01 - Trainning Material - Basic Pump Theory PDF

DOOSAN HEAVY INDUSTRIEC CO., LTD.
JEBEL ALI POWER AND DESALINATION STATION M

TRAINING OF HORIZONTAL & VERTICAL PUMP OPERATION
AND MAINTENANCE
2010. 04.
HYOSUNG GOODSPRINGS, INC.
HYOSUNG GOODSPRINGS,INC.
1 / 68
Contents
BASIC & APPLICATION OF PUMP
OPERATION AND MAINTENANCE
2 / 68
Classification & Types of Pumps
CENTRIFUGAL VOLUTE CENTRIFUGAL PUMP
TURBINE CENTRIFUGAL PUMP
VOLUTE CENTRIFUGAL PUMP
Volute Pump
Multi Pump
TURBO MIXED FLOW
VOLUTE CENTRIFUGAL PUMP
DIFFUSER CENTRIFUGAL PUMP
AXIAL FLOW
AXIAL FLOW PUMP
p
P
U
POSITIVE
RECIPROCATING PISTON, PLUNGER, DIAPHARM
ROTARY GEAR VAME NASA SCREW
VORTEX
JET PUMP
Axial Flow Mixed Flow
M
P
ROTARY GEAR, VAME, NASA, SCREW
WETSCO
VISICOCITY
INERTIA PUMP Diaphragm Pump
Reciprocating Gear Pump
Axial Flow Mixed Flow
P
SPECIAL
BUBBLE PUMP
MAGNETIC PUMP
VACUUM PUMP
Screw Pump
p g
Vane Pump
TUBE Pump
p
Lobe Pump
3 / 68
Pump
4 / 68
Impeller Type & Configuration
AXIAL FLOW
MIXED FLOW
DOUBLE
SUCTION
SINGLE
SUCTION
MIXED FLOW
SUCTION
SEMI-OPEN NON-CLOGGING
WESTCO
OPEN
5 / 68
Impeller Type & Configuration
DOUBLE SUCTION
SINGLE SUCTION
CLOSE TYPE
SEMI-OPEN TYPE
OPEN TYPE
CENTRIFUGAL SCREW VORTEX NON-CLOGGING
6 / 68
C UG SC O O C OGG G
Type Description Remark
Turbo
Centrifugal
Mixed flow
helical diagonal
General
Type Description Remark
Foot mounted
Frame mounted
Lantern mounted
Turbo
machine
- helical, diagonal
Axial flow
Channel
- Side channel, Peripheral
General
classification
Single- stage
Mounting
Lantern mounted
Pedestal mounted
Flange mounted
Wall mounted
Tank mounted
Pi li t d
Method of
mounting the
pump
Stage
Single stage
Two-stage
Multi-stage
Centrifugal
pumps only
Pressure
Low-pressure
High-pressure
Discharge
pressure
Pipeline mounted
Shaft
Direct mounted
Integral
Overhung
g p
Super-pressure
p
developed
Inlet entry
Single/double entry
Axial inlet
Side inlet Suction
Casing
halves
division
Overhung
Split casing (Axial,
Radial, Diagonally
split)
Casing division
where applicable
H i l
Inlet entry
Top inlet (top suction)
Bottom inlet (Bottom
suction
geometry
Single-volute
Layout
Horizontal
Vertical
Inclined
Basic layout of
turbo machine
Casing
shape
Double-volute
Diffuser
Bowl
Tubular
Angle/Barrel
Based on shape
of casing
Etc.
Wet sump pump
Dry sump pump
Canned motor p/p
Wet motor p/p
Submersible p/p
7 / 68
Angle/Barrel
Submersible p/p
TOP
Definition of Suction & Discharge Nozzle Direction
SIDE
END
SIDE
BOTTOM
8 / 68
Liquid (High Temp.);
Heat expansion occur at
lower area of casing
BACK PULLOUT TYPE
lower area of casing.
So alignment become
unbalanced.
BACK PULL OUT TYPE
Without disassembling
piping & a driver, a pump
b di tl d il
CENTERLINE
MOUNTING
FOOT
MOUNTING
can be dismantled easily.
This type needs a SPACER
COUPLING.
9 / 68
Classification by Mounting
CENTERLINE
MOUNTING
BRACKET
O G
MOUNTING
MOUNTING
IN-LINE
VERTICAL FOOT
MOUNTING
10 / 68
IN LINE
MOUNTING
VERTICAL PUMP END SUCTION PUMP
Classification by Inlet Geometry
FOOT
BRACKET
VERTICAL
(PULL OUT TYPE)
MIXED
CLOSE COUPLED IN- LINE
VERTICAL
(PULL OUT TYPE)
MULTI STAGE PUMP
DOUBLE SUCTION
HORIZ-
11 / 68
HORIZ
ONTAL
VERTICAL
Overhung Centrifugal Pump(General Service Pump)
CONSTRUCTION CONSTRUCTION
Separate bearing bracket with grease
or self-contained oiling system
Separate bearing bracket with grease
or self-contained oiling system
Anti-friction radial and thrust bearing
Overhung impeller mounting
Anti-friction radial and thrust bearing
Overhung impeller mounting
Case either foot mounted or centerline
mounted
Case either foot mounted or centerline
mounted
Bearing housing provided with cooling
fins or fan for process pump
Bearing housing provided with cooling
fins or fan for process pump
Overhung Radial Split
12 / 68
Multi-Stage Centrifugal Pump
Radial split casing with nozzles located
in either side or top case
Radial split casing with nozzles located
in either side or top case
Impellers arranged in parallel sets
Stuffing boxes fitted with mechanical seal
Impellers arranged in parallel sets
or packing
Bearing lubrication can be either grease
or oil lubricated
or packing
or oil lubricated or oil lubricated.
Pump mounting on foot or bearing
bracket
or oil lubricated.
Pump mounting on foot or bearing
bracket
B t b i R di l S lit Between bearing Radial Split
13 / 68
Double Suction Horizontal Pump
Impeller is mounted between two external
bearing brackets
Impeller is mounted between two external
bearing brackets
Pump mounting is typically on case center
line
Pump mounting is typically on case center
line
or packing
or packing
Bearing lubrication can be either grease Bearing lubrication can be either grease
or oil lubricated.
Pump mounting is typically on foot
or oil lubricated.
Pump mounting is typically on foot p g yp y p g yp y
Between Bearing Axial Split
14 / 68
Volute & Turbine Pump Configuration
Volute pump Turbine pump
NOZZLE
NOZZLE
CASING CASING
IMPELLER
(diffuser)
IMPELLER
VOLUTE
CASING
IMPELLER
VOLUTE
CASING
SUCTION SUCTION
15 / 68
Radial thrust magnitude of volute casing
R
a
d
ii
a
l

