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A technical presentation by
Jyoti Swarup
Tripatra Engineering & Construction
On
29th
T:\Pumps\Cent Pumps presentation
April 2010
1
Positive Displacement Pumps are "constant flow machines". Centrifugal Pumps are "constant head machines".
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Types of pumps
Centrifugal Pumps - Use centrifugal force to push the fluid through the outlet. Metering Pumps - Bellows, diaphragm, peristaltic, piston, and syringe pumps that pull the fluid through the inlet valve into a chamber, close the inlet valve, and then push the fluid through the outlet valve. Positive Displacement Pumps - Bellows, doublediaphragm, gear, piston, progressing cavity, rotary lobe, rotary vane, and peristaltic pumps - fixed cavity that the fluid is pushed through by rollers, gears, or impeller. It leaves a void or vacuum which pulls in more fluid.
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Centrifugal Pumps
Most commonly used machine (next to electric motors) Consist of a set of rotating vanes, enclosed within a housing or casing, used to impart energy to a fluid through centrifugal force Two main parts: a rotating element which includes an impeller and a shaft, and a stationary element made up of a casing (volute or solid), stuffing box, and bearings. Classified by API Std 610-10th edition as Overhung OH1 to OH6 Between bearings BB1 to BB5 Vertically suspended VS1 to VS7
API Standard 610- Tenth edition 2004 (ISO 13709: 2003 identical) Centrifugal Pumps for petroleum, petrochemical and natural gas industries
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Pumps offer high flow rates, low pressures, and pulseless flow at a low priceideal for general transfer applications. Simple design means quick installation, low maintenance, and easy repair. Most centrifugal pumps must be gravity fed or utilized with a priming chamber; some are self-priming. Can control the flow rate by restricting the flow at the outlet with a nozzle or valve, (H vs Q is drooping) In smaller pumps, can restrict the outlet indefinitely without damaging the pump. Centrifugal pumps should not be run dry.
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6 Accessories ................................................................................... 55
7 Inspection, testing, and preparation for shipment .......................... 64 8 Specific pump types ...................................................................... 71 9 Vendor's data ................................................................................ 84 Annexures Bibliography........................................................................................181
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Centrifugal Pumps
Overhung
Horizontal Flexibly coupled Vertical in-line with bearing bracket Vertical in-line Vertical in-line High-speed integrally-geared
Rigidly-coupled Close-coupled
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FLOWSERVE
Model ERPN Overhung, Single stage, Process pump per API 610 Centerline supported casing (OH2); Double Volute Renewable Wear ring for casing and impeller
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Centrifugal Pumps
Between Bearing
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DMX API 610 (BB3) 10th Edition, Between Bearing Axially Split Multistage, Double Volute, Opposed impeller
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Centrifugal Pumps
Vertically Suspended
Singlecasing Doublecasing
Vertically Suspended
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FLOWSERVE
VPC (VTP-Can) Vertical Turbine, Double Casing Pump Open or Enclosed line shaft construction Option: Solid shaft or hollow shaft motor Pressure upto 150 bar Flow upto 160,000 m3/hr VS6
FLOWSERVE
QL, Vertical, wet pit Enclosed line shaft construction Twin volute casing Double suction impeller Option: Solid shaft or hollow shaft motor Pressure upto 70 bar Column size 100 to 1200 mm VS2
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Applications
general purpose fluids, pure water, sludge and sewage, slurry, high viscosity fluids, power generation, the paper industry, the petroleum industry, chemicals and corrosives, gravel and solid materials, high temperature materials, and marine applications.
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PUMP COMPONENTS
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3000 / 2950
1500 / 1460
3600 / 3550
1800 / 1750
1000 / 970
1200 / 1160
For 3-phase AC motor, HP (output) = 1.73 x Current x Voltage x Eff. x P.F. / 746 Power Factor (P.F.) = KW / KVA Torque in lb-ft = HP x 5250 / RPM
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Head
Energy content of liquid per unit weight
Relationship with pressure Head in ft = psi x 144 / w, w Sp. weight lbf/ft3 (for Water Sp. Wt. w = 62.3 lbf/ft3) Hence Head in ft = psi x 2.31 / Sp. Gr.
