QUALITY CIRCLE PRESENTATION A PRESENTATION ON PUMPS IN POWER PLANTS

BY M.K. ASTHANA, SR. MANAGER (QA)

COMING UP..
BRIEF INTRODUCTION OF THERMAL POWER PLANT EXAMPLES OF MAJOR PUMPS DEFINITIONS CLASIFICATION OF PUMPS FUNDAMENTAL EQUATIONS OF PUMP TYPES & CHARACTERISTICS OF PUMPS MATERIAL SELECTION QUALITY CONTROL & TESTING P.G. TEST OF CW PUMP SIPAT II, KhSTPP - II

SUB - CRITICAL STEAM POWER PLANT

1 3 4

HPT

IPT

LPT

GEN.

1 11
5

BOILER
DEAERATOR

10 7 6 9

CONDENSER

1 1

10

9
BFP

6 7

CWP

HPH

LPH

CEP

s
T-s DIAGRAM

SCHEMATIC DIAGRAM

p =225.65 Kgf/cm2
LIQUID REGION CRITICAL POINT

p = 15 Kgf/cm2

VAPOR REGION

p = 1.0332 Kgf/cm2

LIQUID - VAPOR REGION

Saturated vapor line

Saturated liquid line

v Temperature - Specific Volume Diagram for Water

PUMPS

CONDENSATE EXTRACTION PUMP

HORIZONTAL CENTRIFUGAL PUMP C.W. PUMP

PUMPS
PUMPS DESIGN PARAMETERS
PARAMETERS
TYPE NO. OF STAGES FLOW DISCHARGE HEAD OPERATING SPEED MAX. WATER TEMP. PUMP INPUT MATERIAL SUCTION BELL PUMP CASING 2% Ni CI 2% Ni CI CAST IRON CAST IRON FORGED CARBON STEEL WITH AUSTENITIC SS INLAY IN HIGH VELOCITY ZONE 13 Cr, SS 13 Cr, SS FORGING 1903.22 KW

CW PUMP
VERTICAL SINGLE 30,000 M /Hr 20.50 MWC 331 RPM
3

C.E. PUMP
VERTICAL FIVE 810 M /Hr 307 MWC 1480 RPM 43.1 C
O 3

B.F. PUMP
HORIZONTAL, CENTRIFUGAL FIVE 1080.3 M /Hr 2088 MWC 5690 RPM
3

6765 KW

IMPELLER SHAFT, SHAFT SLEEVE

CF 8M ASTM A 276 Gr. 410, H&T

12% Cr, SS 12% Cr, SS FORGING

PUMPS
PUMPS DESIGN PARAMETERS
PARAMETERS
TYPE NO. OF STAGES FLOW DISCHARGE HEAD OPERATING SPEED SERVICE DUTY MAX. WATER TEMP.

RAW WATER PUMP

VERTICAL, MIXED FLOW SINGLE 5500 M /Hr 11.5 MWC 750 RPM CONTINUOUS 36O C
3

MAKE UP WATER PUMP (PT)

VERTICAL, MIXED FLOW SINGLE 4000 M /Hr 25 MWC 1000 RPM CONTINUOUS 36O C
3

MAKE UP WATER PUMP (ASH)

VERTICAL, MIXED FLOW TWO 2200 M /Hr 40 MWC 1000 RPM CONTINUOUS 36O C
3

Categories
Pump
adds energy to a fluid, resulting in an increase in pressure across the pump.

Turbine
extracts energy from the fluid, resulting in a decrease in pressure across the turbine.

CATEGORIES
For gases, pumps are further broken down into
Fans Low pressure gradient, High volume flow rate. Examples include ceiling fans and propellers. Blower Medium pressure gradient, Medium volume flow rate. Examples include centrifugal and squirrel-cage blowers found in furnaces, leaf blowers, and hair dryers. Compressor High pressure gradient, Low volume flow rate. Examples include air compressors for air tools, refrigerant compressors for refrigerators and air conditioners.

