Presentation on Horizontal Centrifugal Pump

Centrifugal pump
Overview
1. Introduction & Principal of centrifugal pump 2. Main part of centrifugal pump 3. Efficiency of centrifugal pump 4. Minimum starting speed of centrifugal pump 5. Working mechanism of centrifugal pump 6. Advantage & disadvantage of centrifugal pump 7. Multistage centrifugal pump 8. Characteristic of single stage centrifugal pump 9. Cavitation 10. Power & efficiency calculation 11. Pump selection 12. Order of preference 13. conclusion

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CENTRIFUGAL PUMPS
A centrifugal pump is simply a shaft, suspended on bearings with an impeller attached to one end. The impeller is encased in a housing that is filled with a liquid. As the shaft is rotated, centrifugal force expels the liquid out through an orifice, where it is typically piped into a process or another collection point. As the expelled liquid exits the case, additional liquid is added to the case so that a flow develops. That is basically how a centrifugal pump works. The next slide shows a photograph of a typical End Suction Centrifugal Pump.

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PUMP SHAFT

IMPELLER

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A LIQUID IS SUPPLIED TO THE PUMP SUCTION CENTRIFUGAL FORCE EXPELS THE LIQUID OUT FROM THE IMPELLER

AS THE PUMP SHAFT ROTATES

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CENTRIFUGAL PUMPS
The force of the expelled liquid creates pressure. This liquid under pressure will seek areas of lower pressure. This is a known physical principle of hydraulics. Some form of seal must be applied to keep liquid from leaking around the shaft at the point where it enters the case to drive the impeller. This is where our mechanical seal comes into play. Take a look at the same pump again. Can you see the mechanical seal behind the impeller?

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WORKING MECHANISM OF A CENTRIFUGAL PUMP

Simplest piece of equipment in any process plant. Energy changes occur by virtue of impeller and volute Liquid is fed into the pump at the center of a rotating impeller and thrown outward by centrifugal force The conversion of kinetic energy into pressure energy supplies the pressure difference between the suction side and delivery side of the pump
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CENTRIFUGAL PUMPS
WHAT IS CENTRIFUGAL PUMP? WHAT ARE THE MAIN COMPONENTS OF A CENTRIFUGAL PUMP WORKING MECHANISM OF A CENTRIFUGAL PUMP ADVANTEGAES AND DISADVANTAGES OF CENTRIFUGAL PUMPS

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Label the pump

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WHAT IS CENTRIFUGAL PUMP?

Convert the mechanical energy into hydraulic energy by centrifugal force on the liquid Constitute the most common type of pumping machinery Used to move liquids through a piping system

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Label the pump

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MAIN PARTS OF CENTRIFUGAL PUMP

I. II. III. IV.

IMPELLER CASING SUCTION PIPE DELIVERY PIPE

Has two main components: 1. Stationary components, casing, casing cover and bearings 2.. Rotating components, impeller and shaft

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Pump Impeller
Direction of rotation

Vanes

Centrifugal Pumps

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Typical single suction impeller

Centrifugal Pumps

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Single suction impeller

Centrifugal Pumps

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Impeller Types
Open Semi-open Closed - Single suction - Double suction Non-clogging Axial flow Mixed flow
Centrifugal Pumps

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SEALING THE LIQUID

Early packing styles did not seal very well. In fact, until recently, braided packing styles required varying amounts of leakage for lubrication. If leakage was not permitted to occur, the packing would literally burn up and often cause severe damage to the pump shaft. Even with adequate leakage for lubrication, pump shaft wear was a commonly expected occurrence and as the shaft wore it would in turn, cause poor shaft packing life. As leakage becomes more excessive, the gland is tightened to reduce leakage.

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What is going on inside a packed stuffing box?

HOW A STUFFING BOX SHOULD LOOK WHEN IT IS COMPLETELY PACKED

How do solids get into the packing?

LANTERN RING MUST BE POSITIONED BELOW FLUSH INLET TO ALLOW MAXIMUM RESULTS FROM FLUSH FLUID: FLUSH PRESSURE SHOULD BE 10 TO 15 PSI (0.8 TO 1 BAR) OVER MAXIMUM STUFFING BOX PRESSURE.

