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Part1 centrifugal pump

introduction

31 aug.2013

Centrifugal Pump Basic Theory

Basic Function of Pumps
Energy transfer from electrical motor to the
1- A pump is used to increase liquids pressure. rotate the impeller, the liquid adjacent will
2- Pumps transfer or move liquids gain centrifugal force and increase the
3- lift liquid from underground liquid velocity. The volute/ diffuser
converts the velocity into pressure head
Centrifugal Pump Operation

When a centrifugal pump is started, the

impeller begins to rotate.The impeller
blades stir the liquid, causing it to rotate.
This circular motion generates force, which
moves the liquid away from the center of
the impeller. This outward motion has two
effects.
First, it moves the liquid to the outside
edge of the impeller against the casing
wall.
Second, it creates suction at the eye
(center) of the impeller to draw more liquid
into the pump. 2

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Overhung pump
A LIQUID IS SUPPLIED TO
THE PUMP “SUCTION”
PUMP SHAFT
CENTRIFUGAL FORCE EXPELS
THE LIQUID OUT FROM THE
IMPELLER

IMPELLER AS THE PUMP SHAFT

BEARINGS ROTATES

The operation of a centrifugal pump is based on the centrifugal force, which

moves the fluid outward from the centre of rotation
The outside edge of the impeller travels faster than its center. To keep up with
the impeller, the liquid must continue to gain velocity as it moves outward. This
increases the kinetic energy of the liquid
As liquid leaves the outside edge of the impeller, it enters an area of the casing
called the volute. The volute is wider at the discharge than where the liquid
leaves the impeller. This increased area allows the liquid to slow down. As the
velocity decreases, the liquid gives up some its kinetic energy. It is converted into
pressure, which forces the liquid out to the discharge 3

Classification of Pumps

Volute, double volute, diffuser, annular, tubular, split casing, etc

Shape of casing Single suction, double suction, axial inlet, top inlet, etc.

lay out Are horizontal, vertical and inclined

Low pressure, high pressure and medium

Discharge pressure
pressure
Single
Number of stages Double
Multi-stage

Liquid handled Name of liquid

Water pump - Crude oil pump - Condensate pump

Submersible, immersible, wet motor,

Operating condition standby, auxiliary, etc

They are motor, gas turbine, steam turbine, diesel engine, etc.
Drives
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Process pumps must handle a

wide range of fluid
characteristics, including
temperature, pressure,
viscosity, flammability, toxicity,
and corrosiveness.

Pumps can also be classified by

principle of operation and drive
requirements.
From design to manufacturing and at every
Principle of Operation Application
stage in between, the manufacture of process Served
pumps requires an extensive suite of
Materials of Construction
technologies to accommodate these

Liquid Being Pumped
characteristics and realize the pumps' final
applications.
Shaft Orientation (Vertical,
Horizontal)

