02.01.

02 - 000

Process engineering

Pumps, turbines and compressors

Introductory lesson
In a chemical plant, many substances need to be transported or energy must be produced from flowing media. The Pumps, Turbines and Compressors section examines the equipment required for the transport of substances through a piping system in a chemical plant. This section looks at centrifugal pumps in detail. In addition to practical designs, aspects of wear, mechanical seals and controls, we will look at the theoretical foundations of these pumps. This is followed by an examination of rotating positive displacement pumps. This is a type of pump with a fundamentally different principle of operation. In a second part of this section, we will discuss how the energy of steam can be converted to mechanical energy. This conversion can be achieved in a steam turbine. Here, the energy contained in the flowing medium is converted to mechanical energy. In addition, different aspects of working with steam turbines are discussed. Finally, we will look at compressors. These are necessary if substances have to be transported from low to high pressure. In addition to a number of different designs, practical matters such as mechanical seals, control and operation are examined. This introductory lesson contains a table of contents of the lessons dealing with Pumps, Turbines and Compressors systems. This is followed by a key word index containing some difficult words that you may find helpful when studying the material. In addition, there is a list of abbreviations containing all abbreviations that occur in the lessons. Finally, this lesson contains important illustrations and tables, formulae and symbols, which provide a summary of the material covered in the lessons of this section. It is advisable to use this material while studying the lessons. This introductory lesson may be used during the examination. This means that you can consult this lesson while answering the exercises. If you use this lesson during the examination, you must not annotate it or add explanatory text.

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Contents of pumps, turbines and compressors

1 1.1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 5 6 6.1 6.2 7 Purchase specifications and advantages of centrifugal pumps Advantages of centrifugal pumps The design and construction of a centrifugal pump The shape of the centrifugal pump Some constructions of centrifugal pumps Horizontal pumps Vertical pumps Single impeller pumps Multi-stage pumps Horizontal pumps with a single impeller Close-coupled pumps The line resistance Determination of the line resistance Line characteristics The manometric differential pressure The manometric suction pressure The manometric discharge pressure The manometric head Problems and Assignments

Lesson 010 Centrifugal pumps (1)

Lesson 020 Centrifugal pumps (2) 1 2 3 4 5 Suitability and operating conditions Liquid flow in the impeller The pump characteristic Characteristics of pipe systems The operating point of a pump
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6 7 7.1

The occurrence of cavitation Net Positive Suction Head An example of calculating NPSH Problems and Assignments

Lesson 030 Centrifugal pumps (3) 1 1.1 1.2 2 2.1 3 3.1 3.2 4 4.1 4.2 5 6 7 Controlling the pump capacity Controlling the capacity by throttling the discharge valve Controlling the capacity by changing the pump speed Control range of a centrifugal pump A detailed example Parallel line up of centrifugal pumps Parallel line up of two identical pumps Parallel line up of two different pumps Series line up of centrifugal pumps Series line up of two identical pumps Series line up of two different pumps The effect of lining up pipes in series The effect of lining up pipes in parallel The efficiency and the power requirements of centrifugal pumps Problems and Assignments

Lesson 040 Centrifugal pumps (4) 1 2 3 4 4.1 4.2 Pumps for corrosive liquids Design of sealless pumps Submersible pumps Sundyne pump Advantages of Sundyne pumps Disadvantages of Sundyne pumps
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5 6

Seal casing and seal port marking of Sundyne pumps Volute or diffusor pumps Problems and Assignments

Lesson 050 Centrifugal pumps (5) 1 2 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 Wearing rings and their function Pump overhaul Operation of centrifugal pumps Start-up of centrifugal pumps Control of centrifugal pumps Stopping a centrifugal pump Potential failures with centrifugal pumps Insufficient capacity due to low suction pressure Damage to bearings Vibrations Failures and their possible causes Problems and Assignments