PUMPS

PUMP
FUNCTION A MACHINE FOR RAISING A LIQUID

COMPRESSOR
A MACHINE FOR RAISING A GAS

BLOWER
A MACHINE FOR MOVING VOLUMES OF A GAS COMPRESSIBLE

FAN
A MACHINE FOR MOVING LARGE AMOUNT OF A GAS COMPRESSIBLE

TYPE OF FLUID

A RELATIVELY INCOMPRESSIBLE FLUID TO A HIGHER LEVEL OF PRESSURE OR HEAD

A COMPRESSIBLE FLUID TO A HIGHER LEVEL OF PRESSURE

END RESULT

WITH MODERATE INCREASE OF PRESSURE

WITH LOW INCREASE IN PRESSURE

PUMPS
PISTON RECIPROCATING POSITIVE DISPLACEMENT BLOW CASE ROTARY PLUNGER DIAPHRAGM

SINGLE ROTOR MULTIPLE ROTOR RADIAL FLOW

PUMPS

CENTRIFUGAL KINETIC PERIPHERAL SPECIAL

MIXED FLOW AXIAL FLOW

PUMPS

RECIPROCATING PUMP GEAR PUMP

JET PUMP

PITOT TUBE PUMP

PUMPS
CENTRIFUGAL PUMPS
Fluid enters axially, and is discharged radially.

MIXED FLOW PUMPS

Fluid enters axially, and leaves at an angle between radially & axially.

AXIAL FLOW PUMPS

Fluid enters & leaves axially.

PUMPS CURVES
PERIPHERAL PUMP POSITIVE DISPLACEMENT PUMP

PRESSURE INCREASE

CENTRIFUGAL PUMP

VOLUME FLOW

PUMP CURVES FOR DIFFERENT PUMP TYPES

PUMPS CURVES

PRESSURE INCREASE

e cr n I

a m r No

m te s y lS

s Re

25% Speed

50% Speed

75% Speed

VOLUME FLOW
POSITIVE DISPLACEMENT PUMP AND SYSTEM CHARACTERISTICS

haracte C p m u P

ed s a

ce n a is t

ristics

m te s Sy

Re

ce n ta s is

100% Speed

THE CONTINUITY EQUATION

A1 A2 v1

v2

m = 1* A1* v1 = 2* A2* v2 For an incompressible liquid flow, Q = A1* v1 = A2* v2

THE CONTINUITY EQUATION

A3

v1

v2

A1

A2

For an incompressible liquid flow, Q1 = Q2 + Q3 A1* v1 = A2* v2 + A3* v3

BERNOULLIS EQUATION
v2 A2

A1 v1

z2
Horizontal Datum p1 + v21 + gz1 = p2 + v22 + gz2 + pf 2 2

z1

p1 + v21 + z1 = p2 + v22 + z2 + pf w 2g w 2g w

STATIC, TOTAL & DYNAMIC PRESSURE HEAD

STATIC PRESSURE TAP PITOT TUBE PRANDTL TUBE

p p0 pv

p p0

STATIC HEAD

p1 w v2 2g z

TOTAL PRESSURE OR STAGNATION PRESSURE

p w

v2 2

VELOCITY HEAD

POTENTIAL HEAD =

PUMPS
Impeller Friction Losses Blade Losses Internal Leakage (Slip)

Pi

Pblade

Puseful
External Leakage

Bearing & Sealing Friction Losses

Impeller friction Sealing friction

Internal Leakages (Slip)

Bearing Losses

External Losses

Blade Losses

Centrifugal Pumps

Snail--shaped scroll Most common type of pump: homes, autos, industry.

Centrifugal Pumps

Centrifugal Pumps: Blade Design

Side view of impeller blade.

Vector analysis of leading and trailing edges.

PUMPS
H = h = u = Cu = Differential Head Hydraulic Efficiency peripheral velocity tangential component of absolute velocity

Change in Angular Momentum of fluid from inlet to exit = Mt = m* (r2C2u r1C1u) Mt *= * m * (r2C2u r1C1u) t Work Done per unit mass = Blade Work = Mt * = Ib = * (r2C2u r1C1u) = gH m h gH h = (u2C2u u1C1u)

PUMPS

C1u 0, gH h

u2C2u

If h = 1, Hi = Ideal Differential Head = Euler Head Hi = u2C2u/g = u2 [u2 C2m/tan2 ]/g C2m = Q / (2 * r2 * b2)

