Module Iv & V
Module Iv & V
PUMPING OF FLUIDS
5.1 Introduction
Pumps are devices for supplying energy or head to a flowing fluid in order to overcome
head losses due to friction and also if necessary, to raise liquid to a higher level. For the pumping
of liquids or gases from one vessel to another or through long pipes, some form of mechanical
pump is usually employed. The energy required by the pump will depend on the height through
which the fluid is raised, the pressure required at delivery point, the length and diameter of the
pipe, the rate of flow, together with the physical properties of the fluid , particularly its viscosity
and density.
The pumping of liquids such as sulphuric acid or petroleum products from bulk store to
process buildings, or the pumping of fluids round reaction units and through heat exchangers, are
typical illustrations of the use of pumps in the process industries. On the one hand, it may be
necessary to inject reactants or catalyst into a reactor at a low, but accurately controlled rate, and
on the other to pump cooling water to a power station or refinery at a very high rate. The fluid may
be a gas or liquid of low viscosity, or it may be a highly viscous liquid, possibly with non-
Newtonian characteristics. It may be clean, or it may contain suspended particles and be very
corrosive. All these factors influence
the choice of pump. Because of the wide variety of requirements, many different types are in use
including centrifugal, piston, gear, screw, and peristaltic pumps, though in the chemical and
petroleum industries the centrifugal type is by far the most important.
The factors that influence the choice of pump for a particular operation include:
(i) The quantity of liquid to be handled: This primarily affects the size of the pump and
determines whether it is desirable to use a number of pumps in parallel.
(ii) The head against which the liquid is to be pumped: This will be determined by the difference
in pressure, the vertical height of the downstream and upstream reservoirs and by the frictional
losses which occur in the delivery line. The suitability of a centrifugal pump and the number
of stages required will largely be determined by this factor.
(iii) The nature of the liquid to be pumped: For a given throughput, the viscosity largely
determines the friction losses and hence the power required. The corrosive nature will
determine the material of construction both for the pump and the packing. With suspensions,
the clearances in the pump must be large compared with the size of the particles.
(iv) The nature of the power supply: If the pump is to be driven by an electric motor or internal
combustion engine, a high-speed centrifugal or rotary pump will be preferred as it can be
1
coupled directly to the motor. Simple reciprocating pumps can be connected to steam or gas
engines.
(5) If the pump is used only intermittently, corrosion problems are more likely than with
continuous working.
4.1
2
The suction head (hs) decreases and the discharge head (hd) increases with increasing liquid flow
rate because of the increasing value of the friction head loss terms (hF)s and (hF)d. Thus the total;
head (Δh) which the pump is require to impart to the flowing liquid increases with increasing the
liquid pumping rate. Note that if the liquid level on the suction side is below the center line of the
pump, z is negative.
4.3
quote
4.4
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4.6 docu
This equation (4.6) gives the head available to get the liquid through the suction piping. or the
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The available NPSH in a system should always be positive i.e. the suction head should always be
capable of overcoming the vapor pressure (Pv) since the frictional head loss (hF)s increases with
increasing pumping rate.
At the boiling temperature of the liquid Ps and Pv are equal and the available NPSH
becomes [zs-(hF)s]. In this case no suction lift is possible since zs must be positive. If the term (Ps-
Pv) is sufficiently large, liquid can be lifted from below the centerline of the pump. In this case zs
is negative.
From energy consideration it is immaterial whether the suction pressure is below atmospheric
pressure or well above it, as long as the fluid remains liquid. However, If the suction pressure is
less than the vapour pressure at the pumping temperature, vaporisation will occur and the pump
may not be capable of developing the required suction head. Moreover, if the liquid contains gases,
these may come out of solution giving rise to pockets of gas. This phenomenon is known as
cavitation and may result in mechanical damage to the pump as the bubbles collapse. The tendency
for cavitation to occur is accentuated by any sudden changes in the magnitude or direction of the
velocity of the liquid in the pump. The onset of cavitation is accompanied by a marked increase in
noise and vibration as the vapour bubbles collapse, and also a loss of head.
To avoid cavitations, the pressure at the pump inlet must exceed the vapor pressure by a
certain value, called the “ Net Positive Suction Head (NPSH)”. The required values of NPSH is
about 2-3 m H20 for small pump; but it increases with pump capacity and values up to 15 m H20
are recommended for very large pump.
