0634841

Pumps and Compressors

Week 7
Impellers
Velocity triangles for an aircraft landing
Impellers
Example: Consider an office desk fan. It rotates at 200 rpm and has a
diameter of 30 cm. Air enters the fan at 3 m/s, parallel to the axis rotation.
Calculate the relative velocity (W) at the tip of the fan.
Impellers
Radial Pump 3D view of the radial impeller
Impellers
Velocity triangles of a radial impeller
Euler Equation
Torque is equal to the rate of change of angular momentum.
Angular momentum is given by the moment of momentum.
dt
dL
T =
r mV L

=
) (
1 1 2 2
1 1 1 2 2 2
r V r V m
t
r V m r V m
T


=

=
Power is torque times rotational speed.
) (
1 1 2 2
r V r V m T P

= =
Euler turbomachinery equation
) (
1 1 2 2
r V r V w

=
Radial pumps tend to deliver much more power than a corresponding axial pump.
The efficiency of a pump:
) (
1 1 2 2
r V r V m
gH m
r Actualpowe
Idealpower
p

= =

) (
1 1 2 2
r V r V
g
H
p

= For a large head; r

2
>r
1
Euler Equation
2 2 2 2 2 2
tan r V r W V
r


+ = + =
By applying the continuity equation
) 1 ( 2
) 1 ( 2
2 2 2
2 2 2 2 2
t b r
Q
V V t b r Q
r r

= =

Substitute this into the expression for V

2
2
2 2 2
2
2
) 1 ( 2
tan
r
t b r
Q
V

=
If there is no swirl at the entry then V
1
=0. Head becomes
|
|
.
|

\
|
+
(

=
2
2
2
2 2
2
) 1 ( 2
tan
r Q
t b g
H
p

Then the pump power is obtained as

(

= Q r Q
t b
P
2
2
2 2
2 2
2
) 1 ( 2
tan

( )
2
2
2
r
g
H
p

=
At zero flow rate
Euler Equation
Three blade angles at impeller exit
H vs. Q for three blade angles
|
|
.
|

\
|
+
(

=
2
2
2
2 2
2
) 1 ( 2
tan
r Q
t b g
H
p

Euler Equation
Backward leaning is generally preferred to
forward leaning. Backward leaning pumps
have a higher efficiency due to lower exit
swirl and forward leaning blades have an
increasingly steep power curve. If Q is
underestimated, the power requirement
will be greatly underestimated so
backward leaning blades are more tolerant
of flow rate errors.
P vs. Q for three blade angles
(

= Q r Q
t b
P
2
2
2 2
2 2
2
) 1 ( 2
tan

Pump Volute and Diffuser

Approximately one third of the static pressure developed in a centrifugal pump
occurs downstream of the impeller. Designers use volutes and/or diffusers to
efficiently convert kinetic energy imparted by the impeller into static pressure and to
direct the flow to the next stage or pump discharge. Kinetic energy is converted to
static pressure rise by reduction of fluid velocity. Increasing the flow passage area,
and/or flow path radius, will result in a velocity reduction.
The simplest volute is the circular volute.
Circular volutes are sometimes used for pumps
that require high solids passing capability.
When operated away from the pumps best
efficiency point (BEP), the impeller side loading
for a circular volute is typically lower than for a
single spiral volute, but is higher than for most
other designs. Flow paths in a circular volute
are often split as flow takes the path of least
resistance to the stage exit. This causes a good
deal of turbulence within the volute, resulting
in a loss of stage efficiency relative to other
volute designs.
Pump Volute and Diffuser
Spiral volute pumps incorporate a logarithmic spiral, the purpose of which is to
closely match the volumetric flow-rate of the impeller at the best efficiency point.
Spiral volute pumps are manufactured in both single and multiple volute
configurations. Flow in a spiral volute travels in a single direction from impeller
discharge to the volute exit.
In a properly designed single volute pump
operating at BEP, pressure is closely balanced at
the periphery of the impeller. Off-BEP operation
results in a pressure imbalance around the impeller
that causes increased bearing loads and shaft
deflection, adversely impacting pump bearing and
mechanical seal life. Multiple volutes or diffusers
are sometimes used to reduce off-BEP forces.
Multiple volute pumps may have a separate
discharge for each volute. Most pumps of this type
use a single discharge nozzle that incorporates a
splitter vane that extends approximately half way
around the casing. This is referred to as a double
volute pump.
Pump Volute and Diffuser
Single volute designs have higher efficiency and a larger solids passing capability
than similarly rated multiple volute designs. The primary advantage of a multiple
volute design is its reduced side loading over a broader operating range. Unless
operation can be strictly limited closely to BEP, from a reliability standpoint, multiple
volute designs become necessary in high energy pump design.
Diffuser pump designs are characterized by vaned
or vane-less sections of expanding volume. They
are most commonly used on multistage pumps as
an efficient means of delivering fluid from one
stage to the next. When used in combination, a
vaned diffuser and volute often provide higher
efficiency than is available with other designs.
However, commercial application has thus far been
limited due to the increased costs associated with
the manufacture of these units. Most industrial
pump applications require relatively small pumps
where the increased pump efficiency does not
readily justify the additional purchase cost.
Pump Diffuser
For a pump with radial exit flow, the kinetic energy may be reduced either by means
of a vaned diffuser or a vaneless diffuser. For a vaneless diffuser, as the flow goes out
radially by continuity;
1
K r V
r
= r K V
r
/
1
=
or
By conservation of angular momentum;
2
K r V =

r K V /
2
=

or
The exit kinetic energy is therefore given by;
) (
2
1
2 2
2
2
2
1
2
2 2
2
K K
r
V V V
r
+ =
+
=