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Lantern Ring Position

Bottom of Stuffing Box

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Packing needs to compress to work.

Due to the compressibility of the packing the gland force is not effectively transferred through each packing ring.

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The lack of compression transmitted to the bottom rings Causes them to run loose. This allows solids from the process fluid being pumped to accumulate between the sleeve and packing.

Conventional flush arrangements are not effective at keeping solids out of packing. This is a major source of LOGO packing and30 sleeve wear.

Lantern Ring Position

Bottom of Stuffing Box

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Sleeve damaged by stock trapped under the bottom packing rings

Bottom of Stuffing LOGO Box

Condition of Shaft Sleeve After Two Years Run Time

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CENTRIFUGAL PUMPS
First centrifugal pump invention by 1475 in a treatise by the Italian Renaissance engineer The centrifugal pump work on the principal of forced vortex flow

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EFFICIENCY OF CENTRIFUGAL PUMP

1.MANOMERIC EFFICIENCY

2.Mechanical efficiency

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3.Overall efficiency

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minimum starting speed of centrifugal pump

The expression is given by:

Where
Starting speed =N Manometric efficiency = whirl velocity = diameters =

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ADVANTAGE OF CENTRIFUGAL PUMP

Advantages

i. ii. iii. iv. v.

Simple in construction and cheap Handle liquid with large amounts of solids No metal to metal fits No valves involved in pump operation Maintenance costs are lower
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DISADVANTAGE OF CENTRIFUGAL PUMP

Disadvantages

i. Cannot handle highly viscous fluids efficiently ii. Cannot be operated at high heads iii. Maximum efficiency holds over a narrow range of conditions
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Multistage Centrifugal Pump

A centrifugal pump that consists of two or more

impellers mounted on the same shaft or on different shafts is called the MULTISTAGE centrifugal pump.
Multistage pumps are employed to accomplish the following two important functions.
1. To produce a high head
2. To develop a high discharge

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1. To produce a high head

If a high head is to be developed the impeller are connected in series or same shaft

Total head developed= n Where n = no. of impellers in series

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2.to discharge a large quantity of liquid

If discharging large quantity of liquid the impeller are connected in parallel

Total discharge = n Q

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characteristic curves of single stage centrifugal pump

1. Main characteristic curves 2. Operating characteristic curves 3. Constant efficiency or muschel curves

1.Main characteristic curves

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2.Operating characteristic curves

If speed is kept constant ,the variation of manometric head ,power and efficiency with respect to discharge

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3.constant efficiency curve

Head vs efficiency and efficiency vs discharge

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Preparation for start-up

After the above-mentioned checks have been completed, the stage is set for the start-up. The sequence from now is: Pump suction valve is opened slowly and all the joints are checked for any leakage. The pump casing is opened to vent any vapor. This can be tricky in case of flashing hydrocarbons so it has to be done a numerous times. If the pumping temperature is high, the pump should be allowed to warm up. For multistage pumps with long rotors, it would be a good idea to keep rotating the rotor 180 after every 30 min. The sealant and cooling water lines are opened and circulation of the liquids is insured. The opening of the discharge valve is dependent on the type of centrifugal pump. For low specific speed pumps, it is kept closed and opened for higher specific speed pumps. This prevents overloading of the motor drive. Once these checks are made, it is time to confirm if the electrical supply has been energized. The pump is started!
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Pump in operation
Once the pump has started, check the discharge pressure and insure it is along expected lines. If the pressure does not come up, the most probable reason is that the pump has not been primed properly. The pump should be stopped and re-primed. In case of a low specific speed pump, the discharge pressure falls when the discharge valve is opened. The flow rate should be confirmed. Vibration measurements of the entire train should be taken with a data collector. The overall and filtered readings should be recorded. The frequency plots be recorded and stored. These should be studied for possible defects.
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Pump in operation
The overall vibration reading can vary with the point of operation on the pump curve. Therefore, it is recommended to record vibration reading and frequency plots at the 4 or 5 operating points that include the normal and rated points. The mechanical seal leakage should be confirmed. It is possible that there could be leakage in the initial stages, which may settle down after wear-in. The bearing temperatures of both the pump and motor/turbine should be not more than 1020 above ambient. A temperature higher than this is an indicator of bearing in distress unless they are of the greased type. In that case, the most probable cause is over greasing. A vibration or a shock pulse analysis can confirm this fact. In such a case, it is better to wait for 24 h and allow the flowout of excess grease. Once steady state has been achieved, it is recommended to carry out a performance check of the pump and know its efficiency. It is recommended that this should be plotted on the pump characteristic curves. 48 LOGO

