A Presentation

On

Pump Fundamentals

24-Jun-16 This is a proprietary document of KEPL 1

History of Centrifugal Pump

Year 1680 First Centrifugal pump was developed by Johann

Garden.

Year 1818 Improved version of centrifugal pump was developed

Boston, USA.

Year 1846 More efficient pump was developed in USA with

curved blade impeller. Since then continuous

improvements are taking place in centrifugal pumps.

This is a proprietary document of KEPL 2

 What is a Centrifugal Pump ?

A centrifugal pump is a machine which converts Mechanical energy into

Hydraulic energy. It consists of a set of rotating vanes enclosed within a
casing to impart energy to fluid through centrifugal force.

Working principle of centrifugal pump

When impeller of a centrifugal pump whose casing & suction piping is
filled with liquid to be pumped is rotated at a particular speed, the liquid
inside the casing is expelled out into delivery pipe creating drop in
pressure at suction side of impeller. Then the new liquid is forced by
atmospheric or other pressure into the rotating impeller. The impeller
discharges the liquid at its periphery at a higher velocity. The velocity is
converted into pressure energy by means of a volute or by a set of
stationary vanes called as ‘diffuser’.

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Atmospheric Pressure

The Pressure of the Atmosphere on the Earth.

Atmospheric pressure at sea level is
1.033 kg/cm^2

This is a proprietary document of KEPL 4

 Atmospheric Pressure/Elevation Chart

Altitude above sea level Barometric pressure

Air Equi head of water
Feet Meter PSI Feet Meter
0 0 14.7 34 10.36
1000 305 14.2 32.8 10
2000 610 13.7 31.5 9.6
3000 914 13.2 30.4 9.27
4000 1219 12.7 29.2 8.9
6000 1829 11.8 27.2 8.29
8000 2438 10.9 25.2 7.68

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 Absolute Pressure

Absolute Pressure is
sum of the available atmospheric pressure and the Gauge pressure in
the pumping system

Absolute Press(kg/cm^2) = Gauge Press. + Atmospheric Press.

Absolute Pressure =10kg/cm^2(Gauge Press.)

+1.033kg/cm^2 (Atm. Press.)
= 11.033kg/cm^2

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 Vacuum

Vacuum
The full or partial elimination of Atmospheric Pressure
Atmospheric Pressure on the Moon = 0 = Full Vacuum

1 mm Hg Vacuum = 0.0136 m of Water column

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 Specific Gravity

The ratio of the weight of anything to the weight of water.

Example Specific Gravity of HCl = Weight of HCl (/) Weight of Water

= 10.0 (/) 8.34 = 1.2

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 Pressure and Liquid

Pressure and Liquid Height Relationship (Head)

10 m
1
kg/cm^2

1 kg/cm^2 =10 m of Water column

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 Vapour Pressure

Atmospheric Pressure

VAPOUR PRESSURE

The pressure pushing against atmospheric pressure on liquids

at elevated temperatures.

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 Water Vapor Pressure Chart

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 Capacity

In a centrifugal pump, the capacity varies with the change in total system
head. The actual flow rate achieved is directly dependent on the Total
Dynamic Head at which the pump is working.

The flow capacity of a centrifugal pump also depends on three other

factors:

 Pump Design
 Impeller Diameter
 Pump Speed

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 Suction Head

A Suction Head (Ht) exists when the liquid is taken from an open to
atmosphere tank where the liquid level is above the centerline of the
pump suction, commonly known as a flooded suction.

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 Suction Lift

A Suction Lift (Ht) exists when the liquid is taken from an open to
atmosphere tank where the liquid level is below the centerline of the
pump suction.

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 Total Dynamic Head

Total Dynamic Head (TDH) = Elevation+Friction head loss+Velocity

head at Delivery

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 Centrifugal Pump Components

The two main components of a centrifugal pump are the impeller and
the volute. The impeller produces liquid velocity and the volute forces
the liquid to discharge from the pump converting velocity to pressure.
This is accomplished by offsetting the impeller in the volute and by
maintaining a close clearance between the impeller and the volute at
the cut-water. Please note the impeller rotation. A centrifugal pump
impeller slings the liquid out of the volute. It does not cup the liquid.

