Fundamentals of Centrifugal Pumps

PRODUCT TRAINING
FUNDAMENTALS OF CENTRIFUGAL PUMPS
Fundamentals of Centrifugal Pumps

A centrifugal pump is a mechanical device that converts energy to hydraulic work Energy is supplied by a driver such as an electric motor, turbine, or engine Hydraulic work is the movement of a liquid mass through a distance This presentation is limited to centrifugal pump types only Sundyne pumps are a special design that will not be covered in this presentation
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Just Say NO!!!!!

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The work takes place at an impeller which accelerates the liquid by whirling it through the impeller thus adding centrifugal force and hence acceleration

When an object is spun around in a circle it is accelerated outward by centrifugal force

When liquid is spun around in a circle, it accelerates outward from the center of the circle due to centrifugal force

An impeller has vanes which are blades that push the liquid through the impeller. The center of the impeller where the liquid enters the impeller is called the eye
Vanes
Eye
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To obtain useful work, the impeller is contained in a casing which directs the accelerated fluid along a desired path
Discharge
Pump Impeller and Shaft

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Pump Impeller and Shaft with Pressure Casing

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Pump Impeller and Shaft with Pressure Casing and Cover

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Adjustment Process Fluid Packing Stuffingbox Cover
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Fundamentals of Centrifugal Pumps-Impellers Pumps-Impellers

Impeller Design The impeller is the most important part of the pump since it is where the work is taking place. Furthermore, the impeller plays an important role in the design of other pump components. It has a direct effect on the seal cavity pressure for example
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Many different types of impeller styles are used. Most, but not all, have vanes that curve away from the flow path so that the liquid is in contact with the impeller longer. These are referred to as reverse curve vane impellers
Vanes
Eye
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Impeller vanes may be enclosed by shrouds. In general impellers with shrouds are slightly less efficient due to the drag of the liquid on the shroud
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Therefore many impellers have no shrouds. They are called open impellers. Note that the bottom impeller is partially shrouded due to a shroud area around the impeller eye
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Some impeller designs may also have a shroud only on one side of the impeller. They are also said to be partially shrouded or semi-open or semi-closed
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Shrouds are generally used on larger impellers to help support the vanes and maintain the impeller shape under extreme pressure and temperature conditions. They also have the disadvantage of limiting the particle size that can pass through the impeller
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There are two different impeller types used in the process industry. They differ by the type of flow through the impeller. The most common type is a radial flow impeller where the liquid makes a 90o turn as it passes through the impeller
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In a turbine type impeller, the liquid also makes a turn as it passes through the pump, but less than 90o. These are most often found in diffuser type pumps which relates to the casing design and will be discussed later. Since the liquid makes less of a turn, a turbine style impeller may be slightly more efficient than a similar radial flow impeller
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The impeller has a direct relationship to pump performance. The design of the impeller is the single most important factor in determining the flow rate and liquid pressure that a pump can generate
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The Master Pumps & Power catalog is an excellent reference resource for most pump application problems. It should be a part of every engineers library. It is free to all of our customers
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Flow through an impeller is determined primarily by three factors
Vane width Number of vanes Impeller speed
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A wide vane impeller will move more liquid per unit time than a narrow vane impeller. The flow is directly proportional to the vane width
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Flow (Q) through an impeller is also directly related to the impeller speed. The more times an impeller rotates per unit time the more fluid is will move
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Finally the flow through a pump is somewhat related to the number of vanes although it is not directly proportional. More vanes will move more fluid
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An impeller creates head by accelerating the fluid to a given velocity. As it spins, the fluid is accelerated outward by centrifugal force
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The fluid exits the impeller at a given velocity. Therefore it will rise to a given height in a column based on the exit speed regardless of the weight of the fluid
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Therefore a centrifugal pump is said to be a constant head device. At a given speed it will accelerate a liquid to a given velocity regardless of the weight of the liquid. A heavier liquid would require more horsepower and the discharge pressure would be higher, but it would rise in a column no higher than a light liquid
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This phenomenon is based on simple laws of physics (V2 = 2 AS) where V is the velocity, A is the acceleration of gravity, and S is the height Note that this formula makes no consideration of weight
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If fluids are pushed up a column to the same height, the pressure at the bottom of the column would be different for fluids of different weight. The formulae for this relationship are as follows hd. ft. = (psi X 2.31) / sp. gr. psi = (hd ft. / 2.31) x sp. gr.
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To illustrate, a pressure gauge at the bottom of a 231 ft. high column filled with water would read 100 psi. If the column was filled with butane having a specific gravity of only .5, the gauge would read 50 psi
231 ft.
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Fundamentals of Centrifugal Pumps-NPSH Pumps-NPSH