Lesson 060 Rotating positive displacement pumps 1 1.1 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 4 4.1 4.2 The operating principle of positive displacement pumps Rotating positive displacement pumps Gear pumps Gear pump construction How a gear pump works Leakage losses in gear pumps Operation of a gear pump Screw pumps Design and operating principle of screw pumps Screw pump operation Helical rotor pumps Internal gear pumps Design and operating principle of internal gear pumps Internal gear pump operation
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5 6

Liquid hammer in pipe systems Malfunctions and maintenance of positive displacement pumps Problems and Assignments

Lesson 070 Mechanical shaft seals (mechanical seats) 1 1.1 1.2 2 3 3.1 3.2 3.3 4 5 6 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 8 9 Operating principle of mechanical seals The box pressure Other factors that affect leakage Leak points in a mechanical seal Dynamic secondary seals The O ring Taper ring Selection of the material for the secondary seal Bellows assembly Static secondary seal Defects found in mechanical seals Finding and remedying defects in mechanical seals Chemical attack Fretting corrosion Chemical attack of O rings Leaching Deformation of the sealing face Extrusion of O rings Erosion Evaporation Coking Structured procedure for investigating defects Possible consequences of a defective shaft seal Problems and Assignments

Lesson 080 Steam turbines (1) 1 2 The most important energy conversions Steam
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3 4 5 5.1

Producing steam Enthalpy, the steam table and its use Energy conversion in the steam turbine Mollier chart Problems and Assignments

Lesson 090 Steam turbines (2) 1 2 2.1 2.2 3 4 4.1 5 6 7 8 Important definitions with reference to steam turbines Steam and vane velocities occurring in the De Laval turbine The vane velocity u The steam velocity c Further explanation of the velocity triangles Construction and operating principle of the De Laval turbine The operation of a De Laval turbine The Curtis turbine The pressure and velocity diagram of the Curtis turbine The Coppus turbine The construction of the Coppus turbine Problems and Assignments

Lesson 100 Steam turbines (3) 1 2 3 4 5 6 6.1 6.2 Higher-power turbines Zoelly turbine Partial coverage Construction of the Zoelly turbine Turbine combinations, designs and advantages Shaft seals The labyrinth seal The carbon ring seal
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7 8 9

Power control in turbines Throttle control Nozzle control Problems and Assignments

Lesson 110 Steam turbines (4) 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Different systems The steam circuit The cooling water circuit The lubrication oil system The turbine Starting up the turbine The steam supply when bringing up to speed Preheating The lubricating oil (lube-oil) system The steam supply at operating speed Testing the safe guarding Automatic testing Malfunctions Operational aspects of steam turbine installations Recording important process parameters Pipe system The steam The turbine Axial displacement The lubricating oil system Turbine control Problems and Assignments

Lesson 120 Compressors (1) 1 1.1 1.2 2 3 Principle of operation of a centrifugal compressor Minimum flow in centrifugal compressors Minimum flow control in centrifugal compressors The practical surge curve Choking and Stone Wall

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4 4.1

Seals Labyrinth seal Problems and Assignments

Lesson 130 Compressors (2) 1 2 2.1 2.2 3 4 5 Liquid seals Lubrication systems The operation of the system Safeguarding Start-up Operation Shut-down Problems and Assignments

Lesson 140 Compressors (3) 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 3 3.1 3.2 3.3 3.4 3.5 3.6 Liquid-ring pump Operation Sealing liquid Vacuum attainable Applications Construction Operation with the liquid-ring pump Malfunctioning and maintenance of liquid-ring pumps Rootes blower The operation Screw compressors Design of a screw compressor Operation of screw compressors Lubricated screw compressor (without timing gears) Screw compressor with timing gears The number of compression stages Cooling and alignment Problems and Assignments

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Lesson 150 Compressors (4) 1 2 3 4 5 6 7 8 9 Piston compressor Operation of a piston compressor Thomassen C45-4 compressor Construction of the compressor Valves used in piston compressors Construction of the electric motor Lubricating oil system Cooling system Start-up and shut-down of a compressor Problems and Assignments

