Professional Documents
Culture Documents
Thermofluids TF306
2005
Pump Application, Operation and Specification
Melinda Hodkiewicz
mhodki@mech.uwa.edu.au
Extension: 7911, Room G55
Melinda Hodkiewicz
Version 2 2005
1.2. References
Books
Melinda Hodkiewicz
Version 2 2005
http://www.fpdlit.com/cms/results detail.asp?ModelID=102
http://www.giwindustries.com/lsa.html
http://www.fpdlit.com/cms/results_detail.asp?ModelID=23
Melinda Hodkiewicz
Version 2 2005
Volute/Housing
Impeller
Shaft and sleeve
Mechanical seal or packing
3
3
4
Melinda Hodkiewicz
Version 2 2005
(Ve2 Vi 2 )
W& S ( p e pi )
HP =
=
+ ( ze zi ) +
+ hL
2g
m& g g
The head on the pump is determined by the rate of work W& S in J/s of the shaft/impeller divided by the mass flow
Melinda Hodkiewicz
Version 2 2005
1.5.1.
1.5.2.
1.5.3.
d 2g
Calculation of this will be discussed in Section 1.5.5
1.5.4.
Melinda Hodkiewicz
Version 2 2005
HP =
W& S ( p e pi )
(V 2 Vi 2 )
=
+ ( ze zi ) + e
+ hL where hL = hL(D) + hL(S)
m& g g
2g
This is often done by considering the suction and discharge sides separately as
Total Head (Hp)
Hp = h(d) - h(s)
Total Suction Head
h(s)= p(s)/g +z(s)+V2s/2g - hL(s) - h(i)
z(s) = static suction head, hL(s) = total friction loss in suction line, h(i) = entrance loss, p(s) = pressure other than
atmospheric in suction tank in m, h(s) = total suction head
Total Discharge Head
h(d)= p(d)/g + V2d/2g+ z(d) + hL(d) + h(e)
z(d) = static discharge head, hL(d) = friction loss in discharge line, h(e) = exit loss, hP(d) = overpressure in
discharge tank in m, h(d) = total discharge head
Note: the friction loss is SUBTRACTED on the suction side but ADDED on the discharge side
1.5.5.
There are TWO separate friction calculations, one for the pipes and one for the fittings.
1. Darcys Formula for friction loss in pipes
For turbulent flow
hL =
V 2 L
f
2 g D
hL = pressure drop or friction loss in m, f=friction factor, L=length of pipe (m), V=line velocity (m/s), D= pipe
ID (m),
Friction loss depends on fluid velocity, pipe ID and roughness.
Darcys formula is valid for turbulent and laminar flow only if line pressure >> vapour pressure of the liquid ie
NO cavitation
For laminar flow
2
64 L V
hL =
Re D 2 g
Friction Factor f
The friction factor is determined experimentally. For laminar flow f=64/Re.
For turbulent flow f depends on Re also the relative roughness /d. = roughness of pipe wall, d = pipe diameter
Pump Application, Operation and Specification
Page 7 of 25
UWA Mechanical 3rd yr Thermofluids course
Melinda Hodkiewicz
Version 2 2005
V 2
hL = K
2g
See suitable tables for values, some common values are provided on the pump formula sheet.
Summary for Friction Loss calculation
V 2 L
V 2
+ K
hL = f
2 g D
2g
This can also include the entrance and exit losses if they are significant
Note on Hazen Williams
The Darcy-Weisbach method is the technically correct method however many engineers use Hazen Williams
which is convenient and produces reliable results for water with turbulent flow
See reference book for equation and C factors. Widely used for simple flowsheet calculations
Pipe Friction loss Tables
Pipe friction losses = x m/100 m pipe for a specific pipe ID, material and line velocity and temperature. Depends
on material, condition and age
For example the friction loss of 700 l/s water through 4 Sched 40 steel pipe is 0.194 bar per 100 m or 1.98
m/100 m pipe
The methods above are used for new projects where you have drawings with line sizes, tank elevations etc.
However if you have an existing pump installation the pump head can be determined with a pair of pressure
gauges and a flow meter. Place the pressure gauges in ports as close to the suction and discharge of the pump,
simultaneously read the pressure gauges and the flow rate.