In order for the pump to move fluid, the system must be able to push fluid into the pump as fast as the pump can push it out. Therefore there must be a certain minimum required suction pressure for each pump based on the pump flow This pressure is expressed in head feet and is referred to as NPSH -net positive suction head
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NPSH is expressed in two ways
NPSHA is the net positive suction head available from the system NPSHR is the net positive suction head required by the pump at a particular flow NPSHA must always be greater than NPSHR or damage to the pump will occur due to cavitation
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Cavitation is the flashing of the liquid at the pump impeller eye caused by the pump lowering the pressure in the eye area as it accelerates fluid across the impeller The damage occurs when the flashed gas is compressed back to a liquid as it gains pressure while traveling through the impeller
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Cavitation causes pump problems in two areas Severe cavitation can erode the pump impeller resulting in decrease performance and vibration due to imbalance Cavitation normally results in substantially higher vibration in the entire pump
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NPSH is the total suction head in feet of liquid (absolute at the pump centerline or impeller eye) less the absolute vapor pressure (in feet ) of the liquid being pumped
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NPSHA is the NPSH available at the pump suction nozzle and depends on the suction system design. It must always be equal to or greater than the NPSHR NPSHR is the NPSH required by the pump for stable operation. It is determined by the pump manufacturer and is dependent on many factors including the type of impeller inlet, impeller design, pump flow, rotational speed, nature of the liquid, etc. It is usually plotted on the characteristic pump performance curved supplied by the pump manufacturer
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NPSHA is a difficult calculation. It will require the help of a process engineer from the plant NPSHA can be determined by direct field measurement if the vapor pressure is known. A method for this calculation is presented later
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NPSHA Example for Suction Lift *Assume vapor pressure of water @ 80 F = .5psia or 1.2 feet = hvpa *Assume atmospheric pressure @ sea level Height = hst or 34.0 feet = ha 15 feet *Assume pipe losses = 3.5 feet = hfs *NPSHA = ha - hvpa - hst - hfs *NPSHA = 34 - 1.2 - 15 - 3.5 = 14.3 feet
Atmospheric Pressure = ha
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Atmospheric Pressure = ha *Assume vapor pressure of water @ 80 F = .5psia or 1.2 feet = hvpa *Assume atmospheric pressure @ sea level or 34.0 feet = ha *Assume pipe losses = 3.5 feet = hfs *NPSHA = ha - hvpa + hst - hfs *NPSHA = 34 - 1.2 + 15 - 3.5 = 44.3 feet NPSHA Example for Flooded Suction
Height = hst 15 feet
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Simple Method to Determine NPSHA
NPSHA is the total suction head in feet of liquid (absolute at the pump centerline or impeller eye) less the absolute vapor pressure (in feet) of the liquid being pumped Measure the suction pressure and convert to feet of head (must be absolute not atmospheric) Determine the vapor pressure of the liquid and convert to feet of head Subtract the vapor pressure from the suction pressure
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Fundamentals of Centrifugal Pumps-Performance Curves Pumps-Performance

A pump manufacturer will supply a curve for every pump purchased which graphically represents the expected pump performance For most applications, a copy of the pump curve is required information for properly selecting a sealing system and flush plan
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NPSHR Head
Efficiency
BHP Flow, GPM

