Power Consuming Fluid Machines

BY
Dr. P M V Subbarao
Mechanical Engineering Department
I I T Delhi

Small Things Make Huge Events possible!!!

 Power Consumption for Human Needs

Few basic amenities responsible Industrialization & Urbanization.

One of the important need responsible for Motive Power.
Pumps, Fans, Blower, Compressors etc.
Fluid Machines which need mechanical Power.
Mechanical power of a shaft is converted into Fluid Power.
Significant feature : Rise in Pressure or Position of the fluid.
Volume changes are very small to very high.
Main Goals: Maximization of Efficiency and Maximization of Specific
fluid handling.
 Power Consuming Machines
Qcv WCV
First Laws for SG in SSSF Mode:

mi me
V2 V2
Q CV mi h gZ m e h gZ W CV
2 i 2 e

V2 V2
Q CV mi u pv gZ m e u pv gZ W CV
2 i 2 e

Always a negative value of Power.

Heat transfer is discouraged
Ideal Machines are Reversible Isothermal.
Relatively Better are Isentropic machines.
Practically better are Polytropic Low frictional Machines.
 Polytropic Process in Fluid Machines

Shaft power Disc Power Fluid Power.

2TN
P Td Td m vdp or m pdv
60

Flow Machines & Non Flow Machines.

Compressible fluids & Incompressible Fluids.
Rotary Machines & Reciprocating Machines.
 Pump
Rotate a cylinder containing
fluid at constant speed.
Supply continuously fluid
from bottom.
See What happens?
Flow in

Any More Ideas?

 Definition of A Pump
1. Physiology. A molecular mechanism for the active transport of
ions or molecules across a cell membrane.
2. Physics. Electromagnetic radiation used to raise atoms or
molecules to a higher energy level.
3. Informal. The heart.
 Definition of A Pump

1. A pump stands
essentially as the earliest
form of machine for
substituting natural
energy for human
physical effort.
2. A machine or device for
raising, compressing, or
transferring
incompressible fluids.
Centrifugal Pump
Axial Flow Pump
The role of A Pump in a Fluid Handling System

Delivery Head

Elevation or Static Head

Suction Head
 Basic Pump Terminology
Suction Head or Lift: A pump is expected to
suck fluid from a lower elevation.
Delivery Head: Pump should transport the
fluid to an higher elevation.
The entire fluid will be enclosed in a piping
system.
A finite mass flow rate in a finite diameter
pipe is possible only if fluid attains a
velocity.
Fluid requires kinetic power to possess
velocity.
Suction Velocity: Vs: Velocity of flow in
suction pipe.
Delivery Velocity: Vd
Any fluid flow is associated with frictional
energy loss.
A pump which can supply an excess of
friction loss can only satisfy the pumping
requirements.
 Relation of Pressure to Elevation In a static liquid (a body of liquid at
rest), the pressure difference between any two points is in direct
proportion only to the vertical distance between the points.
Calculate this pressure difference by multiplying the vertical distance
by the density (or vertical distance x density of water x specific gravity
of the fluid).
Static Head
The hydraulic pressure at a point in a fluid when the liquid is at rest.
Friction Head
The loss in pressure or energy due to frictional losses in flow.
Discharge Head
The outlet pressure of a pump in operation.
Total Head
The total pressure difference between the inlet and outlet of a pump in
operation.
Suction Head
The inlet pressure of a pump when above atmospheric pressure.
Suction Lift
The inlet pressure of a pump when below atmospheric pressure.
Actual Burden on A Pump
Kinetic power mvd2/2
Frictional loss in de;overy piping

Pump power or System power:

Vd2
Ppump m gH static,t gh fs gh fd
2

Vd2
Ppump m g H static ,t h fs h fd
2g

Kinetic power mvs2/2

Frictional loss in suction piping
 Vd2
Ppump m g H static ,t h fs h fd
2g

Ppump Vd2

H static,t h fs h fd
mg 2g

Pump Head or System Head:

Ppump Vd2

H static,t h fs h fd
mg 2g
Classification of Pumps
 Centrifugal Pumps
Centrifugal pumps: the fluid enters the centre of a rotating
impeller, where it is accelerated along the impeller blades.
The fluid gains kinetic energy which is converted in pressure
energy in the diffuser.
The performance of centrifugal pumps depends on a big
number of parameters and a satisfactory solution to face with
the problem is dimensional analysis.
Two explicit variables are of our interest in the characteristics
of pumps: the pressure rise and the power consumption.
It is expected the pressure rise, P (N/m 2), depends on:
Impeller size, D (m);
rotation rate, N (s -1);
volumetric flow rate, Q (m3/s);
fluid properties: density (kg/m3) and viscosity (kg/ms);
Axial Flow Pumps
 P f D, N , Q, ,

P Q ND 2
f ,
N D
2 2
ND
3

P
Differential head of pump:
H
g

Hg Q ND 2
f ,
2
N D 2
ND
3

 Hg
2 2
, CH = head coefficient
N D
Q
, CQ = flow coefficient
3
ND

ND 2
, Re = Reynolds number

C H f CQ , Re
A similar analysis may be carried out for the power consumption of
the pump, P:

