Beruflich Dokumente
Kultur Dokumente
Prepared by:
FARAG ALI AL-AWKALI
مركز الشمس الدولي للتدريب و الستشارات
INTRODUCTION
The transfer of fluids from one piece of equipment or plant
to another is a central feature of industrial operation, and a wide
range of pumps is used for this purpose.
The main function of a pump is to raise the pressure of a
liquid to a required value so it can flow. It is necessary to
consider all factors in selecting a pump for a certain duty, this
includes, flow, head, type of fluid, fluid temperature, and fluid
viscosity.
In this course we will discuss the type of pumps, their
construction, and cover in details the maintenance of pumps
similar to those, installed at the GREAT RIVER PROJECT. For
the maintenance of any particular pump the manufacturers
manual should be consulted for the detail of maintenance for
each type of pump. The manufactures have spent many hours
and years of experience to prepare these manuals for the use of
operating and maintenance personnel. These instruction books
should be read carefully and concerned maintenance people
should be very familiar with these instruction manuals.
PUMPS FUNCTION
One of the essential jobs in any plant is to move liquids
such as:
• Water to a boiler to make steam,
• Cooling liquids to equipment,
• Liquids for plant processes, or
• Potable water to city
A pump is a machine that provides energy to move
liquids.
PUMP SELECTION
Successful and efficient operation of pumps depends upon
proper selection and installation. For any particular application, a
pump is chosen that is capable of delivering a specified flow of
liquid with the required head. The size and type of the pump to
be used in each case depends on both the discharge head
(m/feet) and the quantity of flow (m3/Hr or gal/min).
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Fig. (1-1)
Approximate upper limit of pressure and capacity by pump class.
As seen in Fig. (1-1) for very high head but low flows a
positive displacement pump “Reciprocating” will be the obvious
choice, while for very high capacity “Volume flow” the centrifugal
pump is usually used. Rotary pumps are a particularly useful type
since they are suitable for handling a wide variety of fluids from
the very lowest to the very highest viscosities (with suitable
modification of design where very high fluid viscosities are
concerned). As a general rule, however, they are suitable only for
handling fluids free from solid contaminants which could jam in
the small clearance spaces involved or produce high wear.
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Table (3) gives a fairly good guide for type pump selection and
the working range in regards to flow and the head.
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PUMPS CLASSIFICATION
• Classification by mounting
• Classification by operation
• Classification by drive
• Classification by material
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PUMPS
DYNAMIC DISPLACEMENT
CENTRIFUGAL
DYNAMIC
PERIPHERAL
MULTI-STAGE NONPRIMING
JET (EDUCTOR)
GAS LIFT
SPECIAL EFFECT
HYDRAULIC RAM
ELECTROMAGNETIC
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PUMPS
DYNAMIC
DISPLACEMENT
RECIPROCATING
PISTION,
PLUNGER
SIMLEX
STEAM –DUBLE
DUPLEX
ACTIING
SIMLEX
SINGLE ACTING DUPLEX
POWER
DOUBLE ACTING TRIPLEX
MULTIPLEX
DIAPHRAGM
ROTARY
VANE
PISTON
HYDRAULIC RAM
ELECTROMAGNETIC GEAR
MULTIPLE LOBE
ROTOR CIRCUMFERENTIAL PISTON
SCREW
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FLUID MECHANIC
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(A) Furnace duct (b) Pipe of tube (c) Heat exchanger tube
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Fluid surface
The relation between pressure (P) and head (H) thus follows as:
P=W*H
Where: -
(W) is the specific weight OR density of the fluid in gm/cm3.
Density (gm/cm3) x H (metres) SG x H (metres)
Pressure (bar) = --------------------------------------- = ---------------------
10 10
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P=ρ *g*H
Nearly perfect
Where: - vacuum
P Pressure
ρ Density H
g Gravity =9.81 Kg m/s2
H Height of the column Patm
Fig (1-6)
Mercury
ATMOSPHERIC PRESSURE
VENT
LIQUID PRESSURE
Fig (1-7)
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ρ = m/V
Where V is the volume of the substance having a mass m. The
units for density are kilograms per cubic meter Kg/cm3 in the SI
system and slugs per cubic foot in the U.S. Customary System.
