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/WBUT/GIMT/2013
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The design considers all the factors which are involved in power loss. Disk friction and impeller vane angles have an important effect on the pump efficiency. They are also responsible for cavity formation in a centrifugal pump. Vibration at higher speeds is a very critical problem to be solved. Sometimes this can happen due to improper design, but most of
the times it happens due to fault in fabrication. Thrust load on impeller shaft (for single suction impeller) is another factor to be solved. The design will take over all these existing problems regarding smooth pumping.
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Although the centrifugal pump has been in existence for a considerable period, it is only within the last 100 years that it has been widely used or rapidly improved. The reason for this is that the centrifugal pump is a relatively high-speed machine and until there was no form of motive power well suited to it. In the days of slow-speed steam engine the reciprocating pump was better adapted to the conditions. But with the introduction of the steam turbine and electric motor the conditions were reversed. For such sources of motive power the reciprocating pump is not as well adapted as the centrifugal pump. Before 100 years, source of motive power was a problem, and today the primary problem is to conserve this motive power by reducing its losses. Lot of experiments are being done to reach this goal. Greg Case et al proposing design with reduced vibration, rotor rubbing, overstress, cyclic fatigue etc. [6]. E. C. Bacharoudis et al experimented with varying blade angles for the sake of increase in efficiency in 2008 [7]. Mike Swanbom et al had given primary importance to energy conservation in design and manufacturing of centrifugal pump in their project in 2008 [8]. K. W. Cheah et al suggested that the unsteady flow generates in the impeller passage in off design flow rate by their numerical flow simulation experiments in 2007 [9]. Weidong Zhou et al concluded that twisted impeller blades are more efficient than that of the straight impeller blades by CFD analysis in 2003 [10]. Miguel Asuaje et al experimented on the radial thrust on impeller shaft for different speeds, impellers and volutes using CFX code in 2005 [11]. This development is continuously going on with the target of most energy efficient centrifugal pump.
is the total annual cost divided by the total capacity of the pump, meaning by total capacity the water horse-power or the number of 1000 gal per min, or other units of which the pump is capable. It will be a minimum when the pump is not operated at all as it will then consist of the fixed charges only. It will be a maximum when the pump is operated continuously as that will cause the operating expenses to be a maximum. For a motor driven pumping unit the total annual cost of pumping is:
Where, C = total annual cost G = total number of gallons pumped per year h = head in feet S = cost per million B.t.u. supplied to the motor D = duty in ft. ib. per million B.t.u. L = cost of labour and similar items F = total investment i = interest rate on investment d = rate of depreciation t = taxes, insurance etc. M = administration and similar items Since 1000000 B.t.u. = 778000000 ft. lb., we may write Duty = 778000000 Pump efficiency Motor efficiency. Therefore, the first part of the above equation becomes,
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Now the above equation shows that, if the cost of power is high, it may be economical to pay a high price for a high-duty pumping engine. But on the other hand a less expensive centrifugal pump may often effect a saving even though its duty should be somewhat less. The equation would also show that for intermittent service a cheap pump was desirable even though it might be inefficient. But for constant service a high-duty pump is better even though its first cost may be considerably higher.
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thinner vanes, the vane number and thickness are somewhat restricted in cast impellers by the need for wall sections of consistent thickness and the need to be able to remove the impeller cores. The design and variants of semi-open impellers are probably the most common type of impeller in the world. As the name implies, the impeller is a hybrid of the open and closed design. The design has one shroud commonly on the back of the impeller vanes. They share many of the advantages of both the open and closed impellers, such as self-cleaning impeller passages, excellent control of the fluid in the vane passages and the ability to use fairly thin vanes. The absence of one of the shrouds often allows for more advanced vane profiles to be used including the addition of splitter vanes that would be difficult to use on closed impeller designs. One of the most effective techniques used to balance hydrodynamic axial loads is the use of double suction impellers. By using virtually the same impeller profile on both sides of the impeller, the developed forces are nearly equal. These impellers are inherently balanced and develop very low axial loads. One side of the impeller is generally designed to develop a small axial force to load the thrust bearing slightly and prevent the impeller from hunting back and forth during operation. A variant of the double impeller concept, used in multistage designs, is the mounting of an even number of impellers on a single shaft so that they oppose each other. The axial loads are then equalised on the rotor as a whole.
2. 3. 4.
Medium rapidity (specific speed = 30-50): Impeller with radial discharge and double curved blades. Pumps with a middle delivered flow and middle delivery head. Helicoidic impeller (specific speed = 50-80): Impeller with double curved blades. Pumps with larger as middle delivered flow and smaller than middle delivery head. Diagonal impeller with high rapidity (specific speed = 80-135) with double curved blades. Pumps with high delivered flow and a low delivery head.
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5.
Propeller impeller with highest rapidity (specific speed = 135-330) and rotor blades in the form of wings. Pumps with highest delivered flow and lowest delivery head.
3.3.
