TURBINE AND AUXILIARIES PUMPS

CHAPTER 20
PUMPS

Pumps are used widely in industry to provide cooling and lubrication services, to
transfer fluids for processing and to provide the motive force in hydraulic systems. In
fact, most manufacturing plants, commercial buildings, and municipalities rely on
pumping systems for their daily operation. Basically, pumps can be classified in two
categories as below.

20.1 TYPES OF PUMPS

a). Centrifugal pumps
b). Positive displacement pumps

20.2 CENTRIFUGAL PUMPS

A centrifugal pump is one of the simplest pieces of equipment. Its purpose is to convert
energy of an electric motor or engine into velocity or kinetic energy and then into
pressure of a fluid that is being pumped. The energy changes occur into two main parts
of the pump, the impeller and the volute. The impeller is the rotating part that converts
driver energy into the kinetic energy. The volute is the stationary part that converts the
kinetic energy into pressure.

Liquid enters the pump suction and then the eye of the impeller. When the impeller
rotates, it spins the liquid sitting in the cavities between the vanes outward and imparts
centrifugal acceleration. As the liquid leaves the eye of the impeller a low pressure area
is created at the eye allowing more liquid to enter the pump inlet.

20.2.1 GENERATION OF CENTRIFUGAL FORCE

The process liquid enters the suction nozzle and then into eye (center) of a revolving
device known as an impeller. When the impeller rotates, it spins the liquid sitting in the
cavities between the vanes outward and provides centrifugal acceleration. As liquid
leaves the eye of the impeller, a low-pressure area is created causing more liquid to
flow toward the inlet. Because the impeller blades are curved, the fluid is pushed in a
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tangential and radial direction by the centrifugal force. This force acting inside the
pump is the same one that keeps water inside a bucket that is rotating at the end of a
string. Figure next depicts a side cross-section of a centrifugal pump indicating the
movement of the liquid.

20.2.2 LIQUID FLOW PATH INSIDE A CENTRIFUGAL PUMP

Fig. Centrifugal pump

Centrifugal Pumps are classified into three general categories:

 Radial Flow – a centrifugal pump in which the pressure is developed wholly by
centrifugal force.
 Mixed Flow - 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.
 Axial Flow - a centrifugal pump in which the pressure is developed by the
propelling or lifting action of the vanes of the impeller on the liquid.

20.3 CONVERSION OF KINETIC ENERGY TO PRESSURE ENERGY

The key idea is that the energy created by the centrifugal force is kinetic energy. The
amount of energy given to the liquid is proportional to the velocity at the edge or vane
tip of the impeller. The faster the impeller revolves or the bigger the impeller is, then
the higher will be the velocity of the liquid at the vane tip and the greater the energy
imparted to the liquid.

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This kinetic energy of a liquid coming out of an impeller is harnessed by creating a

resistance to the flow. The first resistance is created by the pump volute (casing) that
catches the liquid and slows it down. In the discharge nozzle, the liquid further
decelerates and its velocity is converted to pressure according to Bernoulli’s principle.

Therefore, the head (pressure in terms of height of liquid) developed is approximately

equal to the velocity energy at the periphery of the impeller expressed by the following
well-known formula:

H = v² / 2g

Where,
H = Total head developed in feet.
v = Velocity at periphery of impeller in ft/sec.
g = Acceleration due to gravity – 32.2 feet/ sec²

A pump does not create pressure, it only provides flow. Pressure is a just an indication
of the amount of resistance to flow.

20.4 POSITIVE DISPLACEMENT PUMPS

Positive displacement pumps use a mechanical force such as gears, bladders, pistons,
plungers or diaphragms to push liquid through and out of the pump. They moved fluid
into a fixed cavity so that when the liquid exits, the vacuum that is created draws in
more fluid. Positive displacement pumps are suitable for liquids with high viscosities
and for applications that require high pressures.

