Centrifugal Pumps (Operation)

In this Session.
1. The Concept to understand Centrifugal Pump
2. Parts of centrifugal pump
3. Pump Basic principles

4. Operation of Centrifugal Pumps

5. Operational Problems
6. Centrifugal Pumps troubleshooting
7. Typical Questions & Answers

Pump
Pump is a machine that imparts energy to the liquid.
Why Pumps are Required?
Move liquids from lower elevation to higher

elevation;
Move liquids from lower pressure areas to areas of
higher pressure;
Increase the flow rate of a liquid.

Working Principle of Centrifugal Pumps

The machine which adds centrifugal energy to the

liquid for increasing its pressure is called as

centrifugal pump.
The faster the impeller turns faster the liquid moves.
Centrifugal force moves the liquid away from the
eye, a low-pressure area is formed in the eye.

Working Principle of Centrifugal Pumps

Parts of centrifugal pump

Parts of Centrifugal pumps

A. Stuffing Box
B. Packing
C. Shaft
D. Shaft Sleeve
E. Vane
F. Casing

G. Eye of Impeller
H. Impeller
I. Casing Wear Ring
K. Discharge Nozzle

Impeller
Impeller is the heart of Centrifugal Pump
It rotates the liquid mass with the peripheral
speed of its vane tips.
The whirling movement of Impeller imparts
centrifugal force to the liquid
and increases
the velocity head.
Impeller does not increase liquid pressure.
High velocity head is converted to pressure
head in the volute
Increase in velocity is directly proportional to
Impeller diameter & Pump speed.

Parts of Impeller
Impeller Hub
Central part of Impeller, bored out according to the shaft
diameter.
Suction Eye

The impeller inlet just ahead of the vanes is called the

suction eye.
Impeller shroud
Impeller shroud or enclosing sidewalls totally enclose
Wear rings
the impeller water ways from the suction eye to the
Wear
rings
provide periphery.
protection
and
an
Impeller Vanes
economically renewable
leakage joint between the Vanes are the parts that pick up the liquid and
accelerate it to high velocity. Increase in length of
impeller and casing.
vanes or Impeller dia will increase the liquid velocity,
BALANCING HOLES
hence pump discharge pressure.
These holes are located in an impeller for the balancing of thrust

Types of Impeller

Impeller Types based on construction

Consisting of Vanes only

Shroud on one side only

Shroud on both sides

No shrouds or sidewalls

Least Liquid slippage

Liquid slippage exists

Liquid slippage exists but

less than in open type

Relatively less liquid

velocity

Greater liquid velocity than

open type

Impeller has structural

weakness

Applied in pumps handling

abrasive liquids

Applied in pumps handling

slurries & mud

Greater liquid velocity

than other types
Applied in pumps
handling clear liquids

Impeller Types based on suction

Single-suction impeller

Double-suction impeller

Pump Casing
Enclosed space where the impeller rotates with the shaft
Converts velocity of liquid into pressure
Has close clearance with the impeller

Has two ends, Suction & Discharge

Casing Types
Single Volute Case
Double Volute Case

Shaft
The basic function of a centrifugal Pump shaft is to transmit the
torques encountered in starting and during operation.

It also supports the impeller and other rotating parts.

Impeller

Gland Packing / Mech

Seal

O/B Bearing

Coupling

I/B Bearing

SHAFT SLEEVE
The basic function of the sleeve is to
protect shaft from erosion, corrosion
and wear at stuffing boxes, leakage
joints & internal bearing areas.

Stuffing Box
A space provided for Gland Packing or Mechanical

seal where the shaft passes out through the pump

casing
Primary function is to prevent leakage along the shaft
Prevent air leakage into the pump and liquid leakage
out of the pump.
They are normally designed to allow small amount of
controlled leakage along the shaft to provide
lubrication and cooling of the packing.

Lantern Rings
When a corrosive, erosive or dangerous liquid is being

pumped, lubrications from another liquid are used.