Specific weight
γ = w/V
where V is the volume of the substance having a the weight w.
The units for specific weight are Newton per cubic meter
(N/m3) in the SI system and pounds per cubic foot (Ib/ft3) in
the U.S. Customary System.
Specific gravity
γ s ρ s
SG = ----------------- = --------------------
γ w @ 4˚C ρ w @ 4˚C
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PUMP TERMS
V12 NPSHa =
Ha + -------- + Hs – Hf - Hvap
2g
Where: -
Ha = absolute suction pressure in ft. of liquid
V1 = flow velocity at point of measurement of
suction pressure ft./sec.
g = gravitational acceleration ft./sec2
Hs = static water level ft. of liquid (negative if below
reference datum line)
Usually, a positive value is called a suction
head and negative value is called a suction lift.
Hf = friction loss between point of measurement of
suction pressure and pump suction flange in ft.
of liquid.
Hvap = absolute vapour pressure of the liquid at
pumping temperature in ft. of liquid.
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Four examples are “given in the nest pages” for the method of
calculating the NPSH available for different pump suction
arrangements.
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CASE I
Atmospheric pressure
190 F
15 ft.
14.7 x 2.31
Ha = atmospheric pressure 14.7 psia = ---------------- = 35 ft
0.967
9.33 x 2.31
Hvap = atmospheric pressure 9.33 psia = --------------- = 22.3 ft
0.967
Hf = 5 ft. frictional loss
Hs = 15 ft.
NPSHav = Ha + Hs – Hf - Hvap
= 35 + 15 – 5 –22.3
= 22.7 ft.
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CASE II
2 ft.
Atmospheric pressure
190 F
14.7 x 2.31
Ha = atmospheric pressure 14.7 psia = ---------------- = 35 ft
0.967
9.33 x 2.31
Hvap = atmospheric pressure 9.33 psia = --------------- = 22.3 ft
0.967
Hf = 5 ft. frictional loss
NPSHav = Ha + Hs – Hf - Hvap
= 35 - 2 – 5 –22.3
= 5.7 ft.
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CASE III
9.33 PSIa
190 F
15 ft.
9.33 x 2.31
Hvap = atmospheric pressure 9.33 psia = --------------- = 22.3 ft
0.967
Ha = 22.3 ft.
Hs = 15 ft.
NPSHav = Ha + Hs – Hf - Hvap
= 22.3 + 15 – 5 –22.3
= 10 ft.
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CASE IV
2 ft
V1= 10 ft/sec
0.1 ft. Hf
V12 NPSHa =
Ha + -------- + Hs – Hf - Hvap
2g
(20+14.7) * 2.31
Ha = ---------------------------------- = 83.6 ft.
0.958
V12
--------------- = 1.55 ft.
2g
14.7 x 2.31
Hvap = atmospheric pressure 14.7 psia = --------------- = 35.5 ft
0.967
Hs = 2 ft
Hf = 0.1 ft
NPSH a = 83.6 + 1.55 +2 –0.1 –35.5 = 51.55 ft
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CAVITATION
If the energy in the suction line falls below the liquid vapor
pressure, vapor is formed in the liquid stream. Vapor volume
exceeds liquid volume by a factor of 1000.
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Fig (1-8)
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Steady Rising Curve or a rising
head capacity characteristic is
a curve in which the head rises
continuously as the capacity is
decreased. The rise from best
efficiency point to shut-off is
about 10 to 20%. Pumps with
curves of this shape are used
in parallel operation because
of their stable characteristics.
Drooping Curve characteristic is
a curve in which the head
capacity developed at shutoff
is less than developed at some
capacities. When pumps with
drooping characteristics are
run on throttling systems
operating difficulties can occur
since the system friction curve
can intersect the head capacity
curve at two points, these
pumps will also only operate in
parallel when the operating
point is below the shut-oil
head; therefore, parallel
operation should be avoided
with this curve shape.
