Fluid Flow (Lab) Subject Code: PolyE- 203

Group Presentation Group#6

Mujadid ul Hassan Khawaja 2010-PE-51 Department of Polymer and Process Engineering, UET Lahore

Syed Mohsin Ali Rizvi 2010-PE-57 Department of Polymer and Process Engineering, UET Lahore

Hafiz Adnan Mehmood 2010-PE-28 Department of Polymer and Process Engineering, UET Lahore

1. 2. 3. 4.
5. 6. 7.

Introduction to Pumps Major Classification of pumps and their Working Materials of Construction of Pumps Some important terminologies related to Pumps Selection of Pumps Sizing, Metering and proportionating of pumps Troubleshooting of pumps

Presenter: Mamoon Shahid

Pumps are device used to move fluids. They move fluids by using mechanical action.

The main components of a pumping system are:

Prime movers: electric motors , diesel engines or air

system.
Piping, used to carry the fluid.

Valves, used to control the flow in the system.

Pumps

Dynamic

Positive displacement pump

Energy is added to fluid velocity

At discharge end velocity is reduced and pressure is increased There are two types of dynamic pump 1.Centrifugal pump 2.Special effect pumps

Its purpose is to convert energy of a prime mover first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped.
A centrifugal pump can be single stage or multi stage.


1) 2)

Working mechanism can be expressed in two steps

Generation of centrifugal forces Conversion of kinetic energy to pressure energy

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. Because the impeller blades are curved, the fluid is pushed in a tangential and radial direction by the centrifugal force.

The key idea is that the energy created by the centrifugal force is kinetic energy. 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.

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 Bernoullis principle.

Energy changes

Impeller

Diffuser


1.

The main components of a centrifugal pump are

Rotating components: an impeller coupled to a shaft. Stationary components: casing, casing cover, and bearings.

2.

An impeller is a circular metallic disc with a built-in passage for the flow of fluid. Impellers are generally made of bronze, polycarbonate, cast iron or stainless steel, but other materials are also used.

Shaft
The shaft transfers the torque from the motor to the Impeller during the startup and operation of the pump.

The main function of casing is to enclose the impeller at suction and delivery ends. A second function of casing is to provide a supporting and bearing medium for the shaft and impeller.

A volute is a curved funnel increasing in area to the discharge port .

Circular casing has stationary diffusion vanes surrounding the impeller periphery that convert speed into pressure energy.

Presenter: Hafiz Adnan Mehmood

 Contents
Introduction

Construction & working

Types

A positive displacement pump is one in which a definite volume of liquid is delivered for each cycle of pump operation. This principle applies to all types of positive displacement pumps

Positive Displacement Pumps has an expanding cavity on the suction side and a decreasing cavity on the discharge side.

Liquid flows into the pumps as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses.

A Positive Displacement Pump must not be operated against a closed valve on the discharge side of the pump because it has no shut-off head like Centrifugal Pumps. A Positive Displacement Pump operating against a closed discharge valve, will continue to produce flow until the pressure in the discharge line are increased until the line bursts or the pump is severely damaged - or both.

Positive Displacement Pumps are "constant flow machines.

A relief or safety valve on the discharge side of the Positive Displacement Pump is therefore absolute necessary. The relief valve can be internal or external.

There are two main types of PD pumps

Reciprocating pumps

Rotary pumps

Reciprocating pumps are those which cause the fluid to move using one or more oscillating pistons, plungers or membranes (diaphragms). Plunger pumps

Diaphragm pumps

Plunger pumps comprise of a cylinder with a reciprocating plunger in it. In the head of the cylinder the suction and discharge valves are mounted. In the suction stroke the plunger retracts and the suction valves opens causing suction of fluid into the cylinder. In the forward stroke the plunger push the liquid out the discharge valve.

 Displacement by rotary action of gear, cam or

vanes

Typical rotary pumps are

Gear pumps Lobe pumps Vane pumps Cam pumps Screw pumps

In gear pumps the liquid is trapped by the opening between the gear teeth of two identical gears and the chasing of the pump on the suction side. On the pressure side the fluid is squeezed out when the teeth of the two gears are rotated against each other. the gear pump is well suited for handling viscous fluids such as fuel and lubricating oils.
Rotary pumps are further classified such as internal gear, external gear, lobe and slide vane etc

Pressure
Change in Pressure have little effect on the PD pump efficiency.

Viscosity
When the viscosity of fluid increases the flow also increase in PD pumps. The reason is the liquid fill in the clearances of the pump causing a higher volumetric efficiency .

if there is changing viscosity in the application the PD pump is the best choice.