Lubricating fluid is pumped into the packing box under
pressure higher than the pressure inside the casing of
pump.
This pressure keeps away the liquid in the pump from
entering the packing box.
Lantern rings are normally for lubrication of the packing.
Lantern ring packing is also used in a pump operating
at less than atmospheric pres-sure.
To keep air out, the pressure of the sealing lubricating
fluid must be above the pressure of the atmosphere

Lantern Rings

Mechanical Seals
In some situations, packing material is not adequate for

sealing the shaft.

One common alternative method for sealing the shaft is
mechanical seals.
Mechanical seals consist of two basic parts:

A rotating element
A stationary element

Bearing
Allow the shaft to rotate with practically negligible

friction.
Hold the rotating element in its proper position relative

to the stationary parts of the pump, both radially and

axially, so that the rubbing cannot occur.
Be able to absorb forces that are transmitted to them

from the impeller.

Give trouble free service for long periods of time

Radial Load
Axial or thrust load

Angular Load

What is a Balance Drum

In

any centrifugal pump, each impeller tends to

produces some amount of thrust because of different
pressures and different geometries on the two sides of
the impeller.

In a high pressure multi-stage pump (such as BFW) the

number of impellers is high, thus the net thrust would

be large unless something is done to balance it out.
The two main ways to reduce the net thrust are to

oppose the impellers or to use a balance drum.

Balancing Drum

Couplings
The device which which joins two separate shafts together is called a
coupling
It is a common method of transferring force or torque from one machine to
another
Rigid Coupling

A coupling that permits neither

radial nor axial relative motion
between the driving and driven
shaft is called Rigid Coupling

Flexible Coupling

A Flexible coupling is a device that

connects two shafts while allowing for the
minor misalignment (angular, parallel or a
combination)
A flexible coupling must also permit some
lateral float of the shafts so that the two
shaft ends may move closer or farther
apart under the influence of thermal
expansion

Pump Basic principles

Pump Head
Head is the height of liquid
The static head corresponding to any specific pressure is
dependent upon the weight of the liquid according to the
following formula.

Head =

Pressure (psi)

Sp. Gravity x 0.433

Pump Head
Suction Lift
It exists when the source of supply is below the center line of

the pump.
Static Suction Lift
It is the vertical distance in feet from the centerline of the
pump to the free level of the liquid to be pumped.
Suction head
It exists when the source of supply is above the centerline of
the pump.
Static suction head
It is the vertical distance in feet from the centerline of the
pump to the free level of the liquid to be pumped.

Pump Head
Static discharge head

It is the vertical distance in feet between the pump

centerline and the point of free discharge or the

surface of the liquid in the discharge tank.
Total static head
It is the vertical distance in feet between the free
level of the source of supply and the point of free
discharge or the free surface of the discharge liquid.

HEAD

Question: Will Different Density Liquids Pump to the

Same Level (As Shown Here) or: ?

S.G.- 1.2

S.G.- 1.0

S.G.- 0.7

Or Will They Pump to Different Levels as Shown

Here?

S.G.- 1.2

S.G.- 1.0

S.G.- 0.7

Answer: They Will Pump to the Same Height (Head)

but Will Show Different Pressure Gauge Readings.

H=115ft

H=115ft

60 psi

50 psi

S.G.- 1.2

S.G.- 1.0

35 psi

S.G.- 0.7

NPSH
Liquids can flash into vapor near boiling
point which depends on pressure:

Ps
S

In the suction of the pump impeller eye, there may be lower

pressure( or vacuum) created due friction losses and sucking by
the impeller. If the liquid flashes, pump performance will be
affected
NPSH is a related subject to solve this problem.

Net Positive Suction Head

(NPSH)
NPSH Available:
Absolute pressure at the pump suction, changed into head minus the
vapour pressure of the liquid being pumped, changed to head.

NPSH Required:
Minimum head needed at the suction to get the liquid into the impeller
without vaporizing

NPSHa must always be greater than NPSHr

NPSH = Absolute pressure at Pump suction - Vapor pressure at pump temp

Specific Gravity x 0.433

NPSH of vacuum system

Vacuum

In the vacuum system like surface

condensers, you will find either the
level is high/the equipment is elevated
and some cases the pump is under the
ground to meet the required NPSH.
Example: condensate pump

Net Positive Suction Head

NPSHa

Available,

Case 1
Positive Suction
from an open tank.