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CENTRIFUGAL PUMP
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CENTRIFUGAL PUMPS
The description centrifugal pump is applied generally to all
type of pumps with an impeller having fixed blades housed in a
suitable shaped casing,
PRINCIPLE OF OPERATION
This high velocity, which the liquid has gained by the time it
leaves the blade tips, is changed to pressure head as the liquid
passes into the volute chamber C and then out of the discharge
nozzle. The efficiency of a centrifugal pump is determined by the
ease with which the kinetic energy is converted to pressure
energy.
Pump operation
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The main parts of the centrifugal pumps are as shown in fig (2-2).
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CASING
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A B
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IMPELLER
It is the main part of the centrifugal pump which picks up
the liquid by it is vanes and accelerated to high velocity by the
rotation and discharge it by the centrifugal force into the casing
out the discharge nozzle.
When the liquid forced away from the center of the impeller
a reduced pressure is produced and there is more liquid flow
forwards. The steady flow continues unless something happen to
break the suction at the inlet or unless the flow at the discharge is
restricted by pressure greater than the pressure head developed
by the pump.
A variety of different shapes and arrangements of the
blades can be produced within a particular form, a main
classification being whether the impeller is shrouded (close) or
unshrouded (open). Closed impellers are common to centrifugal
pumps (and some mixed-flow pumps), with shrouds rigidly
attached on both sides to enclose the liquid passage. However,
for the handling of fibrous material in suspension in liquid the
impeller may be semi-open (one side shroud) or fully open or
skeleton impeller rotating between stationary discs. See fig (2-7).
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2nd radial ribs are used on the back shroud to reduce the pressure
in the space between the impeller and the pump casing.
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Multi-stage
Fig 2-11 Four-stage pump. Axial thrust due to shaft shoulder and impeller
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Fig 2-12 Delaval boiler feed pump with automatic balance disk
مركز الشمس الدولي للتدريب و الستشارات
SHAFT SLEEVES
A) Sleeve with external locknut and B) Sleeve with internal impeller nut,
impeller key extending into sleeve to external shaft sleeve nut, and
prevent slip. separate key for sleeve.
Fig 2-13
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STUFFING BOXES
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WEARING RINGS
Impeller
Suction
head
Flow
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Impeller
Suction
head
Flow
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General Parts
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SHAFT SEAL:
Soft packing
Compressive force
System Pressure through gland spigot
Reaction
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Design guidelines
Additional
Lubricant / coolant
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Above 16 to 25 5 Above 35 to 70 6
Above 90 to 150 10
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Axial force
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Basic components
5. Spring
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Type classification
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In a few cases seals are fitted in pair. These two seals are
fitted with the rotating units either back to back, in tandem, or
face to face.
2. gases
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Sealant
system
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Hydraulic balance
Sealed pressure forces the face on the seat to create the seal.
Too little force will lead to seal failing, and too large force seal
faces may wear out too quickly.
1. Unbalanced seals
2. Balanced seals
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Unbalance seals
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Balance seals
A.P.I. 610 calls specifically for balance seals only for all
process duties, while balance mechanical seals extend the
application up to 85 bar (1250 Ib/in2).
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Packing
1. Low initial cost 1. Relatively high leakage.
2. Easily installed as rings and 2. Requires regular
glands are split. maintenance
3. Good reliability at medium 3. Wear of shaft sleeve can
pressures and shaft speeds be relatively high.
4. Can handle large axial 4. Power losses may be high.
movement.
5. Can be used in rotating or
reciprocating application.
6. Leakage increases
gradually, giving adequate
warning of impending breakdown.
Mechanical seals
1. Very low leakage. 1. High initial cost.
2. Require no maintenance. 2. Easily installed but requires
some disassembly of pump.
3. Eliminate sleeve wear.
4. Very good reliability.
5. Can handle higher
pressures and speeds.
6. Easily applied to
carcinogenic, toxic, or radioactive
liquids.
Source: Crane Packing Co.
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BEARING HOUSING
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BEARINGS
Bearing Names
BEARING TYPES
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Journal bearing
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1. Cylindrical bearing
• Simple construction.
