Pump – File notes

 Centrifugal pump types

Centrifugal pumps find the widest application in the industry. Centrifugal pumps can be divided into 3
major types –

o Radial flow pumps - a centrifugal pump in which the pressure is developed wholly by
centrifugal force.
o Mixed flow pumps - a centrifugal pump in which the pressure is developed partly by
centrifugal force and partly by the lift of the vanes of the impeller on the liquid.
o Axial flow pumps - a centrifugal pump in which the pressure is developed by the propelling or
lifting action of the vanes of the impeller on the liquid. authoritarian

 Pump specific speed

The specific speed determines the general shape of a centrifugal pump impeller. As the specific
speed increases, the ratio of the impeller outlet diameter to the inlet of the eye diameter decreases.
This ration becomes 1.0 for an axial flow pump. Radial flow impellers develop head through
centrifugal force. Radial impellers are low flow high head designs. Pump of higher specific speeds
develop head partly by centrifugal force and partly by axial force. A higher specific speed indicates a
pump design with head generation more by axial forces and less by centrifugal forces. An axial flow
or propeller pump with a specific speed of 10,000 or greater generates its head exclusively through
axial forces. Axial flow impellers are high flow low head designs.
Specific speed (Ns) identifies the approximate acceptable ration of the impeller eye diameter (D1) to
the impeller maximum diameter (D2) in designing an impeller:

o Ns 500 to 5000 D1/D2 > 1.5 - radial flow pump

o Ns 5000 to 10000 D1/D2 < 1.5 - mixed flow pump
o Ns 10000 to 15000 D1/D2 = 1 - axial flow pump

As a thumb rule it can be said that a lower specific speed values produce flat characteristic curve for
the pump, whereas a higher specific speed value produces a steeper curve.

 Pump affinity laws

The affinity law for a centrifugal pump with the impeller diameter held constant and the speed
changed:

o Flow: Q1 / Q2 = N1 / N2
o Head: H1/H2 = (N1) x (N1) / (N2) x (N2)
o Horsepower(BHP): BHP1 / BHP2 = (N1) x (N1) x (N1) / (N2) x (N2) x (N2)

The affinity law for a centrifugal pump with the speed held constant and the impeller diameter
changed:

o Flow: Q1 / Q2 = D1 / D2
o Head: H1/H2 = (D1) x (D1) / (D2) x (D2)
o Horsepower(BHP): BHP1 / BHP2 = (D1) x (D1) x (D1) / (D2) x (D2) x (D2)
 NPSH available

o For flooded suction –

Atmospheric Pressure (- ) Vapor Pressure (+) Liquid Height (-) Friction in the Suction Line.

o For suction lift –

Atmospheric Pressure (-) Vapor Pressure (-) Liquid Ht. (-) Friction in the Suction Line.

 NPSH required

The NPSHr curve for pumps may sometimes have a small region of head drop with flow towards the
left of the BEP. This region of the rise is a very unstable region. The pumps are not to be operated in
this region. Normally the curve is not plotted for this region.
The reason for this fall in NPSHr with flow is due to “Inlet eye recirculation”. This region is to be
interpreted as a rise in NPSHr with a fall in flow. Normally this is more likely to occur in pumps with
high specific speeds (i.e. more in mixed flow pumps and the most in axial flow pumps).
Usually that’s the reason it is recommended that centrifugal pumps with specific speeds more than
10,000 should not be accepted. In case, such high specific speed pumps are accepted, it should be
taken care that the pump operates very close to the BEP and not towards the left of BEP (since
suction cavitation will start usually at less than 70% of the pump speed).

The determination of NPSHr curve – there are many methods followed…

o 3% reduction method (most widely used for centrifugal pumps – a sharp 3% reduction in
discharge flow will signify the loci of the NPSHr curve)
o 0% reduction method (used for CW pumps – since a 3% drop in flow will need large suction
requirements which may not be possible sometimes)
o Noise method (alt method used – the head at the start of cavitation noise)
o Incipient inspection (close inspection for formation of bubbles at its starting stages – usually
done for special pumps).