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Fundamentals of Centrifugal Pumps-Performance Curves Pumps-Performance Contents

What pump curves represent How to read pump curves
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A Pump Curve
NPSHR Head Efficiency
BHP Flow, GPM

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Summary of Pump Curve Info
Graphical representation of performance Head BHP Efficiency NPSHR
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Summary of Pump Curve Info
Graphical representation of performance Contains more than performance data speed stages may have info about liquid impeller, case patterns wear ring clearances
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Actual Sample Curve Pricebook Curve
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Actual Sample Curve -Job Curve
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How Pump Curves are Made
P2 P1 Flow Meter
Pump
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Test Data
Flow 0 400 800 960 P2 - P1 311 291 234 195 BHP 20 117 156 163
Pressure in PSIG
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Convert Pressure to Feet of Head Head = 2.31 (P2-P1) / S.G. Head is in Feet!
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Compute Efficiency Efficiency = Theoretical Horsepower divided by Actual Horsepower Convert to Percent
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Test Data
Flow 0 400 800 960 Head 718 672 540 450 BHP 20 117 156 163 Efficiency *** 58% 70% 67%
Now in feet
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Head Portion of Pump Curve
800 700 600 500 400 300 200 100 0 0 200 400 600 Flow, GPM 800 1000 1200
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TDH

BHP Portion of Pump Curve
180 160 140 120 100 80 60 40 20 0 0 200 400 600 Flow, GPM
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BHP
800
1000
1200

Efficiency Portion of Pump Curve
80 70 60 50 40 30 20 10 0 0 200 400 600 Flow, GPM
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Eff
800
1000
1200

NPSH Net Positive Suction Head NPSHR: Required NPSHA: Available
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NPSH Net Positive Suction Head NPSHR: Required NPSHA: Available NPSH = Actual Pressure - Vapor Pressure, then convert to feet of head
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NPSH Required
Determined during pump test Throttling suction to pump Hot water Based on 3% head loss-reduce NPSHA until 3% loss in produced head is observed Based on water
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Test Data
Flow 0 400 800 960 Full Head 718 672 540 450 3% Loss - 22 = 696 - 20 = 652 - 16 = 524 - 14 = 436
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NPSHR Portion of Pump Curve
35 30 25 NPSHR 20 15 10 5 0 0 200 400 600 Flow, GPM
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800
1000
1200

35 N P S H R 30 25 20 15 10 5 0 0 200 400 600 800 1000 1200
NPSH
TDH
800 700 600 500 400 300 200 100 0 0 200 400 600 800 1000 1200
T D H
EFF
E f f
80 70 60 50 40 30 20 10 0 0
180 160 140 120 100 80 60 40 20 0 0 200 400 600 Flow, GPM 800 1000 1200
200
400
600
800
1000
1200
BHP
B H P
FLOW IN GPM
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A Pump Curve
NPSHR Head Operating Point Efficiency
BEP
BHP Flow, GPM
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The pump manufacturer will normally show the point on the curve where the pump is expected to operate BEP is the best efficiency point taken at the highest point of the efficiency curve
At BEP the pump normally operates the most stably Operation below BEP can result in mechanical and hydraulic problems
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Summary of Pump Curve Information
Graphical representation of performance Contains more than performance data
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Fundamentals of Centrifugal Pumps-Impeller Effect Pumps-Impeller

Balance Holes
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Effect of back wear rings and balance holes
Pressure at O.D. of impeller breaks down across back wear ring Balance holes bleed pressure back to suction Seal chamber at same pressure as balance holes
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Impeller with PumpoutVanes

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Effect of pump out vanes
Vane O.D. is the same as the impeller O.D. and is turning at the same speed Therefore vane puts up same head as impeller Therefore back of impeller at shaft is at same pressure as front
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Impeller with no back wear rings or pumpout vanes
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Effect of no back wear rings or pump out vanes Pressure at impeller O.D. is present behind entire impeller Seal chamber at discharge pressure
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Fundamentals of Centrifugal Pumps-Pump Case Design Pumps-Pump

