Pump Cavitation Definition

Pump cavitation is the formation and subsequent collapse or implosion of vapor bubbles in a
pump. It occurs when gas bubbles are formed in the pump due to drop in absolute pressure
of the liquid below vapor pressure. These gas bubbles occupy space inside the pump and
affect the pump's operating pressure and flow. With vapor bubbles in the low-pressure zones
of the pump, the motor's energy is wasted expanding the bubbles instead of bringing more
liquid into the pump. As the bubbles pass into the pump's high-pressure zones, the motor's
energy is wasted compressing the bubbles instead of expelling the liquid from the pump. The
bubbles can collapse as they pass from low- to high-pressure zones in the pump. When vapor
bubbles collapse inside the pump the liquid strikes the metal parts at the speed of sound.
The noise generated from these collisions of gas bubbles into the metal parts of pump
sounds like pumping marbles and stones.

Causes of Pump Cavitation

Drop in pressure at the suction nozzle due to low NPSHa

If the fluid at pump suction is not available sufficiently above the vapor pressure of liquid at
operating conditions, then vaporization of liquid and formation of gas bubbles is very likely,
leading to cavitation.

Increase of the temperature of the pumped liquid

Increase in liquid temperature at the pump suction point increases the vapor pressure of the
liquid. Thus it becomes more likely for operating pressure to fall below this vapor pressure
limit, hence leading to bubbles and cavitation.

Increase in the fluid velocity at pump suction

Increase in fluid velocity at pump suction can typically be caused by higher liquid flowrates
than the design case. As per Bernoullis principle, higher liquid velocity means higher velocity
and lower pressure head. Frictional pressure drop in the pump suction also rises with rise in
the flowrate, making low pressure and cavitation at pump suction more likely to occur.

Reduction of the flow at pump suction

Certain minimum flow is required by the centrifugal pumps to keep them from running dry,
as indicated by the pump performance curves. If liquid flow falls below this limit, possibility of
developing vapor in pumps and cavitation increases.

Undesirable flow conditions caused by obstructions or sharp elbows in the suction

piping

Sharp elbows, valves, other fittings and obstructions cause more frictional pressure loss in
the pump suction, thus increasing possibility of low pump suction pressure leading to
cavitation.

The pump is not selected correctly.

Every centrifugal pump has a certain requirement of positive suction head (NPSHr). If the
pump is not selected properly NPSHa might fall below this NPSHr limit, causing cavitation.

Pump damage caused by cavitation

Damage to pump mechanical seal
Mechanical seal are very important in any pumps as they prevent any foreign materials from
entering into the pump casing and the pumped liquid to escape to the environment so any
damage that may occur to the mechanical seal will increase operating cost and consumption
of natural resources. Cavitation can badly affect the performance of the mechanical seal as it
will cause damage to the seal faces and if the cavitation phenomena continues the seal may
run dry without continues cooling or lubrication.

Damage to pump shaft alignment

Shaft miss-alignment can occur after pump operation due to many reasons but the most
important one is the vibration that may be caused due to cavitation and expansion of pump
shaft due to heat generated in the pump due to cavitation.

Damage to Bearings
The bearing life will decrease significantly due to the vibration which will be transmitted from
the pump casing to the bearing housing, the vibrations cause the balls and rollers to jam into
the raceways causing the very small bents the races will appear like a corduroy cloth

Pump Impeller damage

When pressure in the eye of the impeller falls below the vapor pressure of the fluid, then
cavitation can begin and gas bubbles are formed the bubbles can collapse as they pass from
low- to high-pressure zones in the pump. When vapor bubbles collapse inside the pump the
liquid strikes the metal parts at the speed of sound. The noise we hear from outside the
pump when we say that cavitation sounds like pumping marbles and rocks.

Types of pump cavitation

1. Vaporization cavitation, also called inadequate NPSHa cavitation.
2. Internal re-circulation cavitation.
3. Vane passing syndrome cavitation.
4. Air aspiration cavitation.
5. Turbulence cavitation.
Prevention or Action measures to be taken against pump cavitation are discuseed in the
following sections.

Pump cavitation due to vaporization

Its called classic Cavitation. According to Bernoullis Law, when

velocity goes up, pressure goes down. Centrifugal pump works by acceleration and imparting
velocity to the liquid in the eye of the impeller. Under the right conditions, the liquid can boil
or vaporize in the eye of the impeller. When this happens we say that the pump is suffering
from vaporization cavitation. This type of cavitation is also called inadequate NPSHa
cavitation. To prevent this type of cavitation, the NPSHa in the system (the available energy in
the system), must be higher than the NPSHr of the pump (the pumps minimum energy
requirement).