R
e
a
c
t
i
o
n
BEP
n
Double Volute Casing has been employed to reduce
Flow Rate
radial thrust which is developed from the tip of impeller
There are two reaction forces opposing each other due
to symmetry of double volute casing
16 / 68
Axial Thrust Balance
Front Area < Back Area
L
Pressure Drop
After passage
Lower
Pressure
Area
No Balance Device With Balance Holes
The direction of axial thrust will forward toward
impeller suction inlet if no axial balance device
There would cause some trouble on bearing life
The effect of balance holes is to form passage of
fluid flow and in addition
Development of pressure drop due to friction loss
17 / 68
and strength of shaft
Balance of Axial Force Features Application
Balance of axial thrust
Achieve pressure drop in chamber when
fluid flows through clearance between wear
rings then the fluid flows toward impeller
suction through balance holes.
Inappropriate to apply concentration solid
t i l i i li id
Lower Speed for small &
medium centrifugal volute &
turbine pump
a
n
c
e

H
o
l
e
material in pumping liquid
Disadvantage on increase of leakage loss
Provision of Back Vane Ribs to reduce axial
thrust
Mainly applied open type
i ll
B
a
l
a
The number & diameter of back ribs as well
as clearance between tip of vane and casing
affect axial thrust so that it is necessary to
install adjustment device of clearance
Pumping Liquid for Slurry & solid
concentration
impellers
B
a
c
k