Number of Stages

Suction Port Arrangement 5

Pump application
•API Process Pumps - designed to meet the 610 standard set by the American Petroleum Institute (API).
•Boiler Feed Pumps - built to control the amount of water that enters a boiler. They are centrifugal pumps, and most are multistage.
•Borehole Pumps - made to pump liquid from a borehole.
•Chemical Pumps - built to handle abrasive and corrosive industrial materials. They can either centrifugal or positive displacement type.
•Circulator Pumps - used to circulate fluid through a closed or looped system. They are usually centrifugal pumps, but a few use positive
displacement technology.
•Dewatering Pumps - a de-watering process involves using a centrifugal pump (submersible or vertical turbine) to remove water from a
construction site, pond, mine shaft, or any other area.
•Drill Pumps - a type of pump powered by attaching an electric power drill.
•Drum Pumps - used to empty fluid from barrels or drums. They can be a small centrifugal pump used for thin liquids or for more viscous fluids a
progressive cavity or piston pump can be used.
•Fire Pumps - a type of centrifugal pump used for fire fighting. They are generally horizontal split case, end suction or vertical turbine.
•Flooded Suction Pumps - include a suctioned chamber that is always full of the fluid being pumped.
•High Pressure Pumps - used in many applications including water blast, hydro-mining, and jet cutting. They can be a wide variety of pumps
types including positive displacement pumps, rotary pumps and reciprocating pumps, or centrifugal pumps.
•Industrial Pumps - used in industrial applications such as slurry, wastewater, industrial chemicals, oil and gas, etc. There are dozens of different
industrial pumps both in positive displacement and centrifugal pump types.
•Irrigation Pumps - usually some form of centrifugal pump type. They are often used for agriculture application where water needs to be moved
from a water source to dry land.
•Marine Pumps - built to pump sea water. They are often used in large salt water tanks to continuously circulated water so it stays fresh.
•Mixed Flow Pumps - incorporate the features of both axial flow pumps and radial flow pumps. Axial flow pumps operate on a vertical plane and
radial flow operate on a horizontal plane to the flow direction of water.
•Mud Pumps - built to transfer heavy sludge or mud. Some larger versions are used to pressure. They are sometimes used on oil rigs to
pressurize and circulate fluid.
•Paint Pumps - built to dispense paint, either for direct application or into a separate paint container. They are used in many applications
including electric paint sprayers.
•Petrochemical Pumps - made to transfer petroleum products that are often very viscous and corrosive. They can be magnetic drive pumps,
diaphragm pumps, piston pumps and others.
•Pneumatic Pumps - uses compressed air to pressurize liquid through the piping system.
•Pond Pumps - used in gardens, fish pools, ponds, and fountains to prevent water from becoming stagnant. The two main types include
submersible pumps and external pumps.
•Pool Pumps - used to circulate the water in a pool.
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•Pressure Pumps - used to create either high or low pressure. They can be metering pumps, and sometimes booster pumps.
•Process Pumps - are many times centrifugal pumps or positive displacement pumps used in process applications. The type
of pump and construction details vary depending on the application in which these pumps are used.
•Pump Companies - manufacturer and sell pumps. They can include manufacturers, distributors or representatives.
•Pump Distributors - businesses that sell pumps, made by pump manufacturers. They are private businesses that often sell
several different product lines.
•Pump Manufacturers - companies that research, engineer, test, and manufacturer pumps. Some sell direct, and some also
utilize distributors and reps to sell and service their pumps.
•Pump Suppliers - sell and service pumps. They can include distributors, reps, or manufacturers.
•Sanitary Pumps - a type of pump used to transport fluids that must be processed for sanitary standards. They are designed
to meet regulatory requirements.
•Sewage Pumps - considered submersible pumps and they are mostly used to pump sewage to a waste treatment facility.
•Sludge Pumps - used to pump waste fluids with high solids content. They can be positive displacement (progressive cavity)
or centrifugal pumps.
•Slurry Pumps - a heavy duty pump that is made to handle thick, abrasive slurries. They are made of durable materials, and
capable of handling abrasive fluids for long periods of time.
•Solar Pumps - powered by the sun. They can be PD pumps or centrifugal pumps.
•Sprinkler Pumps - work within a sprinkler system. They are the mechanism that creates pressure to move the water
through the system.
•Transfer Pumps - used to move a fluid from one receptacle to another. They are used in residential, commercial or
agriculture applications where a fluid needs to be moved from one tank to another.
•Trash Pumps - Trash pumps are a type of pump used to handle fluids containing solid content such as mud, trash, fish,
or waste products. They are also referred to as grinder pumps, chopper pumps, or sludge pumps.
•Utility Pumps - a type of submersible pump used to remove water from an area, often times after a flood. They are
used in industrial, residential and agricultural applications.
•Wastewater Pumps - used to move wastewater toward or within a waste treatment facility.
•Water Pumps - a type of equipment used to move water through a piping system. They rely upon principles of
displacement, gravity, suction, and vacuums to move water. They can be both positive displacement or centrifugal
pumps.
•Well Pumps - designed to draw water to the surface from an underground water source. Depending on the well depth
and configuration, they pumps can be jet pumps, centrifugal pumps, or submersible pumps. 7

(a) Centrifugal for low speed. (b) Mixed-flow for

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intermediate speed. (c) Axial-flow or propeller for high
speed.

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End suction
Incl.
Close coupled submersibles
Signal & two
stage
In-line
Overhung
impeller Separately
coupled In-line
Single & two Centerline
stage Support
API 610
Frame
mounted
Frame mounted
ANSI B3731
Wet pit
volute Axial flow
impeller
Centrifugal (propeller)
Volute type
Horiz. & vert.

Split Case

Separately
coupled
Single stage
Radial ( vert.)
Impeller
Between Split case
bearings
Axial (
Horiz.)
Split case
Separately
coupled
Multi stage
Radial ( vert.)
Split case

Turbine
Vertical Type Deep well
Type
Single & stage Incl.
submersibles
Kinetic Barrel or
Can pump

Axial flow impeller

(propeller or mixed
flow type 9 Horiz. &
vert.)

