Pumping Technology

TEA. www.tea.ie

Agenda Pump Types Pump Selection Parameters Performance Curves Variable Speed Motor Efficiency Pipe Design Control Systems
TEA. www.tea.ie
2

Pump Types
Positive Displacement Pump Progressive Cavity Mono or Seepex. Rotary Lobe Pump

Centrifugal Pump
End suction Multi-Stage vertical and horizontal Split Case Unlike positive displacement pumps , centrifugal pumps deliver a variable flow rate Q (increasing with decreasing head H) when operating at constant speed.
TEA. www.tea.ie
3

Progressive Cavity Pump

TEA. www.tea.ie

How do Progressive Cavity Pumps work?

When the rotor and stator are combined cavities are created As the rotor rotates these cavities are progressed through the pump stator

Two complementary cavities are formed, as one is finishing the other is beginning This results in an uninterrupted continuous flow
TEA. www.tea.ie
5

Progressive Cavity Pump

TEA. www.tea.ie

Rotary Lobe Pump

TEA. www.tea.ie

Rotary Lobe Pump

TEA. www.tea.ie

End Suction Centrifugal Pump

TEA. www.tea.ie

Centrifugal Pump

TEA. www.tea.ie

10

Centrifugal Pump Runs at fixed speed (electrical frequency of power) Flow will be determined by resistance to flow (head). Motor will supply as much or as little power as is required to maintain fixed speed (within capabilities). Power consumed based on pump curve.
TEA. www.tea.ie
11

End Suction Centrifugal Pump

TEA. www.tea.ie

12

Centrifugal Pump Impeller

TEA. www.tea.ie

13

Mechanical Seal

TEA. www.tea.ie

14

Multi-Stage Pump

TEA. www.tea.ie

15

Horizontal Multi-Stage Pump

TEA. www.tea.ie

16

Split Case Centrifugal Pump

TEA. www.tea.ie

17

Split Case Centrifugal Pump

TEA. www.tea.ie

18

Vertical Multi-Stage Pump

TEA. www.tea.ie

19

Submersible Borehole Pump

TEA. www.tea.ie

20

Submersible Sewerage Pump

TEA. www.tea.ie

21

 TEA. www.tea.ie

22

Pump Selection Parameters

TEA. www.tea.ie

23

Pump System
Key components to be dealt with individually: 1. Pump 2. Motor 3. Pipework 4. Rising main Pipework (Pumphouse & Rising Main) (3) Reservoir

Motor (4) Pump: impellor & stator only (1) Source

TEA. www.tea.ie
24

Energy in pumping
Typical Energy efficiency of a pump set today

Real work Done Pump losses

Pipe losses
TEA. www.tea.ie

Motor losses
25

Flow Flow means the quantity of liquid to pass across a surface, such as the delivery flange of a pump or a cross section of a pipe, in a unit of time. Gallons per minute (gpm) Litres per minute (I/min) Litres per second (I/s) Cubic metres per hour (m3/h)
TEA. www.tea.ie
26

Head
Head means height, difference in level or gradient. A pump has a flow of 10 litres per second and a head of 30 metres, this means that the pump is capable of raising 10 litres of liquid through 30 metres every second. The pump will achieve this head no matter what liquid is being pumped. This means that the pump will lift water, petrol, mercury, etc. and only the power demand on the motor will have to be different.
TEA. www.tea.ie
27

Head
Static Head: This is the vertical height from the water level at the intake to the highest point to which the water is to be delivered. Friction Head: This is the head generated through losses generated in the rising main, suction pipework and valves. Counter Pressure: Pressure head requirements in water softeners, pressure filters, control valves, etc.
TEA. www.tea.ie
28

 TEA. www.tea.ie

29

Friction Head / Head loss

Head loss is that part of the head, possessed by the liquid, which is lost in passing through a pipe, valve or filter. This loss is not recoverable as it is lost due to friction. The head loss is proportionately greater as the speed of the liquid increases. So the more the flow is restricted by scaled pipes, clogged filters, partially closed valves etc. the greater the head loss will be.
TEA. www.tea.ie
30

