NEW AGE

ROTODYNAMIC PUMPS
(Centrifugal and Axial)

Non-met allic
Containment
Gas

K.M. Srinivasan

(f.D NEW AGE INTERNATIONAL PUBLISHERS

ROTODYNAMIC PUMPS
(Centrifugal and Axial)
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ROTODYNAMIC PUMPS
(Centrifugal and Axial)

K.M. Srinivasan
B.E.(Hons), PhD.(USSR)
Dean (R&D) Mechanical Sciences
Department of Mechanical Engineering
Kumaraguru College of Technology
Coimbatore, Tamil Nadu

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Copyright © 2008, New Age International (P) Ltd., Publishers
Published by New Age International (P) Ltd., Publishers

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ISBN (13) : 978-81-224-2976-3

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 THIS BOOK is dedicated to
My Parents
Sri. K. MUTHUSAMY PILLAI
And
Smt. K.T. SAMBOORNAM
As well as
To my Professor and guide
Dr
Dr.. A.A. LOMAKIN
And
Dr
Dr.. A.N. P APIR
PAPIR
Leningrad P olytechnic, Leningrad, K-21, USSR (at present called as St. Petersburg
Polytechnic,
Polytechnic, St. Petersburg, Russia)
Who brought me to this level

Comp-1/Newage/Pump-co.pm6.5—29.12.07 3.1.08
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 PREFACE

It was my very long felt ambition to provide a detailed and full information about the theory,
design, testing, analysis and operation of different types of rotodynamic pumps namely Centrifugal,
Radial, Diagonal and Axial flow types. I have learned a lot during the period 1959–62 about pumps at
PSG College of Technology, Coimbatore, while working as Senior Research Assistant for CSIR Scheme
on Pumps, Turbo chargers and flow meters. At the same time, I was undergoing training in foundry,
pattern making, moulding, production, testing and design for different pumps at PSG Industrial Institute,
Coimbatore and also during the period 1967 and 1975.
I cannot forget my study at Leningrad Polytechnic, Leningrad K-21, USSR (now St. Petersburg
Polytechnic, St. Petersburg, Russia), for my doctorate degree in pumps. Dr. A.A Lomakin, Dr. A.N.
Papir, Dr. Gurioff, Dr. N.N. Kovaloff, Dr. A.N. Smirnoff, Dr. Staritski, Dr. Gorgidjanyan, Dr. Gutovski
are the key professors who made me to know more about pumps from fundamentals to updated technology.
I am very much grateful to Dr. A.A Lomakin and Dr. A.N. Papir, who were my professors and guides
for my doctorate degree in pumps. As a consultant, for different pump industries in India and abroad, I
could understand the field problems. My experience, since 1959 till date, has been put up in this book to
enable the readers in industries, and in academic area, to design, to analyze and to regulate the pumps.
Complete design process for pumps, losses and efficiency calculation, based on boundary layer theory
for axial flow pumps are also given. Computer programmes for the design of pump and for profile loss
estimation for axial flow pumps are also given. All the design examples in the last chapter are real
working models. The results are also given with pump drawings.
I do hope that the reader will be in a position to understand, design, test and analyze pumps, after
going through this book. I shall be very much honoured if my book is useful in attaining this. I am
grateful to my wife Smt. S. Nalini, my sons Sri S. Muthuraman and Sri S. Jaganmohan and my daughter
Smt. S. Nithyakala, who were very helpful in preparing the manuscript and drawings.
Last but not the least I am grateful to the editorial department of M/s New Age International (P)
Ltd. Publishers for their untiring effort to publish the book in a neat and elegant form, in spite of so
many problems they come across while formulating this book from the manuscript level to this level.
Constructive criticisms and suggestions are highly appreciated for further improvement of the
book.

