TOPIC 2

2.1 PUMPS
2.2 STEAM TURBINES/ENGINE
2.3 GAS TURBINE

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 PUMP
APPLICATIONS
Used to move / transfer liquids
Used in a variety of
applications & process (e.g:
refrigeration, automobiles,
home heating systems, water
well)
used in refineries/chemical
plants to move liquid (similar
to conveyor belt used in
factories to move solid
product)
No pump needed using
gravity flow to transfer liquids
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
CLASSIFICATION
Classified as dynamic &
positive displacement
Both are designed to
transfer liquid but the way
the transfer is accomplished
is different
Dynamic Pumps
accelerate liquids axially or
centrifugally
Positive Displacement Pump
transfer liquid using a
rotary or reciprocating
motion
DYNAMIC POSITIVE DISPLACEMENT
accelerate liquids axially Transfer specific amount of liquid by
(straight line) or centrifugally using a rotary or reciprocating
(circles) motion that displaces liquid on each
Operates at high speed to rotation or stroke
generate large flow rates at Transfer specific amount of fluid no
low discharge pressure matter what the discharge pressure
Transfer of fluid affected by is
discharge pressure For rotary deliver specific amount
Centrifugal Spinning with each rotation of screw, gears,
impeller inside a shell casing vanes or similar element
propel or push liquid outward For reciprocating move fluid by
to the discharge port drawing them into a chamber on the
Axial Similar spinning intake stroke & pushing them out of
motion to propel liquid, but the chamber with piston, diaphragm
the liquid moves in a straight & plunger on the discharge stroke
line CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 (1) DYNAMIC PUMPS
VERTICAL

HORIZONTAL
CENTRIFUGAL
DYNAMIC SINGLE STAGE
AXIAL
MULTISTAGE

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

(2) POSITIVE DISPLACEMENT PUMPS
SCREW
EXTERNAL
GEAR

ROTARY INTERNAL GEAR

SLIDING VANE

FLEXIBLE
VANE
POSITIVE
DISPLACEMENT LOBE
PISTON

RECIPROCATING PLUNGER

DIAPHRAGM
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 CENTRIFUGAL PUMP
volute
As liquid enters the suction eye,
it encounters the spinning
impeller and get propelled or
pushed in a circular rotation that
Suction
force it to exit from volute eye
(discharge chute)
Centrifugal force and volute
design convert velocity energy to
pressure
As the liquid leaves the volute, it
slows down, building pressure
Diffuser plates can be added to
the impeller and volute area to
slow it down
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 CENTRIFUGAL PUMP
ADVANTAGES DISADVANTAGES
Cheaper & require less Not self-priming
maintenance Respond poorly to viscous
Operate with a constant head materials or variations in
pressure over wide capacity suction pressures
range
Easy to change the element
(impeller vs piston) compare
to others
Easy to change the driver
The adaptability of the
selected driver variable
horsepower & fixed or
variable speed
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 IMPELLER DESIGN
Open impeller
Vane are connected only to
the shaft
Self cleaning but does not
have structural support & less
efficient at producing pressure

Semi Open Impeller

Vane horizontally
attached to a plate for
structural support
Closed Impeller
Vane are sandwiched
bet. 2 plates
Strongest & most efficient
design
Use with clear liquid only
Most common type in
industry
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 CENTRIFUGAL PUMP DESIGN
Vertical or horizontal : refers to shaft (motor) Vertical
position.
single stage or multiple stage : refers to the
number of impellers.
single or multiple suction inlets : refers to
number of inlets.
volute or diffuser
axial flow, radial flow or mixed flow
open, semi-open, or closed impeller design
Mixed Flow
Horizontal

Axial Flow

CHE 324 PROCESS PLANT OPERATIONS &

MAINTENANCE
 INTERNAL SLIP
Slip =% of fluid that leak / slips past the internal clearances of a pump over a given time /
difference bet. how much liq. a pump can move & how much it actually does move

