Marine Auxiliary

Machinery
Chapter 1 Lesson 3
Rotodynamic pumps
By Professor Zhao Zai Li
05.2006
 Learning objectives

After successfully completing this lesson, you

will be familiar with:

1. Different types of rotodynamic pumps

2. The component parts of roto dynamic

pumps

3. Maintenance of rotodynamic pumps

The lesson will end with a test and your score

will be recorded.
Rotodynamic pumps

There are three

different types of
rotodynamic pumps:

Axial-flow pumps

Centrifugal pumps

Mixed flow pumps

Axial-flow Pumps

Introduction
An axial-flow pump uses a screw propelle
to axially accelerate the liquid. The outlet
passages and guide vanes are arranged
to convert the velocity increase of the
liquid into a pressure.As distinct from the
centrifugal pump, the axial flow pump
absorbs the maximum power at zero flow.
Axial-flow Pumps

A mechanical seal prevents leakage

where the shaft leaves the casing.
A thrust bearing of the tilting pad
type is fitted on the drive shaft. The
prime mover may be an electric
motor or a steam turbine.
 Axial-flow Pumps
The axial flow pump is used where large
quantities of water at a low head are
required,or example in condenser circulating.
The efficiency is equivalent to a low lift
centrifugal pump, and the higher speed fs
possible enable a smaller driving motor to be
used.
The axial-flow pump is also suitable for supplementary use in a
condense scoop circulating system, since the pump will offer little
resistance to flow when idling.
With scoop circulation, the normal movement of the ship will draw in
water; the pump would be in use only when the ship was moving slowly
or stopped. The pump is reversible and this, in conjunction with high
capacity flow, makes it suitable for trimming and heeling duties as well.
Axial-flow Pumps

The impeller
The pump casing is of gunmetal for
condenser cooling duties and cast iron
for heeling and trimming pumps. The
impellers are of aluminium bronze
and guide vanes of gunmetal are
arranged immediately after the
impeller, the pump shaft being of
stainless steel.
Quick quiz

Which part of the pump is the screw

propeller?

Click on the screw propeller.

If you are not sure go to the previous

screen to refresh your memory.
 Centrifugal pumps

In this part of the lesson we will take a closer look at Centrifugal pumps
Centrifugal pumps - theory and
characteristics
Centrifugal pump duties are usually for the
movement of large volumes of liquid at low
pressures, although higher pressures can be
achieved with multi-staging.

Energy input

Energy transformations inside the Dump

Velocity and pressure levels Fluid flow

Click on an item to jump to it.

Centrifugal pumps - theory and
characteristics

A centrifugal pump can be further defined as a machine

which uses several energy transformations in order to
increase the pressure of a liquid. The energy input into the
pump is typically the fuel source energy used to power the
driver.
 Centrifugal pumps - theory and
characteristics
 Energy input
 Most commonly, this is electricity used to power an electric motor.
 Alternative forms of energy used to power the driver include high-
pressure steam used to drive a steam turbine.
 Fuel oil used to power a diesel engine.
 High-pressure hydraulic fluid used to power a hydraulic motor.
 Compressed air used to drive an air motor.
 Regardless of the driver type for a centrifugal pump, the input energy
is converted in the driver to a rotating mechanical energy, consisting
of the driver output shaft, operating at a certain speed, and transmitting
a certain torque, or horsepower.
 Centrifugal pumps - theory and
characteristics
The remaining energy
transformations take place
inside the pump itself.
The rotating pump shaft is
attached to the pump impeller,
which rotates in a volute
housing.

The impeller imposes a centrifugal force, which imparts kinetic

energy to the fluid. Kinetic energy is a function of mass and velocity
(K.E = $Sv7.Raising a liquids velocity increases its kinetic energy.
This causes the fluid to accelerate out of the impeller with this
increased velocity.
The volute casing or diffuser provides gradually widening passages
i.e. an expansion of the flow area, which reduces the fluid velocity and
this energy is converted into pressure.
 Centrifugal pumps - theory and
characteristics
Velocity and pressure A particular feature of
levels Fluid flow centrifugal pumps is that the
power absorbed is a minimum
at zero flow, and therefore can
be started up against a closed
valve.
By increasing the size of the
impeller, and/or the speed of
pump rotation, we can achieve
larger pumping rates.
The diagram illustrates that velocity and pressure levels vary as the fluid
moves along the flow path in a centrifugal pump.
 Centrifugal pumps - theory and
characteristics

