Prepared by/ Ali Mohammed Ismail Elgazzar

Mechanical production department

1 / Centrifugal Pump 1 / Centrifugal Pump
Performance Experiment Performance Experiment
Overview of Presentation Overview of Presentation
Objectives Objectives
Methodology and Background Methodology and Background
Experimental Setup Experimental Setup
Discussion of Results Discussion of Results
Conclusions and Conclusions and
Recommendations Recommendations
Objectives Objectives
Become familiar with centrifugal Become familiar with centrifugal
pump operation pump operation
Analyze the principles of fluid flow Analyze the principles of fluid flow
at 5 different shaft speeds at 5 different shaft speeds
Evaluate pump performance Evaluate pump performance
Methodology and Background Methodology and Background
Key Equations Key Equations
eD
d
R
B
C 53 . 6 907 . 0 =
)
4
1
2
B
A
=
P
C V
d t
V
t t d
V A C Q !
Assumptions: = .75, =998, and =9.55x10-4
P and was recorded during experiment.
)
1 2
2
1
2
2 1 2
2
Z Z
g
V V
g
P P
Hp +

'
+

'

'
+

'

=
V
Q
V
1
2
D V
R
t
ED
&
!
(1)
(2)
(3)
(4)
(5)
0
Methodology and Background Methodology and Background
Cont. Cont.
Affinity Laws Affinity Laws
1
2
1 2
N
N
Q Q !
2
1
2
1 2

'
+

'

!
N
N
Hp Hp
3
1
2
1 2

'
+

'

!
N
N
P P
Key Equations Continued Key Equations Continued
)
1 2
P P Q W
pump
=

)
m
n
T
P P Q
pu p
1 2

!
(6)
(7)
Experimental Setup Experimental Setup
Experimental Setup
Experimental Setup
Motor
E I
T[
Pump
Water Tank
Venturi
AP
( )
Valve Paddle meter
Dynamometer
Pin
Pout
Overall System Schematic
Experimental Setup Cont. Experimental Setup Cont.
Experimental Setup Cont. Experimental Setup Cont.
= 1.5 in
= 2 in
Venturi Flow Meter
Results Results
Uncertainty Values for Experiment Uncertainty Values for Experiment
wQ = 38.0% wQ = 38.0%
w w = 39.7% = 39.7%
Affinity Law Results
Value found
from
Experiment
Calculated
Using Affinity
Laws
%
Difference
1165 RPM
Q (m
3
/s) 5.61E-03 5.30E-03 5.55
P (W) 435.8 470.8 7.43
Hp (m) 7.92 9.06 12.58
1530 RPM
Q (m
3
/s) 7.49E-03 6.96E-03 7.12
P (W) 906.1 1066.4 15.03
Hp (m) 12.33 15.6 20.96
Results Cont. Results Cont.
Pump Head vs. Flow Rate
y = -130514x
2
+ 273.53x + 17.664
R
2
= 0.999
y = -109848x
2
+ 75.198x + 14.49
R
2
= 0.9972
y = -123314x
2
+ 197.32x + 10.708
R
2
= 0.9945
y = -37652x
2
- 285.26x + 8.3396
R
2
= 0.9714
y = -54121x
2
- 192.77x + 7.0513
R
2
= 0.9559
0
2
4
6
8
10
12
14
16
18
20
1.5E-03 2.5E-03 3.5E-03 4.5E-03 5.5E-03 6.5E-03 7.5E-03 8.5E-03
Flow Rate (m^3/s)
P
u
m
p

H
e
a
d

(
m
)
900.2 RPM
992.8 RPM
1165 RPM
1352 RPM
1530 RPM
Results Cont. Results Cont.
Pump Efficiency vs. Flow Rate
y = -9353.1x
2
+ 165.91x - 0.0087
R
2
= 0.9985
y = -19075x
2
+ 183.32x + 0.0023
R
2
= 0.9955
y = -9886.8x
2
+ 151.87x - 0.0003
R
2
= 0.9989
y = -15032x
2
+ 166.37x - 0.0027
R
2
= 0.9987
y = -15468x
2
+ 165.33x + 0.0014
R
2
= 0.9976
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.0E+00 1.0E-03 2.0E-03 3.0E-03 4.0E-03 5.0E-03 6.0E-03 7.0E-03 8.0E-03
Flow Rate (m^3/s)
P
u
m
p