Pressure, Liquid Height (Head) and Specific Gravity Relationship - FPS units
231 ft
100 psi
120 psi
80 psi
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Performance Curves
Shut off head for parallel operation to be > 110% of rated head. Min. continuous stable flow (% of BEP) Rated operating point flow to be 80% to 110% of BEP (preferred range 70% to 120% of BEP) Best Efficiency point (BEP) flow rate at which highest efficiency is achieved End of curve Minimum continuous stable flow % increases as Suction Specific speed increases.
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given RPM between Flow Dynamic Head Efficiency NPSH required BHP required BHP = Flow (GPM) X TDH (FT) x SG / 3960 x EFF. (%) [BKW = Flow (m3/hr) x TDH (m) x SG / 367 x EFF. (%) ]
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Characteristics Curves
Figures are non-dimensional curves which indicate the general shape of the characteristic curves for the various types of pumps radial, mixed and axial flow. They show the head, brake horsepower, and efficiency plotted as a percent of their values at the design or best efficiency point of the pump.
MIXED FLOW
AXIAL FLOW
RADIAL FLOW
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Affinity Laws
The generated pump head depends upon the exit fluid velocity at impeller periphery, which is V = p x D X N, where D = Imp. diameter, N = RPM. Head a V , Head a D or Head a N For given D, H1/H2 = N1 / N2 For given N, H1/H2 = D1 / D2 Capacity Q a D or Capacity Q a N For given D, Q1/Q2 = N1 / N2 For given N, Q1/Q2 = D1 / D2 Power a D or Power a N
Affinity Laws
140 120 100
H1
N1
Diff Head
80 60 40 20 0
H2
N2
Q2 Q1
80
20
40
60
100
120
140
Capacity
Affinity laws also may be loosely applied to NPSHR & Pump shaft deflections (square law) and pump wear rates (cubic law)
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For varying flow or pressure, a variable speed drive may be used. Using affinity laws, one can calculate the flow rate & head at any given operating speed. The drives may be using hydraulic couplings, variable frequency drive, or a steam/ gas turbine for variable speed operation.
q (gpm)
q* (desired) q produced by pump with no flow control
Ns = N (Q)0.5 / (g H)0.75 Ns Specific Speed, dimensionless N Rotative speed RPM Q total pump flow m3/sec
(Alternate Q m3/sec per impeller eye)
H Head per stage, m Example: Q = 100 m3/hr (0.0278 m3/sec) H = 100m, RPM 2950, Ns=15.55 SI units Conversion to US units x 51.64 = 802.9
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N Q Ns 3 / 4 H
D2
D1
D2/D1 > 2
D2/D1 = 1.5 to 2
D2/D1 = 1
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Specific Speed
High Ns pump impellers have inlet diameters (D1) that approach or equal the outlet diameter (D2), and relatively large open flow passages. Low Ns pump impellers have outlet diameters (D2) that are much larger than the inlet diameters (D1) and relatively narrow flow passages.
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NPSHA Calculations
Calculation of system Net Positive Suction Head Available for typical suction conditions.
a b
NPSHA =
a) PB- (VP+Ls+hf) b) PB+ LH - (VP+hf) c) p - (VP+Ls+hf) d) p + LH - (VP+hf)
c d
Note: Enclosed sheet is a sample NPSH and DH calculations 40 of 69
Nss = N (Q)0.5 / (NPSHR)0.75 Nss Suction Specific Speed, dimensionless N Rotative speed RPM Q pump flow per impeller eye m3/sec NPSHR Net Positive Suction Head required at best eff. Point, max. impeller diameter, m Example Q = 100 m3/hr (0.0278 m3/sec) NPSHR = 5m, RPM 2950, Single suction impeller Nss=147.0 (SI units) Conversion to US units x 51.64 = 7593
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NPSHR of a pump is the NPSH that cause the total head (Ist stg head of multistage pumps) to be reduced by 3%, due to flow blockage from cavitation vapor in the impeller vanes. NPSHR is not the point at which cavitation starts. (that level is referred to as incipient cavitation). The NPSH at incipient cavitation can be from 2 to 20 times the 3% NPSHR value, depending on pump design.