V
a
n
e
concentration
Disadvantage on increase friction loss
Provide balance disk at the rear of final stage
impeller then achieve pressure drop between
those clearance.
Applied high pressure
multistage pumps
D
i
s
k
Connection between Suction Casing and
Balance Pipe
No necessary to install thrust bearing
No application for foreign material of liquid
B
a
l
a
n
c
e

D
18 / 68
pp g q
B l f A i l F F t A li ti
Balance of axial thrust
Balance of Axial Force Features Application
No requirement balance device since a double
suction impeller is balanced due to symmetry
(Self balance)
Double Suction Volute Pump
c
e
( )
Necessary thrust bearing considering axial
thrust in piping system
Easy disassembly and inspection since casing
can be split upper and lower way.
S
e
l
f

B
a
l
a
n
c
Symmetry arrangement of impellers
Self thrust balance
Axially Split, Multi-Stage
Pump
Self thrust balance
Complex casing structure and necessary
casing pattern with same as stage of impellers
Possible on slurry & foreign liquid material
l
f

B
a
l
a
n
c
e
y g q
Disadvantage on increase of friction loss
S
e
l
19 / 68
Basic Hydraulic Performance
Specific Speed(Ns)
Definition : Specific Speed is the speed in RPM at which an impeller would run if reduced in size to deliver 1
m
3
/min against a total head of 1m. In order to determine impeller shape and geometry, total head, capacity & RPM
will be used as follows;
4
3
H
Q
N Ns =
where Ns = Specific Speed
O i S d[ ]
H
N = Operating Speed[RPM]
Q = Flow Rate at Best Efficiency Point [ m
3
/min]
H = Head Per Stage at BEP [m]
* Specific Speed is defined at Best Efficiency Point of pump. The capacity shall be divided by two(2) for double
suction pump. In case of multi-stage pump, total head shall be divided by the number of stages.
20 / 68
Specific Speed Ranges vs. Efficiency
21 / 68
30 40 455560 80 155 230 310390465 620 775 1550 2325 30 40 455560 80 155 230 310390465 620 775 1550 2325
WESTCO RADIAL FLOW MIXED FLOW AXIAL FLOW
22 / 68
WESTCO
Ns = 30 ~ 90
RADIAL FLOW
Ns = 85 ~ 620
MIXED FLOW
Ns = 390 ~ 1625
AXIAL FLOW
Ns=1160 ~ 2325
WESTCO RADIAL MIXED AXIAL
Specific speed determines
the pump characteristics.
HEAD HEAD
POWER
EFF.
NPSHre
23 / 68
Affinity Laws of Pump
Velocity triangle diagram will be equal in
case of that the geometry of two pumps
has similitude relationship
Velocity triangle diagram will be equal in
case of that the geometry of two pumps
has similitude relationship
3
' ' '
|
.
|
\
|
=
D
D
n
n
Q
Q
p
Flow(Q) varies directly as the ration of
change of speed(N) or impeller diameter(D)
p
Flow(Q) varies directly as the ration of
change of speed(N) or impeller diameter(D)
2 2
' ' '
|
.
|
\
|
|
.
|
\
|
=
D
D
n
n
H
H
| |
| | | |
5 3
D' '
H' Q'
L'
Head(H) varies as the square of the ratio of
speeds or impeller diameters
Head(H) varies as the square of the ratio of
speeds or impeller diameters
|
|
.
|
\
|
|
.
|
\
|
|
.
|
\
|