K.M. SRINIVASAN
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 CONTENTS

PREFACE (vii)

1 INTRODUCTION 1–5
1.1 Principle and Classification of Pumps 1
1.1.1 Principle 1
1.1.2 Classification of Pumps 1

2 PUMP PARAMETERS 6–33

2.1 Basic Parameters of Pump 6
2.1.1 Quantity of Flow or Discharge (Q) of a Pump 6
2.1.2 Total Head or Head of a Pump (H) 6
2.1.3 Total Head of a Pump in a System 7
2.1.4 Power (N) 11
2.1.5 Efficiency (η) 11
2.2 Pump Construction 12
2.3 Losses in Pumps and Efficiency 15
2.3.1 Hydraulic Loss and Hydraulic Efficiency (ηh) 15
2.3.2 Volumetric Loss and Volumetric Efficiency (ηv) 15
2.3.3 Mechanical Loss and Mechanical Efficiency (ηm) 16
2.3.4 Total Losses and Overall Efficiency (h) 16
2.4 Suction Conditions 16
2.5 Similarity Laws in Pumps 19
2.5.1 Similarity Laws 19
2.5.2 Specific Speed (ns) 22
2.5.3 Unit Specific Speed (nsq) 23
2.6 Classification of Impeller Types According to Specific Speed (ns) 24
2.7 Pumping Liquids Other than Water 26
2.7.1 Total Head, Flow Rate, Efficiency and Power Determination for Pumps 26
2.7.2 Effect of Temperature 27
2.7.3 Density Correction (ρ or γ) 27
2.7.4 Viscosity Correction 28
2.7.5 Effect of Consistency on Pump Performance 32
2.7.6 Special Consideration in Pump Selection 33
(ix)
(x) CONTENTS

3 THEORY OF ROTODYNAMIC PUMPS 34–64

3.1 Energy Equation using Moment of Momentum Equation for Fluid Flow
through Impeller 34
3.2 Bernoulli’s Equation for the Flow through Impeller 35
3.3 Absolute Flow of Ideal Fluid Past the Flow Passages of Pump 38
3.4 Relative Flow of Ideal Fluid Past Impeller Blades 40
3.5 Flow Over an Airfoil 43
3.6 Two Dimensional Ideal Flow 45
3.6.1 Velocity Potential 45
3.6.2 Rotational and Irrotational Flow 45
3.6.3 Circulation and Vorticity 47
3.7 Axisymmetric Flow and Circulation in Impeller 48
3.7.1 Circulation in Impellers of Pump 49
3.7.2 Vorticity and Circulation Around Impeller Blades 49
3.8 Real Fluid Flow after Impeller Blade Outlet Edge 50
3.9 Secondary Flow between Blades 51
3.10 Flow of a Profile in a Cascade System—Theoretical Flow 52
3.11 Fundamental Theory of Flow Over Isolated Profile 53
3.12 Profile Construction as per N.E. Jowkovski and S.A. Chapligin 55
3.13 Development of Thin Plate by Conformal Transformation 58
3.14 Development of Profile with Thickness by Conformal Transformation 58
3.15 Chapligin’s Profile of Finite Thickness at Outlet Edge of the Profile 59
3.16 Velocity Distribution in Space between Volute Casing and Impeller Shroud 61
3.17 Pressure Distribution in the Space between Stationary Casing and Moving
Impeller Shroud of Fluid Machine 63

4 THEORY AND CALCULATION OF BLADE SYSTEMS IN

CENTRIFUGAL PUMP 65–129
4.1 Introduction 65
4.2 One Dimensional Theory 65
4.3 Velocity Triangles 66
4.4 Impeller Eye and Blade Inlet Edge Conditions 69
4.4.1 Inlet Velocity Triangle 70
4.4.2 Normal or Radial or Axial Entry of Fluid at Impeller Inlet 72
4.5 Outlet Velocity Triangle: Effect due to Blade Thickness 73
4.5.1 Outlet Velocity Triangle: Effect of Finite Number of Blades 74
4.6 Slip Factor as per Stodola and Meizel 75
CONTENTS (xi)