DYNAMIC POSITIVE DISPLACEMENT

Centrifugal can have 100% slip if the
discharge valve is closed
Fluid move from suction inlet into
the impeller, flow accelerate into a
volute (widen within the pump)
When discharge valve closed & flow
stop but circulation continues
within the pump & sustained in the
volute & discharge pipe up to the
discharge valve
Fluid friction heat up the liq. &
vaporized, it will expands & hot
Create tremendous pressure that
will damage the pump
CHE 324 PROCESS PLANT OPERATIONS &
MAINTENANCE
PD designed to have minimal slip
because displace exact fluid volumes
with solid object (e.g. pistons &
gears)
Condition when discharge valve is
closed on a PD pump:
Very little slip occur within the
pump body
Fluid pressure increase with every
stroke
Fluid press is transferred equally to
all isolated parts
Pump/discharge pipe can be
damage if relief valve is not
provided
 HEAD (PRESSURE)
Suction head = pressure required to force/push liquid into a
pump which must be sufficient to run the pump without
cavitations (formation of gas pockets around the impellers)
E.g. = during operation, centrifugal pump will artificially create
low pressure area in suction eye & can cause liquid to boil &
cavitations if suction pressure not carefully controlled
Net positive suction head (NPSH) : the head (pressure) in feet
(ft.) of liquid necessary to push the required amount of liquid
into the impeller of a dynamic pump without causing
cavitations. The same principle applied to discharge head
If the tank is closed, the vapor pressure of the liquid must be
taken into consideration

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 NPSHa & NPSHr
Net Positive Suction Head made available the suction system for
the pump is named as available NPSHa & calculated with the Energy
Equation. When the pump lifts a fluid from an open tank at one
level to an other, the energy or head at the surface of the tank is
the same as the energy or head before the pump impeller
The NPSHr - Net Suction Head as required by the pump in order to
prevent cavitation for safe & reliable operation of the pump &
determined experimentally by the pump manufacturer & a part of
the documentation of the pump
The available NPSHa of the system should always exceeded the
required NPSHr of the pump to avoid vaporization and cavitation of
the impellers eye
The available NPSHa should be higher than the required NPSHr to
avoid that head loss in the suction pipe & in the pump casing, local
velocity accelerations & pressure decreases, start boiling the fluid
on the impeller surface CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 HEAD (PRESSURE)
Restriction in
the suction
line

Flow rate
through Factor that Viscosity
the line affect
suction head
pressure
Level of
liquid in Temperature
the suction
head

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 HEAD (PRESSURE)
Larger
Lower NPSH
diameter
requirements
suction line

Greater feed
Lower speed tank level /
pressure

Solutions
Smaller to Cooler feed
horsepower insufficient
NPSH

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 AXIAL PUMP
Transfer fluid by pushing it axially/in
a straight line (e.g. boat motor)
Motor turns a set of blades, forcing
water to accelerate along a straight
line
Normally located in an elbow on a
piping run (vertically / horizontally)
drive shaft extends via the elbow &
into the process flow
Propeller located end of the drive shaft
& sized to fit the inside dia. of pipe
Balding is engineered to pull fluid axially
down the shaft
Application : - in pipeline service &
as primary transfer device on loop
reactor CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 JET PUMP
Specially designed to utilize the venturi
effect
Screen (PVC) connect to PVC water
pipe (allowed to extend a few ft above
ground level)
Pressure in the water pocket causes
the water level to pass via the screen &
up the pipe
Water level will stop before reaching
the top of the pipe & jet pump will
lifting the water out of the pipe
Application : - used to lift water from
well over 200 ft deep