E
f
f
i
c
i
e
n
c
y
900.2 RPM
992.8 RPM
1165 RPM
1352 RPM
1530 RPM
Results Cont. Results Cont.
Pump Efficiency vs. Pump Power to Fluid
y = -4E-08x
2
+ 0.0008x + 0.0009
R
2
= 0.9999
y = -1E-06x
2
+ 0.0015x - 0.0017
R
2
= 0.9988
y = -2E-06x
2
+ 0.0021x - 0.0003
R
2
= 0.9996
y = -3E-06x
2
+ 0.0027x + 0.0008
R
2
= 0.9985
y = -2E-07x
2
+ 0.001x + 0.0032
R
2
= 0.9992
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0 100 200 300 400 500 600 700 800 900 1000
Pump Power (Watts)
P
u
m
p

E
f
f
i
c
i
e
n
c
y
900.2 RPM
992.8 RPM
1165 RPM
1352 RPM
1530 RPM
Results Cont. Results Cont.
Pump Power to Fluid vs. Flow Rate
y = -1E+07x
2
+ 214130x - 15.3
R
2
= 0.9978
y = -1E+07x
2
+ 168878x - 8.0432
R
2
= 0.9984
y = -8E+06x
2
+ 126678x - 4.5836
R
2
= 0.9983
y = -5E+06x
2
+ 85850x - 0.3415
R
2
= 0.999
y = -5E+06x
2
+ 73781x - 0.2309
R
2
= 0.999
0
100
200
300
400
500
600
700
800
900
1000
0.0E+00 1.0E-03 2.0E-03 3.0E-03 4.0E-03 5.0E-03 6.0E-03 7.0E-03 8.0E-03
Flow Rate (m^3/s)
P
u
m
p