If a higher pressure differential is required across the pump the designer has several options. Two would be to:
Increase the pump speed-the flow would also increase Increase the impeller O.D.
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In most cases neither is practical
There is a practical limit to the impeller diameter. Beyond that limit it would be difficult to control the tolerances to ensure proper fit and balance. The hardware would be prohibitively expensive There is also a practical limit to the shaft speed. Not only would balance be critical, but the bearing and lubrication system would be complex and expensive
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The third option is simpler. To achieve high differential head without the expense more than one stage or impeller are used. Multistage pumps come in many varieties Multistage volute
Split case Double case
Multistage diffuser
Vertical Horizontal
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To understand multistage pump design, it is first essential to know that there are in general two different ways that the pump case directs the flow from the impeller to the discharge nozzle Volute pattern Diffuser pattern
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Volute Pump
One or two passages in the pump case guide the fluid from the impeller to the pump discharge or the next stage Single volute pumps can result in excessive hydraulic load on the impeller and shaft
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Single Volute Double Suction Pump
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Diffuser Pump A multipassage diffuser or bowl assembly surrounds the entire impeller O.D. and guides the fluid to the discharge nozzle or next stage through multiple paths
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Diffuser Pumps
Note that the Byron Jackson design incorporates a mixed flow impeller
The fluid does not make a full 90o turn in the impeller. Since it is not a radial flow impeller, it is termed a mixed flow impeller
Not all turbine pumps are mixed flow. Some are furnished with radial flow impellers such as the horizontal diffuser pump shown previously
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Multistage Volute Split Case
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Fundamentals of Centrifugal Pumps-Seal Cavity Pressure Pumps-Seal

