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Proceedings Vol. 6 pp. 146-152

7th Annual Conference for Postgraduate Studies and Scientific Research
Basic Sciences and Engineering Studies - University of Khartoum
Theme: Scientific Research and Innovation for Sustainable Development in Africa
20-23 February 2016, Friendship Hall, Khartoum, Sudan

Suction Recirculation Cavitation in Condensate Pumps

Mudathir M. I. Shamaoon

Senior Turbine Engineer, Garri 4 Power Plant, Sudanese Thermal Power Generation Company, Sudan

Abstract:This paper presents the engineering design and theoretical fluid analysis of the condensate extraction
pumps vibration problem in Garri 4 Power Plant in Khartoum North. Fluid analysis and problem tracing performed
based on actual monitoring and centrifugal pumps governing laws. Abnormal noise and visual inspection of pumps
internal parts indicated that cavitation is the main problem of pumps. The results showed that the normal
evaporation cavitation did not take place, so far. The net positive suction head available is higher than net positive
suction head required. Suction recirculation cavitation is the main problem of pumps, which is clearly observed in
visual examination and confirmed by calculation.

Keywords:pum; cavitation; recirculation; suction specific speed; suction energy

INTRODUCTION pumps occur, transfer to piping system causing valves and

Steam turbine power plants use a lot of pumps in their
cycle.However, all pumps inside steam and water cycle and
especially condensate pumps have a wide range of operation
due to startup / shut down procedure as well as full/partial
load conditions. Condensate pumps should be capable to
work on a wide range of operation safely, without cavitation
and suction recirculation cavitation.
Bruno [1] states that “the reliability and range ability target is
a new task for the pumps designer/researcher and is made
more challenging by cavitation and or suction recirculation
effects, primarily, the pump damage”. Bruno Schiavello,
Donald R. Smith and Stephen M. Price [2] in their study of
three large vertical pumps that operate satisfactory on the test
stand experienced excessive vibration after installation.
Additionally, pulsation in the system piping was found to be
causing unexpected vibration in downstream equipment.
They discovered that the problems were the result of complex
interaction between several phenomena. Improper inlet
condition caused suction recirculation that generated
broadband turbulence. The turbulent energy excited acoustic
resonance of the pump/piping system, resulting in pulsation at
several discrete frequencies.
The vibration problem of the condensate extraction pumps of
Garri4 Power Plant had been noticed since the first stages of
commissioning. Vibration was escalating with time, water
leakage from pump mechanical seal was observed as well as
high noise at the beginning, damage for all internal parts of
measuring devices damage.
This study covers all possible factors that could cause such a
vibration problem. High noise with a unique pattern guided
the author to accuse cavitation. Visual inspection
oftheinternal parts of pumps gave the author a clear picture
because pitting in inducer and first stage impeller obviously
from cavitation. All kinds of cavitation for centrifugal pumps
were considered and some calculation was done to define the
problem precisely.
MATERIAL AND METHODS
From the commissioning phase of the Garri 4 Power Plant,
the condensate pumps vibration problem was noticed clearly.
The level of vibration increased gradually with time. The
chronological sequence of action wasconsidered to find the
root cause of the problem.A road map was considered to
prevent repeating of the problem and insure high reliability of
the units.
CONFIGURATION AND DESIGN REVIEW
The plant comprises six condensate extraction pumps; three
pumps (3×50%) for each unit as shown in Fig. 1. Each pump
has a capacity 105𝑚3 /ℎ, 140 m head and 1.3 m Net Positive
Suction Head (NPSH). All pumps passed factory test
successfullyexclude from that there is a sudden rise in
NPSHR just after B.E.P.The pumps were arranged in parallel

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20-23 February 2016, Friendship Hall, Khartoum, Sudan

so that two pumps are in service while the third is on standbymode.