So the exit kinetic energy reduces with the inverse square
of the radius;
2
2
1
2 r
V

In a flow where the total pressure is conserved there will be a

corresponding increase in static pressure. If this pressure rise is
large enough to cause separation then vanes may be required to
control the flow.
Pump Losses
The head loss for an impeller is given as
g
W
K H
imp imp
2
2
1
=
For the diffuser the loss coefficient is based on the absolute exit velocity:
g
V
K H
diff diff
2
2
2
=
The loss in a diffuser may also be expressed in terms of a diffuser efficiency:
2
2
2 3
2
1
V
p p
P
P
ideal
actual
diff

=
where station 3 is the diffuser exit
diff diff
K =1
g
V
g
P
g
V
g
P
H H H
diff
2 2
3 3 2 2
3 2
+ = =

Centrifugal Pump Example
Consider a centrifugal pump with data:
Centrifugal Pump Example
Inlet to pump impeller
s m
b r
Q
V V b r Q
m
x x m
/ 183 . 3
2
2
1 1
1 1 1 1
= = =

Continuity equation:
s rad
N
/ 8 . 151
60
2
= =

Angular velocity:
s m r U
m
/ 18 . 15
1 1
= =
Blade speed:
0
1
1
1
1
1
1
1
1
2
1
2
1
2
1
1 . 78 ) ( tan ) ( tan
/ 51 . 15 ) (
=

= =
= + =

x
m
x
m x
V
r
V
W
s m W r V W

From velocity triangle:

Centrifugal Pump Example
Exit from pump impeller
s m V V t b r Q
r r
/ 77 . 5 ) 1 ( 2
2 2 2 2 2
= =
Continuity equation:
s m r U / 36 . 30
2 2
= =
Blade speed:
0
2
2
1
2
2
2
2
2 2
4 . 78 ) ( tan
/ 84 . 28
= =
= + =

r
r
V
V
s m V V V

From velocity triangle:

2 2 2 2 2 2 2
tan
r
W U V V W U + = = +
Backward facing blades with
2
=-20
0
:
s m V / 26 . 28 20 tan 77 . 5 36 . 30
0
2
= + =

Centrifugal Pump Example

kg J V r V r
m
/ 97 . 857 ) (
1 1 2 2
= =


Specific work input:
0
1
=

V where
kW Q P 59 . 171 = =
Power input:
m
g
H H g
i i
46 . 87 = = =

Head and pump efficiency:

losses H H
i a
= where
diff imp
H H losses + =
m
g
V
K H
K
m
g
W
K H
diff diff
diff diff
imp imp
96 . 16
2
4 . 0 1
23 . 1
2
2
2
2
1
= =
= =
= =

m H
a
27 . 69 96 . 16 23 . 1 46 . 87 = =
792 . 0
46 . 87
27 . 69
= =

=
i
a
p
H g
H g

Pump Operation and Testing

In general there are two basic requirements that have to be met at all the times
for a trouble free operation and longer service life of centrifugal pumps.
The first requirement is that no cavitation of the pump occurs throughout the
broad operating range and the second requirement is that a certain minimum
continuous flow is always maintained during operation.
A clear understanding of the concept of cavitation, its symptoms, its causes, and
its consequences is very much essential in effective analyses and troubleshooting
of the cavitation problem.
Just like there are many forms of cavitation, each demanding a unique solution,
there are a number of unfavorable conditions which may occur separately or
simultaneously when the pump is operated at reduced flows. Some include:
o Cases of heavy leakages from the casing, seal, and stuffing box
o Deflection and shearing of shafts
o Seizure of pump internals
o Close tolerances erosion
o Separation cavitation
o Product quality degradation
o Excessive hydraulic thrust
o Premature bearing failures
Pump Operation and Testing
Each condition may dictate a different minimum flow low requirement. The final
decision on recommended minimum flow is taken after careful techno-
economical analysis by both the pump user and the manufacturer.

The consequences of prolonged conditions of cavitation and low flow operation
can be disastrous for both the pump and the process. Such failures in hydrocarbon
services have often caused damaging fires resulting in loss of machine, production,
and worst of all, human life.

Thus, such situations must be avoided at all cost whether involving modifications
in the pump and its piping or altering the operating conditions. Proper selection
and sizing of pump and its associated piping can not only eliminate the chances of
cavitation and low flow operation but also significantly decrease their harmful
effects.