Pump

Technicalreportonpumpsandapplication

By; Majid hamedina

Technicalreportonpumpsandapplication

Introduction
Industrializationimposedaneverincreasingdemandformovingliquidsfromonelocationto anotherfarmorepracticallythanbygravity.Inordertomotivatetheliquidtomovethroughthe pipesandchannels,energyhastobeimpartedtotheliquid. Theenergy,usuallymechanical,providedbyaprimemoveristransferredtotheliquidbyadevice calledapump.Ithasalsogainedwideacceptanceinthehydraulicmachineryfieldbothbythe manufacturersandbytheircustomers. Pumpisadeviceusedtomovefluids,suchasgases,liquidsorslurries.Apumpdisplacesavolume byphysicalormechanicalaction.Onecommonmisconceptionaboutpumpsisthethoughtthatthey createpressure.Pumpsalonedonotcreatepressure;theyonlydisplacefluid, causing a flow. Adding resistance to flow causes pressure.

Classificationofpump
One general source of pump terminology, definitions, rules, and standards is the Hydraulic Institute (HI) Standards, approved by the American National Standards Institute (ANSI) as national standards. A classification of pumps by type, as defined by the HI, is shown in below diagram. Pumps are divided into two fundamental types based on the manner in which they transmit energy to the pumped media: kinetic or positive displacement. In kinetic displacement, a centrifugal force of the rotating element, called an impeller, impels kinetic energy to the fluid, moving the fluid from

pump suction to the discharge. On the other hand, positive displacement uses the reciprocating action of one or several pistons, or a squeezing action of meshing gears, lobes, or other moving bodies, to displace the media from one area into another (i.e., moving the material from suction to discharge). Sometimes the terms inlet (for suction) and exit or outlet (for discharge) are used. The pumped medium is usually liquid; however, many designs can handle solids in the forms of suspension, entrained or dissolved gas, paper pulp, mud, slurries, tars, and other exotic substances, that, at least by appearance, do not resemble liquids. Nevertheless, an overall liquid behavior must be exhibited by the medium in order to be pumped. In other words, the medium must have negligible resistance to tensile stresses. The HI classifies pumps by type, not by application. The user, however, must ultimately deal with specific applications. Often, based on personal experience, preference for a particular type of pump develops, and this preference is passed on in the particular industry. For example, boiler feed pumps are usually of a multistage diffuser barrel type, especially for the medium and high energy (over 1000 hp) applications, although volute pumps in single or multistage configurations, with radials or axially split casings, also have been applied successfully. Examples of pump types and applications and the reasons behind implicational preferences will follow.


Alltypeofpumpdiagram

Liquidtransfer
To truly understand pump operation, one need to carefully examine the specifics of each individual system in which a pump is installed and operating (see below picture).The main elements of a pumping system are: Supply side (suction or inlet side) Pump (with a driver) Delivery side (discharge or process)

Pumpinasystem

The energy delivered to a pump by the driver is spent on useful energy to move the fluid and to overcome losses:

From the pump user viewpoint, there are some major parameters of interest:

Flow:
Flow is a parameter that tells us how much of the fluid needs to be moved (i.e., transferring from a large storage tank to smaller drums for distribution and sale, adding chemicals to a process, etc.).

Pressure:
Tells us how much of the hydraulic resistance needs to be overcome by the pumping element, in order to move the fluid.

In a perfect world of zero losses, all of the input power would go into moving the flow against given pressure. We could say that all of the available driver power was spent on, or transferred to, a hydraulic (i.e., useful) power.

Capacity:
Imagine a piston steadily pushed against pressure, p, inside a pipe filled with liquid. During the time t, the piston will travel a distance L, and the exerting force F on a piston, is doing work to get this process going. From our school days, we remember that work equals force multiplied by
distance

W=F*d

for a steady motion, the force is balanced by the pressure p,

acting on area, A:

Work per unit of time equals power. So, dividing both sides of the equation by t, we get:

Q is the volume per unit of time, which in pump language is called flow, capacity, or delivery. Inside the pump, the fluid is moved against the pressure by a piston, rotary gear, or impeller, etc. (thus far assuming no losses).

Total system head:

"Head" is a very convenient term in the pumping business. Capacity is measured in gallons per

minute, and each gallon of liquid has weight, so we can easily calculate the pounds per minute being pumped. Head or height is measure in feet, so if we multiply these two together we get footpounds per minute which converts directly to work. Pressure is not as convenient a term because the amount of pressure that the pump will deliver depends upon the weight (specific gravity) of the liquid being pumped and the specific gravity changes with temperature, fluid, and fluid concentration.

Headofpumpdefinition

If you will refer to above figure, you should get a clear picture of what is meant by static head. Note that we always measure from the center line of the pump to the highest liquid level. To calculate head accurately we must calculate the total head on both the suction and discharge sides of the pump. In addition to the static head we will learn that there is a head caused by resistance in the piping, fittings and valves called friction head, and a head caused by any pressure that might be acting on the liquid in the tanks including atmospheric pressure, called "surface pressure head". Once we know these heads it gets simple, we will then subtract the suction head from the discharge head and the amount remaining will be the amount of head that the pump must be able to generate at the rated flow. Here is how it looks in a formula: System head = total discharge head - total suction head H = hd - hs The total discharge head is made from three separate heads: hd = hsd + hpd + hfd 1hd = total discharge head 2hsd = discharge static head 3hpd = discharge surface pressure head 4hfd = discharge friction head The total suction head also consists of three separate heads; hs = hss + hps - hfs hs = total suction head hss = suction static head hps = suction surface pressure head

hfs = suction friction head As we make these calculations, you must sure that all calculations are made in either "feet of liquid gauge" or "feet of liquid absolute". In case you have forgotten "absolute means that you have added atmospheric pressure (head) to the gauge reading.