Three condensate
pumps in parallel

Fig1. Condensate System inGarri 4 Power Plant

OPERATION PERFORMANCE CAUSE AND EFFECT ANALYSIS

The system flow rate at maximum load is 156.678 𝑚3 /ℎ ,
while during partial load is around 115𝑚3 /ℎ, Fig. 2. New
condensate pumps fulfill system requirements, but after
running for almost 8 months a reduction in pumps capacity
happened, each unit required three pumps in service in case
of full load, as well as head retardation to reach around 125m
instead of 140m.
The operation reflected retardation for all pumps with
adistinctive noise in thesuction stage. It was seen as a
symptom of cavitation. Considering all possible types of
cavitation:
CAUSE AND EFFECT ANALYSIS
The operation reflected retardation for all pumps with
adistinctive noise in thesuction stage. It was seen as a
symptom of cavitation. Considering all possible types of
cavitation:

Fig 2. Heat and Mass Balance at 55 MW

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20-23 February 2016, Friendship Hall, Khartoum, Sudan
VAPORIZATION CAVITATION
A common type of cavitation, bubbles will form when the
fluid temperature gets too high or the fluid pressure becomes
too low. Pump cavitation occurs at the suction side of the
pump. Although the cavitation was occurred on the suction
side of pumps, the vaporization cavitation is no longer
existed; that because fluid temperature is not too high,
maximum temperature of condensate 45 C. Fluid pressure
will not get to that too low (NPSHA is 2.3 m which is higher
enough than NPSHR 1.3 m). NPSHA was calculated
considering the minimum level of condenser, lowest level,
after this level pumps will trip.
VANE PASSING SYNDROME
The bubbles collapse just beyond the cutwater and there is
where you should look for volute damage. The damage is
limited to the centre of the tip of the impeller vane and does
not extend into the shrouds. One needs a flashlight and a
mirror to see the damage unless it has penetrated to the
outside of the volute. Visual examination of damage shape
eliminates this type of cavitation.
AIR INGESTION
The effect of air sucked into the pump even it is not a
cavitation, but it will cause harmful damage to pumps. “A
centrifugal pump can handle 0.5% air by volume. At 6.0%
air, the results can be disastrous”[3].All air ingestion ways to
the pumps or their associated pipes were examined precisely
that include, reviewing of pump priming (pump full of water
Fig 3.Suction recirculation
Budris [5] states that “ suction specific speed alone has not,
however ,been able to explain why pumps with suction
specific speed values as low as 6900 have experienced
recirculation damage, while pumps with suction specific
speeds as high as 18000 and higher can operate over their
entire flow range without any detrimental effects. The
suction specific speed is one factor in determining whether
or not a pump will experience suction recirculation damage,
but there are other four (equally important) factors, which
when properly combined with the pump suction specific
speed, have proven to be able to predict suction recirculation
specific speed is not the only factor; In 1998 the Hydraulic
Institute presented the guideline ANSI/HI 9.6.1
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at starting and no air existing inside pump or piping), valves
and flanges on the suction side of pump and through the
pump stuffing box and this problem could occurs in any
packed pump that lifts liquid or pumps from a condenser,
evaporator or any piece of equipment that runs in vacuum.
The air ingestion is so far not existed.
INTERNAL RECIRCULATION CAVITATION
Warren H. Fraser[4] states that “recirculation in centrifugal
pumps is a flow reversal at the inlet or at the discharge tips of
the impeller vane”, Fig.3 and Fig. 4. Through analysis and
tests it is now possible to determine the flow patterns that
must exist to produce the observed results. All impellers
exhibit a point of suction recirculation and a point of
discharge recirculation at some specific capacity, and
depending on the size and speed of the pump, the effects of
recirculation can be very damaging. The minimum flow rate
at which suction recirculation occurs is directly related to the
design suction-specific speed S of the pump. The higher the
suction-specific speed, the closer will be the beginning of
recirculation to the flow rate at best efficiency [3], the suction
specific speed is given by
𝑵 𝑸
𝑺= 𝟑
𝑵𝑷𝑺𝑯 𝟒
Where:-
3
For metric: N: RPM, Q:m h, NPSH: m
For US Units: N: RPM, Q: USGPM, NPSH: FEET
Fig 4. Discharge recirculation
damage with the higher degree of accuracy.” This good
combination between all factors generate suction
recirculation factor SRF which given by
𝑆𝑅𝐹 = 𝑆 × 𝑈𝐼 × 𝑆. 𝐺
Where
UI: Peripheral velocity in impeller eye at vane leading edge
maximum radius (ft./sec.)
S.G.: Specific gravity of liquid pumped.
Moreover, recent studies regarding suction recirculation
damage is totally on the same line with Budris that suction
usingthesuction energy S.E. term which is the most
commonly used
 7th Annual Conference for Postgraduate Studies and Scientific Research - Basic Sciences and Engineering Studies
20-23 February 2016, Friendship Hall, Khartoum, Sudan