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 JET PUMP OPERATION
During operation, water is forced back down the void
between the center drop pipe and outer casing
As water is pumped back into the well casing, the
check valve close and pushed the water to flow
through the small opening on the jet (venturi effect)
along the suction line of the pump
As the pressure increases in the casing, velocity
increases across the jet
A low-pressure zone is established inside the drop
pipe as water quickly flows up toward the pump.
A back-pressure regulator holds pressure inside the
pump until it reaches operating conditions.
When pressures reach operating conditions, water
flows is divided as some water circulates down the
casing and the excess flows to a storage tank
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 POSITIVE DISPLACEMENT PUMPS
Rotary Pump
Displace liquid with rotary-motion (gears, screws, vanes or
lobes)
The drive shaft turns the rotary elements inside a leaktight
chamber that has a defined inlet and outlet
Require close running clearances between the rotating
elements & chamber wall
most widely used in industry specifically to move the more
viscous type of fluids: heavy hydrocarbons, syrup, paint and
slurries
has very little internal slip (can damage the pump if the
discharge pump is blocked during operation)

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 SCREW PUMP
Single-screw rotary pumps (progressive cavity pump)
Consist only 1 moving part (rotor)
When the self-priming rotor turns (inside an elastomer-lined
stator), cavities/voids are formed between the rotor & stator
Voids progress axially from the suction casing to the discharge
outlet
The voids/cavities will fill with fluid during operation
Advantages: high suction, extremely low shear, & smooth
pulsation-free operations
Used for heavy / viscous fluid service
Elastomer-lined stator
screw
Suction
casing

Discharge outlet
 SCREW PUMP
Two-screw pump
Has 2 rotor (power rotor & idler rotor)
Set of external timing gears and bearing (allow the rotor/screw to turn in
unison without making contact with each other)
Screw do not touch so pump can run empty without damaging the system
Operation :
As fluid enter the pump it is divided into 2 equal streams & directed to the 2 end of
shaft
Pumping action of the screw moves 2 stream in a straight line between the close
space rotor until they combine at the discharge port
The rotating rotor are balanced because the 2 streams have equal & simultaneous
flow paths
Advantages : high flow rate & pump any fluid regardless of abrasiveness,
lubricity, or viscosity

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 SCREW PUMP
Three-screw pump
Consists power rotor / driver rotor & two idler rotor
Power screw meshes with idler screws during operation
The 3 screw is touching each other
Each screw rotate on a set of heavy bearings
Operation:
The self-priming screw rotate, creating voids that transfer fluid in a continuous, pulsation-free
flow

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 GEAR PUMP
Similar to screw pumps in that they can be used in viscous service
Can be found in 2 common types: (1) External; (2) Internal

External gear pump

Have 2 gears (idler & power) that rotate parallel
to each other, allow fluid to be pick up by the
gears & transfer out of the pump
Rotation of driver gear (mounted on top) turns
the idler gear (follower gear), trapping fluid &
displace it
Operation :
- Once started, air is forced out into the discharged line Power
gear
and creates a low-level vacuum on the suction line
which causes the water to enter the pump
- As the power gear rotates, fluid is swept around the
housing and out of the discharge port outlet
inlet
- An idler gear turn in opposite direction of power gear Idler
gear
 GEAR PUMP
Internal gear pump
Have 2 moving part (power gear driving internal
idler gear)
Operation :
- When the power gear rotates, liquid enters the
pump via suction line
- Pump is self-priming, the voids between power
gears teeth and off-center idler gear fill with
liquid and separated by crescent-shaped spacer
- Liquid is pressed into spaces above and below the
spacer
- As the gears rotate around the circular pump
casing, the liquid discharged out of the pump
outlet
Basic components: power gear / rotor, idler gear,
idler pin, drive shaft, circular casing, crescent
shape spacer, bearings, seals & relief valve inlet crescent-
shaped
spacer
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 SLIDING VANE PUMP
Consist of spring-loaded or non-spring
loaded vanes attached to a rotor/impeller
that rotates inside an oversized circular
casing
Operation :
As the offset impeller rotates by the inlet
port, liquid is swept into the vane slots
A small crescent-shaped cavity is formed
inside the pumping chamber outlet
As the liquid nears the discharge port, it is
compressed as the clearances narrow &
released at the discharge port
Application : used in hydraulic systems, inlet sliding vane