 Pump Characteristic curve

It is to be noted that a centrifugal pump develops head by virtue of the centrifugal force imparted to
the liquid. So irrespective of the liquid (not taking into account the effect of viscosity) the head
developed (in “m” of liquid column) and the flow (in m3/hr) is same for all liquids. The head – flow
curve therefore is the same for any liquid (irrespective of its density).
If process parameters are available in terms of –
1. bar (or) m of water column (or) mm of Hg
2. kg/sec

The above should be suitably converted to m of liquid column (suitably compensating for density and
temp effects) and into (say) m 3/hr to specify the pump parameters…

Shown below is a typical characteristic curves set for all the three types of centrifugal pumps.

Pump characteristic curve – (centrifugal pump)

 It is to be noted that the when the speed changes the HQ curve (design) changes parallely as the
curve change for Impellor trim.

 Variable speed drives are useful in pumps whose flow rates vary constantly. However in cases where
the flow rate is lesser / higher but is constant, using an undersized / oversized impellor may solve the
problem.

While designing a VSD the following should be considered –

o Problems that might arise in gravity fed lubrication systems (like oiler cup, etc…) due to
operation at lower speeds.
o Problems that might arise due to resonance occurring in the operating speed zone of the
VSD.

The curves for a BFP operating with VSD are shown in Attachment-1.

 A back pressure regulator is provided after (in the downstream) the Auto min recirculation valve. It is
provided both in the case of a BFP and in the case of a CEP. This is provided to ensure that the
discharge line after the Auto Min recirculation upto the dearator / condenser are kept under some
pressure (else flashing of water will occur resulting in water hammer in the lines and in the
equipment).
The back pressure regulator is usually provided very close to the equipment (dearator / condenser).
 Pump curve for 2 pump in parallel operation
 CEP pump curve and design conditions…..

Normal operating point

Design point
Head H (mwc)

Flow Q (cum/hr)

Note that the design point has a larger flow and a higher head. The design point shall fall on the
system curve.
 The normal operating point has quite a lesser flow and also the head is lesser than the design point. It
is quite obvious that the point shall not fall on the pump curve. It is OK and this operating point can be
achieved by throttling. Throttling the discharge will bring down the flow since the system curve shifts
towards the left and further passing the flow through a control valve (in the discharge side) will effect
the head loss as well. Thus the operating point can be achieved.
It is definitely a lot of loss of energy but is required since the pump should be capable to evacuate the
hotwell during a turbine trip when a lot of steam is dumped into the condenser. Further the discharge
side would also have to usually meet the extra flow for the cooling spray during bypass operation.
This equipment is a very fine area where a VFD could be introduced and energy savings could be
effected.

CEP’s are also sometimes designed to operate in parallel (if 3 x 50% are planned). The pump curves
in such cases (along with the thumb rule to approximate the run out point) is shown in the
Attachment-2.

 Inducers to improve NPSHr for pumps

An Inducer is an axial flow impeller with blades that wrap in a helix around a central hub. An Inducer
serves as a small booster pump for the main impeller. Usually inducers have between 2 and 4 vanes,
although there may be more. The inducer imparts sufficient head to the liquid so that the NPSH
requirement of the adjacent main impeller is satisfied. Although the inducer usually has a lower NPSH
requirement than the main impeller, it can, and often does, cavitate during normal operation. The key
is that there is so little horsepower involved with an inducer that there is virtually no noise, vibration,
or resulting mechanical problems. Meanwhile, the higher horsepower main impeller sees sufficient
head to operate without cavitation.
Inducers commonly have suction specific speeds of between 15,000 and 25,000. A pump equipped
with an inducer may operate at 1/2 to 1/3 the NPSHR levels of a non-inducer version of the same
pump.

NPSHr Std Inducer

NPSHr No Inducer

However the use of inducers to solve NPSHr problems is not very advisable since the operating band
of the pump reduces with the inducer. Inducers are recommended only if the pump is capable of
operating in a very small band (at or close to the BEP).
 Pumps (parallel operating) with inter-stage bleed:

Often the BFP’s (operating in parallel) are designed with at least 2 numbers of inter-stage bleed (tap-
offs). The curves for such cases (with inter-stage bleed) are represented in the Attachment-3. (The
thumb rule to approximate the run out point is also shown)….
 Pump testing: (Refer ISO9906)

Head-Flow curve testing –

The flow is usually measured by turbine/electromagnetic flowmeters. In such cases an upstream

straight pipe length of minimum 5 pipe diameters is required. Ultrasonic flowmeters are not preferred
because they are very sensitive to the velocity distribution. However if used they shall be calibrated at
actual operating conditions.
The head is measured by pressure transmitters or bourdon gauges. The measuring section should lie
at least 2 pipe diameters away from the respective pump flange. However any deviations as per
ISO9906 are allowed.