Performance monitoring

The following six parameters should be monitored to understand how a pump is performing: Suction pressure Discharge pressure Flow Pump Speed Efficiency Power
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Shut off Head

The highest head pressure that the pump will develop is called the "shut-off head" of the pump. When a pump reaches shut-off head, the flow from the pump also drops to 0 gpm. This is a valuable piece of information for conducting a quick check of the pump's performance. If the pump cannot generate its rated shut-off head, the pump curve is no longer of any real value to the operator. A loss of shut-off head is probably caused by an increase in recirculation inside the pump due to worn wear rings or worn impellers. There is another factor that might affect the shut-off head of the pump. The pump curve assumes that the pump is running at design speed. If a pump that is supposed to spin at 1750 rpm and it is only turning at 1700 rpm, the shut off head will be lower than the pump curve too. However, if the pump speed is checked with a tachometer and found to be correct, the wear rings or impellers are probably in need of repair.
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Shut off From the operations/ maintenence point of view, operating at the extreme left on the pump curve for extended periods of time can cause serious problems with the pump seal and the pump itself(due to temperature rise of the fluid and increased radial thrust).

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Shut off head

From a pump operation point of view, in water treatment plants and pumping stations we always start the pump up against a 95-100% completely closed valve and then slowly fully open it up. This allows the water to be pumped into a distribution system slowly at first. This protects the distribution system from sudden surges. On pump deenergization, the discharge valve is slowly closed to 95% closed and the pump is then de-energized. The valve continues to 100% closed. This again prevents surging and water hammer in the distribution system The shut in head is the maximum pressure your motorized discharge valve operator has to be able to overcome and the motorized valve operator manufacturer needs to know this. The same goes for the valve itself

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COMMON OPERATIONAL PROBLEMS

The operator should check all pumps and motors every day to insure proper operation. After spending a certain amount of time with these pumps and motors an operator should be able to tell just by listening to them whether they are working properly. The vast majority of pumping problems are a result of one of the three following operational problems.

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CAVITATION
One of the most serious problems an operator will encounter is cavitation. It can be identified by a noise that sounds like marbles or rocks are being pumped. The pump may also vibrate and shake, to the point that piping is damaged, in some severe cases. Cavitation occurs when the pump starts discharging water at a rate faster than it can be drawn into the pump. This situation is normally caused by the loss of discharge head pressure or an obstruction in the suction line. When this happens, a partial vacuum is created in the impeller causing the flow to become very erratic. These vacuum-created cavities are formed on the backside of the impeller vanes.

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Cavitation
As the water surges into the impeller, the partial vacuum is destroyed and the cavities collapse, allowing the water to slam into the impeller vanes. These cavities form and collapse several hundred times a second. As they collapse, they draw the water behind them into the impeller at about 760 mph! The impact created by the water slamming into the impeller is so great that pieces of the impeller may be chipped away.