4.6.1 Slip Factor as Defined by Karl Pfliderer 77

4.6.2 Slip Factor as per Proscura 79
4.7 Coefficient of Reaction (ρ) 81
4.8 Selection of Outlet Blade Angle (β2) and its Effect 83
4.9 Effect of Number of Vanes 86
4.10 Selection of Eye Diameter D0, Eye Velocity C0, Inlet Diameter of Impeller D1
and Inlet Meridional Velocity Cm1 89
4.11 Selection of Outlet Diameter of Impeller (D2) 92
4.12 Effect of Blade Breadth (B2) 92
4.13 Impeller Design 103
4.14 Determination of Shaft Diameter and Hub Diameter 106
4.15 Determination of Inlet Dimensions for Impeller 107
4.16 Determination of Outlet Dimensions of Impeller 108
4.17 Development of Flow Passage in Meridional Plane 109
4.18 Development of Single Curvature Blade—Radial Blades 111
4.19 Development of Double Curvature Blade System 113
4.19.1 Importance of Diagonal Impellers 113
4.19.2 A General Solution for the Flow through the Vane System 114
4.19.3 Axisymmetric Flow of Fluid 115
4.19.4 Flow Line and Vortex Line in Axisymmetric Flow 116
4.19.5 Differential Equation for the Cross-section of Vane with the
Flow Surface 118
4.19.6 Construction of Vane Surface when Wu = 0 118
4.19.7 Construction of Vane Under Equal Velocity Construction 120
4.19.8 Construction of Vane Surface Under Equal Velocity Flow for the
Given w(s) 121
4.19.9 Conformal Transformation of Vane Surface 125
4.19.10 The Method of Error Triangles 126

5 SPIRAL CASINGS (VOLUTE CASINGS) 130–146

5.1 Importance of Spiral Casings 130
5.2 Volute Casing at the Outlet of the Impeller 131
5.3 Method of Calculation for Spiral Casing 132
5.4 Design of Spiral Casing with Cur = Constant and Trapezoidal Cross-section 134
5.5 Calculation of Trapezoidal Volute Cross-section Under Constant Velocity of
Flow CV = Constant (Constant Velocity Design) 135
5.6 Calculation of Circular Volute Section with Cur = Constant 137
5.7 Design of Circular Volute Cross-section with Constant Velocity (CV) 138
(xii) CONTENTS

5.8 Calculation of Diffuser Section of Volute Casing 139

5.9 (A) Design of Diffuser 140
5.9 (B) Calculation of Spiral Part of Diffuser Passage 141
5.9 (C) Calculation of Diverging Cone Part of the Diffuser 142
5.10 Return Guide Vanes 143
5.11 Design of Suction Casing at Inlet of the Impeller 144
5.12 Straight Convergent Cone 144
5.13 Spiral Type Approach Ring 144
5.14 Effect due to Volute 146

6 LOSSES IN PUMPS 147–163

6.1 Introduction 147
6.2 (A) Mechanical Losses 147
6.2 (B) Losses due to Disc Friction (∆Nd ) 147
6.2 (C) Losses Stuffing Box (∆NS) 149
6.2 (D) Bearing Losses (∆NB) 154
6.3 (A) Leakage Flow through the Clearance between Stationary and Rotatory
Wearing Rings 154
6.3 (B) Leakage Flow through the Clearance between Two Stages of a
Multistage Pump 159
6.4 Hydraulic Losses 161

7 AXIAL AND RADIAL THRUSTS 164–181

7.1 Introduction 164
7.2 Axial Force Acting on the Impeller 165
7.3 Axial Thrust in Semi-open Impellers 167
7.4 Axial Thrust due to Direction Change in Bend at Inlet 168
7.5 Balancing of Axial Thrust 169
7.6 Axial Thrust taken by Bearings 170
7.7 Radial Vanes at Rear Shroud of the Impeller 170
7.8 Axial Thrust Balancing by Balancing Holes 171
7.9 Axial Thrust Balancing by Balance Drum and Disc 172
7.10 Radial Forces Acting on Volute Casing 177
7.11 Determination of Radial Forces 177
7.12 Methods to Balance the Radial Thrust 180