4. Materials of Constructions of Pumps

The pumps have different parts ; Impeller , casing , shaft and wear rings etc When selecting the material for the impeller, the following several criteria should be considered

Corrosion resistance

Abrasive wear resistance

Cavitations resistance

Casting & machining properties

Weld ability (for repair)& cost

1.
2. 3.

used for many water and noncorrosive services but these impellers should not be used for pumping temperature in excess of 120C Types: Leaded bronze Non leaded bronze Nickel aluminum bronze Leaded bronze Impellers Used extensively in past because the lead addition to bronze enhances its cast ability and machine ability but due to environmental problems they have been replaced by Non-leaded bronze impellers.

Bronze Impellers

Non-Leaded Bronze Impellers

Although they are efficient than leaded bronze impellers but they have velocity limitations above which they cannot be used because they will suffer accelerated erosion corrosion. So they are used where not so high speed is required.

Nickel Aluminum Bronze Impellers

These impellers are used specially in salt water applications because of their high mechanical properties, good corrosion resistance and the capability to be weld repaired. They are also designed for higher speed than any other bronze alloy impellers.

Cast iron Impellers

They are used to a limited extent in small ,low cost pumps. This material is inferior than bronze in corrosion and cavitation resistance also it can not be welded to repair damage. So only the low cost is the mere justification for the cast iron impeller usage.

Martensitic Stainless Steel Impellers

They are used in the place of bronze impellers where bronze does not satisfy the requirements for cavitation resistance, corrosion and erosion. These impellers are used in boiler feed water, many cooling waters and a variety of cooling applications They do not have pitting corrosion for use in sea water.

1. 2.

Martensitic Stainless Steel Impellers

These impellers are used where higher level of corrosion resistance is required. Austenitic grades having 6% molybdenum for use in salt water Austenitic grades having 20% nickel for the sulphuric acid applications 3. Chrome manganese alloy to eliminate cavitation resistance

Duplex Stainless Steel

These impellers are used because of their higher mechanical properties, better corrosion resistance and weld ability. Nitrogen addition in it improves its cast ability and weld ability. These impellers are widely used in mining ,flue gas desulfurization, paper and pulp industry and for the marine applications. Specially they are used in high pressure water injection in the oil industry. It should contain 25% chromium, 3%molybdenum and 0.15% nitrogen.

When selecting the material for the Casing of pump, the following several criteria should be considered

Corrosion resistance

Abrasive wear resistance

Cost and strength

Casting & machining properties

Weld ability (for repair)& cost

Cast iron Casing

For single stage pumps , cast iron casing is used because it has sufficient for pressure developed. (discharge pressure up to 1000lb/sq.inch and temperature up to 177 C). For multi-stage pumps and pressure up to 2000lb/sq.inch a cast steel is used and for the pressure above this forged steel barrel type casing is used. Ductile iron casing can be used instead of cast iron as its tensile strength is double as compared to cast iron. They can used as a substitute for steels in the intermediate temperature range. But they can not be effectively repaired or welded

Austenitic Irons Casing

They are commonly known by their trade name Ni-resist, are used where ductile irons have insufficient corrosion resistance. They typically contain 15-20% Ni and are used in brackish and salt water applications. But they poor towards welding thats why its new modified grade D2W is used which contains columbium that enhances its weld ability.

Bronze Casing
Leaded bronze, Non-leaded bronze, Tin bronze, Ni-Al bronze are alloys used for the casing depending upon the application. Among them Ni-Al type is expensive and are usually not competitive on cost basis with Ni-resist or other alternatives


1. 2. 3. 4.

Steel Casings
Stainless Steel Martensitic stainless Steel Austenitic Stainless Steel Duplex Stainless Steel All these materials have their own usage according to applications. The first one is used for better corrosion resistance, second one is used for high pressure applications and in many hydrocarbons applications, the third one in chemical applications and corrosive services and Duplex is used where corrosion resistance and mechanical properties higher than other austenitic grades are required

When selecting the material for the shaft, the following several criteria should be considered

Corrosion resistance

wear resistance

Cost and strength

Endurance limit

Notch sensitivity

 1. 2. 3.

The several materials for shaft are available according to the specifications. Carbon steel Stainless steel Martensitic stainless steel etc These materials should have low cost and high wear resistance and good endurance limit thats why a shaft can be plated or coated for an improved corrosion resistance and wear. Chrome plating is one of the example.