How to prevent cavitation due to vaporization

NPSHa > NPSHr + 3 ft or more safety margin
1. Lower the temperature.
2. Raise the liquid level in the suction vessel.
3. Change the pump.

4. Reduce motor RPM if possible.

5. Increase the diameter of the eye of the impeller.
6. Use an impeller inducer.
7. Use two lower capacity pumps in parallel.
8. Use a booster pump to feed the principal pump.

Pump Cavitation by Internal circulation

This is a low flow condition where the discharge flow of the pump is
restricted and the product cannot leave the pump. The liquid is forced to re-circulate from
high-pressure zones in the pump into low-pressure zones across the impeller. This type of
cavitation originates from two sources. First, the liquid is circulating inside the volute of the
pump at the speed of the motor and it rapidly overheats. Second, the liquid is forced to pass
through tight tolerances at very high speed the heat and the high velocity cause the liquid to
vaporize.

How to prevent pump cavitation due to internal circulation

This condition cannot be corrected on pumps with an enclosed impeller.
1. You need to open the restricted discharge valve on the pump.
2. The problem could be a clogged downstream filter.
3. A closed discharge valve.
4. An over-pressurized header.
5. Check valve installed backwards
6. Operating the pump at or close to shut-off head.

Pump Cavitation due to vane passing syndrome

The free space between the impeller blade tips and the cutwater should be 4% of
the impeller diameter
This is caused by use of a larger diameter impeller or from re-metalizing or coating the
internal housing of the pump. Free space between the impeller blade tips and the cutwater
should be at least 4% of the impeller diameter. For smaller spaces, the liquid velocity between
these spaces becomes very high. This high liquid velocity leads to low pressure, heating,
bubble formation and hence cavitation.
With the pump disassembled the damage is seen on the blade tips at the OD of the impeller
and just behind the cutwater on the internal volute wall.

To prevent pump cavitation due to vane passing

To prevent damage due to such cavitation, free space between the impeller blade tips and
the cutwater should be at least 4% of the impeller diameter. For example, for a 10 impeller,
the free space should be 4% of the impeller diameter between the blade tips and the
cutwater. 10 x 0.04 = 0.4.

Pump cavitation due to air aspiration

Air can be drawn into the piping and pump from diverse forms and different points. Air can
enter into the piping when the pump is in vacuum, through following routes

Through pump shaft packing.

Valves stem packing on valves in the suction piping.

Joint rings on suction piping.

Flange faces sheet gaskets at pipe joints.

O-rings and threaded fittings on instrumentation in the suction piping.

O-rings and other secondary seals on single mechanical seals.

The faces of single mechanical seals.

Air can also enter into the pump from bubbles and air pockets in the suction piping.

Liquids that foam can introduce air into the pump.

To prevent pump cavitation due to air aspiration

1. Tighten all flange faces and gaskets.
2. Tighten all pump packing rings and all valve stem packing on suction piping.
3. Keep the velocity of the fluid in the suction piping at less than 8 ft per second. It may be
necessary to increase the diameter of the pipe.
4. Consider using dual mechanical seals with a forced circulation barrier fluid.

Pump cavitation due to turbulence

Turbulent flow leads to formation of vortexes in pump suction. Inadequate piping, sharp
elbows, restrictions, filters and strainers in suction line contribute to turbulence. The waterfall
effect in suction vessels is another contributing factor to pump turbulence.

To prevent pump cavitation due to excess turbulence in suction line

1. Design the pump suction piping and routing to avoid excess turbulence
2. Take precaution while fixing the pump suction line size to avoid turbulence and have
sufficient NPSHa
3. Respect the maximum allowable flow limit of the pumps.

Symptoms and Effects of Pump Cavitation

Pump cavitation causes noise and vibration. If the pump operates under cavitation conditions
for a long time, the following damage can occur:

Pitting marks on the impeller blades and on the internal volute casing wall of the pump

Premature bearing failure

Premature mechanical seal failure

Shaft breakage and other fatigue failures in the pump

Other problems caused due of pump cavitation

Problems with pump packing.

Problems with mechanical seals.

Problems with alignment.

Problems with the bearings.

Problems with impellers, casings, and wear bands.

Problems with pump efficiency.

And these problems wont go away until you resolve cavitation at its source.

Reference:
http://www.enggcyclopedia.com/2011/12/centrifugal-pump-cavitation/