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What to do?
When cavitation occurs, immediate action must be taken to prevent the impeller, pump and motor bearings, and piping from being damaged. Cavitation can be temporarily corrected by throttling the discharge valve. This action prevents damage to the pump until the cause can be found and corrected. Remember that the discharge gate valve is there to isolate the pump, not control its flow. If it is left in a throttled position the valve face may become worn to the point that it won't seal when the pump must be isolated for maintenance. Butterfly valves can be throttled, but it is still not a good idea to throttle a pump with an isloation valve.
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Common Cause of Pump Failures

Poor maintenance Poor operations

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PUMPING PROBLEM
Cavitation Cavitation is defined as the phenomenon of formation of vapour bubbles and sudden collapsing of vapour bubbles effect of cavitation 1.The metallic surface damage and cavities are formed on surface 2.Due sudden collapse of vapour bubble .considerable noise and vibration are produce 3.The efficiency of pump decreases due cavitation To avoid cavitation NPSH

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The pump is not producing enough head to satisfy the application

There is something physically wrong with the motor. Check the bearings etc. Check the voltage of the electric motor. It may be too low. The impeller is damaged or clogged The shaft is running backwards because of a wiring problem.

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The pump is not producing enough head to satisfy the application

The pump is running backwards because the discharge check valve is not holding and system pressure is causing the reverse rotation. This is a common problem with pumps installed in a parallel configuration. Check valves are notoriously unreliable. A bubble is trapped in the eye of the impeller. The eye is the lowest pressure area. When this bubble forms it shuts off all liquid coming into the pump suction. This could cause the pump to lose its prime.
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The pump is not producing enough head to satisfy the application

You cannot vent a running pump because centrifugal force will throw the liquid out the vent leaving the air trapped inside. Air is coming directly into the pump. This happens with a negative pressure at the suction side

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THE PROBLEM IS ON THE SUCTION SIDE OF THE PUMP. THE PUMP COULD BE CAVITATING.

Air is entering the suction piping at some point.

Air is being pumped into the suction piping to reduce cavitation problems Fluid returning to the sump is being aerated by too far a free fall. The return line should terminate below the liquid level. The fluid is vortexing at the pump inlet because the sump level is too low and the pump capacity is too high. Air is coming into the system through valves above the water line, or gaskets in the piping flanges. The liquid source is being pumped dry. If this is a problem in your application you might want to consider a self priming pump in the future.

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A globe valve has been substituted for a gate valve in the suction piping. The loss of head in a globe valve is many times that of a gate valve. The piping inlet is clogged. A filter or strainer is clogged or covered with something. Intermittent plugging of the suction inlet.
Loose rags can do this.
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The pump inlet temperature is too high.

Look for this problem in boiler feed pump applications.
The sun is heating the inlet piping. The piping should be insulated to prevent this problem. The operating temperature of the pumped fluid has been increased to accommodate the process requirements. A discharge recirculation line is heating the incoming fluid. You should direct this line to a reservoir rather than the pump suction.

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Discharge side problems Two pumps are in connected in series. The first pump does not have enough capacity for the second pump. They should be
running at the same speed with the same width impeller. A discharge valve (manual or automatic) is opened too much.

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ADVANTAGES OF CENTRIGUGAL PUMPS

Advantages

Simple in construction and cheap Handle liquid with large amounts of solids No metal to metal fits No valves involved in pump operation Maintenance costs are lower

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DISADVANTAGES OF CENTRIFUGAL PUMPS

Disadvantages

Cannot handle highly viscous fluids efficiently Cannot be operated at high heads Maximum efficiency holds over a narrow range of conditions

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PUMPING PROBLEMS
Cavitation
Reduces the pump capacity Causes metal removal reduced flow loss in efficiency and noise

To avoid cavitation

NPSH

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POWER AND EFFICIENCY CALCULATIONS

The power supplied to the pump:

Where m=mass flow rate, kg/s H= total discharge head, N.m/kg =efficiency
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PUMP SELECTION
The amount of fluid

The properties of the fluid

Type of power supply Cost and mechanical efficiency
of the pump
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Order of Preference

Centrifugal II. Rotary III. Reciprocating

I.

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CONCLUSIONS
1.Centrifugal pump is a kind of machinery used for pumping water through the centrifugal movement 2.positive displacement pumps will always be more efficient than centrifugal pumps due 3. As a conclusion, we had obtained a performance curve at 3 different speed of pump by avariable characteristic. The efficiency of pump have related to the losses mean energy duringthe process. This efficiency will be increase if less loss occurs
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