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Systems
1
PUMP
Cavitation Rotary
Gear
NPSH, NPSHa, NPSHr
Vane
Screw
Lobe
2
Introduction
Specific gravity
6
Total Static Head
8
➘ Power :
- The horse power produced by the liquid is called as
Water Horse Power (WHP) or Liquid Horse Power
which is expressed as
WHP = (γ Q H) / 75
where Q = m3/sec , H = mlc & γ = kg/m3
- The power required to drive the pump is called as
Brake Horse Power (BHP) which is expressed as
BHP = (γ Q H) / 75 η
where η is the efficiency of Pump.
➘ Efficiency :
- It is the measure of the Pump performance.
- It is the ratio of WHP to BHP.
9
Calculation of Pump Performance
H E A D ( m lc )
1600
1400
1200
4 7 .5 H z
1000
P O W E R (k W )
2000
1500
1000
500
90
80
70
E F F IC IE N C Y (% )
60
50 20
N P S H R ( m lc )
40 15
30 Η 10
3% ∆
20 5
10 0
0 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450
S U C T IO N F L O W (c u b . m . / h r.) 11
Pump operating point
Pump performance
• Duty point: rate of flow at curve
certain head Pump
operating
• Pump operating point: Head System point
intersection of pump curve curve
and system curve
Static
head
Flow
12
Pumping System
13
Pump suction performance (NPSH)
• Cavitation or vaporization: bubbles inside pump
• If vapor bubbles collapse
• Erosion of vane surfaces
• Increased noise and vibration
• Choking of impeller passages
• Net Positive Suction Head
• NPSH Available: how much pump suction
exceeds liquid vapor pressure
• NPSH Required: pump suction needed to avoid
cavitation
NPSHA > NPSHR
pa p
NPSH A = − Z i − h fi − v
ρ .g ρ .g Temp Vapor
°F press.
P.S.I.A
212 14.7
210 14.1
Pa - atmospheric or reservoir pressure208 13.7
p p
NPSH A = a − Z i − h fi − v Zi - height from water level to pump inlet
206 13.0
ρ .g ρ .g
Pv - vapor pressure of the fluid 204 12.5
202 12.0
hfi - friction losses on the suction side
200 11.5
190 9.3
160 4.7
120 1.7
80 0.5
40 0.1
15
NPSHA
vent Atmospheric pressure (PA) = 14.7 psia
Water at 90°F SP.GR. =
.99 PV = 0.69 psia
16
NPSHA
Gate Value
Atmospheric pressure (PA) = 14.7 psia Strainer
2.31(PA −P V )
NPSH A = + (H E − H F )
Water at 90°F Sp. Gr. Foot value Sp.Gr.
= 0.99 PV = 0.69 psia 2.31(14.7 − 0.69)
= + (-15 − 2.5)
0.99
= 32.7 - 17.5
= 15.2 ft NPSH A
For Example 550 G.P.M. the pump head as selected from the
system head curve will be 98 ft. T.D.H.
18
CAVITATION
• Very destructive phenomena that occurs when the pressure of the fluid
drops below vaporization point. The result is the formation of tiny
bubles that colapses when pressure increase on the impeller. Those
implosions work as small “explosions” on the impeller that will destroy
it.
19
20
Types of Pumps
Pumps
21
Positive Displacement Pump
• Reciprocating pump
– Displacement by reciprocation of piston plunger
– Used only for viscous fluids and oil wells
• Rotary pump
– Displacement by rotary action of gear, cam or vanes
– Several sub-types
– Used for special services in industry
22
Reciprocating Pump
23
Gear Pump
24
External Gear Pump
25
Internal Gear Pump
1. Liquid enters the suction port
between the rotor and idler teeth.
2. Liquid travels between the teeth of
the "gear-within-a-gear" principle.
The crescent shape divides the
liquid and acts as a seal between
the suction and discharge ports.
3. forcing the liquid out of the
discharge port.
4. Rotor and idler teeth mesh
completely to form a seal
equidistant from the discharge and
suction ports. This seal forces the
liquid out of the discharge port.
26
Lobe Pump
1. Liquid flows into the cavity
and is trapped by the lobes as they
rotate.
2. Liquid travels around the
interior of the casing in the
pockets between the lobes and the
casing
3. Finally, the lobes forces liquid
through the outlet port under pressure.
27
Screw Pump
28
VANE PUMP
1. As the impeller rotates and fluid
enters the pump, centrifugal force,
hydraulic
pressure, and/or pushrods push the
vanes to the walls of the housing.
2. The housing and cam force fluid into
the pumping chamber through holes in
the cam. Fluid enters the pockets
created by the vanes, rotor, cam, and
sideplate.
