Pump design calculations

Kerosene pump
Impeller inlet (assume end - suction pump)
Here we are going to make use of equation (31) and the definitions of
flow coefficient and cavitation coefficient, equations (29) and (30)
expressed in terms of the inlet parameters, to estimate the eye diameter.

2 0.102...........................................................................( a)

1.792 e

Definition of cavitation coefficient in terms of the eye parameters yields:

2 g

NPSHR

Ue

2 g30.70.

1950 re

000158 re

................................. ( b)

Definition of flow coefficient in terms of the eye parameters yields:

Qe
e

Va e

Ae

Qe

Ue

Ue

Ae Ue

207e

0.0127

2
2
re rs re 1950

re 2 rs 2 re

....................................................................... ( c)

Solving the three equations (a, b @c) for the inlet extreme diameters
yields equation "d" below:
7.68e

12

2
2
re rs

0.102 re

158 e

0..... ( d)

Having selecting a shaft diameter of 1.5 cm (see shaft calculations)

reduces equation (d) to equation (e) below followed by its solution:

7.68e

12

re

0.000225

0.102 re

158 e

0.. ( e)

0.022178341245863185451 5.2102993358346036489e-31i

0.102r 0.000158 solve

0.022178341245863185451 5.2102993358346036489e-31i
0.0020560276514765240036 3.3722055220487461209e-30i

12

7.68 10

r2 0.000225

0.0020560276514765240036 3.3722055220487461209e-30i
0.038767428825259291253 1.1922977629916241445e-31i

0.038767428825259291253 1.1922977629916241445e-31i

The above figures are merely mathematical solutions for the equation of
the eye diameter except the value {re = 2.2cm} which goes with real
pumps normal design parameters. For instance, table (10) below
compares calculated values of the inlet design parameters based on tow
values of the eye radii (re = 3.9 cm and re = 2.2 cm) with a typical
blockage factor of 0.85
Table (10). Calculated values of the inlet design parameters based on tow
values of the eye radii (re = 3.9 cm and re = 2.2 cm)
Design parameter
e
e
Ue (m/s)
Ve (m/s)
e,f ( )
b ( )

re = 3.9 cm
0.042
0.105
75.6
3.2
2.9
3

re = 2.2cm
0.350
0.32
43
15
19.2
22

The 3.9 cm eye radius pump will totally be blocked at the inlet due to the
smaller inlet blade angle {3}. Also it has an eye flow coefficient e far
bellow the normal design range which is (0.2 to 0.3)(7). So, the option of
the 3.9 cm eye radius is rejected.
For an eye radius of 2.2cm which is associated with typical design
parameters, the corresponding absolute axial velocity at inlet of the pump
is 15 m/s. Assume that the liquid inters the blades radially. To calculate
the radial velocity "Vf1" which is expected to be greater than 15 m/s due
to the presence of blockage, we have to know the blockage factor (k1)
first. Calculations of blockage factor depend on other parameters (f1, b1,
f2, b2, nb etc) most of which are unknown yet. Therefore, we are going

to assume that the effect of blockage is equivalent to the effect of slip in

pumps which is quantified by the slip velocity Vs (7) according to equation
(45).

Vs sin f
....................................................................... (45)
U 0.7
nb

Now, Assume 8 blades each with 3 mm thickness whereas the blade

leading edge thickness is 1.5 mm.
Consider figure (11), the incomplete inlet velocity triangle constructed
from data of table (10):

Figure (11). Inlet velocity diagram, incomplete.

f1 = tan-1(Ve /U1) = tan-1(15 / 43) = 19.2

1 = (sin19.2)0.5 / 80.7 = 0.134 (equation 45)
Vs1 = 5.75
b1 = tan-1 (15/37.25) = 22
Vf1 = 43tan(22) = 17.3
To continue on the calculations to reside at final values in order to
complete the inlet velocity triangle, we have to estimate the outlet
parameters.

Impeller 0utlet
Substituting the value of specific speed in equation (32) we get:
2 = 0.4/(o.21)0.25 = 0.6
By the definition of the head coefficient equation (28) we get:
2 = gH / (Ut 2 )2 = 9.81079/(1950 r2 )2
U 2 = 133 m/s
r2 = 0.068 m = 6.8 cm
Substituting the value of specific speed in equation (33) we get:
2 = 0.1715 (0.21)1/2 = 0.0786
By the definition of the flow coefficient equation (29) we get:
0.0786 = Vf 2/U 2 = Vf 2/ 133
Vf 2 = 10.5 m/s
The blade tip velocity U 2 and flow velocity Vf 2 are not sufficient to
construct the outlet velocity diagram. We have to set the value of the
whirl velocity Vw2 (the tangential component of the absolute velocity V2)
that satisfies the efficiency and head requirements.
Consider the definition of the hydraulic efficiency equation (35b), the
case of zero inlet whirl, viewed in conjunction with the magnitude of
hydraulic efficiency calculated from equation (39).
Vw2 = 9.81079/(0.79133) = 100.6 m/s.
From the incomplete outlet velocity triangle, figure (12), we deduce the
following:
2 = tan-1(10.5/100) = 6 (The absolute velocity angle).
Vf2 = Vw2 tan 2 = 10.5 m/s (The radial flow velocity).
f2 = tan -1 (10.5/33) = 17.96 (The relative flow angle).
V2 = 101m/s (The absolute velocity).