Typically, these self-priming devices are made of aluminum, brass or bronze, cast iron,
plastic, or stainless steel. Positive displacement pumps are used in a variety of
industrial, commercial, and municipal applications. For example, they are often used in
the construction, maritime, mining, petrochemical, pulp and paper, and power
generation industries. Pumps that are rated for petrochemical and hydrocarbon
applications are designed to move materials such as gasoline, kerosene, diesel oil,
lubricating oil, paraffin wax, and asphalt. Pumps that can operate at 10,000 to 40,000

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psi are used in surface preparation, the internal cleaning of pipes and heat exchangers,
and concrete removal.

Many types of positive displacement pumps are available. Bladder pumps are low-flow
pneumatic devices used in sampling applications. Diaphragm and double-diaphragm
pumps include suction and discharge check valves to prevent backflow. Piston and
plunger pumps use a plunger or piston to move media through a cylindrical chamber.
Peristaltic pumps move media through a tube that is compressed at a number of points
through contact with rollers or shoes.

Gear pumps provide a more continuous, less pulsating flow than many other positive
displacement pumps. Rotary lobe pumps are often used in food applications because of
their ability to process solids. Grinder pumps shred solids, screw pumps transfer fluids
along an axis, and well stimulation pumps are used to increase the production of wells.
Progressive cavity pumps transfer fluid or media with suspended solids or slurries from
the suction side of the pump to the discharge side of the pump from storage tanks or
through pipelines.

20.4.1 RECIPROCATING PUMPS

In a reciprocating pump, a volume of liquid is drawn into the cylinder through the
suction valve on the intake stroke and is discharged under positive pressure through the
outlet valves on the discharge stroke. The discharge from a reciprocating pump is
pulsating and changes only when the speed of the pump is changed. This is because the
intake is always a constant volume. Often an air chamber is connected on the discharge
side of the pump to provide a more even flow by evening out the pressure surges.
Reciprocating pumps are often used for sludge and slurry.

One construction style of a reciprocating pump is the direct-acting steam pump. These
consist of a steam cylinder end in line with a liquid cylinder end, with a straight rod
connection between the steam piston and the pump piston or plunger. These pistons are
double acting which means that each side pumps on every stroke.

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Another construction style is the power pump which converts rotary motion to low
speed reciprocating motion using a speed reducing gear. The power pump can be either
single or double-acting. A single-acting design discharges liquid only on one side of the
piston or plunger. Only one suction and one discharge stroke per revolution of the
crankshaft can occur. The double-acting design takes suction and discharges on both
sides of the piston resulting in two suctions and discharges per crankshaft revolution.
Power pumps are generally very efficient and can develop high pressures. These pumps
do however tend to be expensive.

20.4.2 DIAPHRAGM-TYPE RECIPROCATING PUMP

The diaphragm pump is an offshoot of a plunger pump. Because of the risk that
contamination could travel between the plunger and the cylinder, the diaphragm is safer
for microbial processing. This applet is crude but shows how a reciprocating piston
(plunger) pump works. The flywheel that moves the plunger can attach the arm to the
plunger at various points to change the amplitude of the stroke and thus the pumping
rate. The pumping rate can also be changed with a different rotational speed, but
variable speed motors or mechanical means of changing rpm are expensive.

20.4.3 METERING PUMPS

Metering pumps provide precision control of very low flow rates. Flow rates are
generally less than 1/2 gallon per minute. They are usually used to control additives to
the main flow stream. They are also called proportioning or controlled-volume pumps.
Metering pumps are available in either a diaphragm or packed plunger style, and are
designed for clean service and dirty liquid can easily clog the valves and nozzle
connections.

20.4.4 ROTARY PUMPS

A rotary pump traps fluid in its closed casing and discharges a smooth flow. They can
handle almost any liquid that does not contain hard and abrasive solids, including
viscous liquids. They are also simple in design and efficient in handling flow conditions
that are usually considered to low for economic application of centrifuges. Types of
rotary pumps include cam-and-piston, internal-gear, lobular, screw, and vane pumps.

