Technical case study

Topic Name

Pumps

Groups Members Name

M Arslan M umar

THE UNIVERSITY OF LAHORE

Presentation on Pumps

An Overview
Introduction Types of Pumps Features of various Pumps Selection of pumps

Performance Calculation
Installation Maintenance

Pumps Definition

The purpose of a pump is to add energy to a fluid, resulting in an increase in fluid pressure, not necessarily an increase of fluid speed across the pump.

Types of Pumps
Dynamic Pumps

Centrifugal Axial Radial

Displacement Pumps

Positive Displacement

Dynamic Pumps

A pump that uses the momentum of the fluid to move from inlet to outlet

Positive Displacement Pumps

Pumps that deliver a specific volume of water for each cycle, irrespective of the head that they are pumping against. Such pumps include piston, plunger and screw pumps.

Centrifugal Pumps
Very simple design Two main parts are the impeller and the diffuser Impellers

Bronze poly carbonate cast iron

stainless steel

Pressure developed by the Pump

depends upon

Impeller dia No.of impellers size of the impeller eye shaft speed

Size of the pump

Depends on

Head Capacity

Advantages of centrifugal Pump

Very efficient Produce smooth and even flow Reliable with good service life

Disadvantages
Loss of priming easily Efficiency depends upon operating design

head & speed.

Centrifugal Impellers

Impeller Vanes

Eye of the Impeller Water Entrance Diameter of the Impeller

Thickness of the impeller

Thicker the Impeller- More Water Larger the DIAMETER - More Pressure Increase the Speed - More Water and Pressure

Two Impellers in Series

Direction of Flow

Twice the pressure Same amount of water

Multiple Impellers in Series

Direction of Flow

Direction of Flow

Placing impellers in series increases the amount of head produced The head produced = # of impellers x head of one impeller

Pump Performance calculation

Overall Efficiency =

Hydraulic power ( P2) X 100/ Power input ( P1) Pump efficiency. = Hydraulic power ( P2) X 100/ Power input to pump shaft ( P3) Hydraulic Power ( P2) = Q X Total Head ( hd hs ) X p X g / 1000 Q = discharge in m/s

Pumps Performance Curves

Centrifugal Pumps - Cavitations

When the pressure falls below the vapor pressure of the liquid at a given temperature, boiling occurs and small bubbles of vapor 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 - 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 - 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

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

Key Parameter for determining efficiency

Flow Head Power

Flow Measurement Techniques

Tracer Method Ultrasonic flow measurement Tank filling method Installation of online flow meter

Determination of total head

Suction head

measured from pump inlet pressure gauge reading

Discharge head

This is taken from the pump discharge side Pr. gauge

Net Positive Suction Head

NPSHA NPSH
Otherwise (if NPSHA < NPSHpump), the pressure at the pump inlet will drop to that of the vapor pressure of the fluid being moved and the fluid will boil. The resulting gas bubbles will collapse inside the pump as the pressure rises again. These implosions occur at the impeller and can lead to pump damage and decreased efficiency.

Factors to be considered from user side

Size pump correctly Operate close to the best efficiency point. Size all piping and valves correctly Avoid all leakages.

Flow control Strategies

Varying speed Pumps in parallel stop/start control Flow control valve

By pass control valve

Trimming impeller Use of VFDS

Energy conservation opportunities in pumping

Operate pump near best efficiency point. Replace old pumps by energy efficient

pumps Reduce system resistance by pressure drop assessment and pipe size optimization. Provide booster pump for few areas of higher head.

Energy conservation opportunities in pumping

Conduct water balance to minimize water

consumption. Ensure availability of instruments like pressure gauges, flow meters. Repair seals and packing to minimize water loss. Avoid valves in discharge side as far as possible. Operate pumpset during non-peak hours.

Energy Loss in Valves

Function of valve type and valve position The complex flow path through valves can result in high head loss (of course, one of the purposes of a valve is to create head loss when it is not fully open)

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, casinggunmetal (cast iron for fresh water), impelleraluminium bronze, shaft-stainless steel, casing bearing ring seals-leaded bronze.

Pump Installation
Installation of Pump, Motor and Base:

The foundation area should be rigid and level for maintaining pump alignment. The pump and motor assembly must be securely fastened to the base, and the base must be securely attached to the ground. For long-coupled pumps, the pump is coupled to the motor via a mechanical coupling. To prevent excessive radial loads from being applied to the pump which can cause vibration and lead to premature pump failure the pump and motor shafts must be manually aligned after final installation. On larger machines laser alignment is recommended.

Pump Installation

The pump inlet should be as close to the liquid source as practical and preferably below it. The pump and motor should be accessible for servicing and inspection. The pump and motor should be cleaned periodically to prevent the build-up of dust. Whenever possible, install suction and discharge pressure gauges as close to the pump ports for condition monitoring and for checking hydraulic conditions.

General Precautions:
Never operate the pump without safety

devices installed Never operate the pump with suction and/or discharge valves closed Never operate the pump out of its design specifications

Piping design
Cavitation Performance dropout Impeller failure Bearing and mechanical seal failures Cracked casings Leaks Spills Fires

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.

Centrifugal pumps maintenance

Lubrication Drive Lubrication Bearing Lubricant Grease Inspection Inspection of Rotor Tips Inspection of Rotor, Shaft Key and Keyway Inspection of Gears and Bearings

Centrifugal pumps maintenance

Centrifugal pumps maintenance

Annual Maintenance Cleaning Fluid Head Disassembly Remove Rotor Nut Assemblies Remove Cover Remove Rotors Remove Pump Body Remove Mechanical Seal

Centrifugal pumps maintenance

Gear Case Disassembly Remove Gear Case Cover Remove Shaft

Thank You