=
'
5 3
p
p
p
p
D
D'
n
n'
' H Q
H' Q'
L
L'
q
q
Pump brake horse power varies as the
cube of the ratio of speeds and impeller
diameters.
Pump brake horse power varies as the
cube of the ratio of speeds and impeller
diameters.
Where, L : Brake Horse Power
n : RPM in Pump
D : Impeller Diameter
: Pump Efficiency
p
q
24 / 68
Performance Characteristic with Change of RPM
3
' '
|
.
|
\
|
=
n
n
L
L
2
' '
|
.
|
\
|
=
n
n
H
H
Actual System Curve
Cube Curve
Square Curve
. \
n L
. \
n H
Actual System Curve
Power
Total head Operating Condition
Pump Characteristics will be changed in condition of rotation speed change within some
relationship as shown in Figures
Pump Characteristics will be changed in condition of rotation speed change within some
relationship as shown in Figures
In general Performance Change will be disregarded within 20% fluctuation of specified speed
Head(H) varies as the square of the ratio of speed or impeller diameters
Pump Brake Horse Power varies as the cube of the ratio of speeds and impeller diameters
In general Performance Change will be disregarded within 20% fluctuation of specified speed
Head(H) varies as the square of the ratio of speed or impeller diameters
Pump Brake Horse Power varies as the cube of the ratio of speeds and impeller diameters
25 / 68
Pump Brake Horse Power varies as the cube of the ratio of speeds and impeller diameters. Pump Brake Horse Power varies as the cube of the ratio of speeds and impeller diameters.
Performance Characteristic in Reduced Impeller
3
|
|
|
D Q
' '
|
.
\
=
D Q
Q
Trimmed Impeller Diameter
Effect of Pump Performance due to Reduced
Impeller Diameter
Trimming of Impeller Outer Diameter is alternative to adjust pump characteristics g p j p p
Machining of Impeller Outer Diameter is recommended for centrifugal type pump.
Angle Adjustment for Axial Propeller Pump
Reference of Point P which is intersection between Impeller Inlet and Outlet is Optimumfor
26 / 68
Reference of Point P which is intersection between Impeller Inlet and Outlet is Optimum for
Mixed Flow Pump
Section 3. Cavitation in Centrifugal Pumps Section 3. Cavitation in Centrifugal Pumps
27 / 68
Cavitation in Centrifugal Pumps
Formation of Air
Air bubbles will be produced in pumping liquid due to a local pressure drop when
the pressure of liquid is below saturated vapor pressure at operated temperature
Development of Cavitation
Bubbles
Definition
the pressure of liquid is below saturated vapor pressure at operated temperature.
A local decrease in pressure is occurred by (1) an increase in velocity (2)
development vortex (3) passing obstruction to the flow called as Cavitation.
Sign of Cavitation
This is produced at the entrance of impeller eye.
1. The air bubbles flow with streamline of pumping liquid.
2. When reached at higher pressure, the vapor bubbles will collapse abruptly.
At the same time, vibration and noise shall be observed.
3. Finally the pump will not be operated.
If a pump is operated under cavitation conditions for a long period of time,
i ll t l ill b itti d d d d t h k d h impeller metal will be pitting and damaged due to shock pressure occurred when
collapse of bubbles. As a result, the suction condition should be considered at the
determination of pump
Collapse Collapse of of Vapor Vapor Bubbles Bubbles
Formation of Air Bubbles Collapse of Vapor Bubbles and Pitting
Pressure of Bubble Pressure of Bubble
Collapse !!! Collapse !!!
300 300//
(by Hallers Experiment)
28 / 68
Formation of Air Bubbles Collapse of Vapor Bubbles and Pitting
Pressure Distribution of Suction Entrance (NPSHre vs NPSHav)
A pressure drop at Impeller
Entrance = NPSH re(head)
Impeller Exit
Suction
Impeller Velocity Head = Vs/2g
NPSHre
NPSHav
Absolute
P 0
NPSHav - NPSHre > 1m
Pressure Head =Pv/
NPSH Margin > 1m
29 / 68
Pressure 0
Pump Performance and Cavitation
Relationship of pump performance and cavitations
NPSHav
Relationship of pump performance and cavitations
NPSH re
H - Q Curve NPSH av
NPSH
NPSHav < NPSHre
Pressure & Flow Drop
HEAD
Efficiency Drop
Efficiency
EFFICIENCY
Stable Operation
Range
EFFICIENCY
Unstable
Operation Range
30 / 68
Range Operation Range
Available Net Positive Suction Head (NPSHav)
Definition : The value of NPSHav shall be determined with the condition of pump suction pipe and system.
It has no relationship with pump. It has no relationship with pump.
NPSHav=hsv=Ps/ NPSHav=hsv=Ps/ -- Pv/ Pv/ hs hs -- fVs fVs/ /2 2gg
where , hsv : NPSH Available (m)
Ps : Suction Surface Pressure (kgf/ abs) ( g )
Pv : Liquid Vapor Pressure at operating temperature (kgf/ abs)
: Specific Gravity at operation temperature (kgf/m3)
hs : Height of Suction referred to a datum(m) [Suction Lift (-) Flooded Suction (+)] hs : Height of Suction referred to a datum(m), [Suction Lift ( ), Flooded Suction (+)]
fVs/2g : Total Loss Head at suction pipe(m)
31 / 68
Datum of Available Net Positive Suction Head (NPSHav)
Datum
Datum
Datum in terms of Pump Type and Installation
32 / 68
Calculation of NPSH available
Suction Lift (Atmospheric Pressure at Suction Surface Suction Lift (Atmospheric Pressure at Suction Surface)
l s v a
h h P P NPSHav = ) (
10
, Pa : Atmospheric (1.03 Kgf/cabs)