The fluid flow causes a vacuum to be formed in the pump suction,

which will draw fluid into the impeller suction. Thus fluid flow will
occur from the suction to discharge. The liquid enters the centre or
'eye' of the impeller axially, changes direction and flows radially out
between the vanes.
If the pipeline leading to the pump inlet contains a non-condensable
gas such as air, then the pressure reduction at the impeller inlet merely
causes the gas to expand, and suction pressure does not force liquid
into the impeller inlet
 Centrifugal pumps - theory and
characteristics
 Consequently, no pumping action can occur unless this non-
condensable gas is first eliminated, a process known as
priming the pump.
 Hence we need a fluid flow through the impeller in order to
achieve a vacuum. Thus when these pumps are not primed, or
loose suction during operation they will not self-prime
themselves. In order to prime or re-prime these pumps we can
use a priming system
 If vapours of the liquid being pumped are present on the
suction side of the pump, this results in Cavitation, which can
cause loss of prime or even serious damage to the pump.
 Centrifugal Pumps - Cavitation

When the pressure falls below the vapour pressure of the liquid at a
given temperature, boiling occurs and small bubbles of vapour are formed.
These bubbles will grow in the low-pressure area and implode when they
are transported to an area of pressure above vapour pressure. The term
given to this local vaporisation of the fluid is Cavitation.
 Centrifugal Pumps - Cavitation
 The collapsing of the bubbles is the area of Cavitation we are
concerned with, as extremely high pressures are produced, which
causes noise and erosion of the metal surface.

 The area of pipeline ...

 This cavitation effect...

 To reduce cavitation ...

 Click on an item to jump to it.

 Centrifugal Pumps - Cavitation

When the pressure falls below the vapour pressure of the liquid at a
given temperature, boiling occurs and small bubbles of vapour are
formed. These bubbles will grow in the low-pressure area and implode
when they are transported to an area of pressure above vapour pressure.
The term given to this local vaporisation of the fluid is Cavitation.
 Centrifugal Pumps - Cavitation

 The collapsing of the bubbles is the area of Cavitation we

are concerned with, as extremely high pressures are
produced, which causes noise and erosion of the metal
surface.
 The area of pipeline where Cavitation mainly occurs is the
pump suction, where the liquid is subjected to a rapid rise in
velocity, and hence a fall in static pressure.
 Centrifugal Pumps - Cavitation

When the pressure falls below the vapour pressure of

the liquid at a given temperature, boiling occurs and
small bubbles of vapour are formed. These bubbles will
grow in the low-pressure area and implode when they are
transported to an area of pressure above vapour pressure.
The term given to this local vaporisation of the fluid is
Cavitation.

 The collapsing of the bubbles is the area of Cavitation we are

concerned with, as extremely high pressures are produced, which
causes noise and erosion of the metal surface.
 Centrifugal Pumps - Cavitation
 This Cavitation effect on the pump can cause damage on
the casing and impeller.
 During Cavitation, a liquid/vapour mixture of varying
density is produced.
 This results in fluctuations in pressure (caused by the liquid
column being drawn in), and causes fluctuations in the
discharge pressure, pump power absorbed (shown on the
ammeter), and hence pump revolutions.
Centrifugal Pumps - Cavitation

When the pressure falls below the vapour

pressure of the liquid at a given temperature,
boiling occurs and small bubbles of vapour are
formed. These bubbles will grow in the low-
pressure area and implode when they are
transported to an area of pressure above vapour
pressure. The term given to this local vaporisation
of the fluid is Cavitation.
 Centrifugal Pumps - Cavitation

 The collapsing of the bubbles is the area of Cavitation we

are concerned with, as extremely high pressures are
produced, which causes noise and erosion of the metal
surface.
 To reduce Cavitation we must reduce the 'losses' on the
suction side, hence reduce the pipeline friction and NPSH.
This means reducing the pump flow rates. To reduce 'losses'
on starting, the pump should be started against a closed
discharge valve
 Centrifugal pumps - Priming