8 MODEL ANALYSIS 182–194

8.1 Introduction 182
8.1.1 Real Fluid Flow Pattern in Pumps 187
CONTENTS (xiii)

8.2 Similarity of Hydraulic Efficiency 191

8.3 Similarity of Volumetric Efficiency 192
8.4 Similarity of Mechanical Efficiency 193

9 CAVITATION IN PUMPS 195–215

9.1 Suction Lift and Net Positive Suction Head (NPSH) 195
9.2 Cavitation Coefficient (s) Thoma’s Constant 200
9.3 Cavitation Specific Speed (C) 201
9.4 Cavitation Development 201
9.5 Cavitation Test on Pumps 203
9.6 Methods Adopted to Reduce Cavitation 211

10 AXIAL FLOW PUMP 216–292

10.1 Operating Principles and Construction 216
10.2 Flow Characteristics of Axial Flow Pump 218
10.3 Kutta-Jowkovski Theorem 218
10.4 Real Fluid Flow over a Blade 222
10.5 Interaction between Profiles in a Cascade System 223
10.6 Curved Plates in a Cascade System 224
10.7 Effect of Blade Thickness on Flow Over a Cascade System 233
10.8 Method of Calculation of Profile with Thickness in a Cascade System 234
10.9 (A) Pump Design by Direct Method (Jowkovski’s Method, Lift Method) 243
10.9 (B) Design of Axial Flow Pump as per Jowkovski’s Lift Method—
Another Method 247
10.10 Flow with Angle of Attack 255
10.11 Correction in Profile Curvature due to the Change from Thin to Thick Profile 256
10.12 Effect of Viscosity 259
10.13 Selection of Impeller Diameter and Speed 260
10.14 Selection of Hub Ratio 261
 l
10.15 Selection of   — Aspect Ratio at Periphery 263
t peri
10.16 Calculation of Hydraulic Losses and Hydraulic Efficiency 268
10.17 Calculation of Profile Losses using Boundary Layer Thickness (δ**) 271
10.17.1 Notations and Abbreviations 271
10.17.2 Determination of Profile Losses and Hydraulic Efficiency 274
10.17.3 Determination of Momentum Boundary Layer Thickness (δ**) 277
10.17.4 Computer Programme 283
10.18 Cavitation in Axial Flow Pumps 283
(xiv) CONTENTS

10.19 Radial Clearance between Impeller and Impeller Casing 288

10.20 Calculation for Axial Flow Diffusers 289
10.21 Axial Thrust 291

11 TESTING, PERFORMANCE EVALUATION AND REGULATION

OF PUMPS 293–338
11.1 Introduction 293
11.2 Pump Performance—Relation between Total Head and Quantity of Flow 293
11.3 Pump Testing 301
11.4 Systems and Arrangements 306
11.5 Combined Operation of Pumps and Systems 310
11.6 Stable and Unstable Operation in a System 312
11.7 Reverse Flow in Pump 315
11.8 Effect of Viscosity on Performance 317
11.9 Pump Regulation 232
11.10 Effect of the Pump Performance when Small Changes are made in Pump Parts 336

12 PUMP CONSTRUCTION AND APPLICATION 339–374

12.1 Classification 339
12.2 Pumps for Clear Cold Water and for Non-Corrosive Liquids 339
12.3 Other Pumps 346
12.4 Axial Flow Pumps 354
12.5 Condensate Pumps 357
12.6 Feed Water Pumps 361
12.7 Circulating Pumps 363
12.8 Booster Pumps 365
12.9 Pump for Viscous and Abrasive Liquids 370