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2 Keywords
Amplitude Axial balancing Deflection, extent of motion. Prevention of axial displacement of (worm) shafts. Increase the pressure. Pump without a stuffing box. Become narrower. Become wider. Amount of heat contained in for instance steam, compared with water of 0 C and 1 bar. Speed regulator. Tooth profile in which the tooth face of one wheel rolls over the tooth face of the other wheel, with the tooth faces touching along a single line across the tooth width. Lines of equal enthalpy in the Mollier diagram. Lines of equal pressure in the Mollier diagram. Lines of equal temperature in the Mollier diagram. Collecting vessel for liquid particles. Positive gas flow. Tank for used oil. Disc with a hole, which can be fitted in a pipe to create a pressure loss or limit a volume flow. A unit which maintains a certain pressure in a system. Seal between the stationary sealing ring and the casing. Controlling the supply of steam to the nozzles by means of a throttle valve. Gears on rotors of screw compressor.
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Boost Canned motor pump Converge Diverge Enthalpy

Governor Involute tooth profile

Isenthalpics Isobars Isotherms

Knock-out drum (KO) Minimal flow Monte-jus tank Orifice

Pressure water unit

Static secondary seal

Throttling

Timing gears

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3 Abbreviations
NPSH NPSHA NPSHR PTFE Nett Positive Suction Head Nett Positive Suction Head Available Nett Positive Suction Head Required Polytetrafluoroethylene (Teflon)

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4 Illustrations and tables

Table 1 Total pipe resistance ppr for straight pipes with a length of 100 m at various pipe diameters and various liquid velocities.

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Table 2 Resistance of fittings and accessories in equivalent pipe length

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5539-010-014-P

Figure 1 Resistance of water in new, smooth seamless steel pipes in bar per 100 m of pipe (ppr) 14

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5539-020-014-P

Figure 2 The relationship between the temperature and the vapour pressure for various liquids

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Table 3 Table for 1 kg saturated steam at the pressure given

Column 1 Column 2 Column 3 Column 4 Columns 5 and 6 Column 7

Pressures of the steam for which the various figures are valid. The temperatures of the saturated steam at the given pressures. The enthalpy of the boiling water at the given pressures, in kJ/ kg water. The enthalpy of the saturated steam at the relevant pressure. This is the total amount of heat required to produce the given steam from 1 kg water at 0 C. The specific volume of water and saturated steam, respectively. This is the volume in m3 of a mass of 1 kg water or steam. The density of saturated steam at the given pressure. This is the mass, in kg, of 1 m3 saturated steam at that pressure.

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Table 4 Enthalpy as a function of pressure and temperature (1 kg superheated steam at the given pressure and temperature)

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5539-080-002-P/

Figure 3 Mollier chart

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5 Formulae
Centrifugal pumps pstat.s = pl.s - pn.s pstat.s pl.s pn.s pressure due to liquid column static suction pressure (bar) pressure in the liquid vessel on the suction side (bar) pressure caused by the liquid column on the suction side (bar)

static suction pressure

pnett.s = hnett.s * * g * 10-5 pnett.s hnett.s g 10-5 pressure caused by the liquid column on the suction side (bar) height of the liquid column on the suction side (m) specific density (kg/m3) gravitational acceleration (m/s2) factor to convert the pressure from Pascal into bar (1 bar = 10-5 Pa)

manometric suction head

pman.s = pl.s - pnett.s - ppr.s - pv.s pman.s pl.s pnett.s ppr.s pv.s manometric suction pressure (bar) pressure in the liquid vessel on the suction side (bar) pressure caused by the liquid column on the suction side (bar) pipe resistance on the suction side (bar) velocity pressure on the suction side (bar)