Figure (22). Outlet velocity diagram, incomplete.

To find b2 (the exit blade angle), we have also to quantify the slip effect
Vs2 using equation (45). Hence;
2 = Vs2 / U2 = [sin(17.96)]0.5 / 80.7 = 0.129
Vs2 = 17m/s.
b2 = tan-1(10.5/15.4) = 34.6
Estimating the number of blades
We can now use b1 and b2 in re-estimating the number of blades from
equation (42) which may dictate resetting the previously estimated inlet
and outlet design parameters:
nb = 7.5( 6.8+ 2.2)(sin28.3) / (6.8-2.2) = ( 7 blades).
Recalculations of the previous parameters on the basis of 7 blades give
the following result:
Inlet parameters:
1 = (sin19.2)0.5 / 70.7 = 0.147
Vs1 = 6.3
b1 = tan-1(15/36.7) = 22.2
Vf1 = 43tan22 = 17.6
outlet parameters:
2 = [sin(17.96)]0.5 / 70.7 = 0.142
Vs2 = 18.9m/s.

b2 = tan-1(10.5/13.5) = 37.9
Checking nb again has suggested 8 blades. So, the solidity check equation
(43) is the judge:
Solidity check
The assumption of using 8 blades:
= 89.7/ 26.8 = 1.82 (rejected)
where 9.7 is the blade length " " in cm {( 6.8 2.2) / sin28.3)}
The assumption of using 7 blades:
= 79.2/ 26.8 = 1.5 (accepted)
where 9.2 is the blade length " " in cm {( 6.8 2.2) / sin30}
Blockage factor (equation 44):
k1 = 0.8 (1.5 mm blade thickness).
k2 = 0.92 (before considering the leakage and boundary layer effect).
.
We note that the absolute radial velocity at the eye Vf1, which is computed
on the basis of the slip concept equation (45), can be computed by
assuming a blockage factor k1 = 0.85. This blockage factor of 0.85 can be
achieved by assuming 1.125 mm blade thickness at the leading edge.
The inlet width is computed on the basis of k1 = 0.85:
Inlet width b1 :
b1 = Q/ 2 r1Vf1 k1 = 6.1 mm !
Exit width and blockage
When computing the exit width b2 we have to care for the following two
phenomena:
Leakage.
Boundary layer displacement thickness on blade surfaces and the
walls of hub and shroud.
The leakage is expressed in term of the volumetric efficiency (see
equation
bellow).
The Boundary layer displacement thickness is caused by the adverse
pressure gradients. If the value of the zero- pressure gradient is 0 then it
is assumed that:

 The blade boundary layer thickness b on one surface of the blade

is 20 and therefore, the two surfaces of the blade will suffer 40
thickness.
The hub and shroud boundary layer thickness h,s on the surface of
each wall is 0 and therefore, the two surfaces of hub and shroud
will suffer 20 thickness.

0.2
0.8
0 0.0462

............................................................ ( 47)
v
r2
Hence;
The blockage factor resulting from blade thickness and their associated
boundary layer displacement is
k2b = 1- 7( 40 + t) / 26.8sin37.9....(a)
b2 = 20

+ [Q/v] / 20.068 k2b 10.5 (b)

Equation (47) when applied gives 0 0.2 mm (see 0 computation ),

then:
k2b = 0.9
b2 = 3.4 mm ! ! !

=19.2

Figure (33). Inlet velocity diagram.

Figure (44). Outlet velocity diagram.

Table (11). Summary of inlet and outlet sizing parameters of the fuel
pump.
Number of blades
Eye outer diameter (cm)
Eye inner diameter (cm)
Inlet blade angle ()
Impeller width at inlet (mm)
Impeller outer diameter (cm)
outlet blade angle ()
Impeller width at exit (mm)

7
4.4
3.0
22.2
6.1
13.6
37.9

Table (12): Calculated values of efficiency components (see efficiency

calculations)

efficiency
v
H
m
p

value
0.97
0.79
0.89
0.68

Nitric Acid pump

Impeller inlet (assume end - suction pump)

Again, to estimate the eye diameter we are going to make use of equation
(31) and the definitions of flow coefficient and cavitation coefficient,
equations (29) and (30) expressed in terms of the inlet parameters,.