Net Positive Suction Head

NPSHa

Available,

Case 2
Suction lift from an
open tank.

Net Positive Suction Head Available, NPSHa

Case 3
Suction from a closed tank
and temperatures greater
than ambient.

To Increase the NPSH a

Raise the suction tank (or level in the tank).

Lower the pump.
Increase the pressure in the suction tank.
Cool the liquid to reduce vapor pressure.
Modify the suction piping. - Increase pipe diameter reduce the length - change fittings - modify valve type
- reduce number.

Power and Efficiency

Brake horsepower (bhp)

Actual horsepower delivered to the pump shaft

Hydraulic horsepower (whp)
The liquid horsepower delivered by the pump

Pump Curves / System Curves

Pump Performance Curve

The performance curve is actually four curves
resulting with each other on a common graph.
These four curves are:
The Head-Flow Curve
The Efficiency Curve
The Energy Curve
The Pumps Minimum Requirement Curve

20% 40%

265 mm

60

245mm

50
40

40%

Best Efficiency

225 mm

20%

85%

Head
Meters

20
15
10

265mm
245 mm
225 mm

K
W

NPSHR

2
0

10

15

20

25

30

Capacity

35

40

45

50

55

60

System Curve
It defines Capacity & Pressure needs of any system

graphically.
It represents the relationship b/w flow and hydraulic
losses in a system graphically.
A pumping system operates at the intersection of
System Curve & Pump Performance Curve.

Head - Meters

5
0

4
0
3
0
2
0
1
0

10

15

20

25

30

35

Capacity M3/Hour

40

45

50

55

60

Important Terms & Definitions

Shutoff head is the point of maximum elevation at zero flow

The maximum pressure produced by a pump is called shut off pressure

The pump is operated at shut off pressure during start-up to avoid
overloading / adequate liquid delivery to the required point
Pump runout is the maximum flow that can be developed by a cen
trifugal pump without damaging the pump
Runout can lead to cavitation and can also cause overheating of the
pump's motor due to excessive currents

Centrifugal pumps are protected from runout by placing an orifice or

throttle valve immediately downstream of the pump discharge and
through proper piping system design

We can determine from pump curve:

Where the pump will operate?
What changes will occur if the system head

curve or the pump performance curve changes?

NPSHr (Required)
265 mm

60
50

Head Meters

40

20
15

265mm

10
KW

4
NPSHR

2
0

10

15

20

25

30

35

40

Capacity M3/Hour

45

50

55

60

HEAD

50 Metres
265 mm

60
50
40

Head
Meters

POWER abs 15KW

20
15

265mm

10
KW

NPSHr

1.9

NPSHR

CAPACITY 33 M/3
0

10

15

20

25

30

35

40

Capacity M3/Hour

45

50

55

60

LETS CONSIDER THE PROBLEMS

ORIGINAL DESIGN
ACTUAL SYSTEM HEAD
265 mm

60

1 PAST BEF POINT

50

2 INCREASE IN FLOW

40

3 INCREASE IN POWER
4 INCREASE IN npsh

Head
Meters

265mm

20
15
10
KW

6
4

NPSHR

2
0

10

15

20

25

30

35

40

Capacity M3/Hour

45

50

55

60

Potential Problems

265 mm

60
50

Head Meters

40

20
15

265mm

10
KW

4
NPSHR

2
0

10

15

20

25

30

35

40

Capacity M3/Hour

45

50

55

60

If the head is only

40m instead of
50m we get extra
flow (47m3/hr)
and
use more power
(17.5kW and
require
more NPSHR
(2.8mt)
Can we handle
the
flow? Do we have
extra NPSHA? Is
the motor big
enough?

Affinity Laws for Centrifugal Pumps

The

affinity laws express the mathematical

relationship between the several variables involved
in pump performance.

They apply to all types of centrifugal and axial flow

pumps.

With impeller diameter (D) held constant

Capacity (flow rate) is proportional to speed of

impeller.
Discharge head is proportional to square of the
speed of impeller.
Power required is proportional to the cube of speed
of impeller.

With speed (N) held constant

Capacity flow rate) is proportional to dia of impeller.