Pv : Vapor Pressure of Liquid (Kgf/cabs)
: Specific Gravity of Liquid (Kg/)
: Specific Gravity of Liquid (Kg/)

h
s
: Actual Suction Head(m)
h
l
: Total Suction Loss Head(m)
Flooded Suction Flooded Suction (Atmospheric Pressure at Suction Surface)
l s v a
h h P P NPSHav + = ) (
10
33 / 68
Calculation of NPSH available
Closed Tank
h h P P P NPSHav + = ) (
10
l s v a g
h h P P P NPSHav + = ) (
where, Pg : Pressure in closed tanks (Kgf/cgauge)

If the liquid in suction closed tank is the same with vapor pressure,
NPSH available becomes
h h NPSH
l s
h h NPSHav =
34 / 68
Predetermination of Cavitation Condition
Suction specific speed
; Dimensionless rating number which indicates the relative
ability of centrifugal pumps to operate under conditions of
low available net positive suction head
n Hsv Q S =
4
3
2
1
/
p
The following equation with conversion factor will be
applied except S=1300
NPSHre= x NPSHre
Where NPSHre' : Required NPSH at Specification Where NPSHre : Required NPSH at Specification
NPSHre : Required NPSH at S=1300
: Conversion factor of NPSHre
C
o
n
v
e
r
s
i
F
a
c
t
o
r
Suction Specific Speed
i
o
n

r
35 / 68
The Prediction of NPSHre according to Q, N
Conversion Factor of NPSHre
Suction Specific Speed
Predetermination of Cavitation Condition
Thoma Coefficient Thoma Coefficient
where H : Total Head at Full Impeller Diameter
H NPSHre H Hsv / / = = o
C
o
e
f
f
i
c
i
e
n
t
where, H : Total Head at Full Impeller Diameter
Hsv : NSPH required
The value of cavitation coefficient, , is determined by
i t l I f lti t th 1
st
t
T
h
o
m
a