Pipe Losses
Reservoir
Real work Done

Pump losses

Pipe losses

Motor losses

Motor (4)

Source
TEA. www.tea.ie
31

 TEA. www.tea.ie

32

 TEA. www.tea.ie

33

 TEA. www.tea.ie

34

 TEA. www.tea.ie

35

Rising Main Friction Losses

3 KM Rising Main Flow - 60 m/hr 200mm dia. 150mm dia. 100mm dia. Friction = 0.13m/100m (0.5m/s) Friction = 0.6m/100m (0.9 m/s) Friction = 4.5m/100m (2.1 m/s)

200mm pipe = 3.9m (energy cost = 3/day) 150mm pipe = 18m (energy cost = 14/day) 100mm pipe = 135m (energy cost = 105/day)
TEA. www.tea.ie
36

System Curve

TEA. www.tea.ie

37

Suction Lift
The Suction Lift calculations includes: The vertical height difference from the water level in the sump to the centre of the pump suction flange. Losses in suction pipework and footvalve. Flow velocity at pump inlet. Liquid vapour pressure. Atmospheric pressure This calculation provides the Nett Positive Suction Head available from the system. NPSHa
TEA. www.tea.ie
38

NPSHa

Pi = Surface pressure of fluid (N/m2) Pb = Barometric pressure (N/m2) Pv = Vapour pressure of fluid (N/m2) = Fluid density (kg/m3) Ve = Velocity of fluid at pump inlet (m/s) Ze = Fluid Surface level above pump inlet. (m) Fe = Friction loss is pipe to pump. (m)

The Pump Manufacturer provides the NPSH required by the pump. If the NPSHa is less than the NPSHr cavitation will occur.
TEA. www.tea.ie
39

Cavitation
Cavitation is the vapourisation of liquid caused by the pressure dropping below its vapour pressure at the impeller inlet. As liquid flows from the pump inlet flange into the impellor the head initially falls as the velocity of the fluid is increased. This drop in head may be sufficient to cause the liquid to boil. This results in "cavitation". Cavitation is detectable as a rattling noise and results in low pump efficiency and high risk of damage to the pump. To prevent cavitation the NPSH available from the system must be greater than NPSH required by the pump.
TEA. www.tea.ie
40

 TEA. www.tea.ie

41

Pump Efficiency
Reservoir
Real work Done Pump losses

Pipe losses

Motor losses

Motor (4)

Source
TEA. www.tea.ie
42

Delivered power
Delivered power is the power delivered by the pump to the liquid. The value of this power depends upon three factors: Flow Head Specific Gravity of the liquid i.e. a pump which delivers petrol does less work than when it delivers sulphuric acid, because the specific weights of the two liquids are different. The power which the pump consumes is the absorbed power.
TEA. www.tea.ie
43

Absorbed or Shaft power

This is the power that the pump absorbs from the motor.

The absorbed power includes: Delivered power to the liquid Hydraulic losses within the pump Friction losses within the pump

TEA. www.tea.ie

44

Efficiency
Pump efficiency is obtained by comparing the power delivered to the liquid to the power absorbed by the pump. For example a pump that is 75% efficient only delivers 75% of the absorbed power, the remaining 25% is lost within the pump. The efficiency of a motor is obtained by dividing its nameplate power output by the input power consumed from the ESB sometimes referred to as P1 and P2. The efficiency losses are made up of heat and iron losses within the motor. The overall pump/motor efficiency is calculated by multiplying both.
TEA. www.tea.ie
45

Power - Efficiency
Water kW = . g . Q . H = . Q(m3/hr) x H(m) 367 Pump input power = Q(m3/hr) x H(m) 367 x
TEA. www.tea.ie
46