1.792 e 0.102........................................................... ( a)
2

2 g

Ve
Ue

NPSH R

re

3.77 10

re

...................................... ( b)

7.5 10

re 2 rs 2 re

....................................................... ( c)

Solving the three equations (a, b & c) for the inlet extreme diameters
yields equation "d" below:
1.11 10

10

2
2
re rs

0.102 re 3.77 10
2

0........... ( d)

........................

..........................

( 33)

( 34)

Having selecting a shaft diameter of 2 cm (see shaft calculations) reduces

equation (d) to equation (e) below followed by its solution:
1.11 10

10

re 0.0004
2

0.102 re 3.77 10
2

0.......... ( e)

0.032250615279324423799 1.8154156068739170272e-30i

1.11 10

10

( r) 0.0004
2

0.032250615279324423799 1.8154156068739170272e-30i
2

0.102 ( r) 3.77 10

3.2035534405907569623e-30 0.011536893300647961654i

solve

3.2035534405907569623e-30 0.011536893300647961654i
0.059908898775625068707 3.0861738145719332864e-31i
0.059908898775625068707 3.0861738145719332864e-31i

The above figures are also merely mathematical solutions for the equation
of the eye diameter except the value {re = 3.2cm} which agrees with real
pumps normal design parameters.
Now, Assume 6 blades each with 4 mm thickness whereas the blade
leading edge thickness can be 2 mm.
Impeller inlet:
For re = 3.2 cm we have the following calculated data:
Ae = 1.96E-3 m2 (eye x-section area).
Ve = 11 m/s
(absolute velocity at eye).
Ue = 27.52 m/s
(U = r, = 917.3).
e = 0.4
(equation 29).
f1 = 21.8
(the relative flow angle, figure 15)
Vs1 = 4.8 m/s.
(equation 45).
b1 = 25.8
(the blade angle, figure 15).
Vf1 = 13.3 m/s.
(the radial flow velocity at inlet, figure 15).
Impeller outlet:
2 = 0.6
U2 = 97.3 m/s
r2 = 10.6 cm
2 = 0.0786
Vf2 = 7.6 m/s
H = 0.81
Vw2 = 72 m/s
2 = 0.153
Vs2 =14.9 m/s
2 = 6
f2 = 16.7

(equation 32).
(equation 28).
(U = r, = 917.3 ).
(equation 33).
(the radial flow velocity, equation 29).
(equation 39).
(equation 35b).
(equation 45).
(equation 45).
(the absolute velocity angle, figure 16).
(the relative flow angle, figure 16).

b2 = 36.2

(the blade angle, figure 16).

Solidity check
= 615/ 210.6 = 1.4

(accepted)
where 15 cm is the blade length " " {( 10.6 3.2) / sin31}

Blockage factor:
k1 = 0.8 6 (equation 45, using a blade thickness of 2 mm at the leading
edge ).
k2 = 0.94 (before considering the leakage and boundary layer effect).
.
We note that the same absolute radial velocity at the eye Vf1 = 13.3 m/s,
which is computed on the basis of the slip concept equation (45), can be
attained by assuming a blockage factor k1 = 0.83. This blockage factor of
0.83 corresponds to 2.5mm blade thickness at the eye leading edge.
Inlet width b1 :
The inlet width is computed on the basis of k1 = 0.86 taking into
consideration the leakage effect where the volumetric efficiency v= 0.97
from equation (41).
b1 = Q/ 2 r1Vf1 k1 = 10 mm!
Exit width and blockage

The blockage factor resulting from blade thickness and its associated
boundary layer displacement is:
k2b = 1- 6( 40 + t) / 210.6sin36..2....(a)
b2 = 20

+ [Q/v] / 20.106 k2b 7.6 ...(b)

Equation (47) when applied gives 0 0.25 mm (see 0 computation ),

then:
k2b = 0.92

b2 = 5.5 mm!! !
Velocity diagrams are shown in figures (15) and (16).

Figure (55). Inlet velocity diagram.

Figure (16). Outlet velocity diagram.

Table (12). Summary of inlet and outlet sizing parameters of the oxidizer
pump.
Number of blades

Eye outer diameter (cm)

Eye inner diameter (cm)
Inlet blade angle ()
Impeller width at inlet (mm)
Impeller outer diameter (cm)
outlet blade angle ()
Impeller width at exit (mm)

6.4
4
25.8
10
21.2
36.2
5.5

Table (13): Calculated values of efficiency components (see efficiency

calculations)
efficiency
v
H
m
p

value
0.97
0.79
0.90
0.69