velocity pressure

pv.s = * * cs2 * 10-5 pv.s cs 10-5 velocity pressure on the suction side (bar) specific density (kg/m3) velocity of the liquid in the suction pipe (m/s) conversion factor to convert a pressure in Pa to a pressure in bar

static discharge pressure

pstat.d = pl.d + pn.d pstat.d pl.d pn.d static discharge pressure (bar) pressure in the liquid vessel on the discharge side (bar) pressure caused by the liquid column on the discharge side (bar)

pressure due to liquid column

pn.d = hn.d * * g * 10-5 pn.d hn.d g 10-5 pressure caused by the liquid column on the discharge side (bar) height of the liquid column on the discharge side (m) specific density (kg/m3) gravitational acceleration (m/s2) factor to convert a pressure in Pa to a pressure in bar

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manometric discharge pressure

pman.d = pl.d - pn.d - ppr.d - pv.d pman.d pl.d pn.d ppr.d pv.d manometric discharge pressure (bar) pressure in the liquid vessel on the discharge side (bar) pressure caused by the liquid column on the discharge side (bar) pipe resistance on the discharge side (bar) velocity pressure on the discharge side (bar)

velocity pressure

pv.d = * * cd2 * 10-5 pv.d cd 10-5 velocity pressure on the discharge side (bar) specific density (kg/m3) velocity of the liquid in the discharge line (m/s) conversion factor to convert a pressure in Pa to a pressure in bar

manometric lift head

pman = pman.d - pman.s pman pman.d pman.s manometric lift head (bar) manometric discharge pressure (bar) manometric suction pressure (bar)

manometric discharge head

pman *105 hman = *g

hman pman g 10-5 manometric head (m) manometric differential pressure (bar) specific density (kg/m3) gravitational acceleration (m/s2) factor to convert a pressure in Pa to a pressure in bar

Euler's formula

pE = * u * c * cos pE u c ideal theoretical discharge pressure according to Euler (Pa) specific density (kg/m3) tangential velocity of the impeller (m/s) absolute exit velocity (m/s) angle between c and u (rad) 1 rad (radian) =

360 degrees 2

Nett Positive Suction Head

NPSHA = psuction flange - pvapour pressure NPSHA Nett Positive Suction Head Available (bar)

proper operation of pump

NPSHA - NPSHR = 0.1 bar NPSHA Nett Positive Suction Head Available (bar) NPSHR Nett Positive Suction Head Required (bar)

pump power

P = pman * qv P pman qv power (W) manometric lift head (Pa) capacity (m3/s) 20

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Steam turbines Zeuner's formula c= c hth constant vapour content X=

2000 * hth
the (theoretical) velocity of the steam (m/s) the (theoretical) heat drop (kJ per kg of steam)

mass of water in vapour form initial mass of water

X constant vapour content P = qm * hth *

power

P qm hth Int mech hls = hts hls hts

power (kW) mass flow of steam (kg/s) (theoretical) heat drop (kJ per kg of steam) efficiency, = int * mech internal efficiency mechanical efficiency

throttling

enthalpy of live steam (kJ/kg) enthalpy of throttled steam (kJ/kg)

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cs cd c c g hn.d hn.s hls hts hman hth pman.s pl.s pn.s ppr.s pv.s pman.d pl.d pn.d ppr.d pv.d pstat.s pstat.d pman pE P qv qm u X