Centrifugal pumps although suitable for most general marine duties,

suffer in one very important respect; they are not self priming and require
some means of removing air from the suction pipeline and filling it with
the liquid.
 Centrifugal pumps - Priming
 Where the liquid to be pumped is at a higher level than the
pump, opening an air release cock near the pump suction will
enable the air to be forced out as the pipeline fills up under the
action of gravity. This is often referred to as "flooding the
pump".
 Alternatively, an air-pumping unit can be provided to
individual pumps or as a central priming system connected to
several pumps.
 The water ring or liquid ring primer can be arranged as an
individual unit mounted on the pump and driven by it, or as a
motor driven unit mounted separately and serving several
pumps, known as a central priming system.
Centrifugal Pumps - Central
Priming System
 Centrifugal Pumps - Central
Priming System
 Where several pumps require a priming aid, for example a cargo pumping system
or a number of engine room pumps, a central priming system is often used
 This reduces the number of priming pumps, saving spares, maintenance and cost.
 With this system a central priming unit consisting of two or more liquid ring
primer pumps is arranged to pull a vacuum on a central tank.The tank has
connections to float chambers in each of the suction lines for the system pumps
isolated by either manually operated or solenoid operated valves.
 The priming pumps are controlled by the vacuum of central tank, cutting in and
out as required according to demand. As a system pump is required the priming
connection is opened manually or automatically until good suction is achieved.
 The illustration shows a typical central priming system, including tank, valves,
gauges and switches.

 Centrifugal pumps - selection
The selection of Centrifugal pumps depends mainly upon duty and the
space available.
The duty points are:
Flow and total head requirements. This will
govern the speed of rotation, impeller
dimensions, number of impellers and type e.g.
single or, double inlet,
Range of temperature of fluid to be pumped. If
suction capability is insufficient to accommodate
supply conditions due for example to high inlet
temperature Cavitation can occur
 Centrifugal pumps - selection

 Viscosity of the medium to be pumped,

 Type of medium, e.g. corrosive or non-corrosive, this would
affect the choice of material (although for salt and fresh
water the difference is often just the casing).
 Materials for salt water could be, casing-gunmetal (cast iron
for fresh water), impeller-aluminium bronze, shaft-stainless
steel, casing bearing ring seals-leaded bronze.
 Centrifugal pumps - selection

The selection of Centrifugal pumps depends mainly upon duty

and the space available.

The space points are:

With vertically arranged pumps less floor space is required, this
usually means that no hydraulic balance is necessary, impeller
access is simple and no pipe joints have to be broken.
 Centrifugal pumps - selection

 A typical engine room pump could be a vertical, in-line,

overhung (i.e. suction and discharge pipes are in a straight
line and the impeller is supported, or hung, from above),
either base or frame mounted. From which the impeller can
be removed without splitting the casing, breaking pipe joints
or removing the electric motor.
 Centrifugal pumps - losses

When assessing the amount of power needed to operate a centrifugal

pump you must always take into account the various losses.
 Centrifugal pumps - losses

 - Friction loss in bearings and glands, surfaces of impeller

and casing. Some impellers are highly polished to minimize
friction loss.
 - Head loss in pumps due to shock at entry and exit to
impeller vanes and eddies formed by vane edges.
 - Leakage loss in thrust balance devices, gland sealing and
clearances between cut water and casing and bearing seals.
Centrifugal pumps - losses
A characteristic curve for a
centrifugal pump is obtained by
operating the pump at rated speed
with the suction open and the
discharge valve shut.
The discharge valve is then opened
in stages to obtain
differentdischarge rates and total
head corresponding to them. The
data can then be represented
graphically as a curve.
The illustration shows the
characteristic curves for three
different types of pumps.
 Centrifugal pumps - losses
Losses can be caused by:

 Failure to deliver

 Capacity reduction

 Excessive vibration

Failure to deliver caused by loss of suction may be due to

 Insufficient supply head
 Air leakage at suction pipe (e.g. valve open to empty bilge, etc)
 Loss of priming facility or leaking shaft gland
 Centrifugal pumps – losses

Capacity reduction could be the result of

 A damaged sealing ring
 Leaking gland
 Obstruction (valve partly closed/foreign body)
 Incorrect rotational speed
Excessive vibration may be caused by
 Loose coupling
 Loose impeller
 Bearing damaged
 Impeller imbalance
Centrifugal pumps-component
parts
 Centrifugal pumps-component
parts