4.7
The mechanical efficiency (η) decreases as the liquid viscosity and the frictional losses increase.
The mechanical efficiency is also decreased by power losses in gear, Bearing, seals, etc. These
losses are not proportional to pump size. Relatively large pumps tend to have the best efficiency
whilst small pumps usually have low efficiencies. Furthermore high-speed pumps tend to be more
efficient than low-speed pumps. In general, high efficiency pumps have high NPSH requirements.
4
(ii) Dynamic/Kinetic pumps
4.4.1 Positive Displacement Pumps
5
Kinetic pumps. Kinetic pumps are subdivided into the following groups: centrifugal pumps,
peripheral and special pumps.
(i) Centrifugal Pumps
The centrifugal pump is by far the most widely used type
in the chemical and petroleum industries. It will pump
liquids with very wide-ranging properties and
suspensions with a high solids content including, for
example, cement slurries, and may be constructed from
a very wide range of corrosion resistant materials. The
whole pump casing may be constructed from plastics
such as polypropylene or it may be fitted with a
corrosion-resistant lining. Because it operates at high
speed, it may be directly coupled to an electric motor and
it will give a high flowrate for its size. A centrifugal
pump is a rotating machine in which flow and pressure
are generated dynamically. The energy changes occur by
virtue of two main parts of the pump, the impeller and
the volute or casing. The function of the casing is to
collect the liquid discharged by the impeller and to
convert some of the kinetic (velocity) energy into
pressure energy.
6
The advantages and disadvantages of the centrifugal pump
The main advantages are:
(1) It is simple in construction and can be made in a wide range of materials.
(2) There is a complete absence of valves.
(3) It operates at high speed (up to 100 Hz) and therefore, can be coupled directly to an electric
motor. In general, the higher the speed the smaller the pump and motor for a given duty.
(4) It gives a steady delivery.
(5) Maintenance costs are lower than for any other type of pump.
(6) No damage is done to the pump if the delivery line becomes blocked, provided it is not ran in
this condition for a prolonged period.
(7) It is much smaller than other pumps of equal capacity. It can, therefore, be made into a sealed
unit with the driving motor, and immersed in the suction tank.
(8) Liquids containing high proportions of suspended solids are readily handled.
The main disadvantages are:
(1) The single-stage pump will not develop a high pressure. Multistage pumps will develop greater
heads but they are very much more expensive and cannot readily be made in corrosion-
resistant material because of their greater complexity. It is generally better to use very high
speeds in order to reduce the number of stages required.
(2) It operates at a high efficiency over only a limited range of conditions: this applies especially
to turbine pumps.
(3) It is not usually self-priming.
(4) If a non-return valve is not incorporated in the delivery or suction line, the liquid will run back
into the suction tank as soon as the pump stops.
(5) Very viscous liquids cannot be handled efficiently.
7
Figure 4.2: Types of Pumps
4.5 Priming the Pump
The theoretical head developed by a centrifugal pump depends on the impeller speed, the
radius of the impeller, and the velocity of the fluid leaving the impeller. If these factors are
constant, the developed head is the same for fluids of all densities and is the same for liquids and
gases. A centrifugal pump trying to operate on air, then can neither draw liquid upward from an
initially empty suction line nor force liquid to a full discharge line. Air can be displaced by priming
the pump.
For example, if a pump develops a head of 100 ft and is full of water, the increase in pressure is
8
[100 ft (62.3lb/ft3 ) (ft2 /144 in 2 )] = 43 psi (2.9 atm). If full of air the pressure increase is about
0.05 psi (0.0035 atm).
4.6 Operating Characteristics
The operating characteristics of a pump
are conveniently shown by plotting the
head (h), power (P), efficiency (η), and
sometimes required NPSH against the flow
(or capacity) (Q) as shown in Figure 4.3.
These are known as characteristic curves of
the pump. It is important to note that the
efficiency reaches a maximum and then
falls, whilst the head at first falls slowly
with Q but eventually falls off rapidly. The Figure 4.3 Radial flow pump characteristics
optimum conditions for operation are
shown as the duty point, i.e. the point
where the head curve cuts the ordinate
through the point of maximum efficiency.
