Hydraulic Machinery

Pumps, Turbines...

School of Civil and

Monroe L. Weber-Shirk Environmental Engineering
 Hydraulic Machinery Overview

Types of Pumps
Dimensionless Parameters for Turbomachines
Power requirements
Head-discharge curves
Pump Issues
Cavitation
NPSH
Priming

Pump selection
 Types of Pumps
Positive displacement
piston pump
peristaltic pump
gear pump
two-lobe rotary pump
screw pump
Jet pumps
Turbomachines
axial-flow (propeller pump)
radial-flow (centrifugal pump)
mixed-flow (both axial and radial flow)
 Positive Displacement Pumps

Piston pump
Diaphragm pump
Peristaltic pump
Rotary pumps
gear pump
two-lobe rotary pump
screw pump
 Reciprocating action pumps
Piston pump diaphragm pump
can produce very high pressures
hydraulic fluid pump
high pressure water washers
 Peristaltic Pump
Fluid only contacts tubing
ID and roller
Tubing ___
_______
velocity with respect to the
tubing determine flow rate
Tubing eventually fails from
fatigue and abrasion
Fluid may leak past roller at
high pressures
Viscous fluids may be
pumped more slowly
 Rotary Pumps
Gear Pump
fluidis trapped between gear teeth and the
housing
Two-lobe Rotary Pump
(gearpump with two teeth on each gear)
same principle as gear pump
fewer chambers - more extreme pulsation

trapped fluid
 Rotary Pumps
Disadvantages
precise machining
abrasives wear surfaces rapidly
pulsating output

Uses
vacuum pumps
air compressors
hydraulic fluid pumps
food handling
 Screw Pump
Can handle debris
Used to raise the
level of wastewater
Abrasive material
will damage the
seal between screw
and the housing
Grain augers use
the same principle
 Positive Displacement Pumps

What happens if you close a valve on the

effluent side of a positive displacement pump?
What does flow rate vs. time look like for a
piston pump?
1.2

0.8 1st piston

total flow
2nd piston
0.6
3rd piston
0.4 3 pistons

0.2

0
0 2 4 6 8 10
rads

Thirsty Refugees
 Jet Pump
eductor
A high pressure, high velocity jet discharge is used
to pump a larger volume of fluid.
Advantages
no moving parts
self priming
handles solids easily

Disadvantage
inefficient
Uses
deep well pumping
pumping water mixed with solids
http://spaceflight.nasa.gov/shuttle/upgrades/ojp.html
 Turbomachines

Demours centrifugal pump - 1730

Theory
conservation of angular momentum
conversion of kinetic energy to potential energy in flow
(inefficient ________
expansion ___________ process)
Pump components Tz = r Q ( ) (
r2Vt2 - rV )
1 t1

impeller
rotating element - ___________
encloses the rotating element and seals the pressurized
casing or _________
liquid inside - ________ housing
 Pressure Developed by
Centrifugal Pumps
Centrifugal pumps accelerate a liquid
The maximum velocity reached is the velocity of the
periphery of the impeller
The kinetic energy is converted into potential energy
as the fluid leaves the pump
The potential energy developed is approximately
V2
velocity head
equal to the ________ ____ at the periphery of the hp =
impeller 2g
A given pump with a given impeller diameter and
speed will raise a fluid to a certain height regardless
of the fluid density
 Radial Pumps
also called _________
centrifugal pumps
broad range of applicable flows and heads
higher heads can be achieved by increasing the
_______
diameter or the ________
rotational ______
speed of the impeller
Flow Expansion
Discharge
Casing
Suction Eye Impeller
Impeller
Vanes
 Axial Flow

also known as
__________
propeller pumps
low head (less than 12
m)
high flows (above 20
L/s)
 Dimensionless Parameters for
Turbomachines
We would like to be able to compare pumps with
similar geometry. Dimensional analysis to the
rescue...
To use the laws of similitude to compare
performance of two pumps we need
exact geometric similitude
all linear dimensions must be scaled identically Q
roughness must scale same
homologous - streamlines are similar D 3
constant ratio of dynamic pressures at corresponding
points
also known as kinematic similitude
 Kinematic Similitude:
Constant Force Ratio
Reynolds VD
viscous forces
ratio of inertial to _______

Froude V2 V
gravity force
ratio of inertial to ________
gl gl
Weber
ratio of inertial to surface-tension
_______ ______ forces V 2
l

Mach
V
elastic forces
ratio of inertial to _______
c
 Turbomachinery Parameters
D flow Q e
C p = f Re, F ,W , M , , 3
, Where is the fluid?
Dimpeller w D flow D flow