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 Pump Performance Curve

A Pump Performance Curve is produced by a pump manufacturer

from actual tests performed and shows the relationship between Flow
and Total Dynamic Head, the Efficiency, the NPSH Required, and the
BKW Required.

 Higher Head ~Lower Flow

 Lower Head ~Higher Flow

 Lower Flow ~ Lower Horsepower

 Higher Flow ~ Higher Horsepower

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 Affinity Laws

The performance of a centrifugal pump is affected by a change in

speed or impeller diameter.

The affinity law for a centrifugal pump with the impeller diameter held constant and the
speed changed:
Flow:
Q1 / Q2 = N1 / N2
Example: 100 / Q2 = 1450/2900
Q2 = 200 m^3/Hr.
Head:
H1/H2 = (N1) x (N1) / (N2) x (N2)
Example: 100 /H2 = 1450 x 1450 / 2900 x 2900
H2 = 400 M
Horsepower(BKW):
BKW1 / BKW2 = (N1) x (N1) x (N1) / (N2) x (N2) x(N2)
Example: 5/BKW2 = 1450 x 1450 x 1450 / 2900 x 2900 x 2900
BKW2 = 40

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18
 Affinity Laws

The affinity law for a centrifugal pump with the speed held constant and the
impeller diameter changed:

Flow:
Q1 / Q2 = D1 / D2
Example: 100 / Q2 = 8/6
Q2 = 75 m^3/hr.
Head:
H1/H2 = (D1) x (D1) / (D2) x (D2)
Example: 100 /H2 = 8 x 8 / 6 x 6
H2 = 56.25 m
Horsepower(BKW):
BKW1 / BKW2 = (D1) x (D1) x (D1) / (D2) x (D2) x (D2)
Example: 5/BKW2 = 8 x 8 x 8 / 6 x 6 x 6
BKW2 = 2.1

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 Brake Power Input

BKW = ( Q X H X S.G. ) / ( 102 X  )

Where
 Q is discharge in lit/sec.
 H is total head in m.
 S.G. is specific gravity
  is efficiency in fraction.

Example:
BKW = (102 x 70 x1.0) / (102 x .7)
BKW = 100 kw

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 System Head Curve

To calculate a System Head Curve several points must be chosen to

calculate friction losses on both the suction and discharge sides of the

pump at various flow rates.

The static suction head/lift and the static discharge head remain

constant.

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 Net Positive Suction Head Required
(NPSHR)

The net positive suction head required is a function of the

pump design at the operating point on the pump

performance curve.

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Net Positive Suction Head Required
(NPSHR)

NPSH= Ha-hvp-hst

Ha= atmospheric pressure in mwc

hvp= vapour pressure

hst= Total suction lift/ suction head

NPSH(A) : NPSH AVAILABLE IS A FUNCTION OF THE SYSTEM.

NPSH(R) : NPSH REQUIRED IS THE FUNCTION OF PUMP

DESIGN

FOR SATISFACTORY PUMP OPERATION

NPSH(A) > NPSH(R)

This is a proprietary document of KEPL 23

 Net Positive Suction Head Available
(NPSHA)
The net positive suction head available is a function of the pump
suction system.

The Net Positive Suction Head is the absolute total suction head
in meters.
The NPSH available in a flooded suction system is:
Atmospheric Pressure (- ) Vapor Pressure (+) Liquid Height (-) Friction
in the Suction Line.

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 Net Positive Suction Head Available
(NPSHA)
The NPSH available in a suction lift system is:
Atmospheric Pressure (-) Vapor Pressure (-) Liquid Ht. (-) Friction in the
Suction Line.

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Net Positive Suction Head Available
(NPSHA)

Ways to improve NPSHA:

1) Increase suction pipe size

2) Reduce suction lift by installing pump closer to liquid source

3) Reduce liquid temperature to reduce vapour pressure

This is a proprietary document of KEPL 26

 Suction Cavitation

Suction Cavitation occurs when the pump suction is under a low

pressure/high vacuum condition where the liquid turns into a vapour at

the eye of the pump impeller. This vapour is carried over to the

discharge side of the pump where it no longer sees vacuum and is

compressed back into a liquid by the discharge pressure. This

imploding action occurs violently and attacks the face of the impeller.

