MULTISTAGE CENTRIFUGAL PUMP TEST RIG

INTRODUCTION: In general a pump may be defined as a mechanical device which, when interposed in a pipe line, converts the mechanical energy supplied to it from some external source into hydraulic energy, thus resulting in the flow of liquid from lower potential to higher potential. The pumps are of major concern to most engineers and technicians. The types of pump vary in principle and design. The selection of the pump for any particular application is to be done by understanding their characteristics. The most commonly used pumps for domestic, agricultural and industrial purposes are: Centrifugal, Piston, Axial flow (stage pumps), Air jet, Diaphragm and Turbine pumps. Most of these pumps fall into the main class, namely; Rotodynamic, Reciprocating (positive displacement), Fluid (air) operated pumps. While the principle of operation of other pumps is discussed elsewhere, the Multistage Centrifugal Pump which is of present concern falls into the category of roto dynamic pumps. In this pump, the liquid is made to rotate in a closed chamber (volute casing) thus creating the Centrifugal action which gradually builds the pressure gradient towards outlet thus resulting in the continuous flow. These pumps compared to reciprocating pumps are simple in construction, more suitable for handling viscous, turbid (muddy) liquids, can be directly coupled to high speed electric motors (without any speed reduction), easy to maintain. But, their hydraulic heads per stage at low flow rates is limited, and hence not suitable for very high heads compared to reciprocating pumps of same capacity and stage. But, as the pump is of Multistage (Fourstage) construction, the pressure gradually builds up in successive stages, all most equally in stage.

The present test rig allows the students to understand and draw the operating characteristics at various heads, flow rates and speeds, and also study the pressure buildup pattern in all the four stages. DESCRIPTION: The present pump test rig is a self-contained unit operated on closed circuit basis. The Pump, Electric Motor, Collecting Tank, Sump Tank, Control panel are arranged with the following provisions:
1. For conducting the experiments at constant speed. 2. To measuring the input power to the pump by Energy meter.

3. For recording the RPM using Digital RPM indicator. 4. For recording the pressure in each stage and vacuum. 5. For changing the pressure (Delivery head) by operating the valve. 6. For measuring the discharge by collecting tank height gauge provision.
7. For re circulating of water back to the sump tank by overflow provision.

SPECIFICATIONS: * Electrical Supply * Motor * Centrifugal Pump * Pressure Gauges * Vacuum Gauge * Energy meter constant * Speed Indicator * Control Valves * Measuring (meter in) Tank Size

: : : : : : : :

230V, 15A, AC, 1 Phase, 50 Hz with Neutral & earth Connections. AC Motor, 7.5 HP, 2880 RPM. 7.5 HP, 2875 RPM with Four stages. 4 Nos. 0 - 760 mm of Hg. 100 Rev./KW-Hr. 0 - 9999 RPM (Digital Type). For Delivery. 0.23 m2.

OPERATING INSTRUCTIONS: All the necessary instrumentations along with its accessories are readily connected. It is just enough to follow the instructions below:
1. Fill in the Sump Tank with clean water. 2. Keep the delivery valve, gate valve open (Wheel valve) & keep the

sphere fully closed.

3. Connect the power cable to 3 ph, 440V, and 20A with earth connection. 4. Switch-ON the Mains, so that the Mains-On Indicator glows.

Now,

Switch-ON the pump. 5. Now, you will find the water starts flowing to the Measuring Tank.
6. Close the delivery valve slightly, so that the delivery pressure is readable. 7. Operate the delivery valve to note down the collecting tank reading

against the known time and keep it open when the readings are not taken.
8. Note down the Pressures in each stage.

9. Note down the other readings as indicated in the tabular column. 10.Repeat the experiment for different openings of the delivery valve tabulate the readings. 11.After the experiment is over, keep the delivery open.

PRECAUTIONS AND THINGS TO REMEMBER: 1. Do not start the pump if the voltage is less than 300V. 2. Do not forget to give electrical neutral and earth connections correctly. 3. Add a little Machine Coolant to the water to prevent rusting of parts. 4. There is no danger of water being not there in the Sump Tank, since the Measuring Tank is fitted with overflow pipe. 5. Frequently (at least once in three months) Grease / Oil the rotating parts.

6. Initially, put clean water free from foreign material, and change once in three months. 7. At least every week, operate the unit for five minutes to prevent clogging of the moving parts. CONCLUSION: The performance curves are drawn for one particular speed. The similar curves could be drawn for other sets of readings. The characteristics curves obtained are similar to the typical curves normally obtained for this kind of pumps. An attempt has been made to give an insight to the students as to how the test rig can be used to draw the performance characteristics of various pumps. The performance curves also show the expected trend quantitatively. It should not be assumed as the quantitative analysis as the performance varies with suction, head and speed other than the ones created, and also gland packing tightness. The information presented in this report is to be looked into from the point of view of academic value rather than commercial value. A lot more information can be drawn using the test rig and from the knowledge of the standard text books.