2p Q Q hp gD 4flow
Cp
hp g V CH =
CH =
V 2 Q2
2
V 2 A D flow

hp gD 4flow D flow Q e
= CH = f Re, , ,
Q2 Dimpeller w D flow D flow
3

impeller (Impeller is better defined)
 Shape Factor

Relatedto the ratio of flow passage

diameter to impeller diameter
Defined for the point of best efficiency
What determines the ideal shape for a
pump?
S f ( , Q, p, )

Exercise
 N Q
* Impeller Geometry: w Q
N sp = S=
(h )
p
34
Shape Factor (gh ) p
34

Impeller
N S diameter
500 0.18 Radial: high _______,
pressure low ____
flow

1000 0.37 radial

3400 1.25 mixed

6400 2.33 mixed

10000 axial: high _______,

flow low _______
pressure
3.67

*N in rpm, Q in gpm, H in ft Nsp = 2732S

 Use of Shape Factor: w Q
S= 34
Specific Speed (gh )p

The maximum efficiencies for all pumps occurs

when the Shape Factor is close to 1!
Flow passage dimension is close to impeller diameter!
Low expansion losses!

There must be an optimal shape factor given a

discharge and a head.
Double suction (like two pumps in parallel)
Multistage (pumps in series)
Use Q and H for each stage
 Additional Dimensionless
Parameters
hp g
CH = 2 2
D is the _______
impeller diameter
w D
Q
CQ
D 3
Pw = g Qhp
P
CP P is the _____
power
3 D 5

CQ1 2 Alternate equivalent way

S 34 to calculate S.
CH
(defined at max efficiency)
 Head-Discharge Curve
Theoretical
circulatory flow - hp head-discharge
inability of finite
curve
number of blades to
guide flow
V2
friction - ____
shock - incorrect angle
V2
of blade inlet ___ Actual head-
discharge curve
other losses
bearing friction
packing friction
disk friction Q
internal leakage
Pump Power Requirements
Pw = g Qhp Water power

Subscripts
Pw
eP
Ps
w = _______
water
Ps p = _______
pump
em
Pm s = _______
shaft
g Qhp m = motor
_______
Pm =
eP em
 Impeller Shape vs. Power Curves

S
Power (% of design)

radial 1 - O.33
2 - 0.81
3 - 1.5
4 - 2.1
axial 5 - 3.4
Discharge (% of design)
http://www.mcnallyinstitute.com/ Implications
 Affinity Laws homologous

With diameter, D, held constant: P QH

Q hp g P
CQ CH = CP
D 3 w 2 D2 3 D 5
1
3
Q1 hp1 w1
2
P1 1
=
Q2 2 hp 2 w2
P2 2
With speed, , held constant:
2 5
Q1 D1
3 hp1 D1 P1 D1
= = =
Q2 D2 hp 2 D2 P2 D2
 Dimensionless Performance
Curves
0.08 1
0.07 0.9
0.8
0.06
hp g 0.7 Efficiency
CH = 2 2 0.05 0.6
w D
0.04 0.5
0.03 0.4
0.3
0.02
0.01
D=0.366 m 0.2
0.1
0 0
0 0.02 0.04 0.06 0.08 0.1
Q
12
0.083 4.3
0.5
CQ shape
S
C Q
0.027 0.75 D 3
Curves for a particular pump
C H3 4 (defined at max efficiency)
Independent of the fluid!
____________
 Pump Example

Given a pump with shape factor of 4.57, a

diameter of 366 mm, a 2-m head, a speed of
600 rpm, and dimensionless performance 0.08 1
0.07 0.9

curves (previous slide). 0.06

0.8

Efficiency
Hg 0.7
CH 0.05 0.6
2D 2 0.04 0.5
0.03 0.4
0.3
0.02
D=0.366 m 0.2

What will the discharge be?

0.01 0.1
0 0
0 0.02 0.04 0.06 0.08 0.1
Q
CQ
D 3

How large a motor will be needed if motor

efficiency is 95%?