13 DESIGN OF PUMP COMPONENTS 375–486

Design No. D1-A : Design of a Single Stage Centrifugal Pump 375
Design No. D1-A1 : Computer Programming in C++ for Radial Type
Centrifugal Pump Impeller and Volute 381
Design No. D1-B : Design of a Multistage Centrifugal Pump 395
Design No. D2 : Spiral Casing Design 409
D2-A : Spiral Casing Design Under Cur = Constant and
Trapezoidal Cross-Section 411
D2-B : Spiral Casing Design with CV = Constant and
Trapezoidal Cross-section 414
D2-C : Design of Suction Volute 417
CONTENTS (xv)

Design No. D3 : Design of Axial Flow Pump 418

Design No. D4 : Correction for Profile Thickness by Increasing Blade
Curvature (β) 427
Design No. D5 : Calculation of Correction for Blade Thickness using
Thickness Coefficient (χ) 429
Design No. D6 : Design of Axial Flow Pump 431
Design No. D7 : Profile Losses Calculation 473
Design No. D8 : Design of Axial Flow Pump—as per method Suggested
by Prof. N.E. Jowkovski 482
APPENDICES 487–508
y
Appendix I : Equations Relating Cy, max , δ° for Different Profiles 487
l
Appendix II : ISI Standards 495
Appendix III : Units of Measurement—Conversion Factors 502
LITERATURE—REFERENCES 509–518
INDEX 519–520
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 1
INTRODUCTION

1.1 PRINCIPLE AND CLASSIFICATION OF PUMPS

1.1.1 Principle
Newton’s First law states that “Energy can neither be created nor be destroyed, but can be
transformed from one form of energy to another form.”
Different forms of energy exists namely, electrical, mechanical, fluid, hydraulic and pneumatic,
pressure, potential, dynamic, wave, wind, geothermal, solar, chemical, etc.
A machine is a contrivance, that converts one form of energy to another form. An electric motor
converts electrical energy to mechanical energy. An internal combustion engine converts chemical
energy to mechanical energy, etc.
A pump is a machine which converts mechanical energy to fluid energy, the fluid being
incompressible. This action is opposite to that in hydraulic turbines.
Most predominant part of fluid energy in fluid machines are pressure, potential and kinetic energy.
In order to do work, the pressure energy and potential energy must be converted to kinetic energy. In
steam and gas turbines, the pressure energy of steam or gas is converted to kinetic energy in nozzle. In
hydraulic turbine, the potential energy is converted to kinetic energy in nozzle. High velocity stream of
fluid from turbine nozzle strikes a set of blades and makes the blades to move, thereby fluid energy is
converted into mechanical energy.
In pumps, however, this process is reversed, the movement of blade system moves the fluid,
which is always in contact with blade thereby converting mechanical energy of blade system to kinetic
energy. For perfect conversion, the moving blade should be in contact with the fluid at all places. In
other words, the moving blade system should be completely immersed in fluid.

1.1.2 Classification of Pumps

1.1.2.1 Classification According to Operating Principle
Pumps are classified in different ways. One classification is according to the type as positive
displacement pumps and rotodynamic pumps. This classification is illustrated in Fig. 1.1.
In positive placement pumps, fluid is pushed whenever pump runs. The fluid movement cannot be
stopped, otherwise the unit will burst due to instantaneous pressure rise theoretically to infinity, practically
exceeding the ultimate strength of the material of the pump, subsequently breaking the material. The
motion may be rotary or reciprocating or combination of both.
2 ROTODYNAMIC PUMPS (CENTRIFUGAL AND AXIAL)

PUMPS
PU M PS

Positive
PositiveDisplacement
D isplacem ent PPumps
um ps Other
O ther Pumps
P um ps Rotodynamic
R otodynam ic PPumps
um ps