vacuum systems & low pressure oil

systems (liquid that have good lubricating
qualities
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 LOBE PUMP
outlet
inlet

lobes

Consist of two rotating lobe-shaped screw - mesh during operation

A set of external timing gears & bearings allows the lobes turn in
unison w/o making contact with each other (pump can run empty
w/o damage the system)
Operation :
As lobes turn, voids are created that compress liquids around the outside of
the pumping chamber
Once fluid enters the pump it is divided into 2 equal streams
The lobes moves the liquid in the close space between the casing and the
lobes then combine out at the discharge port
Application : provide high flow
CHE 324 rates
PROCESS at low
PLANT OPERATIONS pressure
& MAINTENANCE
 POSITIVE DISPLACEMENT PUMPS
RECIPROCATING PUMPS
Engineered to transfer small volume of liquid at
relatively high pressure
Self-priming and operated at relatively low speed
back-and-forth motion and effects of inertia on
internal components
Deliver consistently high volumetric efficiencies
Displace liquid using diaphragm, piston or plunger
mechanism (pushes the fluid as it moves back &
forth inside a cylinder or housing)
 DIAPHRAGM PUMPS
Use flexible sheet to displace fluid
Has eccentric wheel attached to a Check
valves

connecting rod that attach to the

center of diaphragm
Pumping chamber below the diaphragm

diaphragm connect to suction &

discharge lines.
As the eccentric starts its rotation, the
diaphragm connecting rod goes up &
down create a pumping action to
displace fluid
The fluid enter through suction valve
and leave through discharge valve
depending on the pressure in the
chamber

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 PISTON PUMPS
Uses a piston create a back-and-
forth motion to displace fluid
has suction stroke and a discharge
stroke (based on piston moving
direction)
During suction stroke, low-pressure
vacuum develops in the cylinder,
causing the discharge valve to close
and the suction line to open, filling Outlet line

Piston Check
the cylinder valves

During the discharge stroke, the

suction valve close, & the fluid is Inlet line

forced out the discharge valve

Advantage : pump continue to
operate no matter how high the
discharge head is

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 PLUNGER PUMPS
Operate with a back-and-forth motion
and a device called a plunger to displace
controlled amounts of liquid
primary difference with piston pumps is
in the shape of the piston or plunger
element and the way they seal
PISTON - has ring mounted on the
piston (moving together) that form a
seal
PLUNGER plunger moves in/out of an
O-ring or packing medium to form its
stationary seal
Advantage the pump seals can easily
be replaced without major breakdown
of the equipment
plunger

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

TROUBLESHOOTING OF PUMP

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

TROUBLESHOOTING OF PUMP

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 TURBINES
Classification :
The principle of operation &
Type of fluid that turn the turbine

STEAM GAS TURBINE HYDRAULIC WIND TURBINE

TURBINE TURBINE
Use high pressure (windmills) use
(Impulse gases (Reaction air pressure
movement) movement)
rotor turns in rotor turns in
response to the response to the
force (velocity) pressure of a
ofa gas liquid

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 STEAM TURBINES CLASSIFICATION

Condensing Noncondensing Reaction Impulse

Turbine Turbine Turbine Turbine

Exhaust steam Exhaust steam is Steam is A steam turbine

flows to surface utilized in low- discharged from a with a blading
condensers and it pressure steam nozzle mounted design that cause
operates at applications on the rotor. rotation of the
vacuum pressure Movement is a blades & shaft
reactive response when high-
to the release of velocity steam
steam from an from external
internal source source push on it