Symbols
velocity of the liquid in the suction line (m/s) velocity of the liquid in the discharge line (m/s) absolute exit velocity (m/s) (theoretical) velocity of the steam (m/s) gravitational acceleration (m2/s) height of the liquid column on the discharge side (m) height of the liquid column on the suction side (m) enthalpy of live steam (kJ/kg) enthalpy of throttled steam (kJ/kg) manometric lift head (m) (theoretical) heat drop (kJ per kg of steam) manometric suction pressure (bar) pressure in the liquid vessel on the suction side (bar) pressure caused by the liquid column on the suction side (bar) pipe resistance on the suction side (bar) velocity pressure on the suction side (bar) manometric discharge pressure (bar) pressure in the liquid vessel on the discharge side (bar) pressure caused by the liquid column on the discharge side (bar) pipe resistance on the discharge side (bar) velocity pressure on the discharge side (bar) static suction pressure (bar) static discharge pressure (bar) manometric lift head (bar) ideal theoretical lift head according to Euler (Pa) power (W) capacity, volume flow (m3/s) mass flow (kg/s) tangential velocity of the impeller (m/s) constant vapour content

Greek symbols
int mech density (kg/m3) angle between absolute exit velocity (c) and the tangential velocity of the impeller (u) (rad) efficiency internal efficiency mechanical efficiency

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Appendices
Greek alphabet
Table 5 Greek alphabet
Name

Alpha Beta Gamma Delta Epsilon Zeta Eta Theta

Upper case

lower case

name

upper case

lower case

name

upper case

lower case

iota kappa lambda mu nu xi omicron pi

rho sigma tau upsilon phi chi psi omega

SI units
Table 6 The SI units (The symbol for the units of current and light intensity is the same!) Quantity SI unit Name Symbol name symbol Length meter m Mass m kilogram kg Time t second s Temperature T kelvin K Current I ampere A Quantity of matter n mole mole light intensity I candela cd

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Derived SI units
Table 7 Some derived SI units and multiples of SI units
Quantity Pressure Unit Pascal Bar Atmosphere Pounds per square inch Joule Calorie kilowatt-hour Poise Stokes Newton Hertz Volt Ohm Siemens Coulomb Farad Watt Decibel Year Day hour minute Degree radian conversion 1 Pa = 1 N/m2 1 bar = 100000 Pa 1 atm = 101.3 kPa 1 psi = 6895 Pa 1J = 1 Nm 1 cal = 4.187 J 1 kWh = 3.6 MJ 1P = 0.1 N * s/m2 1 St = 10-4 m2/s 1N = 1 kg * m/s2 1 Hz = 1/s 1V = 1 W/A 1 = 1 V/A 1S = 1/ 1C =1A*s 1F = 1 C/V 1W = 1 J/s DB 1a = 31557600 s 1d = 86400 s 1h = 3600 s 1 min = 60 s 1 = /180 rad

Energy (work, heat)

Dynamic viscosity Kinematic viscosity Force Frequency Electric voltage Electric resistance Electric conduction Electric charge Electric capacity Power Sound pressure level Time

Angular measurement

1 rad Length inch 1 in

= =

360 degrees 2
25.4 mm

Trigonometry
sin =
opposite hypotenuse adjacent hypotenuse opposite adjacent

cos =

tan =

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SI prefixes
Table 8 Summary of the main prefixes
Prefix Mega Kilo Hecto Deca Deci Centi Milli Micro Designation M K H Da D C M meaning (multiplication factor) 1000000 1000 100 10 0.1 0.01 0.001 0.000001 expressed as a power of 10 106 103 102 101 10-1 10-2 10-3 10-6

Mathematical symbols
Table 9 Summary of the main mathematical symbols symbol or sign Meaning
= < > + x or * : or or /

use
a=b ab ab a<b a>b ab ab a+b ab a x b or a * b or ab a : b or

equal to not equal to approximately equal to smaller than bigger than smaller than or equal to bigger than or equal to Add Subtract Multiply Divide Infinite Angle Triangle sigma or sum sign corresponds to

a or a/b b

ABC ABC (x -)2 1 cm 25 N

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Pressure conversion factors

Table 10 Some pressure conversion factors

Process symbols
Table 11 Summary of process symbols

letter E F G H L M P Q S T W X

description electric variables or heat exchanger mass (volume) flow position (distance, length, position) hand-operator level motor or mixer pressure quality speed or frequency temperature weight or force unclassified variables

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