Beruflich Dokumente
Kultur Dokumente
9. Pumps
9. PUMPS
9.1 Fundamentals of Fluid Mechanics 9.1.1 Bernoulli Equation
(This section is mainly from White)
We consider only two-dimensional, incompressible, frictionless (inviscid) flow. Consider an elemental fixed streamtube control volume of variable area A(s) and length ds (Fig. 9.1), where: s = streamline direction = fluid density (constant) p = pressure v = streamtube velocity A(s) = streamtube cross-sectional area at s.
Conservation of mass gives: mout min = 0 because there can be no accumulation of mass in the control volume if
density is constant. Hence at any s, m = Av .
Now consider Newtons Second Law applied to fluid in the control volume. Sum elemental forces in the streamwise direction.
F = ( mv )
s out
( mv )in = d ( mv )
(9.1)
Neglect shear forces on the walls (inviscid flow) so the forces are due to pressure and gravity.
(z positive up)
9-1
9. Pumps
= g Ads sin
= gAdz = Adz
= g)
To get pressure force, imagine pressure p subtracted from all faces of the control volume. Then:
gAdz Ad = d ( mv ) = Avdv
Divide by A.
dp
+ vdv + gdz = 0
This is Bernoullis equation for steady, frictionless flow along a streamline. Beware of its limitations. We can integrate between any two points 1 and 2 to get:
p1
or
(9.2)
p1
v12 p v2 + z1 = 2 + 2 + z2 2g 2g
(9.3)
Summary of assumptions 1. Steady flow 2. Incompressible flow 3. Frictionless flow 4. Flow along a single streamline: different streamlines may have different Bernoulli constants h0 = p
v2 +z 2g
5. No shaft work between 1 and 2: no pumps or turbines on the streamline 6. No heat transfer between 1 and 2.
9-2
9. Pumps
v2 . Fig. 9.2 shows that this is constant along a streamline and can be measured 2g
with a pitot tube which causes v = 0 at its inlet. Then the pressure at its location in the streamtube is given by p / = h0 z , where z is the height of the streamtube above an arbitrary datum.
Fig. 9.2 Hydraulic and energy grade lines for frictionless flow in a duct (from White).
The hydraulic grade line (HGL) shows the height corresponding to elevation and pressure head z + p / , that is, the EGL minus the velocity head v 2 / ( 2 g ) . The HGL is the height to which liquid would rise in a piezometer tube attached to the wall of the stream tube. In Fig. 9.2 the HGL is rising due to a decrease in velocity as the tube expands.
A pump causes a jump in the head (or the EGL) and (9.3) can be written across the jump as
p v2 p v2 + + z + hpump = + + z 2g in 2g out
If vin = vout because pipe diameters are the same and zin zout across a pump, then
pout pin
= hpump
9-3
9. Pumps
9.2
Positive-Displacement Pumps
Positive-displacement pumps (PDPs) force the fluid along by volume changes. Some types are shown in Fig. 9.3.
Fig. 9.3 Positive-displacement pumps: (a) reciprocating piston, (b) external gear pump, (c) double-screw pumd (d), sliding vane, (e) three-lobe pump, (f) double circumferential piston, (g) flexible-tube squeegee (from White).
9-4
9. Pumps
9.3
Rotodynamic Pumps
Fig. 9.4 is a schematic of a typical centrifugal rotodynamic pump. An impeller rotates within a casing. Fluid enters axially through the eye of the casing. It is caught up in the impeller blades and is whirled tangentially and radially outward until it leaves through all circumferential parts of the impeller into the diffuser part of the casing. The fluid gains both velocity and pressure while passing through the impeller. The doughnut-shaped diffuser, or scroll, section of the casing decelerates the flow through area increase, and further increases the pressure. The diffuser may be vaneless or fitted with fixed vanes to help guide the flow toward the exit.
Fig. 9.5 is a comparison of typical performance of rotodynamic and positive-displacement pumps running at a constant speed.
9-5
9. Pumps
Fig. 9.5 Comparison of performance curves of typical rotodynamic and positivedisplacement pumps at constant speed (from White).
A rotodynamic pump basically increases the Bernoulli head of the flow between point 1, the eye, and point 2, the exit.
p v2 p v2 H = + + z + +z g 2g 2 g 2 g 1
Usually v2 v1 and z2 z1 . Then
p2 p1 p = g g
The power delivered to the fluid equals the specific weight times the discharge (Q m3/s) times the net head change.
Pw = gQH
This is called the water horsepower. The power required to drive the pump is the brake horsepower.
bhp = T
where is the shaft angular velocity and T is the shaft torque. If there are no losses (100% efficiency),
bhp = Pw
9. Pumps
Pw gQH = bhp T
This equation shows that and T applied to the pump can generate Q and H.
Fig. 9.6 Inlet and exit velocity diagrams for an idealised pump impeller (from White).
Fluid enters the impeller at r = r1 with velocity component w1 (tangent to the blade angle 1) plus circumferential speed u1 = r1 matching the tip speed of the impeller. Its absolute entrance velocity is thus the vector sum of 1 and u1, shown as V1.
V
Similarly, the flow exits at r = r2 with component w2 parallel to the blade angle 2 plus tip speed u2 = r2, with resultant velocity V2.
dm Vt
9-7
9. Pumps
L = dmrVt
)
)
Now integrate across all of the impeller. Applied torque T = rate of change of angular momentum
T = Q r2Vt2 rVt1 1
where
Thus:
Pw = T = Q u2Vt2 u1Vt1 H = Pw 1 = u V u V gQ g 2 t2 1 t1
) )
These are the Euler turbomachine equations. For given blade inlet and exit tip angles 1 and
2, they can be used for simple pump design or analysis. They are for flow without losses.
