Pump Training Course

Prepared by / Eng. Ahmed Tolba

PETROMAINT ,AMOC Site
 The Main purpose of pumps

Pumps are used to move liquids

• From a lower pressure system to higher
pressure
• From a lower elevation to higher elevation
• From one place to another place at
different/same elevation and pressure
 The Main purpose of pumps

Pumps are used to move liquids

• Pumps add pressure energy to over come
1. elevation needs ( potential energy).
2. Frictional losses .
• Increase the fluid flow rate.
Pumps Main Categories
‫مقارنه بين المضخات الديناميكية والطلمبات موجبه االزاحة‬
‫وجه المقارنة‬ ‫المضخة الديناميكية‬ ‫المضخة الإيجابية االزاحه‬

‫سرعة الدوران‬ ‫عالية‬ ‫منخفضة‬

‫الحجم‬ ‫صغير وبالتالي الوزن اقل والثمن اقل‬ ‫كبير‬

‫تأكل األجزاء‬ ‫تأكل أجزاءها بسرعة اقل الن الخلو‬ ‫تتآكل أجزاءها بسرعة اكبر‬
‫صات بين األجزاء المتحركة كبير نسبيا‪.‬‬
‫التصرف‬ ‫تعطي تصرف محدد عند سرعة ثابتة يرتبط التصرف والضاغط والسرعة معا‪،‬‬
‫ومعدالت التصرف عالية تصل إلي‬ ‫ومعدالت التصرف تصل إلي ‪25‬‬
‫‪ 400000‬لتر‪/‬دقيقة ولكن عند ضغوط‬ ‫لتر‪/‬دقيقة‬
‫محدودة‬
‫الضغط‬ ‫اقل ‪ ،‬ويصل الى ‪ 200‬بار‬ ‫يعتمد على قدرة المحرك ومدى تحمل‬
‫أجزاء المضخة واألنابيب للضغط لذلك‬
‫تزود بصمام أمان‪ ،‬يصل الضغط الى‬
‫‪ 600‬بار‬
‫التشغيل‬ ‫تمتاز بأنها ذاتية التحضير ولكن ال بد من غالبا تحتاج إلي تحضير لكي تمتلئ‬
‫المضخة بالماء قبل بدء التشغيل‬ ‫استخراج الهواء والغازات منها قبل‬
‫التشغيل‬
‫األداء‬ ‫يعتمد االرتفاع في ضغط الماء علي أبعاد يتأثر الضغط كثيرا بمعدل التصرف‬
‫المضخة وسرعتها وال يتأثر الضغط‬
‫كثيرا بمعدل التصرف‬
Pump Selection Guide
 Centrifugal Pumps Theory
The key idea is that the energy created by
the centrifugal force is kinetic energy.
The amount of energy given to the liquid
is proportional to the velocity at the
edge or
vane tip of the impeller. The faster the
impeller revolves or the bigger the
impeller is,
then the higher will be the velocity of the
liquid at the vane tip and the greater
the energy
imparted to the liquid.
 Centrifugal Pumps Theory
A centrifugal pump is one of the simplest pieces of equipment in any
process plant. Its purpose is to convert energy of a prime mover (a
electric motor or turbine) first into velocity or kinetic energy
and then into pressure energy of a fluid that is being pumped.
The energy changes occur by virtue of two main parts of the pump,
the impeller and the volute or diffuser. The impeller is the
rotating part that converts driver energy into the kinetic energy.
The volute or diffuser is the stationary part that converts the
kinetic energy into pressure energy.
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.
 Centrifugal Pumps Theory
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.
 Conversion of Kinetic Energy to
Pressure Energy
• The key idea is that the energy created by
the centrifugal force is kinetic energy.
• The amount of energy given to the liquid is
proportional to the velocity at the edge or
vane tip of the impeller.
• The faster the impeller revolves or the bigger
the impeller is, then the higher will be the
velocity of the liquid at the vane tip and the
greater the energy imparted to the liquid.
• The first resistance is created by the pump
volute (casing) that catches the liquid and
slows it down.
• In the discharge nozzle, the liquid further
decelerates and its velocity is converted to
pressure according to Bernoulli’s principle.
• Therefore, the head (pressure in terms of
height of liquid) developed is approximately
equal to the velocity energy at the periphery of
the impeller expressed by the following well-
known formula:
v 2
H 
2g

A pump does not create pressure, it only provides flow.