The pressure P on a gauge located close to the flange of the suction of the pump will measure
PS = p S + g z S g .hL ( S )
The conversion to head and addition of the suction velocity head will give a value for the total suction head
A pressure gauge placed on the discharge of the pump will read the following terms.
PD = p D + g z D + g .hL ( D )
It can be seen that the Total Head HP on the pump.
HP =
(P PS ) VD2 VS2
W& S ( p e pi )
(V 2 Vi 2 )
=
+ ( ze zi ) + e
+ hL = D
+
m& g g
2g
2g
g
The values VD and VS are the velocity in the pipe at the pump suction and discharge. This is a function of the
flow rate Q and the line diameter D. V = Q/A = 4Q/(D2), V = line velocity m/s, Q = flow rate m3/s, A =
Pump Application, Operation and Specification
Page 8 of 25
UWA Mechanical 3rd yr Thermofluids course
Melinda Hodkiewicz
Version 2 2005
inside pipe area m2, D = inside diameter m. If the line size are the same for suction and discharge, this term can
be ignored.
Draw System Curve
System curve determined by Total Head (m) at different flow rates (below, design and above design)
Flow (m3/hr)
0 (Static head)
60
100
110
1.5.6.
Duty Point is expressed as the calculated Head for the desired Flowrate
For example 120 l/s at 58m head
Determine high and low operating flow points
1.5.7.
Melinda Hodkiewicz
Version 2 2005
W& S = gQH P
Pump Efficiency:
P = Hydraulic Power ( W& S ) / Power input to the pump shaft from the motor ( W& M )
Pump Efficiency depends on energy loss due to
leakage (recirculation around the impeller outlet to inlet, internal to the pump)
hydraulic losses (viscosity and non-uniform flow)
mechanical losses (friction losses in the bearings and seals)
What is the flow rate at maximum efficiency for a 438 mm impeller using the pump curve in ???
Motor Efficiency: M
W& M is the power from the motor to the shaft = Power supplied to the motor x motor efficiency.
Calculation of the motor power requires
1. Measurement of the power delivered to the motor from the MCC (Motor Control Centre). This is
available as a kW reading.
2. Knowledge of the efficiency of the motor. This information is often available on the motor nameplate or
from the manufacturer. The motor efficiency is dependent on the load on the motor and the speed, if it is
a variable speed drive.
1.5.8.
An acceptable margin of NPSHA - NPSHR must be maintained over the entire operating range to prevent
CAVITATION. Cavitation is caused by the local vaporisation of a fluid when the static pressure drops below the
vapour pressure. The small bubbles filled with vapour that form in the low pressure region (suction eye of the
pump) will collapse on moving into high pressure regions (inside the impeller). This "implosion" causes pitting
on the metal surface, vibration and a drop in efficiency.
For NPSH calculation must understand difference between absolute and gauge pressure
Absolute pressure = Gauge pressure + Atmospheric pressure at elevation
Standard barometric pressure is 1.01325 bar or 760 mm Hg and changes with elevation above sea level.
Gauge pressure is pressure above barometric pressure
Convert gauge pressure readings to m by (x 0.102/SG)
Absolute pressure always refers to perfect vacuum as base
NPSH available
Net positive suction head is the absolute suction head at suction nozzle corrected to datum less the vapour
pressure of the liquid at operating temperature. Determines at what point liquid will vaporize at the lowest
pressure point of the pump (cavitation) and is characteristic of the system. NPSHA varies with capacity and
is always positive.
(P + p atm )
p
+ patm
NPSH A = zsuction + suction
hL ( suction ) hVP ( abs ) OR S
hVP (abs )
g
g
Melinda Hodkiewicz
Version 2 2005
hvp(abs) = head in m corresponding to the ABSOLUTE vapour pressure of the liquid at the temperature being
pumped. This is determined from Tables of vapour pressure (usually given in bar)
NPSH required
The NPSHR is characteristic of pump design and represents the minimum margin required between suction head
and vapour pressure. NPSHR varies with capacity. It is determined by manufacturer and verified by NPSH pump
test. NPSHR depends on impeller design, flow rate, rpm, liquid and other factors. As a rule of thumb there
should be a margin of at least 1m, though depends on application between NPSHA and NPSHR)
What is the NPSHR for a flowrate of 120 l/s on the pump curve in Figure ?.
