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The client will usually specify the desired head and pump capacity. The type and speed of the
driver may also be specified. Speed is governed by considerations of cost and efficiency as well as drivers
available to the client. Given these parameters, the task of the engineer is to minimize cost.
Which cost to minimize, first cost or life-cycle cost, however, is an important consideration.
From a life cycle viewpoint, we must take into account power consumption and operation and
maintenance costs. These considerations call for optimizing efficiency, reliability (the mean time between
failure) and maintainability (the mean time to repair). In general, designing to optimize these categories
results in increased costs. Often, these considerations are not very important and we can design for
minimum first cost. In appropriate cases, the engineer should initiate a dialog with the client concerning
available options. For example, designing a boiler feed pump that operates continuously would probably
call for maximizing efficiency. Efficiency considerations would not be so important, however, for a
drainage pump that is only required to operate occasionally.
PIPE CONNECTIONS AND VELOCITIES
The diameter of the suction pipe is usually made larger that the pump suction flange and both are
made larger than the discharge flange and pipe. Church recommends keeping the velocity at the suction
flange about 9 or 10 ft/s and that at the discharge flange between 18 and 25 ft/s.
LEAKAGE LOSSES
To design the impeller, account must be taken of leakage from the discharge side back to the
suction side. To reduce the leakage, wearing rings are fitted to the impeller and casing. These rings are
designed with specified clearances. The leakage across each ring can be calculated from the following
formula:
QL CA 2 gH L
2
HL
3
U 22 U 12 / 2 g
4
1.
Quantity flowrate:
Q
2.
2500 gal
min
min
ft 3
5.57 ft 3 / s
60 s 7.48 gal
Mass flowrate:
m&
3.
Required head:
h P = 150ft
Required flowrate: Q = 2500 gpm
Required speed
N = 1760 rpm
5.57
ft 3 62.4 lbm
348lbm / s
s
ft 3
Specific speed: Assume a double suction impeller; then, Q = 2500/2 = 1250gpm, and:
N sd
(rpm) Q( gpm)
( ft )
3/ 4
(1760) 1250
1450rpm
(150) 3/ 4
Water horsepower.
WHP
5.
4
5
&
mgh
(348)lbm (32.2) ft (150) ft
s hp
s2
550
s
s2
(550) ft lbf 32.2 ft
WHP 94.6hp
Shaft diameter. Calculate shaft diameter based on torque. Increase the calculated value
somewhat to allow for bending moment which is unknown at this point and to ensure that
the critical speed exceeds the operational speed by a reasonable margin. The bending
moment will depend on the weight distribution of the shaft and any unbalanced radial thrust
acting on the impeller. From the figure shown below, with the given flow of 2500 gpm and
calculated value of specific speed of 1450, we select a tentative value of efficiency of 80%.
BHP
Thus:
WHP 94.6
118hp
0.8
4230lbf in
s hp
(1760)rev min (2)( )rad ft
16T
(16)(4230)lbf in in 2
3
Ds
1.75in
ss
( )(4000)lbf
3
To account for the unknown bending moment and critical speed, increase the shaft diameter to
2 1/8 in. Church states that the hub diameter, DH , is made from 5/16 to in. larger than Ds:
Let
DH 2 in.
6.
VSU
(4)(5.57) ft 3 (144)in 2
10.2 ft / s
( ) s(10) 2 in 2 ft 2
D02 DH2
Q V0 A0 V0 (
)
4
4
(4)(1.02)Q
DH2
( )(2)V0
D0
7.
(4)(1.02)(5.57)(144)
5
(2.5) 2 7.33in, say, 7 in
( )(2)(11)
16
U 1 r
The radial velocity should be slightly higher than V0 because a converging shape is more efficient than a
divergent one. Let Vr be 12 ft/s.
The inlet area will be decreased by the vane thickness. Assume a contraction factor, 16 , of 0.85; the
entering width then is:
b1
Q
(1.02)(5.57)(144)
1.75in
D1Vr 11
( )( 2)( 7.31)(12)( 0.85)
1 tan 1
Vr1
Vr 1
12
tan 1
12.10
U1
56.2
W1
1
U1
1 is usually increased slightly to account for contraction of the stream as it passes the inlet edges as well
as prerotation. The inlet angle is usually between 10 and 25 degrees 7. Let 1 be 130.
8.
The theoretical head can be found from integrating the force on a differential mass:
dF dmr 2
and
dP
dF
;
A
dm d brddr
brddr r 2
2 2
2
rdr
(r2 r12 )
1 dP 1 brd
2
1
2
6
7
but
U r
and
P2 P1 U 22 U 12
H 2 H1
g
2g
P
;hence,
g
For a closed rotating cylinder containing a fluid, the pressure head developed at the outer rim is:
H2
U 22
2g
D2
(2)( ) N
N
(12)
D2
1840 H
N
(13)
Church 8 gives several charts for which have been based on a large number of tests. Most of the plotted
points fall within a range of 0.9 to 1.1. Noting that if the head on test is found to be too high, the impeller
diameter can be machined to an appropriate diameter, select 1.05 for ; then:
D2
9.