When selecting the material for the Wear rings, the following several criteria should be considered

Corrosion resistance

Abrasive wear resistance

Casting and machining properties

Galling characteristics

suitability for coating

 1. 2. 3.

The several materials are available for wear rings according to the Applications. Bronze Stainless Steel Martensitic stainless steel Bronze is used for wear rings because it exhibits good corrosion resistance for wide range of water services and tends to wear rapidly when abrasive particles are used. Due to this limitation Stainless steel is used. Martensitic stainless steel wear rings are usually hard and they are more resistant towards wear because of increased surface hardness. Tungsten carbide is used for high hardness and resistant to abrasion

5.Selection of Pumps

The selection of a pump type for a particular application is influenced by a variety of factors. Such as: Fluid Characteristics Required material of construction System Flow and Head Requirements Intended Equipment life Energy Cost Availabilty of certain uitlities

There are several different types of basic pump designs Every pump design can be used for a range of flow and head combination Flow and head range charts for pumps can help in this respect There are other factors upon which can help us in selecting a suitable pump for a given application

When does the self priming factor becomes important and necessary in pumping???? If a pump is taking suction from a source below the pump suction nozzle Positive displacement pumps are able to self prime within limits in the smaller capacity range Some special types of centrifugal pumps can also do self priming

Centrifugal and Axial flow pumps are available to operate in variable head/flow conditions The head flow range of the pumps can be determined by the their respective pump characteristic curve This curve gives us information about different characteristics (eg power, NPSH, efficiency)of a pump at different capacity and head requirements.. For a given impeller size, a pump can produce any flow rate within its characteristic curve, if sufficient NPSH is available

The system head characteristics can be changed to vary flow rate by Discharge Throttling Varying Pump speed

Some pump Characteristic curves are as follows:

After selecting the required flow rate, either a centrifugal or a piston pump may fulfill the need for high differential head required. If a small flow rate is required, either an integrally geared centrifugal pump or a piston pump may be applied For High flow and high head combinations, a multi stage centrifugal pump can be used.

A proportioning pump is appropriate for such application This type of pump can also be provided with variable flow capacity Certain types of gears, plungers, diaphragm pumps can also be used in combination with a variable speed drive for flow rate regulation.

NPSHR is the amount of liquid pressure required at the intake port of a pre-designed and manufactured pump. NPSHA is the amount (A = available) to the pump intake after pipe friction losses and head pressures have been taken into account. The NPSHA must equal or exceed the NPSHR. The available NPSH is a characteristic of the piping system. If the NPSHA is lower than the NPSHR then gas bubbles will form in the fluid and caviation will occur. The NPSHA is calculated from:

If the available NPSH is low, specially designed Centrifugal pumps may be used Depending on how low the NPSH is, either : Horizontal end suction pump with a suction inducer OR A double Suction arrangement may be applied A vertical Turbine pump may also be used for this purpose

Is the liquid? Fresh or salt water, acid or alkali, oil, gasoline, slurry, or paper stock? Cold or hot and if hot, at what temperature? What is the vapor pressure ofthe liquid at the pumping temperature? What is its specific gravity? Is it viscous or non-viscous? e. Clear and free from suspended foreign matter or dirty and gritty?

If the latter, what is the size and nature of the solids, and are they abrasive? Ifthe liquid is of a pulpy nature, what is the consistency expressed either in percentage or in 1b per cubic ft of liquid? What is the suspended material? f. What is the chemical analysis, pH value, etc.? What are the expected variations of this analysis? If corrosive, what has been the past experience, both with successful materials and with unsatisfactory materials

For a highly viscous fluids such as Toothpaste, peanut butter, and shampoos, a positive displacement progressing cavity pump can be used A rotary variable displacement piston pump might be used for hydraulic control system, but it is not a good choice for potable water application. For pumping hot asphalt and some other limited applications in lube oil systems, a rotary sliding vane pump can be used.

Material selectin is affected both by 1. The fluid being pumped 2. The environment. Resistance to corrosion and erosion are of prime importance . The engineer must determine which material is most suitable for a particular service. Pumps are commonly available in cast iron, ductile iron, carbon steel, alloy steel, and in some composite materials or special alloys such as Monel, Hastelloy or Titanium.

The choice of driver is as important as the pump selection Factors affecting the driver choice are: 1. Capital Cost 2. Driver type availability 3. operation reliability 4. Availability and cost of utilities 5. RPM required for the process

Presenter: Muhammad Belal Malick

Delivery of fluids in precise adjustable flow rates is called metering. A metering pump is a pump used to pump liquids at adjustable flow rates which are precise when averaged over time. The term "metering pump" is based on the application or use rather than the exact kind of pump used, although a couple types of pumps are far more suitable than most other types of pumps.