P f D, N , Q, ,

P Q ND 2
f , C p
N D
3 5
ND
3

C p g CQ , Re
 elec mech therm

Electrical Mechanical Thermodynamical

PT = VI
P = PT elec mech therm = PT = P Q

gHQ C H C Q

P CP
 Q ND 2
f , f (C Q , Re)
ND
3

Constant impeller Constant impeller

diameter speed

Q1 N 1 Q1 D1
Capacity

Q2 N 2 Q2 D 2

H 1 N1 H 1 D1
2
2
Head

H2 N2 2 H 2 D2 2

N1 P1 D1
3 3
Power P1

P2 N2 3 P2 D2 3
Affinity Laws for Centrifugal Pumps
Head Vs Flow Rate & Selection of Operating Point

H f K1 K 2Q 2
PUMPS Running Parallel
 Operation of Pumps at Low Flows
Just like there are many forms of cavitation, each demanding a unique
solution, there are a number of unfavorable conditions which may occur
separately or simultaneously when the pump is operated at reduced flows.
Some include:
Cases of heavy leakages from the casing, seal, and stuffing box
Deflection and shearing of shafts
Seizure of pump internals
Close tolerances erosion
Separation cavitation
Product quality degradation
Excessive hydraulic thrust
Premature bearing failures
Each condition may dictate a different minimum flow low requirement.
The final decision on recommended minimum flow is taken after careful
techno-economical analysis by both the pump user and the manufacturer.
 Cavitation

As the liquid flows onto the impeller of the pump it is accelerated and
initially its pressure falls (Bernoulli).
The pressure subsequently increases as the fluid leaves the impeller
and as the kinetic energy is recovered in the volute chamber.
If the pressure of the liquid falls below the vapour pressure, P v, the
liquid boils, generating vapour bubbles or cavities-cavitation.
The bubbles are swept into higher pressure regions by the liquid flow,
where they collapse creating pressure waves and cause mechanical
damage to solid surfaces.
Moreover, pump discharge head is reduced at flow rates above the
cavitation point.
Operation under these conditions is not desirable and damages the
equipment.
 NPSH (Net Pressure Suction Head).

Net Positive Suction Head Required, NPSHr

NPSH is one of the most widely used and least understood terms
associated with pumps. Understanding the significance of NPSH is
very much essential during installation as well as operation of the
pumps.
Pumps can pump only liquids, not vapors
Rise in temperature and fall in pressure induces vaporization
NPSH as a measure to prevent liquid vaporization
Net Positive Suction Head (NPSH) is the total head at the suction
flange of the pump less the vapor pressure converted to fluid column
height of the liquid.
 NPSHr is a function of pump design
NPSH required is a function of the pump design and is determined based on
actual pump test by the vendor.
As the liquid passes from the pump suction to the eye of the impeller, the
velocity increases and the pressure decreases.
There are also pressure losses due to shock and turbulence as the liquid
strikes the impeller.
The centrifugal force of the impeller vanes further increases the velocity and
decreases the pressure of the liquid.
The NPSH required is the positive head in feet absolute required at the pump
suction to overcome these pressure drops in the pump and maintain the
majority of the liquid above its vapor pressure.
The NPSH is always positive since it is expressed in terms of absolute fluid
column height.
The term "Net" refers to the actual pressure head at the pump suction flange
and not the static suction head.

 NPSHr increases as capacity increases

The NPSH required varies with speed and capacity within any particular
pump.
The NPSH required increase as the capacity is increasing because the
velocity of the liquid is increasing, and as anytime the velocity of a liquid
goes up, the pressure or head comes down.
Pump manufacturer's curves normally provide this information.
The NPSH is independent of the fluid density as are all head terms.

Note: It is to be noted that the net positive suction head required (NPSHr)
number shown on the pump curves is for fresh water at 20C and not for
the fluid or combinations of fluids being pumped.
 Net Positive Suction Head available, NPSHa

Net Positive Suction Head Available is a function of the system in

which the pump operates.
It is the excess pressure of the liquid in feet absolute over its vapor
pressure as it arrives at the pump suction, to be sure that the pump
selected does not cavitate.
It is calculated based on system or process conditions
 NPSHa in a nutshell

NPSHa = Pressure head + Static head - Vapor pressure head of your

product Friction head loss in the piping, valves and fittings.
All terms in feet absolute
In an existing system, the NPSHa can also be approximated by a gauge on
the pump suction using the formula:
NPSHa = hpS - hvpS hgS + hvS
hpS = Barometric pressure in feet absolute.
hvpS = Vapor pressure of the liquid at maximum pumping temperature, in
feet absolute.
hgS = Gauge reading at the pump suction expressed in feet (plus if above
atmospheric, minus if below atmospheric) corrected to the pump
centerline.
hvS = Velocity head in the suction pipe at the gauge connection, expressed
in feet.
NPSHa should always be greater than NPSHr
Performance of A Damaged Impeller
Performance with Reduced Throat Area
Pump with Minor Wears
Pump with Excessive Wear
Pump with rough impeller & casing
Pump with lower NPSH