4. Tilting-pad bearing
Note:
Dynamic Static
4. Smaller dimension
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Antifriction bearings
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Ball bearing
1.1- Single row, deep groove ball bearing Fig (3-17) no1.
1.2- Double row, deep groove ball bearing Fig (3-17) no2.
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Roller bearing
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Oil selection
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For example
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Disadvantage
3. Higher cost
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Operation principle
The diagrams illustrate the operating principles of a “single
acting” reciprocating pump. The operation of the pump is similar to that
of a bicycle pump:
A closely fitting piston moves backwards and forwards inside a
cylinder.
Unlike a bicycle pump [where the piston is driven by human
effort!], this piston is driven, through a system of gears and cracks, by
an electrical motor.
As the piston moves back [Fig 4-1[a]], known as the suction stroke,
‘space’, i.e. a vacuum, is created in the pump chamber. This space will
need to be filled. The ball at the bottom of the pump will be sucked
inwards enabling liquid to enter through the inlet nozzle. The ball at the
top of the pump will be sucked into the opening on the discharge line
and will prevent liquid entering from the discharge pipeline. When the
piston has travelled the full length of its suction stroke, it now moves in
the forward direction [Fig 4-1[b]], known as the discharge or delivery
stroke. The piston moving forward must now push liquid out of the
pump chamber.
Pump
Discharge
chamber
valve closed
Inlet valve
open
From
supply
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Pump
Discharge
chamber
valve open
Inlet valve
close
In attempting this, it pushes the ball at the bottom of the pump over
the inlet line preventing liquid from leaving at that point. However, it
also pushes the ball at the top of the pump out of its seat, opening up the
discharge line so that liquid can leave through it. [The balls are held in
retaining ‘cages’, which prevent them from passing fully out of the
discharge line or into the pump cylinder.] Thus the movement of these
balls creates one way flow through the pump chamber. They are ‘one-
way’ valves, only allowing liquid in through the inlet and through the
outlet.
The cycle of operation is then repeated – a suction stroke drawing
liquid in, followed by a delivery stroke forcing liquid out.
This type of pump, a fixed quantity of fluid to discharge at each
delivery stroke, thus giving what is called positive displacement of the
fluid. It is often referred to as a ‘positive displacement pump’.
The term ‘positive displacement’ refers to the fact that once liquid
has been drawn into the pump, it must leave the pump on the discharge
stroke. For this reason this type of pump can not and must never operate
against a closed inlet or discharge valve. To prevent excessive pressure
built-up if the discharge valve is accidentally closed, these pumps are
fitted with a relief valve, which automatically opens if the pressure goes
above a pre-set limit.
The flow from reciprocating pump is uneven, or pulsating. Such a
flow can be undesirable for some applications. A more even flow can be
obtained if two reciprocating pumps work together. Thus, number 1
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Flow
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Delivery
rate
No Flow during suction
Delivery
rate
Delivery
rate
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Construction features
After the piston passes the mid point of the cylinder it begins to
decelerate. However the liquid has no forces to slow it down and so it
continues at the same speed until it catches up with and collides with
the piston. The pump is then said to “Knock”.
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H
E
A
D
Increasing rev/min
Capacity
Fig 4-6 Displacement pump performance curve
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The diaphragm is fixed and sealed at its edges, is flexible and free to
move at its centre. The piston, in its chamber, is isolated from the liquid
or slurry by the diaphragm. As the piston moves up and down, the
centre of the diaphragm is caused to move “in and out”, or ‘backwards
and forwards’, thus drawing in and forcing out the liquid through the
one-way valves.
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The cavity between the piston and the diaphragm is filled with a
fluid to transmit the pumping action. This is usually air for large
machines, and hydraulic fluid for smaller pumps, which tend to operate
at higher pressures.
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When the pump is started up the liquid enters the pump through
the ‘liquid inlet’, and ‘slugs’ of liquid are caught between the rotor and
the stator and carried to the ‘liquid outlet’. Here as the gear teeth mesh
together, they squeeze the liquid out through the discharge pipeline. As
the teeth then unmesh a space is created between them, which sucks
more liquid in through the inlet pipeline.
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• It is self-priming
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