The higher ratios are associated with high suction energy pumps or pumps with large impeller inlet areas.
Cavitation
Cutaway view of a pump volute shows the passage of flow through the impeller. Top curve System pressure (Ps) > fluid vapor pressure; cavitation cannot occur. Bottom curve Ps < the vapor pressure as it enters the impeller eye. This will cause cavitation.
One cubic foot of water at room temperature becomes 1700 cu. Ft . of vapor at the same temperature.
Cavitation exists in high percentage of pumps, however acceptable life can be achieved.
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Cavitation types
1. 2. 3. 4. Low NPSHA: Fluid Vaporizes at impeller inlet Low Flow (suction recirculation and discharge recirculation) Air Injection (air leaks or entrained gases) Turbulence (Excessive, due to high velocity, bends, TEE at inlet)
Symptoms of Cavitation:
1. "Pumping gravel" cavitation noise 2. Failure history: repeated seal or bearing failures 3. Rapid decrease in discharge pressure when attempting to increase rates 4. High vibrations 5. Lower than expected discharge pressure 6. Repeated impeller replacements
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Suction Cavitation
Suction Cavitation: The pump suction is under a low pressure condition where the liquid turns into a vapor at the eye of the pump impeller.
This vapor carried to the discharge side of the pump 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 which will remove large chunks of material from its face causing premature failure of the pump.
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De = Impeller Eye Diameter (inches) N = Pump Speed (RPM) NSS = Suct. Sp. Speed ...RPM x (GPM)0.5/(NPSHR)0.75 s.g. = Specific Gravity of Liquid
De = Suction Nozzle Diameter x 0.9 (is a good approximation for End Suction Pumps)
De = Suction Nozzle Diameter x 0.75 (is a good approximation for Side/Double Suction Pumps)
(This HIS code 9.6.1 has since been withdrawn now, and thus some slides are now removed from this presentation. A description of various terms of suction energy are as in next three slides.)
http://www.gouldspumps.com/cat_technews.ihtml?pid=9&lastcatid=41&step=4
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Pump 3X2X10 operating characteristics at variable speed Pump RPM 3600 1800 1200 BEP Flow, BEP Head, GPM ft 490 256 170 400 100 43
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Selected Centrifugal pump model for flow capacity 200 GPM @ 80 ft diff head:
3600 RPM, 68 HP, Q= 490 GPM @ DH = 400 ft 1800 RPM, 8.4 HP, Q= 258 GPM @ DH = 100 ft 1200 RPM, 2.4 HP, Q= 170 GPM @ DH = 44 ft
3600 RPM, 3 x 2 x 6, h 70%, NPSHR = 6.2 ft, Imp. diam 5.3 1800 RPM, 3 x 2 x 10, h 78%, NPSHR = 5.5 ft, Imp. diam. 9.0 1200 RPM, 4 x 3 x 13, h 63%, NPSHR = 4.8 ft, Imp. diam 13
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3x4-7
Discharge Diameter Inches Suction Diameter Inches
Pump Selection
Goal is to find a pump whose curve matches the piping system head vs. flow rate curve. We can fit our process conditions on the manufacturers pump curves.
To select a specific pump from a product line, find the pump with the highest efficiency that does not require the use of the largest impeller diameter. This will allow for future production expansions. Suppose that we have a process that requires a flow rate of 300 GPM and has a head requirement of 60 ft. at that flow rate. Can a 3x4-10 model 3196 Goulds pumps be used?