1.5.9.
Melinda Hodkiewicz
Version 2 2005
Allows for performance at one speed to be predicted from known performance at known speed (or impeller
diameter)
Q = Q1 (n/n1) = Q1 (D/D1)
H = H1 (n/n1)2 = H1 (D/D1)2
P = P1 (n/n1)3 = P1 (D/D1)3
n/D = new desired speed rpm/diameter. n1D1=speed rpm/diameter for known characteristics Q1, H1 and P1
1.9.1.
Operational problems
Theoretically as long as NPSHA >> NPSHR then a centrifugal pump can operate over a wide range of capacities
however the exact capacity is determined by intersection of pump head-capacity curve with the system head
curve. Can vary pump curve by changes in speed or system curve by throttling valves however operation is only
optimum at one point called BEP
Melinda Hodkiewicz
Version 2 2005
recirculation through wear rings, suction and discharge recirculation within the impeller, rotating stall,
cavitation, surge and system instabilities. These combine to cause pressure fluctuations, surging and vibration.
p
+ patm
NPSH A = zsuction + suction
hL ( suction ) hVP ( abs ) minus H(ac)
g
H(ac) = LsvsC/Kg, where Ls and vs are the length of and velocity in the suction line.
C=constant dependant on type of pump, 0.4 for simplex single acting, 0.2 for simplex double acting, 0.2 for
duplex single acting. See appropriate reference for full list
K=factor for the relative compressibility of liquid (eg.K=1.4 for hot water, 2.5 for hot oil)
Melinda Hodkiewicz
Version 2 2005
Figure 7
References for figures:
http://www.turfmaker.com/Positive_Displacement_Pump/positi
ve_displacement_pump.html
http://www.learromec.com/Products/PR_Spur.htm
http://www.eng.rpi.edu/dept/chem-eng/BiotechEnviron/PUMPS/reciprocating.html
dmsys
dt
out
Q=v1A1 = v2A2
P = p + gz
Where z = height of the fluid and P = pressure measured at the base of the fluid. For example, a column of cold
water (15 deg C) 10.2m high produces 1 bar pressure at its base.
Pump Application, Operation and Specification
Page 14 of 25
UWA Mechanical 3rd yr Thermofluids course
Melinda Hodkiewicz
Version 2 2005
Laminar Flow occurs at very low velocity or with high viscosity fluids. This is often visualised as
streaks of colored fluid flow in straight lines.
Turbulent Flow flow occurs above critical velocity and involves the irregular, random motion of the
fluid particles
Reynolds Number (Re) determines laminar or turbulent flow and depends on pipe diameter, flow
velocity, density and viscosity of the fluid.
Re = Vd/
Flow is considered if laminar if Re < 2000, turbulent if Re > 4000, critical zone 2000<Re<4000. Reynolds
number is used in the calculation of friction factor for friction loss of fluids flowing in pipes
dPsys
External forces are those applied without mass flow across the control boundary. Surface forces due to pressure
and body forces f ( , g , V ) . For steady state conditions
in
This has applications in piping systems for calculations such as the force exerted on the pipe flange by fluid
moving through an elbow. It can also be used to derive Bernoullis equation from 1st. principles (see any Fluids
text).
Melinda Hodkiewicz
Version 2 2005
V
+ z)
Q& W& = m& (u +
2g
net
This is the steady state general energy equation as presented earlier in Thermodynamics lectures.
W& is the rate of work done by (+) or on (-) the control volume W& = W& shaft + W& normal .stress + W& shear .stress
Shaft work rate is transmitted by the rotating shaft W& shaft = T (shaft torque x rotational speed)
Shear work rate is the product of shear stress, area and fluid velocity component parallel to the control surface.
With pumps the control surfaces lie adjacent to solid boundaries where the fluid velocity is zero. In this case
there is no shear work although there may be shear stress.