A Case Study
A large double suction single stage pump, with an impeller diameter of 2.5 feet and a running speed of 1500 rpm, was designed with close impeller vane/volute tongue clearance to reach an aggressive efficiency level in a facility where energy was at a premium. During installation, it was found that vibration levels got as high as the operating clearances in the wearing rings (0.6 mm diametral), with the primary component at running speed. There was no possibility of a resonance in this pump since both the shaft and the bearing housing natural frequencies were above the 1X and 2X excitations and the 3X excitation due to suction flow asymmetry, which is common in this style pump. The vane passes frequency of 4200 cpm was far removed from the shaft first and second non-critically damped natural frequencies of 2850 and 19000 cpm respectively. The reason for the high vibration was found to be 35 mils of misalignment at the coupling due to the hydraulic loads on the pump discharge flange being far in excess of API 610 (1995) levels. The 30 inch discharge had a piping expansion joint at the flange, with no tie-bars in place across the flange to carry the resulting thrust. After removal of the piping forces through a grounded bulkhead bolted to the discharge flange, the pumps large 1X and 2X vibration levels were reduced to acceptable values per API 610 (1995).
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can the proper values of outlet vane angle, diffusion vane angle and area of stream normal to the direction of flow be chosen. The next step is the selection of the factors speed ratio and flow ratio, whose values may normally range from 0.95 to 1.25 and from 0.1 to 1.25 respectively. The steeper is the characteristic; the larger is the value of speed ratio. Therefore speed ratio is some function of the other relative quantities, as is flow ratio also. If the theory were capable of exact application, we might compute values of speed ratio and flow ratio from the equation given below, but even those equations involve the selection of a factor k which is a matter of experience again. We shall, therefore, have to choose a value for speed ratio according to our best judgement or according to values obtained by test upon a pump similar in design to the one we are attempting. The value of flow ratio may be determined in the same manner as speed ratio. As a check upon the rationality of our values of outlet vane angle, speed ratio and flow ratio we may substitute them in equation,
and see if the value of the expression is in accordance with the customary values for the line of pumps whose data we may have. If our theory were exact the value would be the true hydraulic efficiency, a value for which might reasonably be estimated. As our theory is defective, that is, since the computed value of head imparted to the water by the impeller is higher than the true value, this value will not be any definite physical quantity and is called simply manometric coefficient. Or we might assume a value of the manometric coefficient and compute flow ratio (Kf) from the above equation. To design a centrifugal pump, some empirical formulations and considerations must be followed. Following are some empirical consideration in the design of centrifugal pump: i. Speed ratio (Ku) refers to the ratio of peripheral speed ( theoretical jet velocity corresponding to manometric head. ) at the impeller tip to the
ii.
Flow ratio (Kf) refers to the ratio of flow velocity (Vf2) at exit to the theoretical jet velocity corresponding to manometric head.
The value of Kf varies from 0.1 to 0.25. iii. Knowledge of peripheral speed ( periphery of the impeller. ) helps to compute diameter D2 at the outer
iv.
v.
The selection of outlet vane angle (2) depends on the type of head capacity characteristics desired. For optimum efficiency, usually a value of about 25 is taken for all specific speeds.
vi.
The inlet vane angle is selected so that inlet absolute velocity may be radial. The radius of curvature of vanes is selected depending on the inlet and outlet blade angles, so that a smooth, separation free flow is obtained in the impeller passage.
vii.
The number of vanes in an impeller depends on the pump size, the speed ratio, the vane load and the outlet blade angle. With low values of outlet blade angle, usually six or eight vanes are adopted. The main dimensions which affect the hydraulic features of the pump are thus
determined. The equation may be raised as to what assurance we have that the maximum efficiency will be attained under the conditions of speed, head and discharge for which these computations were made. The only explanation is that the values of speed ratio and flow ratio, upon which the computation hinge, were selected according to values obtained with previous pumps for their point of maximum efficiency. Furthermore all dimensions and angles computed were determined upon the supposition that the flow specified would be the
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normal flow and provisions were made to maximize all the losses at the flow. However the actual point of maximum gross efficiency is affected by the mechanical losses as well as the hydraulic losses. It might be necessary to allow for this if it were not for the fact that it has also entered into the previous pumps for which our values of speed ratio and flow ratio were experimentally determined.
One can directly determine the overall efficiency and also the internal efficiency by attempt, but as for the blade efficiency and the hydraulic efficiency this is not possible. It must be computed from overall efficiency or internal efficiency by excluding the losses, which are not pressure losses.
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Because of the larger difference of pressure between entrance and exit of the impeller, larger gap leakages are caused. However, these disadvantages cannot cover the crucially better hydraulic efficiency. Therefore in centrifugal pumps only backwards curved blades with angles of outlet 2*=140-160 are used.