Characteristic curves have a variety
of shapes depending on the geometry of the
impeller and pump casing. Pump
manufacturers normally supply the curves
only for operation with water. In a
particular system, a centrifugal pump can
only operate at one point on the Δh against Figure 4.4 System and pump total head
Q curve and that is the point where the Δh against capacity
against Q curve of the pump intersect with
the Δh against Q curve of the system as
shown in Figure. 4.4
The system total head at a particular liquid flow rate
9
4.8
4.9
Example 4.1
A petroleum product is pumped at a rate of 2.525 x 10-3 m3/s from a reservoir under atmospheric
pressure to 1.83 m height. If the pump 1.32 m height from the reservoir, the discharge line diameter
is 4 cm and the pressure drop along its length 3.45 kPa. The gauge pressure reading at the end of
the discharge line 345 kPa. The pressure drop along suction line is 3.45 kPa and pump efficiency
η = 0.6 calculate:- (i) The total head of the system Δh. (ii) The power required for pump. (iii) The
NPSH
10
Take that: the density of this petroleum product ρ = 879 kg/m3 , the dynamic viscosity µ = 6.47 x
10-4 Pa.s, and the vapor pressure Pv = 24.15 kPa.
Example 4.2
It is required to pump cooling water from storage pond to a condenser in a process plant situated
10 m above the level of the pond. 200 m of 74.2 mm i.d. pipe is available and the pump has the
characteristics given below. The head loss in the condenser is equivalent to 16 velocity heads based
11
on the flow in the 74.2 mm pipe. If the friction factor = 0.003, estimate the rate of flow and the
power to be supplied to the pump assuming η = 0.5
Q (m3/s) 0.0028 0.0039 0.005 0.0056 0.0059
h (m) 23.2 21.3 18.9 15.2 11.0
Example 4.3
A pump take brine solution at a tank and transport it to another in a process plant situated 12 m
above the level in the first tank. 250 m of 100 mm i.d. pipe is available sp.gr. of brine is 1.2 and µ
= 1.2 cp. The absolute roughness of pipe is 0.04 mm and f = 0.0065. Calculate (i) the rate of flow
12
for the pump (ii) the power required for pump if η = 0.65. (iii) if the vapor pressure of water over
the brine solution at 86°F is 0.6 psia, calculate the NPSH available, if suction line length is 30 m.
Q (m3/s) 0.0056 0.0076 0.01 0.012 0.013
h (m) 25 24 22 17 13
13
When the rotational speed of the impeller N is (rpm), the volumetric flow rate Q in (US galpm)
and the total head Δh developed by the pump is in (ft), the constant Ns in equation (8) is known
as the specific speed of the pump. The specific speed is used as an index of pump types and always
evaluated at the best efficiency point (bep) of the pump. Specific speed vary in the range (400 –
10,000) depends on the impeller type, and has the dimensions of (L/T2]3/4 .[ British gal=1.2USgal,
1ft3 =7.48USgal, 1m3 =264USgal]
14
The characteristic performance curves are available for a centrifugal pump operating at a given
rotation speed, equations (13), (14), and (15) enable the characteristic performance curves to be
plotted for other operating speeds and for other slightly impeller diameters.
Example 4.4
A volute centrifugal pump with an impeller diameter of 0.02 m has the following performance data
when pumping water at the best efficiency point (bep). Impeller speed N = 58.3 rev/s capacity Q
= 0.012 m3/s, total head Δh = 70 m, required NPSH = 18 m, and power = 12,000 W. Evaluate the
performance data of an homologous pump with twice the impeller diameter operating at half the
impeller speed.
15
Example 4.5
Calculate the specific speed for these two pumps
Solution
Given
rev 60s
N 58.3rev / s 58.3 x 3498rev / min
s 1 min
m 3 264USgal 60s
Q 0.012m 3 / s 0.012 x x 190.08USgal / min
s 1m 3 1 min
1 ft
h 70m 70m x 229.66 ft
0.3048m
N Q 3498 190.08
Recall that N s 3
3
817.47
h 4 229.66 4
16
4.8 Centrifugal Pumps in Series and in Parallel
4.8.1 Centrifugal Pumps in Parallel
17
Exercise
4.1 A centrifugal pump used to take water from reservoir to another through 800 m length and
0.15 m i.d. if the difference in two tank is 8 m, calculate the flow rate of the water and the
power required, assume f =0.004.
Q (m3/h) 0 23 26 69 92 115
h (m) 17 16 13.5 10.5 6.6 2.0
0 0.495 0.61 0.63 0.53 0.1
4.2 A centrifugal pump was manufactured to couple directly to a 15 hp electric motor running at
1450 rpm delivering 50 liter/min against a total head 20 m. It is desired to replace the motor
by a diesel engine with 1,000 rpm speed and couple it directly to the pump. Find the probable
discharge and head developed by the pump. Also find the hp of the engine that would be
employed.