3. The vanes sweep the fluid to the
opposite side of the crescent where it is
squeezed through discharge holes of
the cam as the vane approaches the
point of the crescent. Fluid then exits
the discharge port
29
Centrifugal Pump
• Centrifugal pumps are the most widely
used pump
• Centrifugal pumps depend on centrifugal
forces
• The advantages of the centrifugal pump
are its simple construction and operation,
space requirements and rotary action.
30
Centrifugal Pump
31
Centrifugal Pump
32
Centrifugal Pump
Impeller
• Main rotating part that provides
centrifugal acceleration to the fluid
• Number of impellers = number of pump
stages
• Impeller classification: direction of flow,
suction type and shape/mechanical
construction
Shaft
• Transfers torque from motor to impeller during pump
start up and operation
33
Centrifugal Pump
Casings
• Functions
• Enclose impeller as “pressure vessel”
• Support and bearing for shaft and impeller
• Volute case
• Impellers inside casings
• Balances hydraulic pressure on pump shaft
• Circular casing
• Vanes surrounds impeller
• Used for multi-stage pumps 34
• AFFINITY LAWS :
Q α N Q α D
H α N2 and H α D2
P α N3 P α D3
35
Major pumps in a power
station :-
36
Function of Pumps
in a thermal power station
BFPs are used to feed water from deaerator feed storage tank to
the boiler
37
BOILER FEED PUMP
38
BFP BARREL & CARTRIDGE
Barrel
Cartridge
39
BOILER FEED PUMP
40
Boiler Feed BOOSTER PUMP
41
BOOSTER PUMP
42
CONDENSATE EXTRACTION PUMP
43
CIRCULATING WATER PUMP
44
CIRCULATING WATER PUMPS
46
SUMP MODEL STUDIES
47
48
Multiple CW Pumps installations
49
Multiple CW Pumps installations
50
Sump Dimensions versus Flow
51
Multiple CW Pumps installations
52
Multiple CW Pumps installations
53
Multiple CW Pumps installations
54
CLASSIFICATION OF AUXILIARIES
55
CLASSIFICATION OF AUXILIARIES (contd..)
56
AUXILIARY POWER
57
AUXILIARY POWER (contd..)
58
Optimisation Areas in Pumps
Mechanical design
Materials of construction
Performance testing
59
OPTIMISATION OF AUXILIARY POWER
• Layout options
60
Optimisation of sizing & design margins
A. Flow calculations
Description Unit Max. flow Normal Under frq Turbine
Flow Bypass
1 Temperature of the condensate C
0
40.00 45.00 40.00 40.00
2 Density of water kg/m3 992.16 990.20 992.16 992.16
3 Condensate flow (HRSG with 0% BD) TPH 163.89 155.24 163.89 208.89
4 HRSG blow down (3% Con , 2% Int) TPH 8.19 7.76 8.19 10.44
5% 5% 5% 5%
5 Total flow ( 3+4) TPH 172.08 163.00 172.08 219.33
6 Flow with margin due to low TPH NA NA 181.14 NA
frequency
7 Flow with 10% margin . Only 4% in TPH 189.29 NA NA 228.11
turbine bypass
8 Required flow from each pump TPH 189.29 163.00 181.14 228.11
9 Required flow from each pump m3/hr 190.79 164.61 182.57 229.91
Say m3/hr 191 165 183 230
63
CEP SIZING CRITERIA (Typical)
B. Head calculations
D. Final parameters
Capacity of each pump m3/hr 191 165 183 230
Pump differential head required mwc 150 125 145 170
Head developed as per curve mwc 188 198 190 170
65
CEP/ BFP Sizing during turbine bypass condition
BOILER
GEN.