Hi = u2 u2 Q g 2 * r2 * b2 tan2

Pump Head
Net Head

Water horsepower Brake horsepower Pump efficiency

PUMPS
160 150

DIFFERENTIAL HEAD H

140 130 120 110 100 90 80 70 60 50 40 30 20 10

Ideal Differential Head

Actual Differential Head

Hydraulic Losses

20

40

FLOW Q

60

80

100

CENTRIFUGAL PUMP H Q CURVE

PUMPS
160

Medium = Water

N = 1450 rpm

DIFFERENTIAL HEAD H in m

150 140 130 120 110 100 90 80 70 60 50

50

170 160 150 170

70 60

40
40

30 20

150

30 20

10
10

20

40

60

80

FLOW Q in m3/h

CENTRIFUGAL PUMP H Q CURVE

EFFICIENCY IN %
100

Pump Performance Curve Centrifugal Pump

BEP: best efficiency point H*, bhp*, V* correspond to BEP Shutoff head: achieved by closing outlet (V=0)$ Free delivery: no load on system (Hrequired = 0)

Matching a Pump to a Piping System

Steady operating point:

Energy equation:

Centrifugal Pumps: Blade Design

PUMPS
32

DIFFERENTIAL HEAD H in m

50
28

55

60 62 63 62 60

24

20

55 50

16

12

430 429 427 426

425 0 120 240 360 480 600

FLOW Q in m3/h

CENTRIFUGAL PUMP H Q CURVE WITH ISO EFFICIENCY LINES

PUMPS
SHUT OFF HEAD (ZERO DISCHARGE) UNSTABLE PART OF THE CURVE

STABLE

UNSTABLE

STABLE AND UNSTABLE PUMP CURVES

PUMPS

H Hmax HO

QO

QO

QO

FLAT AND STEEP PUMP CURVES FOR CENTRIFUGAL PUMPS

PUMPS
DIFFERENTIAL HEAD POWER REQUIREMENTS

H
NEW PUMP

WORN PUMP

WORN PUMP

NEW PUMP

THE EFFECT ON PUMP PERFORMANCE DUE TO WEAR IN SEALS & CLEARANCES DIFFERENTIAL HEAD POWER REQUIREMENTS

H
NEW PUMP

P
WORN PUMP NEW PUMP

WORN PUMP

Q
THE EFFECT ON PUMP PERFORMANCE DUE TO WEAR ON PUMP BLADES

PUMPS
RELATIVE POWER

RELATIVE DIFFERENTIAL HEAD

1
RELATIVE VOLUME FLOW

1
RELATIVE VOLUME FLOW

ROTODYNAMIC PUMP CURVES RELATIVE TO BEP

PUMPS
50
1 mm2/s

50

150 mm2/s

40
DIFFERENTIAL HEAD IN M

40

100 mm2/s 50 mm2/s

SHAFT POWER IN KW

30
50 mm /s
2

30
30 mm2/s

20
100 mm2/s 150 mm2/s

20
1 mm2/s

10

10

20

40

60

80

100

120 140

20

40

60

80

100

120 140

VOLUME FLOW IN M3/Hr

VOLUME FLOW IN M3/Hr

THE EFFECT OF VISCOSITY ON SMALL CENTRIFUGAL PUMP

PUMPS
50 5 40
DIFFERENTIAL HEAD IN M

20

SHAFT POWER IN KW

30

OPTIMUM POINT

10

10

20

30

10

20

30

VOLUME FLOW IN M3/Hr

VOLUME FLOW IN M3/Hr

PERFORMANCE CURVE OF A PERIPHERAL PUMP

PUMPS
105
DISCHARGE PRESSURE BAR g

70 60 50 40
POWER IN KW

90 75 60 45 30 15

30 20 10

20

40

60

80

100 120 140

20

40

60

80

100 120 140

VOLUME FLOW IN M3/Hr

VOLUME FLOW IN M3/Hr

PERFORMANCE CURVE OF A POSITIVE DISPLACEMENT PUMP

PUMPS
130 125 120
VOLUME FLOW IN M3/Hr

115
MECHANICAL EFFICIENCY %

90 80 70 60 50

70
mech

110 105 100 90

60 50 40 30
POWER

15

30

45

60

75

90

105

DISCHARGE PRESSURE BAR g

40 30 20

20 10 0 0 15 30 45 60 75 90 105
DISCHARGE PRESSURE BAR g

PERFORMANCE CURVE OF A POSITIVE DISPLACEMENT PUMP

PUMPS
Pumped Medium mp

DIFFUSER (VENTURI)

p2 p3 c4 Motive Medium md c5

mp + md

p1

q = mp / md Pressure relationship = z = (p03 p02) / (p01 p03) = Hp/Hd Pump Efficiency = = q*z

DIAGRAMATIC PRINCIPLE OF A JET PUMP

PUMPS

PRESSURE RELATIONSHIP z

EFFICIENCY FLOW RELATIONSHIP q

PERFORMANCE CURVE FOR A JET PUMP

Centrifugal Pumps: Blade Design

Blade number affects efficiency and introduces circulatory losses (too few blades) and passage losses (too many blades)

Axial Pumps

Open vs. Ducted Axial Pumps

Pump Specific Speed

Pump Specific Speed is used to characterize the operation of a pump at BEP and is useful for preliminary pump selection.