Single stage
Regenerative Impeller
Turbine overhung or
between Two stage
bearings

Reversible
centrifugal
Special
effect Rotating
casing
(pitot)
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Centrifugal pump components

External component Internal components

pump shaft, Casing,

impeller, wear rings, Stuffing box,
volute, packing or Bearing housing
mechanical seals Coupling.
and bearings

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Casing
Casing is the largest part of the centrifugal The casing has three purposes
pump
Casing material: It houses the internal parts, and
casings of low-pressure pumps are usually protecting them.
made of cast iron It directs its flow.
steel is used for higher-pressure pumps It forms the volute and connections for
suction and discharge piping
double volute pumps have less radial thrust Note : casing can be solid or spli
than single volute pumps, particularly to the
left of the design point.
Double volute cases are generally more
expensive than single volute cases, and are
difficult to make in small sizes. In many sizes
they offer no overall advantage over single
volute pumps

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Volute
Volute and diffuser had increase in the area which
will lower the velocity
Both the volute and diffuser convert the kinetic
energy ( velocity) into pressure energy (head)

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Inlet flange and inlet

The pump is connected to the piping system through its inlet and outlet flanges. The design
of the flanges depends on the pump application. Some pump types have no inlet flange
because the inlet is not mounted on a pipe but submerged directly in the fluid.

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Packing Mechanical seals

Packing is a soft pliable material like cotton, or
flax, usually braided into a continuous square-
shaped strand. Packing is usually coated with
graphite or Teflon for lubrication
Mechanical seals’ advantages are:
1. They provide no leakage, which
is very important when pumping
hydrocarbons because of the
potential safety risk.
2. They last much longer than
packing.
3.They require less maintenance

The highly polished sealing faces of

the rotating and stationary parts are
held in contact by one or more
springs. Mechanical seals may be
replaced with new ones if a problem
arises

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Packing
Seals function is to prevent liquid
leaks from inside the pump to
outside through the shaft.
• Types are
1. Gland Packing – For Non
dangerous liquids ( water, &
very low pressure liquids)

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Gland Housing/Stuffing Box and shaft sealing

To seal the leakage of fluid from where the shaft penetrates out the pump casing, a gland
packing assembly or Mechanical seal assembly is provided and this assembly is fitted in
the Gland housing / Stuffing box provided in the pump housing.
Specially made asbestos/glass fiber / filled Teflon rings are used for sealing which is
mounted between the stuffing box housing and shaft sleeve.
Gland packing is very economical to use but this requires renewal at fix interval. Also
gland packing do not gives zero leakage assembly by any mean. For cooling of gland
ropes small amount of leakage is mandatory to maintain. For non toxic, non critical
services gland packing are used in industrial pumps but mechanical seal assembly are
used for all hazardous services.
Throttle bush is a stationary device, which forms a restrictive close clearance
around the shaft in the pump casing just in front of gland housing. This helps in
reducing the fluid flow load on mechanical seals and also helps in maintaining the
flushing fluid pressure in the gland boxes.
Basically lantern ring are provided in the stuffing box in case of gland packing rings
sealing system to give a recess and to cool the gland packing rings/elements with
the pump fluid.
It is installed between or in the middle of the gland packing elements and a
cooling line is connected just above the lantern ring from the pump casing
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Mechanical seal
• l – For dangerous liquids (Acids
and flammable liquids

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Pump Bearings
Two types are
1. Frictional bearing (Journal)
2. Anti-friction bearing (ball, roller….)
Bearings will carry the thrust and radial loads
bearings needs lubrication oil or grease

Bearing life is determined by the number of

hours it will take for the metal to "fatigue" and
that is a function of the load on the bearing,
the number of rotations, and the amount of
lubrication that the bearing receives

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Shaft
Pump shafts are normally made of
What is L3/D4 (L cubed over D to the
stainless steel or other corrosive resistant
fourth)? It is a measure of pump rotor
material because of the expense to replace
stiffness, its ability to resist radial load
broken or worn shafts,.
and to minimize deflection.
(
A bent shaft can cause many pump
problems—including wear of supporting
bushings, leaky seals, high vibrations,
overloaded bearings and a multitude of other
issues.