 This is a vertical , single stage ,single entry , centrifugal

pump for general marine use .
 The mainframe and casing, together with a motor support
bracket, house the pumping element assembly.
 The volute casing is split in two halves along a vertical
plane.
 Since the suction and discharge nozzles are provided in the
rear half of the casing, the rotating element can be taken out
by removing only the front half casing without disturbing
the rest of the pump.
 Centrifugal pumps - component
parts
 The pumping element is made up of a top cover, a pump shaft, an
impeller, a bearing bush and a sealing arrangement around the shaft.
 The sealing arrangement may be a packed gland or a mechanical seal
and the bearing lubrication system will vary according to the type of
seal.
 Replaceable wear rings are fitted in the casing around the top and
bottom faces of the impeller.
 The motor support bracket has two large apertures to provide access
to the pumping element, and a coupling spacer is fitted between the
motor and pump shaft to enable the removal of the pumping element
without disturbing the motor or vice versa
Centrifugal pumps - shaft sealing
 Centrifugal pumps - shaft sealing
 To connect the motor to the impeller, the shaft has to pass
through an aperture in the casing.
 To allow the shaft to rotate freely in the casing aperture
there needs to be a gap, but this gap needs to be closed off to
stop air from being drawn in from atmosphere or liquid from
leaking out during operation.
 There are two common methods.
 Packing
 Mechanical seal
 The role of the pump, its speed and the type of liquid being
pumped all play a part in deciding which application works
best.
Packing
 Packing
 A stuffing box with a soft packing material is the traditional seal
for pumps. Normally made from soft impregnated cotton, which
takes the form of a length of square cross-section wound spirally
onto a tube. This enables the correct length, to suit the external
diameter of the shaft, to be manually cut to the correct size.
 The stuffing box is then repeatedly filled with sections until
almost full, the gland can then be tightened down to provide the
axial compressive force. This in turn provides the necessary radial
compressive force required to seal the gap due to the sloping
bottom face of the aperture.
 If the force is insufficient the stuffing box will leak, if the force is
too great, the additional friction, and consequently heat generated
by the rotating shaft can damage the soft packing and/or shaft.
 Mechanical seals

 Mechanical seals The provision of rotary shaft seals

instead of the usual stuffing box
and gland, where conditions are
suitable, possesses many
advantages. The power absorbed is
lower and is constant, whereas a
gland excessively tightened causes
a considerable increase in power
absorbed.
 Mechanical seals
 In small pumps this may result in overloading the motor. In addition
maintenance costs are reduced, the rotary seal operating for long periods
without wear or attention.
 A standard seal consists of a stationary carbon ring insert in the casing,
or seal cover where such is provided, and against this a metal ring of
easy clearance on the shaft sleeve rotates, contact between the faces
being ensured by a lightly loaded coil spring.
 The rubbing faces of both carbon and metal rings are independently
lapped to give a dead flat surface.
 A synthetic rubber ring, of circular cross-section, contained between
shaft sleeve and metal ring, in a groove in the latter, effectively prevents
leakage between them.
 The diameter of the groove is such that a squeeze is exerted on the
rubber ring, thus a sufficient frictional force is provided to rotate the
metal ring, with certain exceptions.
 Mechanical seals

 The width of the groove is, however, made considerably

greater so that the metal ring is capable of free axial float
with accompanying rolling action of the rubber ring.
 Materials used for the various seal parts are as follows
 Carbon stationary ring.
 Synthetic rubber ring.
 Bronze rotating ring with bronze spring for standard and
all gunmetal pumps.
 Stainless steel rotating ring for all iron pumps.
 Mechanical seals

 For non-lubricating liquids, such as ammonia,

 section, contained between shaft sleeve and metal ring, in a
groove in the latter, effectively prevents leakage between
them.
 The diameter of the groove is such that a squeeze is exerted
on the rubber ring, thus a sufficient frictional force is
provided to rotate the metal ring, with certain exceptions.
 The width of the groove is, however, made considerably
greater so that the metal ring is capable of free axial float
with accompanying rolling action of the rubber ring.
 Quick quiz

where is the packing material located?