𝑆𝑢𝑐𝑡𝑖𝑜𝑛𝐸𝑛𝑒𝑟𝑔𝑦 𝑆. 𝐸. = 𝐷𝑒 × 𝑁 × 𝑆 × 𝑆. 𝐺. required; specialist in vibration analysis was invited to

thesite. Expert take all required measurement did analysis
𝐷𝑒 : Impeller eye diameter (inches) for all running pumps the results for all pumps were same as
shown in Fig. 5. We know that all pumps on factory test
N : Pump speed running without vibration as well as that vibration values
increase with time so that this unbalance phenomena occurs
S : Suction specific speed recently due to cavitation. The normal cavitation appears in
frequency domain spectrum as in Fig. 6. While cavitation
S.G. : Specific gravity of liquid pumped
due to recirculation appears with sharp peaks at vane pass
VIBRATION ANALYSIS frequency as shown in Fig. 7. If we do zooming on fig.6 we
can get Fig. 8, from this Figure we could notice the sharp
Vibration values were increased gradually with time until peaks at vane frequency. So suction recirculation cavitation
reach unacceptable values. An expert judgment was is affecting condensate pumps.

Fig 5. Vibration frequency domain spectrum for condensate pump number 1

Fig 6. Normal cavitation signatures on frequency domain spectrum

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20-23 February 2016, Friendship Hall, Khartoum, Sudan

Fig 7. Suction recirculation cavitation signatures on frequency domain spectrum.

Fig 8.Zooming of figure 5

(positive/negative) pressure sides see Fig. 9. Pitting on the

VISUAL INSPECTION
Since the first running of condensate pumps there was
hunting in pressure gauges at suction and discharge pipes of
pumps. This hunting could be noticed clearly during start-up
of unit, also during partial load operation, when the discharge
pressure is higher than 140 m. After dismantling pumps a lot
of pitting was found in pump inducer at both sides
direction of flow is reasonable, but that appears on the
negative pressure side indicate that sudden capacity changes
or reverse flow happened. At the beginning the first stage
impeller seems have no pitting at all , after accuse suction
recirculation cavitation a mirror test for the inside part of
impeller a pitting appears clearly. Fig. 10 [4] shows the way
for doing mirror test.

Negative side

Positive side

Fig 9.Cavitation pitting at inducer.

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20-23 February 2016, Friendship Hall, Khartoum, Sudan

Fig10.Mirror inspection for vane.

RESULTS AND DISSCUSSION
Hallam [6] states that“centrifugal pumps with a suction
specific speed (S) greater than 11,000 failed at a frequency
nearly twice that of centrifugal pumps with suction specific
speed less than 11,000.”Fraser, Lobanoff, Ross and even the
14th edition of the “Hydraulic Institute Standards” link the
suction recirculation cavitation directly with suction specific
speed (S).
(S=21009). It’s clearly high suction specific speed, but as
mentioned earlier a lot of researchers consider the other
factors. According to Burdis, the suction recirculation factor
SRF can be calculated for condensate pump as that the
maximum tip diameter is 195 mm (0.63976 foot). To give
SRF = 1,937860, this value can be inserted on Burdis' Table
1, on the raw of end suction pump with inducer we can
confirm that suction recirculation cavitation happened for
those pumps.