Jet Pump Centrifugal, Mixed and

Reciprocating Type Rotary Type Hydraulic Ram Axial Flow
Regenerative

Piston Vane, Lobe

plunger Screw, Gear
Perialistic,
Metering,
Diaphram,
Radial piston,
Axial piston

Fig. 1.1. Pump classfication

The principle of action, in all positive displacement pumps, is purely static. These pumps are also
called as ‘static pumps’. The pumps, operated under this principle, are reciprocating, screw, ram,
plunger, gear, lobe, perialistic, diaphram, radial piston, axial piston etc.
In rotodynamic pumps, however, the energy is transferred by rotary motion and by dynamic
action. The rotating blade system imparts a force on the fluid, which is in contact with the blade system
at all points, thereby making the fluid to move i.e., transferring mechanical energy of the blade system
to kinetic energy of the fluid.
Unlike turbine, where pure pressure or potential energy is converted to kinetic energy, in pumps,
the kinetic energy of the fluid is converted into either, pressure energy or potential energy or kinetic
energy or the combination of any two or all the three forms depending upon the end use in spiral or
volute casing, which follows the impeller.
In domestic, circulating and in agricultural pumps, the end use is in the form of potential energy
i.e., lifting water from low level to high level.
In process pumps, used for chemical industries, the fluid is pumped from one chamber under
pressure to another chamber under pressure. These chambers may be at the same level (only pressure
energy conversion) or may be at different levels (pressure and potential energy conversion).
Pumps used for fire fighting, for spraying pesticides, must deliver the liquid at very high velocity
i.e., at very high kinetic energy. These pumps convert all available energy at the outlet of the impeller
into very high kinetic energy.
In turbines, the fluid is water or steam or chemical gas-air mixture at constant pressure and
temperature, whereas, pumps deal with fluid at different temperatures and viscosities such as water,
acids, alkaline, milk, distilled water, and also cryogenic fluids, like liquid hydrogen, liquid oxygen, liquid
nitrogen, liquid ammonia, which are in gaseous form under normal temperatures.
Pumps are also used to pump solid-liquid, liquid-gas or solid-liquid-gas mixtures, with different
percentage of concentration called ‘consistency’. Hence pumps are applied in diversified field, the
pumping fluid possessing different property, namely, viscosity, density, temperature, consistency, etc.
INTRODUCTION 3

A third category of pump, called jet pump, wherein, the fluid energy input i.e., high head low
discharge of fluid is converted into another form of fluid energy i.e., low head and high discharge.
These pumps are used either independently or along with centrifugal pumps.
The reverse of Jet pump is ‘Hydraulic Ram’ wherein low head and high discharge of water is
converted into high head and low discharge. Hydraulic Rams are installed at hills near a stream or river.
The natural hill slope is the low head input energy. Large quantity of water at low head is taken from the
river. A portion of water is pumped at high pressure and is supplied to a nearby village as drinking water.
Remaining water is sent back to the river. This system does not need any prime mover like diesel or
petrol engine or electric motor. Repair and maintenance is easy, in hydraulic ram since moving part is
only the ram.

1.1.2.2 Classification According to Head and Discharge

Another classification of pump is according to the head and discharge or quantity of flow to be
pumped. Any customer, who is in need of a pump specifies only these two parameters. A quick selection
of the pump is made referring standard charts for selecting the pump. Fig.1.2 gives the selection of
pump according to head and discharge.

10000
H.m

PISTON
1000

CENTRIFUGAL
100

10

AXIAL

1 10 100 1000 10000 100000

3
Q.m /hr

Fig. 1.2. Pump selection as per head and discharge

1.1.2.3 Classification According to Specific Speed

Most accurate method of pump selection is based on the non-dimensional parameter called ‘specific
speed’ which takes into account speed of the pump along with head and discharge.

n Q
Specific speed, ns = 3.65 ...(1.1)
H 3/ 4
where ns–specific speed, n–speed in rpm, Q–discharge in m3/sec, H–head in m. If pressure rise is
known instead of total head then p = γH, where p–pressure rise of pumping fluid in N/m2 and
γ–specific weight of the fluid at the given temperature in N/m3. It is essential that all parameters must be