Kinetic pump
Kinetic pumps are dynamic devices that impart the energy of motion (kinetic energy) to a liquid by use of a rotating impeller, propeller, or similar device. Kinetic pumps have the following characteristics: - Discharge is relatively free of pulsation. - Mechanical design lends itself to high throughputs, so that capacity limits are seldom a problem. - Efficient performance over a range of heads and capacities. - Discharge pressure is a function of fluid density and operational speed. - They are relatively small high speed devices. - They are economical.

Centrifugal pump
A centrifugal pump is known to be a pressure generator, vs. a flow generator, which a rotary pump is. Essentially, a centrifugal pump has a rotating element, or several of them, which impel (hence the name impeller) the energy to the fluid. A collector (volute or a diffuser) guides the fluid to discharge. A centrifugal pump is one of the simplest pieces of equipment in any process plant. The below figure shows how this type of pump operates: Liquid is forced into an impeller either by atmospheric pressure. The vanes of impeller pass kinetic energy to the liquid, thereby causing the liquid to rotate. The liquid leaves the impeller at high velocity. The impeller is surrounded by a volute casing. The volute or stationary diffuser ring converts the kinetic energy into pressure energy.

Centrifugalpumpcomponent

Take a look at the below figure, with regard to performance of pump we can conclude:

Head

Flow

The head and flow rate determine the performance of a pump, which is graphically shown in the Figure.

The figure shows a typical curve of a centrifugal pump where the head gradually decreases with increasing flow. As the resistance of a system increases, the head will also increase. This in turn causes the flow rate to decrease and will eventually reach zero. A zero flow rate is only acceptable for a short period without causing to the pump to burn out.

A centrifugal pump has two main components. First, a rotating component comprised of an impeller and a shaft. And secondly, a stationary component comprised of a casing, casing cover, and bearings. In the below pictures are shown.

Centrifugalpumpanditscomponents

Casing: have two functions The main function of casing is to enclose the impeller at suction and delivery ends and thereby form a pressure vessel. A second function of casing is to provide a supporting and bearing medium for the shaft and impeller. There are two types of casings Volute casing (see figure) has impellers that are fitted inside the casings. One of the main purposes is to help balance the hydraulic pressure on the shaft of the pump. Circular casing has stationary diffusion vanes surrounding the impeller periphery that convert speed into pressure energy. These casings are mostly used for multi-

stage pumps. The casings can be designed as solid casing (one fabricated piece) or split casing (two or more parts together) Impeller: An impeller is a circular metallic disc with a built-in passage for the flow of fluid. Impellers are generally made of bronze, polycarbonate, cast iron or stainless steel, but other materials are also used. The number of impellers determines the number of stages of the pump. A single stage pump has one impeller and is best suited for low head (= pressure) Impellers can be classified on the basis of (which will determine their use): Major direction of flow from the rotation axis Suction type: single suction and double suction Shape or mechanical construction: Closed impellers have vanes enclosed by shrouds; Open and semi-open impellers; Vortex pump impellers. The figure shows an open type impeller and a closed type impeller. Impellers could be open, semi-open or closed.

Pipe: Suction pipe is connected to the inlet of the pump and other side is dipped into the fluid in a sump. Shaft: Delivery pipe is connected to the outlet of the pump and other end delivers the fluid at required height.

The shaft transfers the torque from the motor to the impeller during the startup and operation of the pump. On the next page there are two figure that show centrifugal pump and its related components and how liquid to pump.

Cavitations If the suction pressure at the eye of the impeller falls below the vapor pressure of the fluid being pumped, the fluid will start to boil. Any vapor bubbles formed by the pressure drop at the eye of the impeller are swept along the impeller vanes by the flow of the fluid. When the bubbles enter a region where local pressure is greater than saturation pressure farther out the impeller vane, the vapor bubbles abruptly collapse. This phenomenon is called cavitation. There are several effects of cavitations: It creates noise, vibration, and damage for many of the components. We experience a loss in capacity. The pump can no longer build the same head (pressure). The output pressure fluctuates. The pump's efficiency drops.

Effectofcavitation

Prevention of cavitation: Raise the liquid level in the tank Lower the pumping fluid temperature Use a pump with a larger, impeller eye opening. Pump should be airtight Friction losses should be decreased

Parameter
OptimumFlow andPressure Applications MaximumFlow Rate LowFlowRate Capability Maximum Pressure RequiresRelief Valve Smoothor PulsatingFlow Variableor ConstantFlow Selfpriming Space Considerations Costs

CentrifugalPumps
Medium/HighCapacity, Low/MediumPressure

Reciprocating Pumps
LowCapacity, HighPressure 10,000+GPM Yes 100,000+PSI Yes Pulsating Constant

RotaryPumps
Low/Medium Capacity, Low/Medium Pressure 10,000+GPM Yes 4,000+PSI Yes Smooth Constant

100,000+GPM No 6,000+PSI No Smooth Variable No RequiresLessSpace LowerInitial LowerMaintenance HigherPower Suitableforawide rangeincludingclean, clear,nonabrasive fluidstofluidswith abrasive,highsolid content. Notsuitableforhigh viscosityfluids Lowertolerancefor entrainedgases

Yes Yes RequiresMoreSpace RequiresLessSpace HigherInitial LowerInitial HigherMaintenance LowerMaintenance LowerPower LowerPower Suitableforclean, Requiresclean,clear, clear,nonabrasive nonabrasivefluiddue fluids.Specially toclosetolerances fittedpumpssuitable forabrasiveslurry service. Optimum performancewith Suitableforhigh highviscosityfluids viscosityfluids Highertolerancefor Highertolerancefor entrainedgases entrainedgases

FluidHandling

ComparisonTable