Normal stress work can be written in most situations as a function of the pressure acting on the control surface
m&
W& pressure = p
net
p V2
W& S = m& (u + +
+ zg ) + m& ghL
2
net
This is commonly written as in terms of Power required at the shaft to drive a centrifugal pump. For pumps it is
assumed that u e u i = 0
( p pi ) (Ve2 Vi 2 )
W& S = m& g e
+
+ ( z 2 z1 ) + hL
2g
This is the foundation equation for sizing pumps used in unit and we will spend time discussing how to
determine the values in this equation.
If one is dealing with a compressor substitute for the internal energy with u e u i = cv (Te Ti ) and use the ideal
gas law p = RT
For systems with no friction we have the MECHANICAL ENERGY EQUATION
( p pi ) (Ve2 Vi 2 )
W& S = m& g e
+
+ ( z 2 z1 ) where Mechanical Energy is that which can be converted to
2g
g
Melinda Hodkiewicz
Version 2 2005
p1 V12
p
V2
+
+ z1 = 2 + 2 + z 2
g 2 g
g 2 g
The terms in this equation are referred to as, pressure head, velocity head and static head respectively.
Dimensional analysis will show that all three terms are in meters.
p1 V12
p
+
= 2 ; where p2 is pressure at the stagnation point and p1 and V1 are the pressure upsteam.
g 2 g g 2
V12 p 2 p1
=h
=
2 g g
Thus the velocity at a point in the pipe is equal to the square root of the height difference between the tubes
multiplied by 2g. v =
2 gh
Melinda Hodkiewicz
Version 2 2005
piezometer
Fluid flow
Pitot tube
dL0 sys
dt
= M 0, j + m& i ( ri Vi ) m& e ( r e Ve )
j
out
in
This equation can be written in scalar form to illustrate its application to pumps. The fixed coordinate system is
chosen with the z axis aligned with the axis of rotation of the machine. The fluid enters the rotor at a radial
location ri with uniform velocity Vi and exits at re with absolute velocity Ve. Thus the equation above becomes:
H Theo =
1
(U 2V 2 U 1V1 )
g
This figure shows the inlet and exit radii, and the tangential components of the fluid velocity V at the inlet and
exit. It should be noted that the fluid velocity V is not the same as U = r the velocity of the impeller.
It is conventional is pump design to describe flow passing through the impeller in velocity terms relative to the
rotating coordinate system of the rotating impeller. This is best done using velocity triangles.
Melinda Hodkiewicz
Version 2 2005
V 1 = U 1 W1 cos 1
V1
W1
and
V1
U1
Q = 2.r1.b1.Vr1
If Q and the impeller dimensions are known, Vr1 can be calculated and from this W1. If the speed in rps of the
impeller is known then U1 can be calculated and from this V1.
The values of V1 and V2 are used to determine the torque Tshaft or power draw W& on the impeller using Eulers
equation (from Section 1.12.9).
Melinda Hodkiewicz
Version 2 2005
Centrifugal pump
Suction side
Discharge side
On the suction side, the level of the fluid is 10 m above the centreline of the pump and the overpressure in the
closed tank is 100 kPa. There is a gate valve between the suction side tank and the pump. Line length is 5 m.
On the discharge side, the level of the fluid is 30 m above the centreline of the pump and the overpressure in the
closed tank is 200 kPa. There is a butterfly valve on the discharge line and three 90 degree elbows. Line length is
50 m.
All line sizes are diameter 150 mm.
The desired flow rate is 100 l/s, the fluid is water at 15 deg C.
1. What is the head on the pump at the desired flow rate?
2. What is the hydraulic power?
3. Draw a system curve for this installation.
Solution:
Start with the Pump sizing equation (see Section 1.3). Note that D (discharge) and S (Suction) have been
substituted for e (exit) and i (inlet).
W& S ( p D p S )
(VD2 VS2 )
HP =
=
+ (zD zS ) +
+ ( hL ( D ) + h L ( S ) )
m& g
g
2g
Suction side
Static head
zS = 10m
Pressure head pS/g = 100 x 103/(103x 9.8) = 10.2 m
Velocity head at entrance = very small.