An impeller that has been operating under a suction cavitation

condition has large chunks of material removed from its face causing

premature failure of the pump.

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 Low Pressure / High Vacuum

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 Parallel Operation of Pumps

Parallel operation of pumps is done in order to meet higher capacity

demands. Also where capacity variation is required, parallel operation

of pumps provides good solution.

Operating two identical pumps in parallel the assumption is made that

the flow will double. This however is not the case. In order to calculate

the additional flow realised by running two identical pumps in parallel,

one must study the system head curve.

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Parallel Operation of Pumps

Important factors for selection of pumps in parallel operation.

1) Select pumps of similar characteristics as far as possible.

2) H-Q curve should be of rising nature.
3) Duty point should lie in best efficiency zone or slightly towards left
side of the best efficiency.

Pumps with dissimilar characteristic curves can operate in parallel if

the system head does not exceed the shut-off head of any pump at
any capacity produced by a combination of other pumps on the
system. The shut-off heads of the pumps should preferably be equal.

This is a proprietary document of KEPL 30

 GATE VALVES
CHECK VALVE

A PUMP No. 1 B

PUMP No. 2

SUCTION DISCHARGE
CHECK VALVE
GATE VALVES

PIPING HOOK - UP FOR TWO PUMPS IN

PARALLEL OPERATION

TURBINE PUMP - 1

TURBINE PUMP - 2
DISCHARGE

TURBINE PUMP - 3

PIPING HOOK - UP FOR THREE TURBINE

PUMPS PARALLEL OPERATION

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 CHARACTERISTIC OF THREE PUMPS IN PARALLEL OPERATION

Q = 325 lit. / sec. Q = 633 lit. / sec. Q = 920 lit. / sec.

POINT A H = 57 m. POINT B H = 59.5 m. POINT C H = 64 m.
= 79.5 % = 81.6 % = 83 %
Q = 354 lit. / sec. Q = 693 lit. / sec. Q = 1005 lit. / sec.
POINT A ' H = 43 m. POINT B ' H = 46.5 m. POINT C ' H = 52.5 m.
= 66.5 % = 72 % = 76 %

105
1-P 3 - PUMPS IN PA
RALLEL OPERAT
UM ION
95 P IN
SO
2 - PU
MPS
IN
TOTAL HEAD IN METRES H

LO PARA
O LLE
PE L O
85 RA PE
RA
TI TIO
O
N N C
65 MAX. STATIC HEAD B
A
VE C'
55 SYSTEM RESISTANCE CUR

MIN. STATIC HEAD

B'
45 A'
VE
SYSTEM RESISTANCE CUR
35
25 85
THREE PUMPS BHR 42 - 30° 80
15 EFFICIENCY CURVE IN PARALLEL OPERATION 75
70
5 65
0 60
100 200 300 400 500 600 700 800 900 1000

DISCHARGE IN LIT. / SEC. Q

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 Parallel Operation of Pumps

Different Pumps:

Operating two different size pumps in parallel the assumption is made

that the flow will increase dramatically. This however is not the case. In

order to calculate the additional flow realized by running two different

size pumps in parallel, one must study the system head curve.

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 Series Pumping

Pumps in series double the head at the same flow condition point. One

pump discharge is piped into the suction of the second pump producing

twice the head capability of each pump separately. The second pump

however must be capable of operating at the higher suction pressure

which is produced by pump number one.