Open Axial Pumps

Blades generate thrust like wing generates lift.

Propeller has radial twist to take into account for angular velocity (=r)

Ducted Axial Pumps

Tube Axial Fan: Swirl downstream

Counter-Rotating Axial-Flow Fan: swirl removed. Early torpedo designs Vane Axial-Flow Fan: swirl removed. Stators can be either preswirl or post-swirl.

Ducted Axial Pumps - Blades

Absolute frame of reference

Relative frame of reference

Dimensional Analysis
analysis gives 3 new non-dimensional parameters
Head coefficient Capacity coefficient Power coefficient

Reynolds number also appears,but in terms of angular rotation

Reynolds number

Functional relation is
Head coefficient Power coefficient

Dimensional Analysis
If two pumps are geometrically similar, and The independent s are similar, i.e., CQ,A = CQ,B ReA = ReB A/DA = B/DB Then the dependent s will be the same CH,A = CH,B CP,A = CP,B

Dimensional Analysis
When plotted in nondimensional form, all curves of a family of geometrically similar pumps collapse onto one set of non-dimensional pump performance curves Note: Reynolds number and roughness can often be neglected,

AFFINITY LAWS

PUMPS

C.W. PUMP SUMP TEST BED

FLOW NORMALIZER
CRES T

TRASH RACK

WIER

FLOWMETER

LAY OUT OF CW PUMP TEST BED

PUMPS
FLOW MEASUREMENT BY RECTANGULAR WEIR H

Q = VOLUME FLOW IN M3/SEC.

Q = 0.4046 +

0.003607

2gLH1.5 M M

L = LENGTH OF WEIR H = HEIGHT OF LIQUID

PUMPS
FLOW MEASUREMENT BY ORIFICE PLATE

d p1 p2

PUMPS
COST

MANUFACTURIN G TECHNIQUES

PROCESS VARIATIONS

STRENGTH

MATERIAL & MATERIAL COMBINATION

PROCESS UPSET CONDITIONS

CORROSION

CAVITATION

EROSION

FACTORS AFFECTING MATERIAL SUITABILITY FOR PUMPS

PUMPS
TYPICAL MATERIALS
MATERIAL WITH IRON AS ITS MAIN CONSTITUTENT MATERIAL WITH SIGNIFICANT PROPORTIONS OF Cr & Ni MATERIAL WITH Cu OR Al AS ITS MAIN CONSTITUENTS OTHER METALLIC MATERIALS NON METALLIC MATERIALS

PUMPS
COMMONLY USED MATERIAL COMBINATIONS FOR CENTRIFUGAL PUMP
CASING
GREY CAST IRON GREY CAST IRON GREY CAST IRON GREY CAST IRON S. G. IRON CAST STEEL CAST STEEL CAST STEEL CAST STEEL CAST STEEL 13 Cr STEEL STAINLESS STEEL TITANIUM

IMPELLER
GREY CAST IRON GUN METAL PLASTIC STAINLESS STEEL STAINLESS STEEL GREY CAST IRON CAST STEEL BRONZE 13 Cr STEEL STAINLESS STEEL 13 Cr STEEL STAINLESS STEEL TITANIUM

SHAFT
STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL STEEL STEEL STEEL STEEL STAINLESS STEEL 13 Cr STEEL STAINLESS STEEL TITANIUM

APPROX. RELATIVE COST

0.97 1.0 0.95 1.08 1.25 1.1 1.2 1.25 1.3 1.5 1.4 1.8 10

PUMPS
MATERIAL STANDARDS
MATERIAL
CAST IRON Ni RESIST CARBON STEEL SS 304 SS 316 SS 410 K MONEL BRONZE CF8M CF8C CA 15 CAST STEEL Al. BRONZE IS 305 Gr.2 BS 3100 410 C 21 BS 1504 101A IS 1570 Gr. 05Cr18Ni11Mo3 GREY CAST IRON IS 3444 Gr. 22 IS 318 Gr. LTB 2 IS 3444 Gr. 9