Tolerances allowed are as follows –

o flow = ± 4.5% (for ISO9906 Grade 1)

= ± 8.0% (for ISO9906 Grade 2)

o Head = ± 3.0% (for ISO9906 Grade 1)

= ± 5.0% (for ISO9906 Grade 2)

o Efficiency = - 3.0% (for ISO9906 Grade 1)

= - 5.0% (for ISO9906 Grade 2)

The design guarantee operating point is identified and then the flow and head tolerances are marked
about the operating point as shown in the curve below. At least 5 points are plotted and the curve is
drawn. Once the curve is obtained it needs to pass through the tolerance margin axes. (Refer the
dotted lines – they are possible curves passing through the tolerance margins).

Tolerance margins for

head
Tolerance margins for
flow

Pump HQ curve
HEAD

Design Operating Point

FLOW

NPSHreq testing –
 The NPSHreq is tested by various methods like 3% head drop criteria, 0% head drop method,
Incipient inspection, Increase in noise due to cavitation, etc…Usually the most common method
adopted (also as per Siemens standard) is 3% head drop in the first stage criteria.
The test is conducted by throttling the flow steadily (step by step) in the suction side until the head of
the first stage drops by 3%. (Sometimes measurement of the first stage head is not possible. In such
cases the total discharge head can be divided by the number of stages to approximate the first stage
discharge head). The same procedure is repeated for other flows of the pump and the NPSHreq
curve is plotted.
The maximum permissible value of the difference between the measured and the guaranteed NPSHr
is as given below:

- for Grade 1: 3% or +0.15m (whichever is higher)

- for Grade 2: 6% or +3.00m (whichever is higher)

 Boiler Feed Pump warm-up line

The BFP warm up line is provided to ensure that the standby pump is kept in a warm condition to
facilitate immediate start during emergency. (If a warm–up line is not provided, it may lead to thermal
shock / warping / differential expansion in the pump).
The best practice is to provide a small high pressure tap off from the upstream of the discharge valve
(automatic recirculation valve) of the pump and connect it inside the pump (maybe near the discharge
flange). This will facilitate flow throughout the pump and the flow will continue through the suction
valve and into the de-aerator. A small orifice may be provided to limit the pressure of hot water
entering the pump. (Care to be taken to ensure that the hot water does not short circuit and enter the
recirculation line without warming the pump).
For combined cycle plants the boiler feed temperatures may be in the order of say 150 – 160 deg C.
No warm up systems should be required for this.
However for conventional plants (coal fired plants) the feed temperature is usually higher and will
usually require a warm up line.

 Motor design

Motors are usually designed for upto 40 deg C and 1000 m altitude.

If ambient conditions are going to be higher than the above, the same shall be carefully considered
before motor design/ordering.
If pump + motor assembly is going to be placed in a noise enclosure there shall be a 10degK higher
temperature inside the enclosure and this should be considered during design.

 Salient points to take care of in the pump package

1. Pump related information –

a. Type of pump
b. Pump main parameters (like NPSH, TDH, Discharge pressure, etc.)
 c. Pumping media and its properties like temp, viscosity, etc.
d. Inter-stage tappings
e. Motor type
f. Any special requirement (like material of construction, speed coupling, variable speed
drive, etc…) with scope
2. Valves (ARC, Back pressure regulator, Discharge valve, Suction valve, etc) – with scope
3. Instrumentation requirement – with scope
4. Performance guarantee parameters
5. Terminal points –
a. Flanges (counter flange requirement & scope)
b. Foundation frame with the anchor bolts
c. Electrical terminals (clearly define scope & check compatibility with electrical)
d. Instrumentation terminals (clearly define scope & check compatibility with I&C)
6. Insulation requirement – with scope
7. Erection / commissioning supervision (scope)
8. Guarantee period
9. Spares (amount & scope)
10. Special tools (amount & scope)
11. Erection & commissioning consumables, also lube oil etc (amount & scope)
12. Noise protection – requirement & scope
13. Weather protection – requirement & scope
14. Painting with color code
15. Documentation
16. Testing (including all the required tests to be performed)