Friction head
V 2
V 2 L
+ K
hL = f
2g
2 g D
Melinda Hodkiewicz
Version 2 2005
4Q
= (4 x 0.1)/(3.14 x 0.152) = 5.66 m/s
D 2
V 2
V 2 L
+ K
hL = f
2g
2 g D
4Q
= (4 x 0.1)/(3.14 x 0.152) = 5.66 m/s
2
D
From tables, K value for a butterfly valve is 45f and for each elbow is 30f. Total K value = (45+90)f.
Discharge side Valve/fitting friction loss = 135 x 0.015 x (5.662/2x9.81) = 3.3 m
Discharge side friction head = 8.2 + 3.3 = 10.8 m.
Summary
Static head
Pressure head
Velocity head
Friction head
Total
Suction (m)
10.0
10.2
~
1.0
19.2
Discharge (m)
30.0
20.4
~
11.5
61.9
Melinda Hodkiewicz
Version 2 2005
1.13.2.
A water distribution pump has a 150 kW electric motor with a motor efficiency of 94%. The flow rate through
the pump is 350 l/s. The diameters of inlet and outlet pipes are the same and there is no significant elevation
difference across the pump.
If the inlet and outlet pressures are measured at 100 kPa and 400 kPa (absolute) respectively, determine,
a. The mechanical efficiency of the pump [74.5%]
b. The temperature rise of the water as it flows through the pump due to mechanical inefficiency. [0.024
deg C]
Let specific heat of water be 4.18 kJ/kg. Deg C.
Solution:
Calculate mass flow rate through pump kg/s = x m3/s = 1 kg/l x 350 l/s= 350 kg/s
Power to shaft = motor efficiency x motor power = 0.94 x 150 = 141 kW.
( p e pi ) (Ve2 Vi 2 )
P Pi
+
+ ( z 2 z1 ) = m& e
2g
g
&g
Change in energy of fluid (or Hydraulic Power) = m
Melinda Hodkiewicz
Version 2 2005
1.13.3.
Examine the pump curve for the Southern Cross ISO-PRO 200x150-400 pump, fixed speed 1475 rpm above
a) If the total head on the pump is 60m and you are using a full size impeller, what is the expected flowrate
in l/s and efficiency (%) ?
b) What standard size motor is required for the head-flow combination in (a)?
c) If you wanted to deliver 107 l/s at 50 m of total head, what is the optimum impeller diameter?
d) Calculate the hydraulic power and the motor power draw at 107 l/s and 50 m head for the impeller
diameter selected in c)?
e) If the pump was running as in c) and you slowly closed a discharge butterfly valve to achieve 60 l/s,
what would happen to the total head and the pump efficiency?
f) For c) what would be the calculated power draw on the pump?
Solution:
a) Full size impeller is 438 mm, flowrate at 60 m total head is 107 l/s, efficiency = 82.5%.
b) Motor size 90 kW.
c) 410 mm
d) Hydraulic power = 107 * 3.6 * 50 * 1/368 = 52 kW, efficiency from graph = 0.83, Power draw on motor
= 52/0.83 = 63 kW
e) The head value would increase to 57 m as the system curve would steppen due to greater friction head
component. The intersection of the pump and system curve would move to the left along the line of the
impeller diameter. The efficiency would decrease to 71%. Resulting power draw on motor = 60 * 3.6 *
57 / (368 *0.71) = 47 kW
Melinda Hodkiewicz
Version 2 2005
1.13.4.
Impeller design
Given the following details about the design of a closed centrifugal impeller, determine
a) The flow rate through the impeller
b) Torque on the impeller shaft
c) Hydraulic power
Rotating speed
Inlet radius r1
Discharge radius r2
Inlet width b1
Discharge width b2
Inlet blade angle 1
Discharge blade angle 2
Discharge velocity relative to the
impeller W2
148 rad/s
0.0375 m
0.0875 m
0.025 m
0.015 m
25
30
4 m/s at 30
U2
W1
r1
U = impeller velocity relative to inertial
Reference
V = fluid velocity relative to inertial
Reference
W = fluid velocity relative to impeller
U1
r2
Melinda Hodkiewicz
Version 2 2005
W2
V2
Wr2
V2
2
U2
& reVe rV
Torque calculation W&M = TSHAFT = m
i i
Melinda Hodkiewicz
Version 2 2005