IS
IS 210, Gr. FG 260 IS2749, Gr. AFG Ni 15Cu 6 Cr3 IS 1570 Gr. 40C8

EQUIVALENT INTERNATIONAL STANDARD BS

BS 1452 Gr. 250 BS 3468 AUS 102 Gr. B BS 970 080M40 BS 970 304S15 BS 970 304S16 BS 970 410S21 STEEL BS 1400 LG 2C BS 1632 Gr. B

ASTM
ASTM A 48 CL 35 ASTM A 436 TYPE 2 ASTM A 107 Gr. 1040 ASTM A 276 TYPE 304 ASTM A 276 TYPE 316 ASTM A 276 TYPE 410 ASTM A 743 Gr. M-35 ASTM B 62, B145 ALLOY 4A ASTM A 351 Gr. CF8M ASTM A 351 Gr. CF8C ASTM A 217 Gr. CA 15 ASTM A216 Gr. WCB ASTM B 148, B271 ALLOY 9A

PUMPS
MATERIAL OF CENTRIFUGAL PUMP & MAIN AREAS OF APPLICATION MATERIALS
CAST STEEL SG IRON, NODULAR IRON GREY CAST IRON 13 Cr STEEL

APPLICATIONS
DE-AERATED HOT WATER, BOILER FEED PUMPS AS ABOVE. BETTER RESISTANCE TO CORROSION AT HIGH LIQUID VELOCITIES THAN CAST STEEL BUT NOT AS GOOD AS CI HAS GOOD RESISTANCE TO MANY FLUIDS 120O C MAXIMUM, pH > 5.5 DE AERATED HOT WATER, BOILER FEED PUMPS 360O C, A GOOD REPLACEMENT OF CAST STEEL ABOVE 200O C BETTER THERMAL STABILITY HIGHER PRESSURE CAPABILITIES RESISTANT TO ACID CORROSION, HCL, H2SO4 AND STRONG SALT SOLUTIONS NOT SUITABLE FOR THERMAL SHOCK HOT, SEA WATER SALT WATER, SEA WATER, BRINE & OTHER MODERATELY CORROSIVE WATER SOLUTIONS SEA WATER, BRINE BFP, GENERAL CORROSIVE APPLICATIONS, POOR IN CHLORIDE SOLUTION VERY RESISTANT TO CORROSION CHLORIDE SOLUTIONS

Si IRON 14Si

Ni RESIST, 20Ni3Cr GUN METAL, BRONZE MONEL AUSTENITIC SS HAST ALLOY C TITANIUM

PUMPS
H+ CONCENTRATION mol/l OH- CONCENTRATION mol/l

101

102

103

104

105

106

107

106

105

104

103

102

101

pH

10

11

12

13

14

STRONG ACID

WEAK ACID

WEAK ALKALINE

STRONG ALKALINE

NEUTRAL

ION CONCENTRATION, pH VALUE, DEGREE OF ACIDITY AND ALKALINITY

PUMPS
SULPHURIC ACID 10% FORMIC ACID WINE CITRIC ACID 10% ACETIC ACID CONCENTRATED CARBONIC ACID AMMONIUM CHLORIDE BORIC ACID

STAINLESS STEEL, PLASTIC

ACID HCL , H2SO4, HNO3 CONCENTRATED

1 2 3
CIDER WINE LEMON VINEGAR ORANGE GRAPE FRUIT BEER TOMATO CABBAGE COWS MILK MOTHERS MILK SEWAGE EGG WHITE HOUSE HOLD WASHING UP & CLEANING PREPARATIONS SALIVA STOMACH ACID

4 5 6 7 8 9 10 11 12 13 14
DRINKING WATER

HUMUS ACID

BRONZE,CAST IRON,STEEL ALLOYS

BRONZE

NEUTRAL

SODIUM BICARBONATE 10% NATRON SOAP MAGNESIA BORAX 1% MAGNESIUM HYDROXIDE AMMONIA 1% AMMONIA CONCENTRATED, NaOH 1% NaOH 10% KOH 10% NaOH CONCENTRATED KOH CONCENTRATED

STAINLESS STEEL, PLASTIC,Ni-Si ALLOYS,CAST IRON

OH- CONCENTRATION

H+ CONCENTRATION