4.3 Calculate the available net positive section head NPSH in a pumping system if the liquid
density ρ = 1200 kg/m3 , the liquid dynamic viscosity µ = 0.4 Pa s, the mean velocity u = 1
m/s , the static head on the suction side z = 3 m, the inside pipe diameter di = 0.0526 m, the
gravitational acceleration g = 9.81 m/s2 , and the equivalent length on the suction side (∑Le)
= 5.0 m. The liquid is at its normal boiling point. Neglect entrance and exit losses.
4.4 A volute centrifugal pump has the following performance data at the best efficiency point:
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MODULE V
NON -NEWTONIAN FLUID
5.1 Introduction
A Newtonian fluid at a given temperature and pressure has a constant viscosity which
does not depend on the shear rate and, for streamline (laminar) flow, is equal to the ratio of the
shear stress ( ) to the shear rate (- = dux/dy) as shown in equation 5.1:
y
5.1
du x
dy
The modulus sign is used because shear stresses within a fluid act in both the positive and negative
senses. Gases and simple low molecular weight liquids are all Newtonian, and viscosity may be
treated as constant in any flow problem unless there are significant variations of temperature or
pressure. Many fluids, including some that are encountered very widely both industrially and
domestically, exhibit non-Newtonian behaviour and their apparent viscosities may depend on the
rate at which they are sheared and on their previous shear history. At any position and time in the
fluid, the apparent viscosity a which is defined as the ratio of the shear stress to the shear rate at
that point is given by equation 5.2:
y
a 5.2
du x
dy
For Newtonian fluids, a plot of shear stress (), against shear rate (- = du/dy) on Cartesian
coordinate is a straight line having a slope equal to the dynamic viscosity (µ) but for Non -
Newtonian fluid a plot of shear stress against shear rate does not give a straight line.
There are two types of non-Newtonian fluids: (i) Time-independent and, (ii) Time-
dependent.
(i) Time-Independent Non-Newtonian Fluids
In this type the apparent viscosity depends
only on the rate of shear at any particular moment
and not on the time for which the shear rate is
applied. For non-Newtonian fluids the
relationship between shear stress and shear rate is
more complex and represented by equation (5.3 a
& b):
k ( ) n (For Power Fluids) 5.3a
0 k ( ) (Bingham Plastic Fluid) 5.3b
Figure 5.1
19
The shape of the flow curve for time-independent
fluids compared with Newtonian fluid is shown in
thee Figure 5.1, where
A: Newtonian fluids
B: Pseudoplastic fluids [power-law n<1] Examples: Polymer solution, detergent.
C: Dilatant fluids [power-law n>1] Examples: Wet beach sand, starch in water.
D: Bingham plastic fluids, it required (o) for initial flow. Examples: Chocolate mixture,
soap, sewage sludge, toothpaste.
(ii) Time-Dependent Non-Newtonian Fluids
For this type, the curves of share stress versus shear rate
depend on how long the shear has been active. This type
is classified into:
(i) Thixotropic Fluids
Which exhibit a reversible decrease in shear stress
and apparent viscosity with time at a constant shear
rate. Example Paints.
(ii) Rheopectic Fluids
Which exhibit a reversible increase in shear stress
and apparent viscosity with time at a constant shear
rate. Example: Gypsum suspensions, bentonite clay.
Figure 5.2
5.4
where, u: is the mean (average) linear velocity; u = Q/A
5.5
Figure 5.3
4u 8u
w w 5.6
R d
Equation (5.6) is the flow characteristic and therefore, for laminar flow,
8u
w w 5.7
d
20
The force balance on an element of fluid of L length is:
5.8
5.9
5.3 Flow of General Time-Independent Non-Newtonian Fluids
The slope of a log-log plot of shear stress at the pipe walls against flow characteristic [8u/d]
at any point along the pipe is the flow behaviour index (n')
5.10
Equation (5.10) leads to equation (5.11):
5.11
where, Kp' and n' are point values for a particular value of the flow characteristic (8u/d).
Equation (5.11) can also be written as:
5.12
By the analogy of equation (5.9) with equation (5.12), the following equation can be written for
non-Newtonian fluids in equations (5.13) to (5.16):
5.13
where, (µa)P is apparent viscosity for pipe flow.