TABLE OF READINGS
RPM OF PUMP: P Kg/cm2 Delivery pressure Vacuum Energy meter / Head stages. in mm of reading for Hg Pv n revn in I II III IV time t secs Discharge height of water collected in mm h Discharge taken in Secs T

TABLE OF CALCULATIONS
Head in meter Discharge in m3/sec Power output, HPpump in KW HPelec in KW HPshaft in KW %pump %overall

FORMULAE USED Basic data/ constants: 1. 1HP 2. 1kg/cm2 3. Density of water, W 4. Energy meter constant 5. Area of Collecting tank A 1. = = = = = 745 watts 760mm of Hg(10m of water) 1000 kg/m3 100 rev/ kw-hr 0.23 m2

Electrical Power as indicated by Energy Meter: HPelec = 3 1000 3600 ------------------------EMC t 1000

Where, t = Time for 1 Revolution in energy meter EMC (Energy meter constant) 100 rev / KW-Hr HPshaft = HPelec 0.85 0.85 = Motor efficiency. 2. Discharge Rate, Q: AR Q = ------------ m3/sec 1000 t Where, A = 0.23 m2 the area of collecting tank. t = Time taken in secs water in collecting tank. R = Height of water collected in mm. 3. Total Head: H = H = 2 Where, P = Kg/cm Pv = mm of Hg. 4. 10 (Delivery pressure + Vacuum Head) 10 (P+Pv/760)

Hydraulic Horse Power (Delivered by the Pump) : WQH HPPump = ----------1000 Where, W = 9810 N/m3 Q = Flow rate of water in m3/sec from formulae-2. H = Head on turbine in m from formula-3.
7

5.

Overall Efficiency: HPPump % = --------HPShaft Pump Efficiency: %Pump HPPump = -----------HPelec

6.

Sample Tabular Column:

MULTI STAGE CENTRIFUGAL PUMP TEST RIG. ENERGYMETER CONSTANT =100 rev/KW.hr AREA OF COLLECTING TANK = 0.23 m2 I STAGE Pressure P1 in kg/cm2 0 0 0.5 1 1.6 II STAGE Pressure P2 in kg/cm2 0.5 1.6 2.4 3 3.4 III STAGE Pressure P3 in kg/cm2 2.6 3.6 4.6 5.4 6.2 IV STAGE Pressure P4 in kg/cm2 4 5 6 7 8

Speed valve position 2868 2868 2868 2868 2869

Vaccum Pressure "Pv" 600 600 600 600 590

Delivery Pressure PI in kg/cm2 4 5 6 7 8

Time for "5"revs of energymeter,"t" 15.9 15.75 16.55 16.71 17.98

Rise in water level R in mm 200 200 200 200 200

Time Taken for rise in water "t"Sec 10.74 10.76 12.04 12.71 14.88

Total Head "H"in m 47.89 57.89 67.89 77.89 87.76

Discharge Qa in m3/sec 4.28E-03 4.28E-03 3.82E-03 3.62E-03 3.09E-03

Power output, Ppump in KW 2.012 2.428 2.545 2.766 2.662

PUMP INPUT (ELECTRICAL), HP ELEC, in KW 11.321 11.429 10.876 10.772 10.011

PUMP INPUT, HP SHAFT, in KW 9.623 9.714 9.245 9.156 8.509

EFFICIENCY OVERALL 17.78 21.25 23.40 25.67 26.59

EFFICIENCY PUMP 20.91 24.99 27.53 30.20 31.28

Graphs:

10

SAMPLE OF CALCULATION: For Delivery Pressure P4 = 5.2 Kg/cm2 Basic data/ constants: 1. 1HP 2. 1kg/cm2 3. Density of water, W 4. Energy meter constant 5. Area of Collecting tank A 1.

= = = = =

745 watts 760mm of Hg(10m of water) 1000 kg/m3 100 rev/ kw-hr 0.23 m2

Electrical Power as indicated by Energy Meter: HPelec = 5 1000 3600 ------------------------EMC t 1000

EMC = energy meter constant = 100 revolution / KW. Hr. t = Time for 5 revolution of energy meter. = = 5 1000 3600 --------------------------100 17.98 1000 10.011 KW

HPshaft = HPelec 0.85 = 10.011 0.85 = 8.509 KW 85% is the motor efficiency. 2. Discharge Rate Q in m3/sec: Ah Q = -------------- = 1000 T Where, A = h = T = 0.23 200 ------------------1000 14.88 =3.09 x10-3 m3/sec

0.23 m2 is the area of collecting tank. the height of water collected, 200 mm. the time taken in seconds for collecting water, read = 14.88 sec.
11

3.

Total Head H in m: H = 10 (Delivery Pressure + Vacuum Head) = 10 (P + Pv / 760) = 10 (8 + 590/760) = 87.76 m Where, P is the pressure in Kg/cm2 Stage IV. Pv is the Vacuum in mm of Hg.

4.

Hydraulic Horse Power (Delivered by the Pump) : WQH HPPump = --------1000 = = Where, W = Q = H = 9810 x 3.09 x10-3 x 87.76 ------------------------------1000 2.66 KW

9810 Kg/m3 from formula 2 from formula 3

5.

Overall Efficiency: HPPump % = --------- 100 HPelec 2.66 = ------------- 100 = 26.59 10.011

12

6.

Pump Efficiency: %Pump HPPump = -----------HPshaft

2.66 = ----------- 100 = 31.28 8.509

13