Pressure is a just an indication of the amount of
resistance to flow.
 Centrifugal Pumps Construction
1. Rotating Parts
1. Impeller
2. Shaft,(Shaft Sleeves)
2. Stationary Parts
1. Casing, Casing cover.
2. Sealing Device.
3. Bearing ,Bearing Housing.
 Impellers
The purpose of the
Impeller is to give
the fluid high
KINETIC ENERGY at
the impeller exit
 Impeller Construction
1. Impeller (Suction)eye
2. Blades
3. Cover and shroud.
4. Wear rings.
5. Balance Devices.
 Impeller types
1. According to the shrouds
and the covers
1. Closed Impeller.
2. Opened Impeller.
3. Semi Opened Impeller.
Close type :- used
with fluid that
has a small
percent of
impurities
(pure fluid)
Open type :-
used with
fluid that
have high
percent of
impurities
Semi open or
semi
closed:-
used with
fluid that
has medium
percent of
impurities
 Impeller types
1. According to the suction ports.
1. Single suction.
2. Double suction.
 Impeller types
1. According to the suction
ports.
1. Single suction.
2. Double suction.
 Blades
1. Single Blade
2. Multi Blades
 Wear rings
• Wear ring
provides an
easily and
economicall
y renewable
leakage joint
between the
impeller and
the casing.
 Balance Devices
Imbalance Reasons
Balance Holes
Balance Drum
Balance Disk
Balance disk and drum
 Casing
The purpose of the
Casing is to contain
the fluid from the
impeller exit and
convert the KINETIC
ENERGY into
pressure energy.
 Types of Casing
1. Spiral Casing (Volute).
1. Single.
2. Double
2. Diffuser .
Volute
Diffuser
Diffuser
 Shafts
• The basic function 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 rotating
• and stationary parts. The loads involved are (1) the
torques, (2) the weight of the parts,
• and (3) both radial and axial hydraulic forces. In designing
a shaft, the maximum allowable
• deflection, the span or overhang, and the location of the
loads all have to be considered,
• as does the critical speed of the resulting design
 Shaft sleeves
• Shaft Sleeves Pump shafts are usually protected
from erosion, corrosion, and wear at
• seal chambers, leakage joints, internal bearings,
and in the waterways by renewable
• sleeves. Years ago, the most common shaft sleeve
function was to protect the pump shaft
• from wear at stuffing box packing. However, most
pumps today use mechanical seals, not
• packing. Furthermore, most mechanical seals today
are cartridge mechanical seals, and
• the sleeve is part of the seal package.
 Sealing
Static sealing
Labyrinth
Carbon rings
Oil seals(lip Seals)
Packing
Lantern rings
Mechanical seal
• Mechanical seals can generally be divided into two main
design types
• Pusher seals
• Bellows seals.
Pusher seals have one of the seal faces mounted on a flexible
gasket that allows the face to move axially .
Bellows seals have one of the seal faces mounted in a bellows
assembly that provides a pressure boundary while allowing
for axial face motion.
Bellows designs vary from elastomeric construction to more
complex welded metal designs. Each of these designs has
advantages for specific applications
 The flexible element rotates with the
shaft
• Advantages: Good
circulation around spring
components, tends to be
self-cleaning
• Disadvantages: Potential
for erosion of seal
components, less tolerant
of misalignment
The flexible element is stationary with
the gland
• Advantages: More tolerant
of misalignments,
able to operate at higher
shaft speeds
• Disadvantages: Requires
more radial space,
may be more difficult to
design adequate flush
 Multiple Seal Arrangements
Pressure
Multiple Seal Arrangements
 Relationship between Head and
Capacity
• The curve is used by engineers to
determine the suitability of a given pump
for a particular duty.