P
o
w
e
r

(
W
a
t
t
s
)
900.2 RPM
992.8 RPM
1165 RPM
1352 RPM
1530 RPM
Conclusions and Recommendations Conclusions and Recommendations
All R All R
22
were above .95 with most being were above .95 with most being
above .99 above .99
The best overall efficiency was The best overall efficiency was
approximately 70% for an RPM of 1530 approximately 70% for an RPM of 1530
The use of pressure gauges and The use of pressure gauges and
dynamometer that are less affected by dynamometer that are less affected by
vibration would improve results vibration would improve results
A more accurate method of recording A more accurate method of recording
voltage and current would also improve voltage and current would also improve
the results the results
2 / Operation of pump 2 / Operation of pump
2 / Operation of pump 2 / Operation of pump
Centrifugal Pumps (assembly)
Rotating and stationary components
Outline Outline (information is dangerous) (information is dangerous)
Pump systems Pump systems
Pump selection & sizing Pump selection & sizing
Pump performance vs. System curves Pump performance vs. System curves
Pump selection issues Pump selection issues
Installation issues Installation issues
Startup / Operation Startup / Operation
Maintenance Issues Maintenance Issues
Trouble shooting (performance changes) Trouble shooting (performance changes)
Pump Systems Pump Systems
Clear liquid Clear liquid
Slurries Slurries settling vs. non settling vs. non--settling settling
Minimum stable pumping velocities Minimum stable pumping velocities
Pipeline system stability Pipeline system stability
Pump selection & sizing Pump selection & sizing
Flow (gpm or M Flow (gpm or M
33
/hr) /hr) determines size determines size
Head (TDH) Head (TDH) determines speed/impeller size determines speed/impeller size
Specific gravity (concentration/% solids) Specific gravity (concentration/% solids) affects HP affects HP
demand demand
Maximum particle size Maximum particle size sets impeller design sets impeller design
NPSH NPSH available vs. required available vs. required
Material of construction Material of construction alloys, hard irons, non alloys, hard irons, non--
metallics or elastomers metallics or elastomers
Motor selection Motor selection HP considerations HP considerations
Pump performance vs. Pipeline System Pump performance vs. Pipeline System
curve curve the key the key
Centrifugal pumps always operate at the Centrifugal pumps always operate at the
intersection of the pipe lines system curve and intersection of the pipe lines system curve and
the pump curve. the pump curve.
When? When?
ALWAYS ALWAYS
Place conservatism in motor HP (not head or Place conservatism in motor HP (not head or
flow figures), do not use safety factors. flow figures), do not use safety factors.
Installation considerations Installation considerations
Allow access for maintenance on pump Allow access for maintenance on pump
Pumps do not support piping, use flexible Pumps do not support piping, use flexible
connections connections
Supply adequate foundations for pump & motor Supply adequate foundations for pump & motor
assemblies assemblies
Sump design is important Sump design is important consider 2 minute consider 2 minute
retention minimum retention minimum
Startup & operation Startup & operation
Check for proper rotation Check for proper rotation
Check and remove debris from sump and pipes Check and remove debris from sump and pipes
Check valves (open) Check valves (open)
After startup check sump level (stable) After startup check sump level (stable)
Maintenance Maintenance
Adjustment of pump internals Adjustment of pump internals
Replacement of hydraulic components Replacement of hydraulic components
Lubrication Lubrication
Record keeping Record keeping
Trouble shooting Trouble shooting
(determine root cause) (determine root cause)
If conditions change, adjustments in pump speed and/or If conditions change, adjustments in pump speed and/or
impeller diameters may require changes. impeller diameters may require changes.
Flow rate increases Flow rate increases check if system head decreased, is check if system head decreased, is
motor tripping on overload? motor tripping on overload?
Flow rate decreased Flow rate decreased check if system head is check if system head is
increased, obstruction in pipe, worn impeller, check increased, obstruction in pipe, worn impeller, check
pump speed is as specified. pump speed is as specified.
Vibrations Vibrations check obstruction in suction, cavitations, check obstruction in suction, cavitations,
impeller with solid particle logged in vane. impeller with solid particle logged in vane.
Dynamic seal leakage Dynamic seal leakage while running or at shut down? while running or at shut down?
check suction conditions, wear in parts, pump speed, check suction conditions, wear in parts, pump speed,
changes in system? changes in system?
Centrifugal pumps Centrifugal pumps -- shaft sealing shaft sealing
Centrifugal pumps Centrifugal pumps -- shaft sealing shaft sealing
To connect the motor to the impeller, the shaft has to To connect the motor to the impeller, the shaft has to
pass through an aperture in the casing. pass through an aperture in the casing.
To allow the shaft to rotate freely in the casing To allow the shaft to rotate freely in the casing
aperture there needs to be a gap, but this gap needs aperture there needs to be a gap, but this gap needs
to be closed off to stop air from being drawn in from to be closed off to stop air from being drawn in from
atmosphere or liquid from leaking out during operation. atmosphere or liquid from leaking out during operation.
There are two common methods. There are two common methods.
Packing Packing
Mechanical seal Mechanical seal
The role of the pump, its speed and the type of liquid The role of the pump, its speed and the type of liquid
being pumped all play a part in deciding which being pumped all play a part in deciding which
application works best. application works best.
Packing Packing
Packing Packing
A stuffing box with a soft packing material is the A stuffing box with a soft packing material is the
traditional seal for pumps. Normally made from soft traditional seal for pumps. Normally made from soft
impregnated cotton, which takes the form of a length impregnated cotton, which takes the form of a length
of square cross of square cross--section wound spirally onto a tube. section wound spirally onto a tube.
This enables the correct length, to suit the external This enables the correct length, to suit the external
diameter of the shaft, to be manually cut to the diameter of the shaft, to be manually cut to the
correct size. correct size.
The stuffing box is then repeatedly filled with sections The stuffing box is then repeatedly filled with sections
until almost full, the gland can then be tightened down until almost full, the gland can then be tightened down
to provide the axial compressive force. This in turn to provide the axial compressive force. This in turn
provides the necessary radial compressive force provides the necessary radial compressive force