Exercise
 Pumps in Parallel or in Series

Parallel
Flow adds
________
same
Head ________

Series
Flow ________
same
Head ________
adds

Multistage
 Cavitation in Water Pumps
water vapor bubbles 8000
form when the pressure 7000

Vapor pressure (Pa)

is less than the vapor 6000

pressure of water 5000

4000
very high pressures 3000
(800 MPa or 115,000 2000
psi) develop when the 1000
0
vapor bubbles collapse 0 10 20 30 40
Temperature (C)
 Net Positive Suction Head
NPSHR - absolute pressure in excess of vapor
pressure required at pump inlet to prevent
cavitation
given by pump manufacturer
determined by the water velocity at the entrance to the
pump impeller
NPSHA - pressure in excess of vapor pressure
available at pump inlet
determined by pump installation (elevation above
reservoir, frictional losses, water temperature)
If NPSHA is less than NPSHR cavitation will occur
 Net Positive Suction Head

2 Elevation datum
Absolute pressure
z
ps Vs2 pv s = suction
NPSH R = + - Total head -pv!
1 g 2g g

2
peye
pv Veye
NPSH R = - + At cavitation!
g g 2g
NPSHR increases with Q2!
How much total head in excess of vapor pressure is available?
 NPSHA
p1 V12 p2 V22
+ + z1 = + + z2 + hL
g 2g g 2g

patm ps Vs2
+ zreservoir = + + hL
g g 2g

patm ps Vs2
- Dz - hL = +
g g 2g

patm pv ps Vs2 pv
- Dz - hL - = + - Subtract vapor pressure
g g g 2g g
patm p
- Dz - hL - v = NPSH A
g g
 NPSH problem

Determine the minimum

?
reservoir level relative to the
pump centerline that will be 18C
acceptable. The NPSHr for
the pump is 2.5 m. Assume
you have applied the energy
equation and found a head
loss of 0.5 m.

Exercise
 Pumps in Pipe Systems
Pipe diameter is 0.4 m
and friction factor is
0.015. What is the pump
discharge? 60 m
1 km

p1 V12 p2 V22
z1 hp z 2 hl 11m
m
2g 2g

hp z 2 z 1 hl

hp f(Q) often expressed as hp = a - bQ 2

 Pumps in Pipe Systems
system operating point
120

100

80 Head vs. discharge

Head (m)

curve for ________

pump
hp 60

40
Static head
20

0
0 0.2 0.4 0.6 0.8
Discharge (m /s)
3

What happens as the static head changes (a tank fills)?

 Priming
hp g
The pressure increase created is CH = 2 2
w D
proportional to the _______
density of the fluid
p
being pumped. CH
2 D 2
A pump designed for water will be
unable to produce much pressure p CH 2 2
D
increase when pumping air
1.225 kg/m3
Density of air at sea level is __________
Change in pressure produced by pump is
about 0.1% of design when pumping air
rather than water!
 Priming Solutions
Applications with water at less than atmospheric
pressure on the suction side of the pump require a
method to remove the air from the pump and the
inlet piping
Solutions priming tank to vacuum pump
foot valve
priming tank
vacuum source
self priming

foot valve
 Self-Priming Centrifugal Pumps

Require a small volume of liquid in the

pump
Recirculate this liquid and entrain air from
the suction side of the pump
The entrained air is separated from the
liquid and discharged in the pressure side of
the pump
 Variable Flows?

How can you obtain a wide range of flows?

Valve
__________________________
Multiple pumps (same size)
__________________________
Multiple pumps (different sizes)
__________________________
Variable speed motor
__________________________
Storage tank
__________________________

Why is the flow from two identical pumps

usually less than the 2x the flow from one
pump?
 RPM for Pumps

number of
60cycle poles sync full load rad/sec
2 3600 3500 367
Other options 4 1800 1750 183
6 1200 1167 122
variable speed 8 900 875 92
10 720 700 73
belt drive 12 600 583 61
14 514 500 52
16 450 438 46
18 400 389 41
20 360 350 37
22 327 318 33
24 300 292 31
26 277 269 28
28 257 250 26
30 240 233 24
 Estimate of Pump rpm

The best efficiency is obtained when S=1

Given a desired flow and head the
approximate pump rpm can be estimated!
34

S=
w Q
w
( gh )
p
34
(gh )
p Q

Pump for flume in DeFrees Teaching Lab

Q = 0.1 m3/s, hp = 4 m.
Therefore = 50 rads/s = 470 rpm
Actual maximum rpm is 600!
 Pump Selection

Material Compatibility
Solids
Flow
Head
NPSHa
Pump Selection software
A finite number of pumps will come close to
meeting the specifications!
 Pump Selection Chart

http://www.pricepump.com/

Model M

Model X
 End of Curve Operation

Right of the BEP (Best Efficiency Point)

is sufficient NPSH available for the pump to operate
properly?
fluid velocities through the suction and discharge
nozzles of the pump could be extremely high, resulting
in increased pump and system noise (and wear)
Left of BEP operation
high thrust loads on the pump bearings and mechanical
face seals result in premature failure.
The pump is oversized, resulting in lower efficiency
and higher operating and capital costs.
 w Q
S=
Goulds Pump Curves (gh )p
34

890 rpm = 93.2 rad/s

Splitcase double suction

BEP = 1836 L/s

S=0.787

Check the Power!