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Impellers
Impellers are circular devices with curved blades that stir the fluid in a centrifugal
pump. Impellers fit tightly on the shaft and are usually pressed on it. The most
common method to hold the impeller in place on the shaft is the key and keyway.
The impeller is the most critical part of a centrifugal pump because of its size,
shape and speed
Types of Impellers

1- Open impellers are blades mounted on a shroud with just enough backing to
maintain the rigidity of blades.
2- Semi-open impellers has one shroud.
3- Closed impeller has shrouds covering both sides of blades with a central hole
(eye) on either side to allow fluid to enter the impeller

Higher pressure/ capacity can be obtained by increasing the rotation speed of

the impeller or by using a larger impeller. Design and material limitations
generally dictate the use of multi-staging.
1. increase the speed
2. Increase the diameter of the impeller
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Four different types of impeller options

available:
Closed Impeller – RD
Open Impeller – RG
Channel Impeller – RB
Vortex Impeller – RC

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Radial Flow Pumps

Axial Flow Pumps

Mixed Flow Pumps

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Effect of Entrained Solids

If the water to be pumped (for example, domestic waste water, rainwater or mixtures)
contains small amounts of entrained solids, special impeller and pump types are used (for
example with cleaning covers or special shaft seals)

For pumping sludge, non-clogging channel impellers can be used up to 3% solids content,
single vane impellers up to 5%, free flow impellers up to 7% and worm type impellers for
even higher concentrations.

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Use of Diffuser blades

• for larger centrifugal pumps,
there will be additional diffuser
blades also present, in order to
reduce velocity further. Or they
aid in dynamic to static energy
conversion.

The purpose of the diffuser is to

increase the efficiency of the
centrifugal pump by allowing a more
gradual expansion and less turbulent
area for the liquid to reduce in
velocity.
Use of diffuser blades in large
capacity centrifugal pumps

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Most Suited Blade for Industrial Use

• For backward curved blades as
energy head decreases with
discharge power consumption
stabilizes with flow. In radial
blades since head does not
have any connection with flow
rate, power consumption
increases linearly. In forward
curved blades since energy
head increases with flow
Power consumption in different blade geometries
power consumption increases
exponentially.This will make
the operation unstable, which
will eventually lead to burnout
of motor.
So backward curved blades which has got self stabilizing characteristics in
power consumption is the most preferred one in industry

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Pump cut-water

Schematic showing secondary flows associated

with a typical centrifugal pump operating at
off-design conditions (adapted from Makay
1980
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Double suction and single suction

impeller

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Wear rings
Located in the a space between the
impeller and casing so the impeller can
rotate without touching the surface of
casing

Function:
1. it prevents wear to the impeller and
casing
2. control the fluid leakage, some
leakage is important for lubrication,
and balance (counteracts) the thrust
forces which built in the pump

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Wear rings
Wearing ring provide easy and economically renewable relative movement joint
between the impeller and the casing and to protect the damage of impeller or casing in
that area. OEM generally recommends the clearances between the casing wear ring and
impeller wear rings and if these clearances exceeds, pump efficiency will be lowered
and abnormal vibration increase will be some of the consequences.

wear rings impact pump reliability by
increasing rotor stability—reducing vibration
and shaft deflection—thereby increasing the
life of the mechanical seals
For typical process pumps, reducing wear ring
clearance by 50 percent will produce an
efficiency gain in the range of 2 to 4 percent.
The exact gain
Reducing the internal leakage within
the pump also reduces the net
positive suction head required
(NPSHR). Therefore, pumps with
reduced wear ring clearance are less
likely to cavitate

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Material of Construction of Pump

Components:
• however the service of the pump, The most widely used materials
in which it has to perform, in pump components are
cast iron, bronze, cast steel,
dictates the material of
austenite steel, martensite steel
construction of the pump and different grades of plastics,
components selected according to application
i) Corrosion Resistance
ii) Abrasive Wear Resistance
iii) Cavitation Resistance
iv) Strength
v) Tensile Strength
vi) Endurance Limits (Staying
power)
vii) Fatigue Strength
viii) Cost
ix) Maintenance

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Pump Installation Arrangements

The major parameters classifying the pump
installation arrangement are:
the position of the shaft, i. e. horizontal or
vertical (see Figs. a and b, also i and c or h and
f),
• the arrangement of the feet, i. e. underneath
or shaft centreline (see Figs. d and e),
• the mode of installation of the pump set, i. e.
with or without foundation (see Figs. b and f),
• the arrangement of the drive, i. e. on its own
or a common baseplate or flanged to the
pump (see Figs. g, a, h and i),
• the weight distribution of the pump and drive,
• the arrangement of the discharge nozzle on
tubular casing pumps (see Figs. k, l, m and n),
• the environment of the pump casing, i. e. dry
or wet (see Figs. b and o).