This class of pumps moves liquids in two stages: the suction stroke and the discharge stroke.(Reciprocating)
The basic principle of metring is to change the displacement per stroke or the stroking speed.

Positive displacement reciprocating pumps can be adapted to function as metring or proportioning devices. Three basic types of pumps with several variations can be used for this service: Packed Plunger pump(piston pump) Mechanically actuated diaphragm pump Hydraulically actuated diaphragm pump

Manually adjusted while stopped Manually adjusted while running Pneumatic Electric Variable Speed

Sizing a pump is to figure out the presure required to pump the gallons per minute of fluid.

There are two items required to size a pump: Fluid flow rate Pressure to be developed

A Pump Performance Curve is produced by a pump manufacturer from actual tests performed and shows the relationship between Flow and Total Dynamic Head(TDH) or presure.

The system curve is a plot of the Total Head vs. the flow for a given systems.

Not all system operating points are directly on top of a pump graph or curve as shown below:

It would be best to choose a pump on the curve above the operating point.

It would be best to operate a pump at a lower speed if possible to prolong the life of the pump and bearings.

PUMPS IN PARALLEL TO MEET VARYING DEMAND

Operating two pumps in parallel and turning one of when the

demand is lower, can result in significant energy savings. Pumps

providing different flow rates can be used. Parallel pumps are an option when the static head is more than fifty percent of the total head.

If W is negative a pump is required; if it is positive a turbine could be installed to extract energy from the system.

The power is given by:

where m = mass flow-rate, kg/s,

efficiency = power out/power in.

Power requirements for pumping liquids

The total energy required can be calculated from the equation:

where W = work done, J/kg, z = difference in elevations , m,

P = difference in system pressures , N/m2,

P= pressure drop due to friction, including miscellaneous losses, and equipment losses, N/m2, p = liquid density, kg/m3, g = acceleration due to gravity, m/s2.

The efficiency of a pump is a measure of the degree of its hydraulic and mechanical perfection.Pump efficiency is expressed in percentage as:
Pump Efficiency =GPM X Total Head X 100/(input HP X 3,960) HorsePower=HP= A unit of power equal to 745.7 watts.

The pump's efficiency varies throughout its operating range. The efficiency will depend on the type of pump used and the operating conditions. The B.E.P. (best efficiency point) is the point of highest efficiency of the pump. All points to the right or left of the B.E.P have a lower efficiency.

Undersizing the zones will cause the pump to cycle often.

wears out the motor
excessive overload tripping

Operation requires greater NPSH High pressure drop Cavitation Greater power consumption High purchase cost Vibration

Higher Head = Lower Flow Lower Head = Higher Flow Lower Flow = Lower power Higher Flow = Higher power

Presented by: Shahzab Idrees

Suction Problems

Mechanical Problems

Troubleshoots

System Problems

Hydraulic Problems

Pump not primed Insufficient available NPSH Air leaks into suction line Vortex formation at suction Excessive friction losses in suction line Clogged impeller Selection of pump with too high suction speed

Pump does not deliver liquid Insufficient capacity Requires excess power Vibration Overheating and Seizing Impeller vanes are eroded Corrosion Mechanical seal leaks Coupling fails

 Speed of pump too high/low

Wrong direction of rotation

Static head higher than shut-off head Total head of system higher/lower than design of

pump Excessive wear

Foreign matter in impeller Misalignment Bent shaft Rotor out of balance Parts loose on shaft Shaft running off-center because of wrong bearings Incursion of hard particles into running clearance Inadequate tightening of casing bolts Pump material not suitable for liquid handled

 Pump fails to discharge

Noisy
Wear rapidly Pump starts, then loses suction Takes excessive power

Pump not properly primed Suction pipe not submerged Foot valve leaking Suction pipe too small

Pump worn Air leak Pipe strain Corrosion

 Wrong direction of rotation

Low speed
Insufficient liquid supply Pump runs dry

 Noise

Oil leak
Overheated Water in crankshaft Loss of prime Pitted valves

 Insufficient suction pressure Cavitation Lift too high

System shooks Overpressure/ overspeed Dirty environment Air in liquid

 Does not develop rated pressure

Lose capacity
Vibrates Operation is erratic

 Suction line leaks Suction lift too high Cavitation

Low steam pressure High exhaust pressure Entertained air or vapors

Worn piston rings Misalignment Piping not supported