C
experimental. In case of multi-stage pump, the 1
st
stage
impeller is total head for NPSH calculation.
Ns
36 / 68
Coefficient of Thoma Cavitation
Stable operation
diti
For stable pump operation without cavitation trouble, the suction pressure at
impeller eye shall be higher than liquid vapor pressure which is[ NPSHav >
Stable Operation Condition
condition
impeller eye shall be higher than liquid vapor pressure which is[ NPSHav >
NPSHre x (1 + )]. In general it is safe that the margin shall be no later than 0.3
and NPSHre x 0.3 0.5 for minimum requirement.
Stable Operation
Possible Operating Range Left Side
refer to A design condition
Impossible Operating Range Right Impossible Operating Range Right
Side refer to A design condition
Not Allowable
Allowable Operation Range
37 / 68
Relationship between NPSHav and NPSHre
Specific speed characterize the overall impeller profile shape. Suction specific
speed(Nss) characterized the eye size for give specific speed.(Ns)
38 / 68
C t f i i i t it ti b bbl f ti d th t f ll b ili
39 / 68
Concept of incipient cavitation, bubble formation and growth to full boiling
(a) Hemispherical bubble attached to wall ( ) p
(b) Bubble moving into pressure gradient
(such as venturi diffuser flow)
(c) Bubble collapsing near wall
40 / 68
(c) Bubble collapsing near wall
Suction Condition will be improved by installation Suction Condition will be improved by installation
Prevention of Cavitation
of Inducer which is located at pump suction. It will
make fluid flow smooth and reduce friction loss.
of Inducer which is located at pump suction. It will
make fluid flow smooth and reduce friction loss.
41 / 68
Sign of Surging
Pressure pulsation in a pressure gage indicator with high magnitude periodically during
pump operation
The discharge flow rate is changed with some extent of specified condition in period
Prevention of Surging
Cause
The discharge flow rate is changed with some extent of specified condition in period
Produce period noise and vibration at suction and discharge pipe
Unstable Head Characteristic in Figure 1
The length of discharge pipe is long and the collection of air in the middle of piping in
Figure 2 Figure 2
Control Discharge Valve B where located in the downstream
Operation at below of discharge flow Q
Prevention Apply a pump with continuous rising head characteristics Prevention Apply a pump with continuous rising head characteristics
Locate discharge flow valve at the pump discharge
Use bypass pipe to achieve continuous rising head characteristics
Piping design to acquire no area where are would be gathered Piping design to acquire no area where are would be gathered
Tank
Pump
Valve B
Valve A
42 / 68
Figure 1
Figure 2
Section 4. Starting Torque & Operation Section 4. Starting Torque & Operation g q p g q p
43 / 68
Starting torque and operation
A li ti
General Centrifugal Pump (BHP at Shut Off < 1)
Starting Discharge V/V Closed
Application
Characteristics
General Centrifugal Pump (BHP at Shut-Off < 1)
Starting Torque increases cube of RPM until the normal speed reaches from stopping of
pump
Starting Torque is the same as zero capacity approximately when normal speed reaches Starting Torque is the same as zero capacity approximately when normal speed reaches
Starting Torque of motor increases square of RPM approximately. Shut-off Torque(T2)
reach Point C as shown on Fig. 1 Toque Characteristics
- T1 : Torque to overcome the static mechanical friction and rotor inertia moment
(Approximately 10~30%of Rating Torque T3) (Approximately 10 30% of Rating Torque, T3)
- T2 : RPM 100% ( B C : Water Horse Torque)