Discharge head is proportional to square of dia of

the impeller.
Power required is proportional to cube of dia of the
impeller

Minimum Flow For Recycle

There are four main factors determining pump

Minimum Recycle Flow.

Fluid Temperature Rise
Minimum Stable flow
Internal recirculation
Thrust capacity

Pumps - operation

What you should Know

Start up
Pump lubricating mechanism must be checked

Surface of mechanical seals are cooled

A pump that is to handle hot liquid should be

warmed before it is started to prevent damage

from unequal expansion of parts.

Alignment of valves
On most pumps, the discharge valve is closed when

the pump is started.

Closing the discharge valve has number of aspects,
Minimum capacity
Minimum power
Maximum head
Minimum NPSH required
Cavitation minimized

Alignment of valves Conti

If the pump operates for any length of time with

the discharge valve closed:

It may overheat

Then liquid may vaporize

pump losses suction

Mechanical inspection before and after

startup
1. Ensure Shaft is free
2. Ensure direction of rotation in the first start up and after
motor maintenance.
3. Look for no load amperage and record it . It will be a
good reference for trouble shooting.
4. Increase the load gradually and in steps especially for
big pumps.
5. Ensure vibration after start up is normal and is within
the limits.

SHUT DOWN
Pump discharge valve should be closed to

avoid any reverse direction rotation.

If the pump to be taken to the shop for repairs:

The suction discharge valves are closed.

all liquid is drained from the pump to a safe
location.
it is purged or flushed out disconnected from the
base.
Blind are installed on the process lines.
Hazardous vapors or liquids are purged from the
pump with an inert material.

Pumps - operation

Operational Problems

Cavitation
Cavitation can be termed as:

The Heart attack of the pump

Cavitation means Different Things to different

people
It has been described as
A reduction in pump capacity

A reduction in the head of the pump

The formation of bubbles in a low pressure area of the
pump
A noise that can be heard when the pump is running
Damaged that can be seen on the pump impeller and
volute

Concept of Cavitation
In

summary,

condition

that

cavitation
can

is

an

result

in

abnormal
loss

of

production, equipment damage and worst of

all, personnel injury.

Steps In Cavitation

Mechanism of Cavitation
Formation of bubbles
-Vaporization of Liquid
-Increase in Temperature of
Liquid
-Decrease in Pressure
Growth of bubbles

Operating Conditions
Collapses of bubbles
Implosion
Liquid Micro Jet
Impeller Pitting

MECHANISM OF CAVITATION

Cavitation erosion or pitting

Pits

are plastic deformations of very small

dimensions (order of magnitude of micrometers).

The damage caused due to action of bubble

collapse is commonly referred as Cavitation erosion

or pitting.
The erosion or pitting effect is quite similar to sand

blasting.

Mechanical deformations
Longer duration of cavitation condition can result in

unbalancing of radial and axial thrusts on the

impeller. This unbalancing often leads to following
mechanical problems:

bending and deflection of shafts,

bearing damage and rubs from radial vibration,
thrust bearing damage from axial movement,
breaking of impeller check-nuts,
seal faces damage etc

Cavitation Corrosion
The implosion of bubbles destroys existing protective

layers making the metal surface

activated for the chemical attack.

permanently

The rate of erosion may be accentuated if the liquid

itself has corrosive tendencies

Suction Cavitation
Suction Cavitation occurs when the pump suction is

under a low pressure/high vacuum condition where

the liquid turns into a vapor at the eye of the pump
impeller.
This vapor is carried over to the discharge side of the
pump where it no longer sees vacuum and is
compressed back into a liquid by the discharge
pressure.
This imploding action occurs violently and attacks the
face of the impeller.

Discharge Cavitation
Discharge

Cavitation occurs when the pump

discharge is extremely high. It normally occurs in a
pump that is running at less than 10% of its best
efficiency point.
The high discharge pressure causes the majority of
the fluid to circulate inside the pump instead of being
allowed to flow out the discharge. As the liquid flows
around the impeller it must pass through the small
clearance between the impeller and the pump
cutwater at extremely high velocity.

Centrifugal Pumps troubleshooting