Each of these designs can have one or more stages

(impeller/turbine blade number)
CHE 324 PROCESS PLANT OPERATIONS &
MAINTENANCE
 STEAM TURBINES
Basic principle - convert steam energy
(kinetic energy) into mechanical energy
used to drive rotating equipment
Application :- use to drive pumps,
compressors, ocean vessels & electric
power generation
Operation:-
As high-pressure steam enter a turbine,
it passes a nozzle (restrict the flow to Rotating shaft
increase steam velocity) and hit the
turbine blade - causing it to rotate
Steam passes through alternate sets of High
pressure
fixed and revolving blades, it constantly steam

expands as it moves along

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 TYPE OF STEAM TURBINES
2 types of steam turbines:
a) Impulse
Have a blading design that causes rotation of the blade and shaft
assembly (rotor) high velocity steam pushes on the blade.
External source of steam.

b) Reactive
Occurs when steam escapes from a fixed nozzle attached to the rotor and
propelling the rotor.
Internal source of steam.
Both impulse and reactive steam turbines operate under similar principles.
 Both impulse and reaction turbines can be either condensing or
noncondensing.

a) Condensing b) Non condensing (extraction type)

Exhaust steam into a heat
exchanger (surface condenser)
that cools and condenses the
steam.
Condensate is sent to boiler
converted back to steam.
The most efficient type extract
the maximum amount of energy
from the steam.
Multistage turbines.
Use high pressure steam, and
some portion of the steam are
extracted for other use.
As the pressure steam passes
over the turbine wheel, the steam
expands.
This expansion allow the turbine
to divert low pressure steam to
other units.
ASSIGNMENT 2:
Explain function of each basic components of a steam turbine:
a) Rotor
b) Fixed Parts
c) Fixed Blades
d) Casing
e) Steam chest
f) Nozzle
g) Bearings
h) Seals
i) Governing Mechanism
j) Lubrication system
 STEAM TURBINES PROBLEMS

Vibration Hunting
Excessive vibration could Steam turbine designed to be
indicate failing bearings or operated at a controlled speed
internal problems Hunting occur when a turbines
2 types of vibration radial speed fluctuates while the
vibration & axial movement controller searches for the correct
Radial vibration increases when operating speed (operated above /
turbine surges / after a cold start below normal operating set point)
when the machinery passes
through critical speed Cause by:
Surging affect axial movement Mechanical linkage binding
in the rotor also can cause steam turbine
Monitoring & troubleshooting to speed up & slow down
vibration problems must consider Inlet steam pressure
the axial movement problems can also cause a
steam turbine to hunt
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 STEAM TURBINES STARTING UP
PROCEDURE
Visually inspect turbine for damage. Reset overspeed
trip. Check lube oil level for turbine governor. Ensure
that rotating equipment covers are in place.

Drain condensate from turbine. Slowly back-feed low

pressure steam into turbine exhaust.

Check lubrication systems constant-level oiler. Check

cooling system. Check seal system where the shaft
enters the casing.

Slowly open the throttle valve & bring the turbine

speed up 10% to 20% normal operating speed.

Bring turbine up to operating speed by opening the

throttle valve, listening for line-out sound, and
checking governor linkage.
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE
 GAS TURBINES

Basic principle use high pressure combustion gases to turn a series of turbine
wheel to provide rotational energy to turn an axle or a shaft
Consist of 3 parts: (1) axial compressor; (2) combustion chamber; (3) gas
turbine
Application :- drives the electric generators, ships and racing cars, & a primary
component of jet aircraft engines

CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE

 Exhaust
Air
gas

Compression Combustion Gas turbine

During operation, a fraction of the power generated by turbine is used to run

the compressor
The compressed air mixes with fuel in the combustion chamber and ignited
by spark plug
Higher pressure allows the mixture to burn better
The hot combustion gases rush into the gas turbine, causing the turbines
wheels to turn
Hot exhaust gases are discharged from the body of the gas turbine
The air compressor and the gas turbine are mounted to the same axle, which
is connected to the workload
CHE 324 PROCESS PLANT OPERATIONS & MAINTENANCE