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Capital cost (initial) Performance Reliability Operational costs (life-cycle) For many organizations only the first two items are considered in the purchase
decision, with initial cost being of primary importance. Focus on initial costs and performance often leads to high life-cycle costs and reduce reliability. The initial cost of a system can often be quite low when compared to the operational costs of the equipment over time. Factors such as the cost of power, repair costs and lost production are less commonly considered in most purchasing processes. Making sound, informed purchasing decisions during the front end of the purchasing process can often improve performance, increase reliability, reduce life-cycle costs and occasionally reduce initial purchase costs. 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. Here in the design of centrifugal pump impeller we have considered the values of head, discharge and operating speed from experience of practical applications. Specified conditions: Head (H) = 60 ft Discharge (Q) = 2500 gpm Speed (N) = 1500 rpm
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Here, Ks = 0.0174 We find the value of specific speed 43, which is permissible. Now, we have to calculate the corresponding shape number.
2. Shape Number:
Shape number =
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According to graph (fig. 5.1) the value is within safe limit. 3. Quantity Flow rate: Discharge in cubic feet per second (q) = 1 cubic feet per second = 448 gallon per minute 4. Water Horsepower: Output power (Pw) = 5. Shaft Power: From graph (fig. 5.2) we have taken the value of gross efficiency ( ) is 80%.
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Now, shaft power or power input = 6. Values from Experience: Now, calculated value from graph for double suction impeller, Width ratio ( ) = 0.175 Speed ratio ( ) = 1.085 Diameter ratio ( ) = 0.585
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Inner diameter (d1) = d2 Outer width (b2) = Inner width (b1) = 8. Shaft Diameter:
diameter ratio =
Assuming a shear stress of 4000 psi for the shaft (material - Steel SAE 1045), shaft diameter (Ds) = To account for the unknown bending moment and critical speed increase the shaft diameter to 1.8 inch. 9. Hub Diameter and Length of Hub: The hub diameter Dh is generally taken in the range of Let, Dh = 1.8 + 0.5 = 2.3 inch and length of the hub lh = 10. Suction line velocity and the Diameter of Suction Flange: Now, assume a velocity of 10 ft/sec at the suction flange, thus, to inch and larger than Ds.
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11. Diameter of the Impeller Eye: Assume the velocity at the eye of the impeller is 11 ft/sec. For a double suction pump, assume that the leakage will not exceed 2%. Dividing the total,
12. Assumption of Blade Number and Thickness from Experience: Now, we are assuming impeller blade number 8 and thickness 5 mm. As the blade number varies from 6 to 12 and the blade thickness varies from 4 mm to 8 mm. 13. Hydraulic Efficiency: Now,
Hydraulic efficiency ( ) = 89% 14. Outlet Velocity and Outlet Blade Angle: Now, we have to calculate the actual outlet tangential velocity,
.
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Where,
is a factor can be taken as about 3 for low specific speed and as about 5 for high
Figure 5.4: Relation between impeller radius, velocity and vane angle
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The inertia of the rotating fluid causes a circulatory flow opposite to the direction of rotation of the impeller. This flow, superimposed on the outward flow, results in the fluid leaving the impeller at an angle less than that calculated from angular momentum theory. Thus 2 must be decreased and , therefore, the absolute angle, 2 , increased. The effect of circulatory flow is to reduce V2 and the theoretical head. Now,
And,
and
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18. Impeller Width: Now, correction to impeller width, in order to allow a margin for wear, the leakage loss q1 may be taken as 2% of the net flow q. We know, Corrected inlet width = Corrected outlet width =
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Chapter 7: Conclusion
Centrifugal pump and specifically its impeller is a very common device for a present day child of either urban or rural area in our country. It looks very simple and common in design and construction. There nothing looks special in this device that can make it attractively charming. During four years of our B. Tech. course, we have studied different theories about different technologies. The application fields and results were also studied by us in details. But, before going through this project, we never could imagine how hard to try to implement a theory in practical application. We didnt know the importance of studying any simple looking element in details; we just studied it for exams. I was unknown to us that how much knowledge it needs to design something. But, finally we got success in designing a centrifugal pump impeller. This project is a successful design of a centrifugal pump impeller. We designed a double suction impeller to solve the problem of unbalanced axial force on the shaft. We studied and understood the theory of centrifugal pump. More importantly we learnt the limitations of the theory. A large number of previous works were reviewed. Different relationship curves were studied and some values were retrieved from those curves and charts. A little hardship were faced in selection of the outlet vane angle and pump characteristics. Completion of this project was impossible without the help of our project guide, our other teachers and some of our friends. This project has left a considerable space for further study and research. We hope it will help others in future to study about design of centrifugal pump impeller.
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References
Books:
[1] Kumar. D. S., Fluid Mechanics and Fluid Power Engineering, Katson Books, 2010. [2] Daugherty. R. L., Centrifugal Pumps, McGraw-Hill Book Company, 1915. [3] Evolution of the Turbine Pump, Proc. Inst. Of Mech. Eng., 1912. [4] Webber. W. O., Trans. Amer. Soc. Of Mech. Eng., 1905. [5] Greene, Pumping Machinery.
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[12] Asuaje. M., Numerical Modelization of the Flow in Centrifugal Pump: Volute Influence in Velocity and Pressure Fields, International Journal of Rotating Machinary, 2005:3, P: 244255.
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