use it with proper precautions. In selecting a pump, one of the
concerns is to optimize pump efficiency. It is good to examine the performance charts at different speeds to see if the
pump satisfies the requirements more efficiently than another and avoid valve cavitation, avoid vibration and noise,
circumvent wastewater gas can cause relay oxidation, avoid problems with the operation of the level regulators from
floating debris and facilitate maintenance and protect pump from erosion.
Energy efficient, reliable, low maintenance cost – A PAH high-pressure water pump from Danfoss is the ideal solution for a
multitude of different applications!"