Pumps, Compressors, Fans,

Ejectors and Expanders

Chapter 20
ChEN 4253 Design I
Terry A. Ring
Pumps
Moves Liquid, Creates Pressure
Vapor bubbles
Causes Cavitations
Erodes Impeller
Solids Erode Impeller
Pump Types
Centrifugal
Positive Displacement
Piston
diaphragm

Pump Power = Q*P = brake (delivered) (horse) power
from motor
Centrifugal Pumps
Two Basic Requirements for Trouble-
Free Operation of Centrifugal Pumps
no cavitation of the pump occurs throughout
the broad operating range
a certain minimum continuous flow is always
maintained during operation
Pump around loops
Reduced Flows
Unfavorable conditions which may occur
separately or simultaneously when the pump is
operated at reduced flows
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
Centrifugal Pump
Electric Motor
Centrifugal Pump

Electric
Motor

Centrifugal Pump
Converts
kinetic
energy to
pressure
energy
Impellers
Converts Kinetic Energy to
Pressure Energy
Different Types of Pump Head

Total Static Head - Total head when the pump is not running
Total Dynamic Head (Total System Head) - Total head when the
pump is running
Static Suction Head - Head on the suction side, with pump off, if the
head is higher than the pump impeller
Static Suction Lift - Head on the suction side, with pump off, if the
head is lower than the pump impeller
Static Discharge Head - Head on discharge side of pump with the
pump off
Dynamic Suction Head/Lift - Head on suction side of pump with
pump on
Dynamic Discharge Head - Head on discharge side of pump with
pump on
Pump Head
The head of a pump can be expressed in metric
units as:
head = (p
2
- p
1
)/(g) + (v
2
2
- v
1
2
)/(2g) + (z
2
-z
1
)
where
h = total head developed (m)
p
2
= pressure at outlet (N/m
2
)
p
1
= pressure at inlet (N/m
2
)
= density of liquid (kg/m3)
g = acceleration of gravity (9.81) m/s
2
v
2
= velocity at the outlet (m/s)

Pump Efficiency
Centrifugal Pump
Pump Performance Curves
Resistance
Pump Design Scaling
Pump Flow rate
Q2 = Q1 x [(D2xN2)/(D1xN1)]
Pump Head
H2 = H1 x [(D2xN2)/(D1xN1)]2
Pump Brake Horse Power
BHP2 = BHP1 x [(D2xN2)/(D1xN1)]3
D = Impeller Diameter
N = specific speed
Net Positive Suction Head-NPSH

Pumps can not pump vapors!
The satisfactory operation of a pump
requires that vaporization of the liquid
being pumped does not occur at any
condition of operation.
Net Positive Suction Head
Required, NPSH
R
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 (absolute pressure) required at the
pump suction to overcome these pressure drops in the pump and maintain the
liquid above its vapor pressure.
Net Positive Suction Head
Available, NPSH
A


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.
Head to Feed Pump Subcooling before Pump
To overcome suction head
Head
Designed
into
Installation
HX
Cool a few Degrees
To overcome suction head
Piston Pumps
Gear Pumps
Lobe Pumps
food applications,
because they
handle solids
without damaging
the pump.
Particle size
pumped can be
much larger in
these pumps than
in other PD types
Screw Pump
Centrifugal
Pump
Positive Displacement Pumps
Piston Pumps
Gear Pumps
Lobe Pumps
Diaphragm Pumps
The lower the speed of a PD
pump, the lower the NPSH
R
.
Pump Costs
Cost based upon Size Factor
Centrifugal Pump
S=QH
1/2

Gear Pump
S=Q
Piston Pump
S= Power (brake)
Must cost Electric Motor also
S=P
c
=P
B
/
M
Compressors
Types
Centrifugal
Others
Piston
Lobed
Screw
Methods of Calculation in Simulators
Polytropic, PV
k-1/k
= constant,
Polytropic - This model takes into account both a rise in temperature in the gas as well as
some loss of energy (heat) to the compressor's components. This assumes that heat may
enter or leave the system, and that input shaft work can appear as both increased
pressure (usually useful work) and increased temperature above adiabatic (usually losses
due to cycle efficiency). Compression efficiency is then the ratio of temperature rise at
theoretical 100 percent (adiabatic) vs. actual (polytropic). (k-1)/k = polytropic coefficient
Isentropic, s(T
1
,P
1
)=s(T
2,isentropic
,P
2
)

Theoretical Power
Power
isentropic
= FlowRate*(h
2,isentropic
-h
1
)
Efficiency
s
=Power
isentropic
/Power
brake

s
= (h
2,isentropic
-h
1
)/(h
2
-h
1
)
Cost of Compressors
Size Factor is Compressor Power
s
k
k
P
P
T
T T
q
(
(
(

|
|
.
|

\
|
+ =

1
1
1
2
1
1 2
Positive Displacement Compressor
Positive Displacement Compressor
http://www.city-compressors.co.uk/
Centrifugal Compressors
Rotors
Stators

Jet
Engine
Design
Piston Compressor
Expander
Reverse of Compressor
Let flow produce shaft work
Types
Centrifugal
Positive Displacement
Piston
Lobed
Screw
Methods of Calculation in Simulators
Polytropic, PV
k-1/k
= constant,
Isentropic, s(T
1
,P
1
)=s(T
2,isentropic
,P
2
)
Theoretical Power
Power
isentropic
= f*(h
2,isentropic
-h
1
)
Efficiency
s
=Power
brake
/Power
isentropic
= (h
2
-h
1
) /(h
2,isentropic
-h
1
)
Cost
Size factor = Power



http://www.city-compressors.co.uk/
Fans and Blowers
Types
Centrifugal (10
3
-10
5
acfm, P=1-40 in H
2
O)
Backward Curved
Straight radial
Vane Axial
Tube Axial
Cost of Fans and Blowers
Size factor = Volumetric Flow Rate
Motor
Choice to Increase Pressure
Heuristic 34
Use a Fan
Atm to 1.47 psig
Use a Blower
< 30 psig
Compressor (or staged system)
> 30 psig
Heuristic 34 - Number of Stages
Up to a Compression ratio 4 for each stage
With intercooler between stages (P=2 psi)
Equal Hp for each stage (equal compression ratio)
Producing Vacuum
Steam Ejector

Producing Vacuum
Types
Ejector - advantage = large volumetric flow rate
Multi-Stage with interstage condensers
Liquid (Oil) Ring Vacuum Pump
Dry Vacuum Pump (rotary screw, lobe) (advantage =low
pressure) Designs similar to Expanders
Design for
Flow Rate at suction plus
Air Leakage Rate
Function of pressure and Volume of vessel
Cost
Size factor = Flow Rate at suction
Motor for pumps

Ejector
Produces Vacuum
Provides Low Pressures for
Distillation Columns
Fluid (P P
sat
)
Steam
for suction pressure below 100 mbar
absolute, more than one ejector will be
used, with condensors between the
ejector stages
Air
Water
Collects Particles in Gas Stream
Venturi Scrubber