Documenti di Didattica
Documenti di Professioni
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Thermofluids TF306
2004
Melinda Hodkiewicz
mhodki@mech.uwa.edu.au
Extension: 7911, Room G55
References
• Centrifugal pumps 2nd ed., Karassik and McGuire
• Fundamentals of Fluid Dynamics, Gerhart and Gross
• Centrifugal Pumps - Design and Application 2nd ed, Lobanoff & Ross
• FM200 lecture course notes, http://www.cwr.uwa.edu.au/cwr/teaching/
• Introduction to Fluid Mechanics - Fox and McDonald MPSL 620.106 1998 INT/1992 INT
• Fundamentals of Thermal-Fluid Sciences – Cengal and Turner MPSL 621.402 2001 FUN
Vendor references
• Crane Technical Paper 410(metric)
• Flow of Fluids through valves, fittings and pipes
• Goulds Pump manual GPM6
• Basic Principles for the Design of Centrifugal pump installations (SIHI)
• Sulzer Centrifugal pump handbook
• Warman Slurry Pumping Handbook
• Cameron Hydraulic data
This section was adapted from an Honours Project by Alicia Webb in 2003.
An understanding of these concepts is important for an understanding of pump systems, which are a major
component of industrial plants.
Rate at which the mass = Rate at which mass enters - Rate at which mass leaves
accumulates in the control the control volume the control volume
volume
dmsys
= ∑ m& in − ∑ m& out CONSERVATION OF MASS EQUATION
dt in out
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.
According to laminar flow theory, the velocity of fluid in a pipe has a parabolic profile as shown below:
In piping systems the flow is usually turbulent. Turbulent flow also has a rounded velocity profile, but rather
than a parabolic shape, the curve is flatter as shown below:
• 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.
Re = Vdρ/µ d=pipe ID (mm), v=flow velocity (m/s), ρ=density kg/m3, µ=viscosity (cP).
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
= ∑ Fext , j + ∑ mV
& i i − ∑ m& eVe
dt j in out
External forces are those applied without mass flow across the control boundary. Surface forces due to pressure
and body forces f ( ρ , g , V ) . For steady state conditions
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 Bernoulli’s equation from 1st. principles (see any Fluids
text).
In pipe flow, as with any situation, energy is conserved from one point in fluid flow to another. The energy can
be in the form of kinetic energy (KE), potential energy (PE) or internal energy (IE).
[Rate of heat transfer in]+[Rate of work done on sys]=[Rate of increase of IE +KE + PE]
Mathematically this is written as for steady, uniform, incompressible flow as (where u is specific internal
energy)
2
V
Q& − W& = ∑ m& (u + + z)
net 2g
This is the steady state general energy equation as presented earlier in Thermo section of this course and AT200.
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 = Tω (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.
p V2
W& S = ∑ m& (u + + + zg ) + m& ghL
net ρ 2
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 PUMP SYSTEM SIZING EQUATION
ρg 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 ρ = 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
ρg 2g
mechanical work completely by a mechanical device such as a turbine or pump.
It is derived from the previous equation for the special case when W& S = 0 and hL = 0.
p1 V12 p V2
+ + z1 = 2 + 2 + z 2
ρg 2 g ρg 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.
Due to layers of fluid shearing across each other, the velocity of a liquid is maximum in the centre of the flow,
and zero at the pipe wall. This means that the pressure due to velocity at the pipe wall is zero. Thus, head due to
velocity can be measured as the difference between the head at the centre of the pipe and the edge (See Figure).
Physically this can be done using a pitot tube for the centre reading and a piezometer for the pipe wall reading.
This can be seen in the test facility in the CWR Fluids laboratory.
The velocity can be estimated from the pressure difference between the fluid at the side wall and the stagnation
pressure at the centre of the pipe. From Bernoulli’s equation
p1 V12 p
+ = 2 ; where p2 is pressure at the stagnation point and p1 and V1 are the pressure upsteam.
ρg 2 g ρg 2
V12 p 2 − p1
= =h
2 g ρg
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
The conservation of angular momentum principle when applied to the shaft of a pump can be used to show that
torque is transformed to a change in velocity of fluid through the impeller. This is done from first principles
using the equation below:
dL0 sys
= ∑ M 0, j + ∑ m& i ( ri × Vi ) − ∑ m& e ( r ×e Ve )
dt j in out
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 Vθi and exits at re with absolute velocity Vθe. Thus the equation above becomes:
(
W&M = ωTSHAFT = m& ω reVθe − rV
i θi )
where Tshaft is the shaft torque
.
m is the mass flow rate
r is the radius
Vθ is the tangential component of the absolute fluid velocity
e is the exit of the impeller
This is Euler’s turbomachinery equation, which is used to calculate the hydraulic power a pump is supplying,
which in turn can allow the calculation of pump efficiency
This figure shows the inlet and exit radii, and the
tangential components of the fluid velocity Vθ at
the inlet and exit. It should be noted that the fluid
velocity V is not the same as U = ωr 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”.