required to seal the gap due to the sloping bottom required to seal the gap due to the sloping bottom
face of the aperture. face of the aperture.
If the force is insufficient the stuffing box will leak, if If the force is insufficient the stuffing box will leak, if
the force is too great, the additional friction, and the force is too great, the additional friction, and
consequently heat generated by the rotating shaft can consequently heat generated by the rotating shaft can
damage the soft packing and/or shaft. damage the soft packing and/or shaft.
Mechanical seals Mechanical seals
Mechanical seals Mechanical seals
The provision of rotary shaft seals
instead of the usual stuffing box
and gland, where conditions are
suitable, possesses many
advantages. The power absorbed is
lower and is constant, whereas a
gland excessively tightened causes
a considerable increase in power
absorbed.
Mechanical seals Mechanical seals
In small pumps this may result in overloading the In small pumps this may result in overloading the
motor. In addition maintenance costs are reduced, the motor. In addition maintenance costs are reduced, the
rotary seal operating for long periods without wear or rotary seal operating for long periods without wear or
attention. attention.
A standard seal consists of a stationary carbon ring A standard seal consists of a stationary carbon ring
insert in the casing, or seal cover where such is insert in the casing, or seal cover where such is
provided, and against this a metal ring of easy provided, and against this a metal ring of easy
clearance on the shaft sleeve rotates, contact between clearance on the shaft sleeve rotates, contact between
the faces being ensured by a lightly loaded coil spring. the faces being ensured by a lightly loaded coil spring.
The rubbing faces of both carbon and metal rings are The rubbing faces of both carbon and metal rings are
independently lapped to give a dead flat surface. independently lapped to give a dead flat surface.
A synthetic rubber ring, of circular cross A synthetic rubber ring, of circular cross--section, section,
contained between shaft sleeve and metal ring, in a contained between shaft sleeve and metal ring, in a
groove in the latter, effectively prevents leakage groove in the latter, effectively prevents leakage
between them. between them.
The diameter of the groove is such that a squeeze is The diameter of the groove is such that a squeeze is
exerted on the rubber ring, thus a sufficient frictional exerted on the rubber ring, thus a sufficient frictional
force is provided to rotate the metal ring, with certain force is provided to rotate the metal ring, with certain
exceptions. exceptions.
Mechanical seals Mechanical seals
The width of the groove is, however, made considerably The width of the groove is, however, made considerably
greater so that the metal ring is capable of free axial greater so that the metal ring is capable of free axial
float with accompanying rolling action of the rubber ring. float with accompanying rolling action of the rubber ring.
Materials used for the various seal parts are as follows Materials used for the various seal parts are as follows
Carbon stationary ring. Carbon stationary ring.
Synthetic rubber ring. Synthetic rubber ring.
Bronze rotating ring with bronze spring for standard Bronze rotating ring with bronze spring for standard
and all gunmetal pumps. and all gunmetal pumps.
Stainless steel rotating ring for all iron pumps. Stainless steel rotating ring for all iron pumps.
Mechanical seals Mechanical seals
For non For non--lubricating liquids, such as ammonia, lubricating liquids, such as ammonia,
section, contained between shaft sleeve and metal ring, section, contained between shaft sleeve and metal ring,
in a groove in the latter, effectively prevents leakage in a groove in the latter, effectively prevents leakage
between them. between them.
The diameter of the groove is such that a squeeze is The diameter of the groove is such that a squeeze is
exerted on the rubber ring, thus a sufficient frictional exerted on the rubber ring, thus a sufficient frictional
force is provided to rotate the metal ring, with certain force is provided to rotate the metal ring, with certain
exceptions. exceptions.
The width of the groove is, however, made considerably The width of the groove is, however, made considerably
greater so that the metal ring is capable of free axial greater so that the metal ring is capable of free axial
float with accompanying rolling action of the rubber ring. float with accompanying rolling action of the rubber ring.
Centrifugal pumps Centrifugal pumps -- hydraulic hydraulic
balance balance
The arrangement keeps the rotating assembly in its correct The arrangement keeps the rotating assembly in its correct
position under all conditions of loading .Water at the position under all conditions of loading .Water at the
approximate pressure of the pump discharge passes from the approximate pressure of the pump discharge passes from the
last stage of the pump between the impeller hub and the last stage of the pump between the impeller hub and the
balance restriction bush C into the annular space B dropping in balance restriction bush C into the annular space B dropping in
pressure as it does so .The pressure of water in the chamber B pressure as it does so .The pressure of water in the chamber B
tends to push the balance piston towards the drive end. When tends to push the balance piston towards the drive end. When
the thust on the balance piston overcomes the drive and the the thust on the balance piston overcomes the drive and the
impeller thrust the gap A between the piston and balance ring impeller thrust the gap A between the piston and balance ring
widens and allows water to escape .This in turn has the effect widens and allows water to escape .This in turn has the effect
of lowering the pressure in chamber B allowing the rotating of lowering the pressure in chamber B allowing the rotating
assembly to move back towards the pump end . assembly to move back towards the pump end .
Theoretically this cycle will be repeated with a smaller Theoretically this cycle will be repeated with a smaller
movement each time until the thrust on the balance piston movement each time until the thrust on the balance piston
exactly balances the other axial forces acting on the assembly. exactly balances the other axial forces acting on the assembly.
In practice the balancing of the forces is almost instananeous In practice the balancing of the forces is almost instananeous
and any axial movement of the shaft is negligible. and any axial movement of the shaft is negligible.
Centrifugal pumps Centrifugal pumps -- maintenance maintenance
When the pump is due for
overhaul, it will be necessary to
dismantle it to its component parts
to examine them for wear. The
following procedures are intended
as a general guide only, and your
attention should be drawn to the
manufacturer's operational
instructions regarding specific
pump requirements before
commencing to dismantle the
pump.