- T3 : Discharge Flow Rate 100% ( C D : Brake Horse Torque)
Sequence of
Starting Torque
Ch t i ti
Torque,
%
Characteristic
A B C D
Flow Rate, %
RPM%
44 / 68
A B C D
Fig. 1 Torque Characteristics at Discharge Valve Closed
RPM,%
Starting Discharge V/V Opened
Application
Characterstics
Application of General Centrifugal Pump (BHP at Shut-Off < 1)
Starting pumping from partial speed, n (variable point D).
When reached 100% of RPM, Starting Torque becomes Rating Torque T3 since rating
flow begins as shown on Fig 2.
Starting Torque is higher than starting when discharge valve closed
Sequence of
Torque,
Power
Sequence of
Starting Torque
Characteristic
Torque,
%
System Resistance Curve
A B D E
RPM,%
Flow Rate, %
45 / 68
Fig. 2 Torque Characteristics at Discharge Valve Opened
Starting Discharge V/V Opened
Application
Characteristics
Axial-Flow Pump
Rating Toruqe, T3, for axial flow pump is lower than T2, which is brake-horsepower at
shut-off Standard motor cannot obtain such T2 pull-in torque as shown on Fig 3 shut off. Standard motor cannot obtain such T2 pull in torque as shown on Fig 3.
Sequence of Torque
Torque,
%
Torque
(Power)
%
A B D E
RPM,%
Flow Rate, %
System Resistance Curve
46 / 68
Fig 3. Starting-Torque Characteristics for Axial-Flow Pump
Section 5. Pump Operating Point Section 5. Pump Operating Point p p g p p g
47 / 68
PUMP OPERATING POINT
Actual Head
Constant
Operating Point : An intersection, A of H-Q curve and system curve
If the system curve is changed to R then the operating point is B
Actual Head ; Constant
48 / 68
Actual Head
Changeable
Operating Point : The range of an intersection of H-Q curve and R, R
g
Actual Head Change
Actual Head ; Changeable
Dis. Rate Change
49 / 68
Valve Control
Operating Point : An intersection of H-Q curve and each system curve
By controlling the open and close of the discharge valve the system
curve R is changed curve, R is changed.
Valve Loss
Pipe Loss
Valve Control
50 / 68
Velocity
Control
Operating Point : A1 B2 B3
An intersection of the new H-Q curve (n1, n2, n3) and a system
curve
Velocity Control
51 / 68
Parallel Parallel and and Series Series Operation Operation
According to the shape of a system curve, parallel or series operation is determined.
In case of an intersection, a, which has both parallel and series characteristic, the choice is limited. , , p ,
A system curve, R1 is lower than R2 Parallel operation is profitable.
A system curve, R3 is higher than R2 Series operation is profitable.
In case of the actual head and a system curve is changed widely, combine 2 pumps in series or parallel.
52 / 68
Characteristic of Parallel and Series Operation of the same pumps
Section 6. Temperature Rise & Over-Heating in Pumps Section 6. Temperature Rise & Over-Heating in Pumps p g p p g p
53 / 68
Temperature rise & Overheating in pump
Temperature Rise
The temperature of operating liquid rises since the power of motor will be converted to
heat when either zero-capacity or less than minimum flow of pump operation.
Temperature Rise & Preventive
Decrease the ratio of temperature rise sharply till some discharge flow rate
Increase with total head characteristics
Temperature rise will be higher If RPM increase at the same discharge head.
Effects of
OverHeating
Occur thermal distortion.
Produce Cavitation Problem due to development of vapor
Seizure between Rotating Element.
Possible to occur vapor explosion
** Prevention Countermeasure Prevention Countermeasure
Install Relief V/V continuous
operated
Use check valve with automatic
d i l
T
e
m
p
e
r
a
t
u
r
rate
device valve
Operate Relief Valve sensing flow
rate
Temperature Rise
Capacity m3/min
r
e