Vθ1
There are many different styles of centrifugal pumps, but they can essentially be divided into three broad groups
a. horizontal or vertical
b. single impeller (end suction/split case, single volute, double volute, double suction) or multi-stage
impeller designs
c. Impeller design: Radial, mixed flow, axial. Open and closed, semi open designs.
The governing principles of all centrifugal pumps are the same but the design details vary.
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
• Volute/Housing
• Impeller
• Shaft and sleeve
• Mechanical seal or packing
• Bearing housing, bearings and seals
• Coupling
• Motor
• Foundation and baseplate
Ref: Goulds Pumps – this is the pump on the PUMP TEST RIG (Engine lab)
Look at this in the context of the Pump System sizing equation given earlier
W& S ( p e − p i ) (Ve2 − Vi 2 )
HP = = + + ( z 2 − z1 ) + h L
m& g ρg 2g
Identify from the layout given above how each of the contributions to the equation.
One very important point obvious from this equation is that the power draw on a centrifugal pump is dependent
on the SYSTEM in which the pump is installed.
In order to correctly size a pump for a particular application it is necessary to understand the system in which it
is installed. One selects a pump based on its ability to supply the required flowrate for the system. The operating
point of a pump is set by the intersection of the PUMP curve (specific to the pump) with the SYSTEM curve
(defined by the piping system, tank elevation, over-pressures etc)
1. Determine flowrate
2. Obtain fluid property information
3. Design piping system
4. Determine the System Head Curve
5. Decide on duty point
6. Calculate Power required and Specific speed values
7. Calculate Net Positive Suction Head available
8. Develop pump specification sheet
9. Select a pump
10. Evaluate pump selection
• Density, specific gravity, Dynamic or Absolute viscosity, Kinematic viscosity, Density (ρ (Rho) = mass/unit
volume, SI units kg/m3).
• Water density at 20 deg C = 1000 kg/m3
• Specific weight γ = ρg , Weight of fluid per unit volume.
• Specific gravity S= ρ/ ρH20.
• Dynamic (Absolute) Viscosity µ . Shear stress = µ x strain rate. Newtonian fluids obey this rule. Units 1
cp(centipoise) = 10-3 Pa s. 1 Pa s = 1 N s/m2 = 1 kg/(ms). Viscosity varies greatly with temperature. Use
engineering tables and Formula sheet.
• Absolute viscosity examples. Water at 15 deg C = 1.0 cp, 60 deg C = 0.47 cp, 100 deg C = 0.3 cp, Gasoline
at 15 deg C = 0.6 cp, SAE 10 Lube at 60 deg C = 12cp, SAE 70 Lube at 60 deg C = 120cp
• Kinematic Viscosity is the Ratio of viscosity to density ψ = µ/ρ, Units 1 m2/s = 106 cSt (cSt = centristokes)
L V2
( p1 − p2 ) = hL = f
1
ρg D 2g
Darcy’s formula is valid for turbulent and laminar flow only if line pressure >> vapour pressure of the liquid ie
NO cavitation
64 L V
2
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 ε/d. ε = roughness of pipe wall, d = pipe diameter
Need to see appropriate table
Examples for the Friction factor values for clean commercial pipe with turbulent flow, see Pump Formula sheet.
L V 2 L V 2
hL = ∑ f + ∑ f
d 2 g pipe d 2 g fittings
This can also include the entrance and exit losses if they are significant
HP = − = + + ( zout − zin ) + hL
mg
& ρg 2g
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
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 … WHY?
For an existing pump installation you will need a set of pressure gauges
The pressure P on a gauge located close to the flange of the suction of the pump will measure
Total Head = [Disch gauge + Vel Hd (at DG)] - [Suction gauge + Vel Hd (at SG)]
All gauge readings converted to m and corrected to pump centreline
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
W& P = ρ gQH P
ηP = W&P W&M
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
• For flooded suction,
p + patm
• NPSH A = zsuction + suction − hL ( suction ) − hVP ( abs )
ρg
• 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)
• Vapour pressure water at 15 C = 0.17m abs at sea level, 100 C = 10.3 m abs
NPSH required
• 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
• There should be a margin (at least 1m though depends on application between NPSHA and NPSHR)
Affinity Laws
Use of the affinity laws to select the optimum impeller diameter and/or pump rotating speed (if a variable
frequency drive or sheave drive system is appropriate)
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
Operational problems
Theoretically as long as NPSH(A) >> NPSH(R) 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
Cavitation
Occurs when NPSHr>NPSHa
Causes impeller damage on visible side of vanes due to implosions (collapsing of the bubble). Identified by loud
continuous noise “pumping rocks" and high vibration
Avoid cavitation by increase NPSHA or decreasing NPSHR
Increase NPSHA by raising suction level, lower pump, reduce friction losses in suction, Subcool liquid
(injection)
Decrease NPSHr by using slower speed (or variable freq drive), installing a double suction impeller, increasing
impeller eye area, using an oversize pump or installing an inducer ahead of impeller
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/Biotech-
Environ/PUMPS/reciprocating.html