 Pump Installation Design

Why not use one big pump?

Can the system handle a power failure?
Can the pump be shut down for
maintenance?
How is the pump primed?
Are there enough valves so the pump can be
removed for service without disabling the
system?
 Pump Summary

Positive displacement vs. turbomachines

Dimensional analysis
Useful for scaling
Useful for characterizing full range of pump
performance from relatively few data points
Turbomachines convert shaft work into increased
pressure (or vice versa for turbines)
The operating point is determined by where the
pump and system curves intersect
NPSH
 Water problem?
Early in my college days I took a break and spent 17 months in Salvadoran
refugee camps in Honduras. The refugee camps were located high in the
mountains and for several of the camps the only sources of water large enough
to sustain the population of 6-10,000 were located at much lower elevations. So
it was necessary to lift water to the camps using pumps.

When I arrived at the camps the pumps were failing frequently and the pipes
were bursting frequently. Piston pumps were used. The refugees were
complaining because they needed water. The Honduran army battalion was
nervous because they didnt want any refugees leaving the camp. There was
only one set of spare parts (valve springs and valves) for the pump and the last
set of parts only lasted a few days. The pump repair crew didnt want to start
using the pump until the real cause of the problem was fixed because spare
parts have to be flown in from Miami.
 Water problem:
proposed solutions?

2 km pipeline (2
galvanized and then
3 PVC) with rise of
100 m

piston pump (80 L/min)

 Shape Factor Solution

Create a dimensionless grouping

S f ( , Q, p, )

Q
p S 34
mass
Eliminate ______ p


p
length
Eliminate _______
Q 2 3 w Q
S= 34
p time
Eliminate ______ (gh )
p
Q 2 3 4 3
 Pump Curve Solution

600rev 1 min 2
62.8 / s

min 60s rev

hp g 2m 9.8m / s 2
CH = CH 0.037
w 2 D2 62.8 / s 2 0.366m 2
Q CQ 0.068
CQ
D 3
Q 0.06862.8 / s 0.366m 0.21m3 / s
3
Q CQD 3

g Qhp
P=
(9800 N / m 3
)(0.21m 3
/ s ) (2m)
= 5.55kW
Pm =
eP em (0.78)(0.95)
 Pump Curve Solution
0.08 1
0.07 0.9
0.8
0.06
hp g 0.7 Efficiency
CH = 2 2 0.05 0.6
w D
0.04 0.5
0.03 0.4
0.3
0.02
0.01
D=0.366 m 0.2
0.1
0 0
0 0.02 0.04 0.06 0.08 0.1
Q
CQ
D 3
 NPSH solution

NPSH A = NPSH R
?
patm - pv
NPSH A = - Dz - hL
g
18C
patm - pv pv 2000 Pa
Dz = - hl - NPSH R
g
patm = 101300 Pa
101300 Pa 2000 Pa 9789 N / m3
z 0.5m 2.5m
9789 N / m3

z 7.14m
 Implications of Power Curves

You are going to start a radial flow pump

powered by an electric motor. You want to
reduce the starting load on the motor. What
can you do?
What would you do if you were starting an
axial flow pump?
How could reducing the head on a radial
flow pump result in motor failure?
 Find Q

Tz = r Q
r2V (
t 2
- rV
1) (
t1

) Let A = 10 cm2
Tz = r QVt2 r2

Tzw = r QwVt2 r2 work

Tzw wVt2 r2 Tzw wVt2 r2
Dimensional analysis
hp = = =
gQ g gVA g
p1 V12 p2 V22
z1 hp z 2 hl Datum is reservoir level
2g 2g

wVt2 r2 V22 Neglect head loss

= + z2
g 2g
 How could we lift water more
efficiently?

vt cs2

wVt2 r2 V22
= + Dz Solve for Q=AV r
g 2g

Q = A 2wVt2 r2 - 2 g Dz = AV2 Tzw = r QwVt2 r2

Decrease V without decreasing Q! (

hp Tzw Dz g ADz 2wVt2 r2 - 2 g Dz
= =
Dz g Q Dz hp Tzw
 Lost energy

wVt2 r2 V22
= + Dz
g 2g

wVt2 r2 V22
= + Dz
g 2g
 Selection of Pump Type
1000
Positive
displacement
100 Radial
6000
Pumping head (m)

4000

Power (kW)
2000
hp 10 Mixed 1000
600
400
200
1 100
Axial 60
40
1 2 4 6 20
0.1 10
0.0001 0.001 0.01 0.1 1 10
Flow (m3/s)