R
i
s
e
H
T
e
m
E
f
54 / 68
Fig. 1 Water Temperature Rise Curve Fig. 2 Typical Temperature Rise Curve
Capacity, m3/min
Pump Efficiency
H
e
a
d
m
p
.

r
i
s
e
f
f
i
c
i
e
n
c
y
Temperature rise & Overheating in pump
CASE OF PUMP CASE EXPLOSION DUE CASE OF PUMP CASE EXPLOSION DUE
TO SHUT-OFF OPERATION
1 hour operation during discharge v/v closed
TO SHUT-OFF OPERATION
1 hour operation during discharge v/v closed p g g
Shut off pressure ; 10.3kgf/cm
2
Vapor pressure : 15.7kgf/cm
2
Max casing pressure : 26kg/cm2
p g g
Shut off pressure ; 10.3kgf/cm
2
Vapor pressure : 15.7kgf/cm
2
Max casing pressure : 26kg/cm2 Max. casing pressure : 26kg/cm2
T = 184
Max. casing pressure : 26kg/cm2
T = 184
55 / 68
Section 7. Case Study: Pump Trouble Section 7. Case Study: Pump Trouble y p y p
56 / 68
Case Study: Pump Trouble
Customer : N Steel Company (Japan), MODEL : VMF350-390 , Service : Pressure Filter Feed Pump
Effect
Crack occurred Crack occurred
Shaft was cut
Because of cavitation, the holes are
made on the surface of a suction bell
Crack occurred
made on the surface of a suction bell.
Crack occurred
Vibration occurred
Suction bell
Destruction
57 / 68
CASING =GC250, 2000.11.22.
Changed water inflow
(150mm, 7 holes)
PUMP3 PUMP2 PUMP1
Cause
A suction bell was cut
by induced bubbles
Unstable water flow
Vibration occurred.
The original
water inflow water inflow
(CLOSED)
Crack was occurred.
BAFFLE
Rotating parts were stuck
Then the shaft was cut.
Bubble WALL
BAFFLE
58 / 68
Bubble WALL
Customer : P Steel Company , MODEL : HDR 300-400B , Service : Water Treatment Facility
Effect
Because the flow
rate was small, the
impeller was p
damaged.
A i ll An impeller
Material
: GC200
59 / 68
: GC200
Cause
1. The suction strainer was closed. ( Among 4pumps, 2 were closed and the other were not.)
2 The water fromBYPASS pipelines was dropped then bubbles were induced into pump suction 2. The water fromBY-PASS pipelines was dropped then bubbles were induced into pump suction.
It became the cause of cavitation.
3. Because a suction bell mouth is horizontal, the probability of inducing air is increased.
Solution
WRONG
RECOMMENDED
1. BY-PASS pipeline should be 1. BY PASS pipeline should be
location which is far from pump
suction.
2 Th d f i li t b 2. The end of pipelines must be
under the water and install a baffle
to eliminate the flow of the bubbles
PUMP SUCTION
B
A
F
F
L
E
into the pump suction.
60 / 68
Customer : L Oil Company, MODEL: 150x80 UCW 40 , Service : DESALTED WATER PUMP
Effect
Impossible to rotate
A ball was damaged.
Impossible to rotate
A shaft was damaged.
1995 07 21
61 / 68
1995.07.21.
Customer : S Oil Company, MODEL : 250x200 KS-40, Service : HVGO pump
Cause
When performing the weld at site, the electricity was induced inside a pump.
So spark was occurred in a gap of the bearing. So spark was occurred in a gap of the bearing.
WELD
Melted
Metal
Compression
(0.5~1mm)
High temp.
Expansion
Spark
T t
ARC WELD
POINT WELD
Spark was made SPARK caused the weld.
Flaking was
occurred
Balls and the shaft
were damaged.
Compression was
occurred by high temp.
Test
POINT WELD
It was impossible
to rotate.
A bearing was damaged and
62 / 68
A bearing was damaged and
became useless.
Customer : L Oil Company, MODEL : 50x40UCWM-25, Service : RECYCLE LIQUID PUMP
Effect
The oil color was changed.
Cause
The oil level was lowered but the oil wasnt supplied from an oiler. (04.01.20)
OIL LEVEL
Current
Oil Level
Gauge
TRICO
Oil Level
Gauge g g
OIL LEVEL POSITION
Half of a brain bottle
was empty but the oil
wasnt supplied.
In case of a current oil level gauge, if it
is stood, then the oil cant be supplied.
However if a TRICO oil level gauge is used,
then the problem can be solved
63 / 68
then the problem can be solved.
1. Attach an oil level
gauge to a
rotating part rotating part.
2. Install an auto-air
vent.
3 Avoid the effect of 3. Avoid the effect of
wind.
64 / 68
Customer : H Chemical Corp., MODEL :50x40 IFWM 1613, Service : Waste Solvent Transfer Pump
Effect
2003.03.03. Material : SSC14, Liquid : HEXANE
Cause
During implementing test working,
65 / 68
Highly corrosive and unstable was induced.
Customer : P Steel Company, MODEL : HDR200-500 , Service : Cooling Water Pump
Effect Cause
By mixing of corrosive liquid and water,
the impeller was corroded during pump operation.
- PH 2.2~PH2.6
- Corrosion is concentrated on the end of impeller vanes.
- The corrosion caused by cavitation starts from an entrance
f th of the vanes.
- Elbow, shaft, key and etc. were also corroded.
Material: GC200 2003 03 12
66 / 68
Material: GC200, 2003.03.12
67 / 68
68 / 68

01 - Trainning Material - Basic Pump Theory PDF

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JEBEL ALI POWER AND DESALINATION STATION M

, Pa : Atmospheric (1.03 Kgf/cabs)

: Specific Gravity of Liquid (Kg/)

where, Pg : Pressure in closed tanks (Kgf/cgauge)

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