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Pump Intake Structures

Pump Sump

Pump sumps (or suction tanks) are designed to

collect liquids and be intermittently drained
With dirty liquids, solids must be prevented
from being deposited and collecting in dead
zones and on the floor. Walls arranged at a 45°,
or better still 60° angle, help prevent this

Suction Piping

The suction pipe should be as short as

possible and run with a gentle ascending
slope towards the pump.

Fig. : Flow-accelerating elbow upstream of a

Fig. : Eccentric reducer and branch vertical volute casing pump with high specific
fitting to avoid air pockets speed 34

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Fig. 63: Intake elbow with

Fig. 64: Installation of a
multiple turning vanes upstream
positive deflector in the intake
of a double-entry, horizontal
chamber of a submersible
volute casing pump (plan view)
motor pump

Fig. 66: Clearances between wall and

suction pipe in the suction tank or
pump sump according to relevant
German regulations

taken to prevent
air-entraining vortices Wherever
the required minimum
Fig. 68: Raft to prevent air submergence cannot or
entraining Hollow vortices not always be ensured,
Fig. 69: Use of swirl preventers 35

Priming Devices
centrifugal pumps are not self-priming; i. e. their suction pipes and suction-side
casings
must be deaerated prior to start-up unless the impeller is arranged below the
liquid
level. This often inconvenient procedure can be avoided by installing a foot valve
(functioning as a non-return valve) at the suction pipe mouth next figure.
Deaerating is then only necessary prior to commissioning and after a long period
of standstill.
A closed suction tank (static tank) serves the same purpose, in particular when
contaminated liquids are handled (it does, however, increase the flow losses and
therefore reduces the NPSHa). The tank is under negative pressure and mounted
upstream of the pump suction nozzle next figure). Prior to commissioning it must
be filled with liquid. When the pump is started up, it empties the tank, and the air
in the suction or siphon pipe is drawn into the suction tank across the apex until
the liquid to be pumped follows. After the pump has been stopped, the tank is
refilled with liquid via the discharge pipe either manually or automatically.
The air stored in the tank escapes into the suction pipe

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Fig. : Foot valve (cup valve) with

Fig. : Suction tank arrangement
suction strainer

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Arrangement of Measurement Points

Minimum values for

undisturbed straight
lengths of piping at
measurement points in
multiples of the pipe
diameter D

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Shaft Couplings
In centrifugal pump engineering, both rigid and flexible shaft
couplings are used. Rigid couplings are mainly used to connect shafts in perfect
alignment, since the smallest degree of misalignment will cause considerable
stress on the coupling and on the adjacent shaft sections. Flexible couplings to
DIN 740
are elastic, slip-free connecting elements between drive and pump which
accommodate axial, radial and angular misalignment and damp shock loads.
Flexibility is usually achieved by the deformation of damping and rubber-elastic
spring elements whose life is governed to a large extent by the degree of
misalignment. Fig shows two of the most common types of flexible shaft
coupling. Fig. shows a spacer coupling between a volute casing pump and
drive. It permits removal of the pump rotating assembly without having to
dismantle the suction and discharge piping or
move the pump casing or drive (back pull-out design).

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Shaft Couplings

Fig. 77: Flexible (left) and highly flexible coupling

Fig. 78: Pump with spacer coupling compared

with normal coupling 40

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Pump Nozzle Loading

Pump Nozzle Loading A centrifugal pump mounted on the foundation should not
be used as an anchorage point for connecting the piping. Even if the piping is fitted to the
nozzles without transmitting any stresses or strains, forces and moments, summarized as nozzle
loading, will develop under actual operating conditions (pressure and temperature) and
as a result of the weight of the liquid-filled piping. These cause stresses and deformation in the
pump casings, and above all changes in coupling alignment, which, in turn, may affect the
pump’s running characteristics, the service life of the flexible elements in the shaft coupling,
as well as the bearings and mechanical seals. For this reason limits have been defined for
permissible nozzle loading

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