Leakage through impeller casing clearances Non-ideal flow losses (viscous effects) Friction in bearings and seals
Design of a practical pump is very complicated and is based very much on experimentation. Fig. 9.7 shows the measured performance of two centrifugal pumps, each with a different casing diameter (pump size) and three different impeller diameters. (Unfortunately, data is in American units.)
NPSH is the Net Positive-Suction Head which is the head required at the pump inlet to prevent the liquid from cavitating or boiling locally. The pump inlet is the low-pressure point where cavitation will occur first. Apart from the damage caused to the impeller, cavitation can also lead to rotating unbalance.
9-8
9. Pumps
NPSH =
pi V2 p + i v g 2g g
where
Given NPSH from the pump performance curves, we must ensure that the right hand side is equal or greater in the actual system to avoid cavitation. This might involve putting the pump in a pit to increase pi (from Bernoulli equation).
Fig. 9.7 Measured performance curves for two models of a centrifugal water pump: (a) basic casing with three impeller sizes; (b) 20 percent larger casing with three larger impellers at slower speed (from White).
9-9
9. Pumps
Similarity
For a given geometry of pump (fixed casing/impeller diameter ratio, blade inlet and outlet angles) a technique called dimensional analysis gives rise to a number of dimensionless coefficients. Capacity coefficient CQ = Head coefficient
Q nD 3
CH =
gH n2 D 2
Power coefficient CP =
bhp n3 D 5
where n = shaft speed in revs/s and D = impeller diameter. Consistent units must be used throughout. It follows that: Efficiency =
CH CQ CP
We can see how this agrees with the pumps in Fig. 9.7. They must be geometrically similar, so we can look at only two pumps, viz. those with impeller diameters D = 38 in and D = 32 in. These have approximately the same ratio of casing/impeller diameter.
Fig. 9.8 shows that these dimensionless coefficients work well. Then we can answer questions such as:
What if we use a larger pump? What if we run the pump away from the condition of maximum efficiency?
It follows that if pump 1 and pump 2 are from the same geometric family and are operated at homologous points (the same dimensionless position on a chart such as Fig. 9.8, their flow rates,
Fig. 9.8 Nondimensional plot of the pump performance data from Fig. 9.7 (from White).
9-10
9. Pumps
Q2 n2 D2 = Q1 n1 D1
2
H 2 n2 D2 = H1 n1 D1
3
P2 2 n2 D2 = P 1 n1 D1 1
These similarity rules can be used to estimate the effect of changing the fluid, speed or size on any rotodynamic pump, within a geometrically similar family. A graphic display of these rules is given in Fig. 9.9, showing the effect of speed and diameter changes on pump performance. The curves are plotted to scale but with arbitrary units. The speed effect is substantial, but the size effect is even more dramatic, especially for power, which varies as
D5. Generally, a given pump family can be adjusted in size and speed to fit a variety of
system characteristics. Strictly, there must be similarity of efficiencies also; 1 = 2 , but it can be shown that viscous and leakage effects are less significant in large pumps, leading to higher efficiencies. Corrections for this have been developed (see White).
Fig. 9.9 Effect of change of speed on homologous pump performance: (a) 20 percent change in speed at constant size; (b) 20 percent change in size at constant speed (from White).
9-11
9. Pumps
9.4
Table 9.1 Power station pump applications (from Black and Veatch).
9-12
9. Pumps
Fig. 9.10 Bottom inlet single-entry impeller concrete volute pump (from MPSP).
9-13
9. Pumps
Gearboxes, when included on vertical pump units, must be of the coaxial type with the pump, motor and gearbox centrelines positioned vertically above each other to ensure equal load distribution on the support ring. With an epicyclic design it is possible to combine the gearbox and the pump by mounting the impeller on the low speed output shaft of the gear unit. This eliminates the need for one journal bearing and reduces overall height.
9-14
9. Pumps
The gearbox is equipped with a complete forced-lubrication oil system for the gears and the thrust and journal bearings.
Fig. 9.12 shows a horizontal split-casing extraction pump. One of the most important factors is the avoidance of oxygen ingress into the condensate through glands which may be required to seal against sub-atmospheric pressures. A secure supply of seal water is necessary.
In recent years the required pump generated head has risen significantly to over 250 m. This causes design problems on large split-casing pumps. A multi-stage vertical caisson type pump (Fig. 9.13) is often preferred, and installed in a pit to reduce the risk of cavitation erosion.
9-15
9. Pumps
To overcome the shortcomings of the multi-stage flexible shaft design of feed pump, a new concept was developed with the emphasis on achieving maximum availability coupled with a design life of at least 45,000 hours for all components. The essential features were a rugged high speed unit capable of surviving dry running and thermal shock operation without damage, and having a cartridge construction that permitted rapid replacement of the complete rotor/stator assembly. An example is shown in Fig. 9.15.
Water treatment plant. These are centrifugal with rolling element bearings. Injection of chemicals into boiler feed water. A measured quantity is obtained with positive-displacement pumps. Fire pumps. These are simple and robust centrifugal pumps.
9-16
9. Pumps
9-17
9. Pumps
9-18
9. Pumps
9-19
9. Pumps
9-20