5.14
This equation (5.14) gives a point value for the apparent viscosity of non-Newtonian fluid flow
through a pipe. Reynolds number for the of non-Newtonian fluids can be written as equation
(5.15):
5.15
5.16
where, m = Kp' (8 n'-1) . Equations (5.15) or (5.16) gives a point value for Re at a particular flow
characteristic (8u/d).
21
A point value of the basic friction factor ( or Jf) or fanning friction factor (f ) for laminar
flow can be obtained from equation (5.17)
5.17
The pressure drop due to skin friction can be calculated in the same way as for Newtonian fluids:
5.18
Equation (5.18) is used for laminar and turbulent flow, and the fanning friction factor (f ) for
turbulent flow of general time independent non-Newtonian fluids in smooth cylindrical pipes can
be calculated from equation( 5.19):
f = a/Reb 5.19
where, a, and b are function of the flow behaviour index (n') as shown in the Table 5.1
Table 5.1
5.20
Example 5.1
A general time-independent non-Newtonian liquid of density 961 kg/m3 flows steadily with an
average velocity of 1.523 m/s through a tube 3.048 m long with an inside diameter of 0.0762 m.
For these conditions, the pipe flow consistency coefficient Kp' has a value of 1.48 Pa.s0.3 [or 1.48
(kg / m.s2)s0.3] and n' value of 0.3. Calculate the values of the apparent viscosity for pipe flow
(µa)p, the Reynolds number Re and the pressure drop across the tube, neglecting end effects.
Solution
22
5.4 Flow of Power-Law Fluids in Pipes
Power-law fluids are those in which the shear stress () is related to the shear rate ( ) by
equation (5.21):
5.21
For shear stress at a pipe wall (w) and the shear rate at the pipe wall ( w),equation (5.21) becomes:
5.22
Equation (5.11) gives the relationship between (ΔP) and (8u/d) for general time-independent non-
Newtonian fluids. But for power-law fluids the parameters Kp' and n' in equation (5.11) are no
longer point values but remain constant over a range of (8u/d), so that for power-law fluids,
equation (5.11) can be written as equation (5.23):
5.23
The shear rate at pipe wall for general time-independent non-Newtonian fluids is:
5.24
and for power-law fluids
5.25
Combine equations (5.23), (5.24), and (5.25) to give the relationship between the general
consistency coefficient (K) and the consistency coefficient for pipe flow (Kp).
5.26
23
The apparent viscosity for power-law fluids in pipe flow:
5.27
The Reynolds number for non-Newtonian fluids flow in pipe:
5.28
For power –law fluids flow in pipes the Re can be written either as:
5.29
Example 5.2
A Power-law liquid of density 961 kg/m3 flows in steady state with an average velocity of 1.523
m/s through a tube 2.67 m length with an inside diameter of 0.0762 m. For a pipe consistency
coefficient of 4.46 Pa.s0.3 [or 4.46 (kg / m.s2)s0.3], calculate the values of the apparent viscosity for
pipe flow (µa)p in Pa.s, the Reynolds number, Re, and the pressure drop across the tube for power-
law indices n = 0.3, 0.7, 1.0, and 1.5 respectively.
Solution
24
5.6 Turbulent Flow and Generalized Friction Factor
25
Figure 5.4 : Friction factor chart for purely viscous non-Newtonian fluids
For rough pipes with various values of roughness ratio (e/d), this figure cannot be used for
turbulent flow, since it is derived for smooth pipes.
Example 5.3
A pseudoplastic fluid that follows the power-law, having a density of 961 kg/m3 is flowing in
steady state through a smooth circular tube having an inside diameter of 0.0508 m at an average
velocity of 6.1 m/s. the flow properties of the fluid are n' = 0.3,Kp = 2.744 Pa.s n . Calculate the
frictional pressure drop across the tubing of 30.5 m long.
Solution
Exercise
26
5.
1
5. Calculate the frictional pressure gradient –ΔPfs/L for a time independent non Newtonian
2
fluid in steady state flow in a cylindrical tube if
the liquid density the ρ = 1000 kg/m3
inside diameter of the tube d = 0.08 m
the mean velocity u = l.0 m / s
the point pipe consistency coefficient K' = 2 Pa. s0.5
and the flow behaviour index n' = 0.5.
27