After applying the suction specific speed formula to the

condensate extraction pumps we get a suction specific speed
Table 1: Suction Recirculation Factor Values

SRF: Lower Limit Problem SRF: Upper Limit No Problem

Pumps Pumps
No Vane Overlap End Suction 330,000 590,000
Radial Suction 550,000 710,000
End Suction Impeller 830,000 950,000
Axial flow Inducer 1,400,000 2,500,000
From ANSI/HI formula we get the S.E. = (Actual Suction Energy /High Suction Energy
356,783,242 for condensate pumps have De = 6.1 Gating Value = 1.0 to 1.5), the suction recirculation
inch. So by dividing this value to corresponded cavitation occurs and will cause damage for pumps
value on (table 2), we get 1.115. We know that for made of low cavitation resistance material such as
cast iron.
Table 2: Suction Energy Gating Values

Start of “High Suction Energy” Start of “Very High Suction

Pump Type Energy”
2 Vane Sewage Pumps 100 × 106 150 × 106
Double Suction Pumps 120 × 106 180 × 106
End Suction Pumps 160 × 106 240 × 106
Vertical Turbine Pumps 200 × 106 300 × 106
Inducers 320 × 106 320 × 106

The allowable or safely range of operation became main , the term Net Positive Suction Head Inception so far solve
problem because of two cavitation boundary points, one this problem, the Cavitation Prediction control considered by
below best efficiency point B.E.P. and the other above B.E.P. Frank [7]gave a clear picture on this issue. Fig. 11. Gives an

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20-23 February 2016, Friendship Hall, Khartoum, Sudan

approximation of what happening in condensate pumps , as
mentioned above those pumps running on the capacity below
the B.E.P. , between 50𝑚3 /ℎ and 90𝑚3 /ℎ,. The flow when
fall below 65𝑚3 /ℎ, the NPSHA will be less that NPSHI so
suction recirculation cavitations’ occurred at this point. The
safe operation range of pumps between 65 𝑚3 /ℎ , and
105𝑚3 /ℎ, because after 105𝑚3 /ℎ, evaporation cavitations’
will occur, due to NPSHR dramatically rose up after this
point.

30
25
HEAD
20
15 B.E.P

10
NPSHI

5 NPSHR
NPSHA
0
-5 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Fig 11. Approximated performance curve for pump

CONCLUSIONS Recirculation Problems", http://turbolab.tamu.edu/,

The most possible causes of cavitation in condensate pumps [6].
at Garri4 Power Plant have been discussed, using root cause
failure analysis methodology [8]. Although the air ingestion
is most probably cause in case of condensate pumps in [7].
general, but the suction recirculation cavitation had been
pointed as the main reason for such cavitation, vibration
and noise.
[8].
Condensate pumps in steam power plant have high range [9].
ability, working in crucial environment represented by low
net positive suction head available as well as working fluid
close to evaporate,appropriate selection of pumps is highly
recommended.Large pumps with low speed are preferable,
and during factory tests the minimum stable flow should be
checked precisely.
accessed: 29-11-2015
Hallam, J.L., “Centrifugal Pumps: which Suction
Specific Speed Are Acceptable?,” Hydrocarbon
Processing (April 1982).
Frank C. Visser. Cavitation in Centrifugal Pumps and
Prediction Thereof, ASME Fluid Engineering Division
Summer Conference , June 19-23, 2005, Huston,
Texas, USA
Mobley R. Keith, Root Cause Failure Analysis, 1999
Mobley R. Keith, Vibration Fundamentals,1999

ACKNOWLEDGEMENT

The Author would like to acknowledge Dr. Mohamed H.

Siddeg, Fluid Mechanics Department, and University of
Khartoum for his encouragement and advice.

REFERNCESE

[1]. Bruno Schiavello, “CavitatiAonAnd Recirculation

Troubleshooting Methodology” Ingersoll-Dresser
Pump Co, accessed: 29-11-2015.
[2]. Bruno Schiavello, Donald R. Smith and Stephen M.
Price, “Abnormal Vertical Pump Suction Recirculation
Problems Due To Pump System Interaction”,
turbolab.tamu.edu, accessed: 29-11-2015.
[3]. Igor J. Karassik, Joseph P. Messina, Paul Cooper,
Charles C.Heald,Pump Handbook, McGraw-Hill, 2nd
Ed.
[4]. Warren H. Fraser, “Flow Recirculation In Centrifugal
Pumps”, http://turbolab.tamu.edu/, accessed: 29-11-
2015
[5]. Allan R. Burdis “ The Shortcoming Of Using Pump
Suction Specific Speed Alone To Avoid Suction
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