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Examples
Example 1: Please select centrifugal pumps for following duties
1. Capacity 250 USGPM, Diff Head 200 ft, Sea Water Sp Gr 1.03, 50 Hz Electric Supply, NPSHA 15 ft. 2. Capacity 36 m3/hr, 41.5m Dhead, Crude Oil Sp Gr 0.80, 60 Hz electric supply, NPSHA 2.5m 2a The best efficiency point of above pump at 50 Hz operation. Show Pump Model, RPM, Eff., Rated BKW, Driver rating, NPSHR, Impeller Diameter, Shut Off Head, Specific Speed, Suction Specific Speed, Nozzle sizes and ratings, in the given format. Please note Model Goulds 3196 is taken as an example only, it is not a suitable model for service. Example 2 Please select suitable centrifugal pumps for following duties 1. Capacity 6000 USGPM, Ps 20 psig, Diff head 200 ft, Hydrocarbon Sp. Gr. 0.9, NPSHA 18 ft 60 Hz Electric Supply 2. Capacity 500 m3/hr, Ps 150 kPa, Diff head 20m, Diesel Oil Sp. Gr. 0.85, NPSHA 3.5 m, 50 Hz 2a. The best efficiency point of above selected pump at 60 Hz operation. Show Pump Model, RPM, Eff., Rated BKW, Driver rating, NPSHR, Impeller Diameter, Shut Off HeadSpecific Speed at BEP,Suction Specific Speed at BEP, Nozzle sizes and ratings, BKW @ End of Curve (Please note Model Bell & Gosset series VSX is taken for example only, it is not a suitable model for service)
Refer Goulds Model 3196 / Bell & Gossett curves available in T:\pumps directory
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API Std 610, 10th ed., 2004 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries-Tenth Edition; ISO 13709 Adoption API Std 682, 3rd ed. 2004, Pumps Shaft Sealing Systems for Centrifugal and Rotary Pumps-Third Edition; ISO 21049 Adoption; Errata: November 10, 2006 API Std 685, Ist ed., 2000 Sealless Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry Services Downstream Segment, Errata 10/2007 ASME B 73.1, 2001 Specification for Horizontal End Suction Centrifugal Pumps for Chemical ProcessReplaces B73.1M (R2007) ASME B 73.2, 2003, Specification for Vertical InLine Centrifugal Pumps for Chemical Process (R2008) ASME B 73.3, 2003, Specification for Sealless Horizontal End Suction Metallic Centrifugal Pumps for Chemical Process (R2008) ASME PTC 8.2, 1990, Centrifugal Pumps
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BSI BS EN 22858, 1993 End-Suction Centrifugal Pumps (Rating 16 Bar) Designation, Nominal Duty Point and Dimensions Second Edition; (CEN EN 22858: 1993) NFPA 20, 2010, Standard for the Installation of Stationary Fire Pumps for fire protection : NFPA 20H, 2010 Stationary Fire Pumps Handbook - Third Edition
There are many other codes available for Centrifugal pumps from various international organizations as
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Unit Conversions
Some unit conversions (for ready Some formulas (for ready reference) reference) USGPM = 449 x CFS Flow m3/hr = 4.403 USGPM Pipe Vel. ft/sec = GPM x 0.321/ (ID in)2 3/hr = 0.2778 liter/sec Flow m BHP = GPM x H x Sp Gr / 3960 / Eff. Flow m3/hr = 0.5886 ft3/min BKW = m3/hr x H,m x Sp Gr/ 367 / Eff. Head 1 m = 3.2808 ft Head H = V2/2g Head 10.19m WC = 1 bar Ns = N Q H pressure Nss = N Q NPSHR Power 1 KW = 1.341 HP 2 2 Accel. due to gr. g = 9.806m/s2 = Q1/Q2 = N1/N2, H1/H2 = N1 /N2 psi = head in ft x Sp Gr / 2.31 32.17 ft/s2 Sp. speed in US units = 51.64 x SI kPa = head in m x Sp Gr / 0.102 units (API 610)
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Thank YOU
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