This mode of operation is a very cost effective way of overcoming high

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discharge heads when the flow requirement remains the same.
 Series Pumping

GATE VALVE CHECK VALVE

SUCTION DELIVERY - 2 PUMPS

PUMP SET - 1 DELIVERY SUCTION PUMP SET - 2

PUMP - 1 PUMP - 2

PIPING HOOK - UP FOR SERIES OPERATION

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 Pumping Viscous Fluid

The performance of centrifugal pumps is affected when

pumping viscous liquids. A dramatic increase in Brake
Horsepower and a reduction of Flow and Head occurs.
To determine the effects of pumping viscous fluids using a
centrifugal pump use the Performance Correction Chart below:

• Ch = Head Correction
• Cq = Flow Correction
• Ce = Efficiency Correction

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 CURVES SHOWING H, P, p AND
TEMPERATURE RISE

TOTAL DYNAMIC HEAD 100 METERS:-

30 10 100

WATER TEMPRATURE RISE- C° :-

HEAD C
27 9 APAC 90
ITY
24 8 80

EFFICIENCY :-
NCY
21 7 EFFICIE 70
TEPMERATURE RISE
18 6 60
15 5 50
O WER
12 4 RSEP 40
K HO
BREA
9 3 30
6 2 20
3 1 10
0 0 0
10 20 30 40 45

CAPACITY LIT. / SEC. :-

H - IN
m. WATER
VISCOUS H-Q
LIQUID
PUMP
IN-PUT N-Q
kW.
-Q
PUMP
%
DISCHARGE IN LIT / SEC.

VISCOUS PERFORMANCE CHANGE

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 Specific Speed

Specific speed is term used to classify pumps on the basis of their

performance & dimensional proportions regardless of their actual size
or the speed at which they operate. It is the speed expressed in RPM
of an imaginary pump geometrically similar in every respect to the
actual pump under consideration & capable of raising 75 kg of water
per second to a height 1 meter (effective output 1 metric H.P). The
mathematical formula for calculating the specific speed.

N √Q
Ns (Metric)= 3.65
H^ 0.75

Specific speed gives us a comparison on an equal footing of all types

of centrifugal pumps, mixed flow & axial flow pumps.

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 Impellers

Impeller Profiles in Terms of Specific Speed

Notes:1) For double suction impeller, Q is to be halved while calculating specific

speed
2) For multistage pumps, head per stage to be considered while calculating
specific speed.
Where N is speed ( min-1 )
N Q Q is capacity ( m3/ sec.)
Ns (Metric)= 3.65 H is total head ( m )
H^ 0.75

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 H - Q CURVES

UNSTABLE

FLAT

STABLE
STEEP

DROOPING
H

This is a proprietary document of KEPL 41

 DESIGN POINT

RISING OR OVERLOADING
FLAT

P
NON - OVERLOADING

FALLING

P - Q CURVES

EFFICIENCY CURVE

NPSH CURVE
NPSH

- Q & NPSH - Q CURVES

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Factors Affecting Pump Performance

1) Specific gravity of liquid:

a) Specific gravity of liquid does not alter head, discharge & efficiency of the pump
b) Power input is directly proportional to the specific gravity.
c) Permissible suction lift reduces with increase in specific gravity.

2) Temperature of the liquid:

a) Specific gravity of liquid reduces with increase in temperature of the liquid.
b) At higher temperatures, viscosity of liquid reduces.
c) With increase in temperature, vapour pressure of the liquid increases. Increase in
vapour pressure, reduces the suction capacity.
3) Viscosity of the liquid:

a) Increase in viscosity reduces head & capacity.

b) Increase in viscosity increases power requirement due to higher internal frictional
losses.
c) Increase in viscosity reduces pump efficiency.
d) Increase in viscosity reduces suction lift of the pump.

This is a proprietary document of KEPL 45

 Selection Of Pumping Equipment /
Pumps
• Total number of pumps required
• Nature of liquid to be pumped i.e. abrasive, corrosive
• Media… If hot then its Temp., Vapour pressure
•Specific gravity, viscosity of the liquid
• Clean liquid or dirty liquid. Content of abrasive particles, size of solid
particles
• If liquid is pulpy in nature then its consistency
• Total capacity or flow requirements
• Suction conditions viz. suction head or lift, constant or variable
suction
• Discharge conditions like diameter of piping, pipe fitting and valves
• System resistance curve to decide total head
•Type of service continuous / intermittent
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 Selection Of Pumping Equipment /
Pumps

• Pump installation horizontal or vertical

• Selection of prime mover

• Weight limitation

• Location of installation

• Type of pump required i.e. End suction, Horizontal Split

Case and Multistage; any specific recommendation from

pump user.
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