Most multistage volute type pumps have front and back wear rings. Therefore the seal cavity pressures would be as follows:
One end-suction The other end-discharge pressure of one of the stages unless some measures are taken to reduce the pressure
Most multistage volute pumps will have several taps on the pump case where various pressures are available for the flush source
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Multistage Volute Double Case
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Most multistage double case volute type pumps have front and back wear rings. Therefore the seal cavity pressures would be as follows:
One end-suction The other end-discharge pressure of one of the stages unless some measures are taken to reduce the pressure
Only pump discharge pressure is available for a flush source
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Many of these pumps as well as other multistage designs will have some provision for reducing the pressure in the seal chamber at the high pressure end
Balance line Close clearance bushing
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A balance line will typically bleed the high pressure seal chamber to about suction plus 70% of one stage differential
Depends on the bushing wear Also depends on the allowable flow in the balance line which represents pump inefficiency
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Dont assume
Check to see if the balance line exists Measure the seal cavity pressure The following slide illustrates a balance line-they are not always so visible
Confucius say - When you assume you make a donkey out of u and me
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Multistage Volute with Balance Line
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Multistage Diffuser Horizontal
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Since all the impellers face and pump the same direction the seal cavity pressures are as follows One end-suction The other end-full discharge unless some measure is taken
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Measure taken to reduce seal cavity pressure on high pressure end Balance drum (piston) Balance disc Both are similar to balance lines and close clearance bushings
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Balance drum (piston) Balance disc
Both have additional function in that they are part of the mechanism to reduce the load on the pump thrust bearing Both are very complex and extremely precise mechanical devices
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Byron Jackson Sumpmaster
Multistage Diffuser Vertical
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Byron Jackson VLT (Very Large Turbine) Process Pump with Case
Multistage Diffuser Vertical
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Vertical Turbine Pumps
Note that the sumpmaster is shown without a mechanical seal. This is typical for low pressures but many of these pump styles do have mechanical seals Since all the impellers are pumping in the same direction and the seal sits in the discharge head of the pump, the seal cavity is at discharge pressure unless measures are taken
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Measures taken depend on the pump seal cavity construction
Internal seal head-the seal actually sits in the pump discharge flow-it can only be at pump discharge pressure External seal or packing head-a close clearance bushing and balance line arrangement are used to reduce the pressure to suction plus 70% of one stage. Again you must measure to be sure
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Measures taken depend on the pump seal cavity construction Internal packing head-the seal chamber is a separate piece but sits in the discharge flowusually some provision is made to reduce the pressure in the packing or seal area
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Internal Seal Head
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External Seal Head
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Fundamentals of Centrifugal Pumps-Seal Cavity Pressure Pumps-Seal Internal Packing Head
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There are three typical styles of pump construction
Overhung: an example follows Double-ended: several examples have been given similar to the previous slides and the slide following the overhung pump Vertical: many variations exist
Turbine style-an example is the previous slide Process with and without a bearing bracket-examples will follow
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Typical end Suction (Overhung) Process Pump
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Many pumps use a double suction impeller design which is a single impeller with two inlets
High flow Low NPSHA
Since a double suction impeller must be radial flow, they are all in volute type cases almost without exception
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Double Suction Pumps In a single stage double suction pump the seal or seals sit in the impeller eye The only pressure they can see is suction There are limited choices to dealing with inadequate vapor suppression margin for these pumps
Close clearance throat bushing with plan 11 or 32 flush Cooling
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Double Suction Radially Split
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Double Suction Axially Split
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Double Suction Overhung
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Vertical Process Pumps
In addition to those previously shown, there are a class of pumps that are process pumps mounted in a vertical configuration. They are almost always volute single stage pumps. There are two styles Rigid coupling-no bearing bracket Flexible coupling with bearing bracket
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Vertical Inline Process Pump with Rigid couplingNo bearing bracket
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Vertical Inline Process Pump with flexible coupling and bearing bracket
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Since these pumps are process style pumps, the seal cavity pressure can be at anything between and including suction and discharge The normal rules apply. It is necessary to know the impeller and case construction to estimate the seal cavity pressure
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Fundamentals of Centrifugal Pumps-Problem Constructions Pumps-Problem

Some pump designs have inherent mechanical problems because of their design and resultant impeller and shaft loads Vertical inline rigid coupling no bearing bracket Overhung double suction or two stage Single volute
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Some pump designs have inherent mechanical problems because of their design and resultant impeller and shaft loads Shaft deflection and vibration are common to these designs Something must be done to address the mechanical situation
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Cure or eliminate problem pump constructions
L3/D4 < or = 40 Vertical inline with rigid coupling Two stage or double suction overhung Internal sealed (glandless) pump designs
Something we havent discussed No seal chamber or stuffingbox-similar to internal seal arrangementfor vertical turbine pumps
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L /D < or = 40
L = distance in inches from center of radial bearing to center of impeller D = diameter of shaft in inches under the seal sleeve
3 4
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L /D < or = 40 Solutions
Replace bearing bracket and stuffingbox with 7th edition upgrade Modify existing pump with heavier shaft and more robust bearings Close clearance non galling wear rings and throat bushing
3 4
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Vertical inline with rigid coupling
Fine for low horsepower (<25 H.P.) and low speed (1750 rpm max.) Above these parameters a 7th edition upgrade with bearing bracket and flexible coupling should be considered Pumps with field renewable throat bushing such as Union VLK and Goulds 3900 give better performance
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Vertical inline with rigid coupling (continued)
Close clearance non galling wear rings and throat bushing Add external bearing assembly on top of seal flange May require more first obstruction-add motor spacer ring and lengthen pump shaft May be oil mist or grease lubricated
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Two stage or double suction overhung, old API pumps with large calculated shaft deflection, single volute pumps
Same problem as L3/D4 < or = 40 Replace bearing bracket and stuffingbox with 7th edition upgrade Modify existing pump with heavier shaft and more robust bearings Close clearance non galling wear rings and throat bushing
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