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Gear pumps are found in home heating systems in which the burners are fired by oil.
Rotary pumps find wide use for viscous liquids.

When pumping highly viscous fluids, rotary pumps must be operated at reduced speeds
because at higher speeds the liquid cannot flow into the casing fast enough to fill it.
Unlike a centrifugal pump, the rotary design will deliver a capacity that is not greatly
affected by pressure variations on either the suction or discharge ends. In services
where large changes in pressure are anticipated, the rotary design should be considered.

20.4.5 LOBE PUMPS

Lobe pumps are similar to external gear pumps in operation in that fluid flows around
the interior of the casing. Unlike external gear pumps, however, the lobes do not make
contact. Lobe contact is prevented by external timing gears located in the gearbox.
Pump shaft support bearings are located in the gearbox, and since the bearings are out
of the pumped liquid, pressure is limited by bearing location and shaft deflection.

 As the lobes come out of mesh, they create expanding volume on the inlet side of
the pump. Liquid flows into the cavity and is trapped by the lobes as they rotate.
 Liquid travels around the interior of the casing in the pockets between the lobes and
the casing -- it does not pass between the lobes.
 Finally, the meshing of the lobes forces liquid through the outlet port under
pressure.

Lobe pumps are frequently used in food applications because they handle solids without
damaging the product. Particle size pumped can be much larger in lobe pumps than in
other PD types. Since the lobes do not make contact, and clearances are not as close as

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in other PD pumps, this design handles low viscosity liquids with diminished
performance.

Loading characteristics are not as good as other designs, and suction ability is low.
High-viscosity liquids require reduced speeds to achieve satisfactory performance.
Reductions of 25% of rated speed and lower are common with high-viscosity liquids.

20.4.6 THREE SCREW PUMPS

Three Screw pumps employ just three screw elements - one power screw and two idler
screws running in the three precision bores in the housing or liner. The screws are so
profiled that they form a liquid tight seal between the thread. As the screws rotate,
pockets/ cavities are formed where liquid gets trapped and conveyed from one end of
the infinite stroke. This results in smooth, pulsation free flow with extremely low noise
and vibration levels, almost impossible to be achieved by any other design of positive
displacement or other types.

The power rotor does not drive the idlers as commonly believed. The hydraulic forces
acting on screw flanks turn the idlers with less torque thus reducing the friction. The
idlers simply roll over the root diameter of idler dia. reduce the unit pressure, centralize
the power rotor and absorb the radial loads. A balance piston integrally machined on
power rotor takes care of axial thrusts.

While in operation, the screws are in hydrodynamic balance on film lubrication and do
not require any additional bearings. The one ball bearing often used is only for axial
positioning of rotor and safer operation of mechanical seals. Small rotor dimensions
enable the pump to be operated at high speeds directly coupled 3000 or 3600 RPM
motors or other prime movers. Such unique design and features has demonstrated
excellent reliability with pumps in operation continuously non-stop for decades together
without replacement of any components or maintenance on clean fluids.

20.5 SPECIFIC SPEED

The net suction specific speed is a dimensionless number defined by centrifugal and
axial pumps inherent physical characteristics and operating point

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 It is one of a number of factors used in selecting a pump for use and is mainly used
to see if there will be problems with cavitation during the pumps operation on the
suction side
 The net suction specific speed of a pump will define the envelope of operation that
a pump will experience stable operation
 The higher the net suction specific speed, then the smaller the operation of stable
operation. The envelope of stable operation is defined in terms of the best efficiency
point of the pump.

20.6 NET POSITIVE SUCTION HEAD LOSSES

Pump cavitates and run dry when the pressure leading into them falls below the vapor
pressure of what they are pumping. At vapor pressure the liquid boils into a vapor and
fills the pipe. In order to know that the pressure to a pump is always above the vapor
pressure it is necessary to calculate that the pressure losses from pipe friction and
suction lift will not cause the pressure to drop under the vapor pressure. The presence of
dissolved gas in the liquid complicates the problem.

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