Click on the packing material.
If you are not sure go to the previous
screen to refresh your memory.
Centrifugal Pumps - Double Entry
Pumps
 Centrifugal Pumps - Double Entry
Pumps
 The incoming liquid enters the double impeller from the top
and bottom and passes into the volute casing for discharge
in the same way as before. A double entry pump has a lower
NPSH required characteristic, which will have advantages in
poor suction conditions.
 It should be noted that different impeller sizes could be
fitted into a basic pumping element. This enables various
discharge head characteristics to be provided for the same
basic pump frame.
 The larger pumps, which are double entry, can achieve flow
rates of 10,000 tonns/hour.
 Centrifugal Pumps - Double Entry
Pumps

Illustration shows a cross-section through a double entry centrifugal pump

 Centrifugal pumps - hydraulic
balance

To control the axial movement of the rotating assembly, a balance

piston is arranged to counteract the effect of the thrust of the
impellers,especially in the multistage pumps.
 Centrifugal pumps - hydraulic
balance
The arrangement keeps the rotating assembly in its correct position under
all conditions of loading .Water at the approximate pressure of the pump
discharge passes from the last stage of the pump between the impeller
hub and the balance restriction bush C into the annular space B dropping
in pressure as it does so .The pressure of water in the chamber B tends to
push the balance piston towards the drive end.When the thust on the
balance piston overcomes the drive and the impeller thrust the gap A
between the piston and balance ring widens and allows water to
escape .This in turn has the effect of lowering the pressure in chamber B
allowing the rotating assembly to move back towards the pump end .
Theoretically this cycle will be repeated with a smaller movement each
time until the thrust on the balance piston exactly balances the other axial
forces acting on the assembly. In practice the balancing of the forces is
almost instananeous and any axial movement of the shaft is negligible.
Centrifugal pumps - maintenance

When the pump is due for

overhaul, it will be necessary to
dismantle it to its component parts
to examine them for wear. The
following procedures are intended
as a general guide only, and your
attention should be drawn to the
manufacturer's operational
instructions regarding specific
pump requirements before
commencing to dismantle the
pump.
Mixed flow pumps

In this type, the pressure is developed

partly by centrifugal action and partly by
the vanes and, as the name implies, the
flow is both axial and radial through the
impeller.
 Question 1
1: Cavitation of the fluid in a centrifugal pump is caused by?

A) Too high a speed of impeller rotation creating adverse heat

.
B) The vapour pressure in the suction pipe falls below the vapour
pressure of the liquid at a given temperature.

C) The viscosity of the fluid is too high, the extra power absorbed being
converted into heat.

D) Do not kown.
 Question 2

Why is the axial flow pump ideal for trimming and heeling
duties?
A) It is reversible and has a high capacity flow.

B) It has excellent suction lift.

C) Its discharge pressure is increased by the speed of the

ship.

D) I do not know.
 Question 3
What is the advantage of a double entry centrifugal pump?

A) It has a lower NPSH required characteristic, giving advantages

in poor suction conditions.

B) It gives double the flow rate.

C) It uses only half the input power for the same flow rate.

D) Don't know
 Question 4

Which one of these options is NOT a cause of excessive vibration in

centrifuga pumps?

A) Bearing damaged.

B) Impeller imbaianced.

C) Discharge valve partly closed

D) Don't know
 Question 5

Centrifugal pumps need priming because?

A) An excellent suction lift causes the surface of the liquid to
vaporise
B) They must be started with the discharge valve open to reduce
the starting load, but this causes the pump to run backwards.
C) It is the movement of the liquid from the eye of the impeller
to the discharge that causes a low-pressure region at the suction,
if the pump is started full of air this movement of liquid does not
occur therefore no suction pressure is created.
D) Don't know
 Question 6
The energy transformation within a centrifugal pump is as follows?
A) Pressure is converted into kinetic energy by the impeller; this
kinetic energy is converted to an increase in velocity by the volute
casing.
B) The impeller creates centrifugal force, which increases the
liquid velocity, an increase in velocity means an increase in kinetic
energy, the increased kinetic energy is converted into pressure by
reducing the velocity in the volute casing.
C) Decreasing the velocity in the impeller decreases the kinetic
energy, decreasing the kinetic energy whilst increasing the velocity
of the fluid in the volute casing increases it's pressure.
 D) Don't know