H
H
HEAD

Q Q Capacity
 PERCENT OF HEAD AT DESIGN POINT

EFF
BHP
HEAD

PERCENT OF DESIGN FLOW

Performance Curve

PERCENT OF BHP AT DESIGN POINT

Radial Flow Pump

PERCENT OF BEST EFFICIENCY

 PERCENT OF HEAD AT DESIGN POINT

EFF
BHP
HEAD

PERCENT OF DESIGN FLOW

Performance Curve

PERCENT OF BHP AT DESIGN POINT

Mixed Flow Pump

PERCENT OF BEST EFFICIENCY

Performance Curve
Axial Flow Pump
 System Curve

It is the relationship between flow and hydraulic losses in

a system.
The point where the pump operates on its curve is
dependent upon the characteristics of the system In
which it is operating.
By plotting the system head curve and pump curve
together, it can be determined:

1. Where the pump will operate on its curve.

2. What changes will occur if the system head curve or the pump
performance curve changes.
System Curve

NO STATIC HEAD - ALL FRICTION

System Curve
POSITIVE STATIC HEAD
System Curve
NEGATIVE (GRAVITY) HEAD
System Curve
MOSTLY LIFT- LITTLE FRICTION HEAD
Net Positive Section Head and Cavitation (NPSH)
it is an analysis of energy conditions on the suction side of a pump to
determine if the liquid will vaporize at the lowest pressure point in the
pump.

Net Positive Section Head and Cavitation (NPSH)

NPSH Required
The NPSH Required is the positive head in feet absolute required at the
pump suction to overcome all pressure drops in the pump and maintain
the majority of the liquid above its vapor pressure.
The NPSH Required varies with speed and capacity within any
particular pump. Pump manufacturer's curves normally provide this
information.
Net Positive Section Head and Cavitation (NPSH)
NPSH Available
Cavitation
It takes place as the following:
1. The pressure of the liquid is reduced to a value equal to or
below its vapor pressure.
2. The liquid begins to boil and small vapor bubbles or pockets begin to
form.
3. As these vapor bubbles move along the impeller vanes to a higher
pressure area above the vapor pressure, they rapidly collapse.
4. As these vapor bubbles move along the impeller vanes to a higher
pressure area above the vapor pressure, they rapidly collapse.
5. In high suction energy pumps, the collapses are generally high
enough to cause minute pockets of fatigue failure on the impeller
vane surfaces.
How to stop vaporization Cavitation
By increasing the suction head
• Raise the liquid level in the tank
• Elevate the supply tank.
• Put the pump in a pit.
• Reduce the piping losses.
• Retrofit the pump with a higher specific speed impeller.
• Install a booster pump or inducer.
• Pressurize the tank.
• Be sure the tank vent is open and not obstructed.
Some vents can freeze in cold weather.
How to stop vaporization Cavitation
By lowering the fluid inlet temperature
• Injecting a small amount of cooler fluid at the suction is often practical.

• Insulate the suction piping from the sun's rays.

• Be careful of discharge re-circulation and vent lines re-circulated to the

pump suction; they can heat up the suction fluid.
How to stop vaporization Cavitation
By decrease the fluid velocity
• Remove obstructions in the suction piping.
•
• Do not run the impeller too close to the pump cutwater.
•
• Reduce the speed of the pump.

• Reduce the capacity of the pump.

• Do not install an elbow too close to the pump suction.

How to stop vaporization Cavitation
By reducing the net positive suction head required (NPSHR)
• Use a double suction pump. Double suction designs can reduce the net
positive suction head required (NPSHR) by as much as 27%, or in some
cases it will allow you to raise the pump speed by 41%.

• Use a lower speed pump.

• Use a pump with a larger impeller eye opening. If possible install an

inducer. These inducers can cut net positive suction head required
(NPSHR) by almost 50%.

• Use several smaller pumps. Three half-capacity pumps can be cheaper

than one large pump plus a spare. This will also conserve energy at lighter
loads.
Performance of Centrifugal Pumps

Series Operation of Centrifugal Pumps

..\PDFs\news_vol7_i4_apr.pdf •
Parallel Operation of Centrifugal Pumps
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