(1840)(1.05) 150
13.4in ; say, 13 in.
(1760)
The normal range for discharge angles is between 20 and 25 degrees 9. Furthermore, 2 is usually made
larger than the inlet angle. Assume 2 = 200.
The radial outlet velocity, Vr2 , is made the same as, or slightly less than, the radial inlet velocity, Vr1.
Assume Vr2 = 11 ft/s10.
Outlet area (based on required flow plus leakage).
3
2
Q (1.02)(5.57) ft s (144)in
A2
74.4in 2
2
Vr 2
s (11) ft ft
b2
(1.02)(5.57) ft 3 s (144)in 2
Q
1.896in
Vr 2 D2 2 s (11) ft ( )(13.5)in ft 2 (0.925)
U 2 r2
V 2 U 2
Vr 2
11
103.7
735
. ft / s
tan 2
tan 20 0
V' 2
V 2
Church assumes a value of of 0.7. This coefficient can be calculated from tests. Pump manufacturers
will maintain records from which a reasonable value might be estimated for a given design.
2' tan 1
11
12.10 , say, 130
515
.
112 515
. 2 52.7 ft / s
V2
'2
V2
Vr2
2
V2
V2
U2
11. Cross-section of impeller.
11
2
Vr2
Wall and vane thicknesses are usually made a minimum consistent with good foundry practice. The
stresses due to centrifugal force and fluid pressure are relatively low for average applications; otherwise,
they need to be taken into account 12.
HL
3 U 22 U 12 (3)(103.7 2 56.2 2 )
88.5 ft
4
2g
(4)(2)(32.2)
From Figure 6-1, p 92, Church, the flow coefficient for 1760 rpm and a 0.013 in clearance is 0.410. Thus,
the leakage is:
0.075
(100) ; or 1.35 %, which is, close enough to the assumed value of 2 %.
5.58
12
Id,, p. 152.
Church attributes this equation to A.J. Stepanoff: Leakage Loss and Axial Thrust in Centrifugal
Pumps, A.S.M.E. Trans., HYD-54-5, 1932.
13
DESIGN OF VANES
The entrance vane angle, 1 , has been found to be 130 ; that at the exit, 200 . For smooth flow,
we must design the vane such that this angle increases smoothly from 13 0 to 200 . We note also that the
radial components of velocity to these two angles are 12 and 11 ft/s, respectively. We also see from the
vector diagram that W Vr / sin . The relative velocities corresponding to the entrance and outlet
stations are then: 12 / sin 130 53.3 ft / s and 11 / sin 20 0 32.2 ft / s . To obtain intermediate
values of radii corresponding to intermediate values of the position angle, , we proceed as follows (see
Fig. 3):
1) Plot , Vr, and W against vane radius, r, for the entrance and outlet stations and connect by a
straight line (or a smooth curve).
2) The corresponding values for vane angle, , are computed from sin Vr / W . These
values are also plotted against their radii.
Alternatively, write a computer program to perform the above functions. Referring to the figure below:
tan
dr
dr
or d
r
tan
rd
dr
rd
180
dr
180 r r
r1 r tan
r1 r tan
Draw the front edge of the vane with the same curvature as the back edge with a thickness of about 1/8
in 14.
NUMBER OF VANES
The number of vanes is given by the Pfleiderer equation 15. First, calculate the average vane
angle:
m
z no. vanes 6.5
1 2 13 20
16.50 ; then,
2
2
D2 D1
(13.5 7.312)
sin m ( 6.5)
sin 16.50 6.21, say ,6.
D2 D1
(13.5 7.312)
( )(7.312 )
3.83in
( 6)
zt
sin
zt
1
D
D sin
1 1
2 1
( 6)( 0.125)
0.855( 0.85assumed )
( 7.31) sin 130
(6)(0.125)
0.948(0.925assumed )
(13.50) sin 20 0
SUMMARY
Diameter of suction flange, Dsu ------------------------------- 10in
Velocity in suction flange, Vsu ---------------------------------10.22 ft/s
Shaft diameter, Ds -----------------------------------------------------------------------2 1/8 in
Impeller hub diameter, DH --------------------------------------2 in
Impeller eye diameter, D0 --------------------------------------7 5/16 in
Velocity through impeller eye,V0-------------------------------11 ft/s
Diameter of inlet vane edge, D1--------------------------------7 5/16 in
Velocity at inlet vane edge, V1 = Vr1 ---------------------------12 ft/s
14
15
Church, p. 115.
Id.
10
11