66
BFP SIZING CRITERIA (Typical)
A. Flow calculations
Description Unit Max. flow Normal Under Transient
Flow frequency Condition
1 Temperature of the feed water C
0
105 105 105 105
2 Density of water kg/m3 954.74 954.74 954.74 954.74
3 HRSG capacity ( with super heater TPH 43.60 41.20 43.60 43.60
spray built in)
4 HRSG blow down (3% Con , 2% TPH 2.18 0.82 2.18 2.18
Intermittent)
5 Total feed water flow TPH 45.78 42.02 45.78 45.78
requirement(3+4)
67
10 SELECTED CAPACITY IN CMH m3/hr 53.00 44.00 50.00 58.00
BFP SIZING CRITERIA (Typical)
B. Discharge Head calculations
2 Pr. due to Height of the De-aerator LWLL Kg/cm2 (a) 1.38 1.38 1.38 1.38
from BFP suction nozzle
3 Total of above (1+2) Kg/cm2 2.61 2.61 2.61 2.61
4 Pr.drop in suction strainer-50% clogged Kg/cm2 0.2 0.2 0.2 0.2
(normal pr. drop approx. 0.1 Kg/cm2)
5 Pr. drop in suction piping, inclusive of Kg/cm2 0.20 0.14 0.18 0.24
fittings, valves, etc
6 Pr. loss on suction side of BFP (4+5) Kg/cm2 0.40 0.34 0.38 0.44
7 Available pr. on pump section side (3 – Kg/cm2 2.21 2.27 2.23 2.17
6)
8 Available NPSH (7 – 1) Kg/cm2 0.98 1.04 1.00 0.94
mwc 10.26 10.92 10.50 9085
9 Considering margin between NPSHA & Kg/cm2 5.13 8.42 8.00 7.35
NPSHR as minm. 2.5 m, the NPSHR of
the pumps shall be limited to max. ( 50
% for rated flow) 69
BFP SIZING CRITERIA (Typical)
E. Final parameters
Capacity of each pump m3/hr 53.00 44.00 50.00 58.00
Pump differential head required mwc 150 125 145 170
70
CWP SIZING CRITERIA (Typical)
A. Flow calculations
Description Unit Max. flow Normal Under Transient
Flow frequency condition
1 Temperature of the feed water C
0
32 32 32 32
2 Density of water kg/m3 1000 1000 1000 1000
3 Maximum water demand CMH 8750 8750 8750 8750
4 Capacity shared by each pump (50%) CMH 4375 4375 4375 4375
5 Margin in flow due to low frequency CMH NA NA 230.26 NA
on feed water flow
9 Thus, capacity of each pump with CMH 4812.50 4375 4606 5250
margin
10 Selected capacity of each pump CMH 4815 4375 4606 5250
71
CWP SIZING CRITERIA (Typical)
B. Discharge Head calculations
Description Unit Max. flow Normal Under Transient
Flow frequency Condition
1 Cooling tower spray nozzle elevation MWC 7.00 7.00 7.00 7.00
from ground level including pr. drop in
spray nozzle
2 Pump impeller / bell mouth level below MWC 4.50 4.50 4.50 4.50
pump-base plate level
3 Atmospheric head MWC 10.30 10.30 10.30 10.30
4 Total static head (1+2+3) MWC 21.80 21.80 21.80 21.80
5 Pr. Drop in discharge piping including MWC 1.60 1.60 1.60 1.60
fittings, valves, etc.
6 Pump Internal losses MWC 1.10 1.10 1.10 1.10
7 Pr. Drop in discharge piping including MWC 3.0 3.0 3.0 3.0
fittings, valves, etc.
8 Pr. Drop in flow element MWC 1.60 1.60 1.60 1.60
9 Pressure drop in Condenser MWC 6.00 4.95 5.49 7.13
10 Pressure drop in rubber expansion joint MWC 0.5 0.5 0.5 0.5
11 Pressure drop in nozzle MWC 0.8 0.8 0.8 0.8
12 Pressure drop in return line MWC 0.5 0.5 0.5 0.5
13 Total variable pressure MWC 13.50 10.65 11.19 12.83
drop(5+6+7+8+9+10+11+12)
14 Margin on variable pr. drop MWC 5.00 NA NA NA
(21% subject to min. 5 mwc) 72
15 Bowl discharge head of Pump (4 MWC 40.30 32.45 32.99 34.63
CWP SIZING CRITERIA (Typical)
1 Pump bell mouth / impeller level below MWC 2.30 2.30 2.30 2.30
sump min. water level
2 Atmospheric head MWC 10.30 10.30 10.30 10.30
6 Vapour pressure head of water at 32ºC MWC 0.61 0.61 0.61 0.61
7 Available NPSH (5-6) MWC 10.99 10.99 10.99 10.99
73
CWP SIZING CRITERIA (Typical)
4 Selected Differential Bowl Head of pump mwc 29.00 21.00 24.00 24.00
E. Final parameters
Capacity of each pump m3/hr 4815 4375 4606 5250
Pump differential head required mwc 29.00 21.00 24.00 24.00
74
PROPER SELECTION OF EQUIPMENT
77
Optimisation of Mechanical Design
Bronze
Cast iron
Cast steel
400 series Stainless steel
300 series Stainless steel etc.
Selection criteria for materials :
•corrosion resistance
•abrasive wear resistance
•cavitation resistance
•casting & machining properties
•endurance limit
•notch sensitivity
•galling characteristics
•cost 79
Optimisation of Quality / Inspection checks
80
PERFORMANCE TESTING
- Vibrations
- Temperatures
- Leakages
83
Thank You
84